KSB Rio-Therm N Series Installation instructions

Hot Water Service Pump
Rio-Therm N
Rio-Therm N 25-30 to 80-80
Installation/Operating
Manual

Legal information/Copyright
Installation/Operating Manual Rio-Therm N
Original operating manual
KSB Aktiengesellschaft
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
KSB's express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft Frankenthal 01.08.2012

Contents
Glossary .................................................................................................5
1 General ..................................................................................................6
1.1 Principles ...........................................................................................................6
1.2 Target group ..................................................................................................... 6
1.3 Symbols .............................................................................................................6
2 Safety .....................................................................................................7
2.1 Key to safety symbols/markings ....................................................................... 7
2.2 General .............................................................................................................. 7
2.3 Intended use .....................................................................................................7
2.4 Personnel qualification and training ............................................................... 8
2.5 Consequences and risks caused by non-compliance with these operating
instructions ........................................................................................................ 8
2.6 Safety awareness ..............................................................................................8
2.7 Safety information for the operator/user ....................................................... 8
2.8 Safety information for maintenance, inspection and installation work ....... 9
2.9 Unauthorised modes of operation .................................................................. 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 Return to supplier ........................................................................................... 10
3.5 Disposal ...........................................................................................................11
4 Description of the Pump (Set) ............................................................12
4.1 General ............................................................................................................ 12
4.2 Designation ..................................................................................................... 12
4.3 Name plate ...................................................................................................... 12
4.4 Design details .................................................................................................. 13
4.5 Configuration and function ........................................................................... 13
4.6 Noise characteristics .......................................................................................14
4.7 Scope of supply ............................................................................................... 14
4.8 Dimensions and weight .................................................................................. 14
5 Installation at Site ...............................................................................15
5.1 Safety regulations ........................................................................................... 15
5.2 Checks to be carried out prior to installation ............................................... 15
5.3 Installing the pump set .................................................................................. 15
5.4 Connecting the piping ...................................................................................16
5.5 Casing/insulation ............................................................................................17
5.6 Electrical connection ...................................................................................... 17
Contents
Rio-Therm N 3 of 30

6 Commissioning/Start-up/Shutdown ...................................................19
6.1 Commissioning/start-up ................................................................................. 19
6.2 Shutdown ........................................................................................................ 21
6.3 Operating limits .............................................................................................. 21
6.4 Shutdown/storage/preservation .................................................................... 22
6.5 Returning to service .......................................................................................22
7 Servicing/Maintenance .......................................................................23
7.1 Servicing/inspection ........................................................................................ 23
7.2 Drainage/cleaning ..........................................................................................23
7.3 Dismantling the pump set .............................................................................. 23
8 Trouble-shooting ................................................................................25
9 Related Documents ............................................................................26
9.1 Sectional drawing with list of components ..................................................26
9.2 Wiring diagrams ............................................................................................. 26
10 EC Declaration of Conformity ............................................................27
Index ....................................................................................................28
Contents
4 of 30 Rio-Therm N

Glossary
Discharge line
The line which is connected to the discharge
nozzle
Noise characteristics
The noise emission to be expected, indicated as
sound pressure level LpA in dB(A)
Pump
Machine without drive, additional components
or accessories
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
Suction lift line/suction head line
The line which is connected to the suction
nozzle
Glossary
Rio-Therm N 5 of 30

1 General
1.1 Principles
This operating manual is supplied as an integral part of 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/size and main operating data. They uniquely
identify the pump (set) and serve as identification for all further business processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
Noise characteristics.
1.2 Target group
This manual is aimed at the target group of trained and qualified specialist technical
personnel.(⇨ Section 2.4 Page 8)
1.3 Symbols
Table 1: 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 General
6 of 30 Rio-Therm N
1 General
1.1 Principles
This operating manual is supplied as an integral part of 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/size and main operating data. They uniquely
identify the pump (set) and serve as identification for all further business processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
Noise characteristics. (⇨ Section 4.6 Page 14)
1.2 Target group
This manual is aimed at the target group of trained and qualified specialist technical
personnel.(⇨ Section 2.4 Page 8)
1.3 Symbols
Table 1: Symbols used in this manual

2 Safety
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 2: 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.
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.
2.2 General
This manual contains general installation, operating and maintenance instructions
that must be observed to ensure safe pump operation and prevent personal injury
and damage to property.
The safety information in all sections of this manual must be complied with.
This manual must be read and completely understood by the specialist personnel/
operators responsible prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the pump must always be complied with and be
kept in a perfectly legible condition at all times. This applies to, for example:
▪Arrow indicating the direction of rotation
▪Markings for connections
▪Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this manual.
2.3 Intended use
The pump (set) must only be operated within the operating limits described in the
other applicable documents.
▪Only operate pumps/pump sets which are in perfect technical condition.
▪Do not operate the pump (set) in partially assembled condition.
▪Only use the pump to handle the fluids described in the data sheet or product
literature of the pump model.
▪Never operate the pump without the fluid handled.
▪Observe the minimum flow rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc).
!DANGER
2 Safety
Rio-Therm N 7 of 30

▪Observe the maximum flow rates indicated in the data sheet or product
literature (to prevent overheating, mechanical seal damage, cavitation damage,
bearing damage, etc).
▪Do not throttle the flow rate on the suction side of the pump (to prevent
cavitation damage).
▪Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
Prevention of foreseeable misuse
▪Never exceed the permissible operating limits specified in the data sheet or
product literature regarding pressure, temperature, etc.
▪Observe all safety information and instructions in this manual.
2.4 Personnel qualification and training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the machinery 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 pump (set) must always be supervised by technical specialist
personnel.
2.5 Consequences and risks caused by non-compliance with these operating
instructions
▪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
2.6 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 and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards and laws
2.7 Safety information for the operator/user
▪The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
▪Never remove a contact guard while the pump is running.
▪Contain leakages (e.g at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
2 Safety
8 of 30 Rio-Therm N

▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
2.8 Safety information for maintenance, inspection and installation work
▪Modifications or alterations of the pump are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Only carry out work on the pump (set) during standstill of the pump.
▪The pump casing must have cooled down to ambient temperature.
▪Pump pressure must have been released and the pump must have been drained.
▪When taking the pump set out of service always adhere to the procedure
described in the manual.(⇨ Section 6.4 Page 22)
▪Decontaminate pumps which handle fluids posing a health hazard.
▪As soon as the work is completed, re-install and/or re-activate any safety-relevant
and protective devices. Before returning the product to service, observe all
instructions on commissioning.(⇨ Section 6.1 Page 19)
2.9 Unauthorised modes of operation
Never operate the pump (set) outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the supplied pump
(set) is only valid if the equipment is used in accordance with its intended use.
2 Safety
Rio-Therm N 9 of 30

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 (as applicable) and the insurer about the
damage in writing immediately.
3.2 Transport
CAUTION
Improper pump transport
Damage to the pump!
▷Never suspend the pump/pump set from the power cable.
▷Prevent the pump (set) from getting knocked or dropped.
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for pump (set) storage.
CAUTION
Damage during storage by humidity, dirt, or vermin
Corrosion/contamination of the pump (set)!
▷For outdoor storage cover the packed or unpacked pump (set) and accessories
with waterproof material.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage to the pump set!
▷Only remove caps/covers from the openings of the pump set at the time of
installation.
Store the pump (set) in a dry, protected room where the atmospheric humidity is as
constant as possible.
If properly stored indoors, the pump set is protected for a maximum of 12 months.
For storing a pump (set) which has already been operated, observe the instructions in
(⇨ Section 6.4.1 Page 22) .
3.4 Return to supplier
1. Drain the pump as per operating instructions. (⇨ Section 7.2 Page 23)
2. Always flush and clean the pump, particularly if it has been used for handling
noxious, explosive, hot or other hazardous fluids.
3. If the fluids handled by the pump set leave residues which might lead to
corrosion damage when coming into contact with atmospheric humidity, or
which might ignite when coming into contact with oxygen, the pump set must
also be neutralised, and anhydrous inert gas must be blown through the pump
for drying purposes.
3 Transport/Temporary Storage/Disposal
10 of 30 Rio-Therm N

3.5 Disposal
WARNING
Fluids and supplies posing a health hazard and/or hot fluids and supplies
Hazard to persons and the environment!
▷Collect and properly dispose of flushing medium and any residues of the fluid
handled.
▷Wear safety clothing and a protective mask, if required.
▷Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Dismantle the pump (set).
Collect greases and other lubricants during dismantling.
2. Separate and sort the pump 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.
3 Transport/Temporary Storage/Disposal
Rio-Therm N 11 of 30

4 Description of the Pump (Set)
4.1 General
▪Non-self-priming in-line pump
Pump for handling clean or aggressive fluids not chemically and mechanically
aggressive to the pump materials.
4.2 Designation
Example: Rio-Therm N 50-80 T
Table 3: Key to the designation
Code Description
Rio Type series
Therm Hot water service pump
N New generation
50 Nominal diameter of pipe connection
25 = Rp 1
30 = Rp 1 1/4
40 ... 80 = DN 40 ... DN 80
80 Head in m x 10 (example: 90 = 9 m)
T Three-phase current
S = single-phase a.c. current
4.3 Name plate
6
1
2
3
4
5
Fig. 1: Name plate (example)
1 Size 2 Voltage, frequency
3 Thermal class 4 Maximum operating pressure,
enclosure, temperature class
5 Speed levels 6 Material number
Example: 1235-0867
Table 4: Key to the designation
Code Description
12 Year 2012
35 Week
0867 Consecutive number
Key to the series code
4 Description of the Pump (Set)
12 of 30 Rio-Therm N

4.4 Design details
Design
▪Maintenance-free, screw-ended or flanged wet rotor pump (glandless) with up to
four speed levels.
Modes of operation
▪Open-loop control mode (n = constant) with manual setpoint
Automatic functions
▪Full motor protection with integrated trip electronics
Manual functions
▪Setting of speed
Drive
▪Three phase asynchronous motor
▪230 V - 50 Hz
▪Enclosure IP 42 for all pumps with 3 speed levels
Enclosure IP 44 for all pumps with 4 speed levels
▪Thermal class F
▪Temperature class TF 110
▪Generic emission standard EN 61 000-6-3
▪Generic immunity standard EN 61 000-6-1
Bearings
▪Product-lubricated special plain bearing
4.5 Configuration and function
1 2
4
5 6
3
Fig. 2: Sectional drawing of the pump
4 Description of the Pump (Set)
Rio-Therm N 13 of 30

1 Discharge nozzle 2 Plain bearing
3 Motor 4 Impeller
5 Suction nozzle 6 Motor shaft
The pump is designed with a radial fluid inlet and a radial outlet arranged on the
same axis. The impeller is rigidly connected to the motor shaft.
The motor housing is equipped with a terminal box. Mechanical sealing is not
required as the rotor is completely separate from the stator winding. The rotor is
lubricated and cooled by the fluid pumped. The motor housing is made of
aluminium. Most of the internal parts are made of stainless steel. The advanced
lubricating system, high-quality carbon bearings and precision-balanced impeller
ensure smooth running and a long service life.
The fluid enters the pump via the suction nozzle (5) and is accelerated outward in a
cylindrical flow by the rotating impeller (4), which is driven by the motor shaft (6). In
the flow passage of the pump casing the kinetic energy of the fluid is converted into
pressure energy. The fluid is pumped to the discharge nozzle (1), where it leaves the
pump. The shaft runs in plain bearings (2), which are supported by the motor (3).
4.6 Noise characteristics
Table 5: Noise characteristics [dB A]
Sound pressure level
All 45 max.
4.7 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪Pump set
▪Installation/operating manual
▪Seal elements
4.8 Dimensions and weight
For dimensions and weights please refer to the data sheet of the pump/pump set.
Design
Function
4 Description of the Pump (Set)
14 of 30 Rio-Therm N

5 Installation at Site
5.1 Safety regulations
DANGER
Installation in potentially explosive atmospheres
Explosion hazard!
▷Never install the pump in potentially explosive atmospheres.
▷Observe the information given in the data sheet and on the name plates of the
pump system.
5.2 Checks to be carried out prior to installation
Before installing the pump make sure that the following requirements are met:
▪Check the data on the name plate of the pump to make sure it can be operated
on the available mains.
▪The fluid to be handled matches the description of suitable fluids.
▪The above safety instructions have been complied with.
5.3 Installing the pump set
Install the pump set in an easily accessible place.
CAUTION
Ingress of fluid into the motor
Damage to the pump set!
▷Install the pump set with the pump shaft in horizontal position. Connect the
piping without transmitting any stresses and strains.
▷Never install the pump set with the motor terminal box pointing downwards.
NOTE
It is recommended to install shut-off valves upstream and downstream of the pump.
Make sure that no leaking water can drip into the pump motor or terminal box.
The terminal box can be positioned correctly by turning the motor head.
Table 6: Permissible installation positions
Pump sizes
All
To do so, undo the bolts/screws and turn the motor head until it has reached its
correct position.
Tighten the bolts/screws again.
DANGER
Leakage at the pump
Leakage of hot fluids!
▷Insert the O-ring in the correct position.
An arrow on the pump casing indicates the direction of flow.
5 Installation at Site
Rio-Therm N 15 of 30

NOTE
The direction of flow of a vertically installed pump should be upwards.
CAUTION
Air entering the pump
Damage to vertically installed pump sets whose direction of flow is downwards!
▷Fit a vent valve at the highest point of the suction line.
NOTE
To prevent any impurities from collecting in the pump do not install the pump at
the lowest point of the system.
1. Place the pump in the specified installation position.
2. Accurately insert the seal element.
3. Establish a screwed connection between pump and piping.
4. Tighten the screwed connection hand tight with an assembly tool (e.g. pipe
wrench).
5. Accurately insert the seal element in the opposite part of the screwed
connection.
6. Tighten the screwed connection hand tight with an assembly tool (e.g. pipe
wrench).
1. Place the pump in the specified installation position.
2. Accurately insert the seal element.
3. Connect the pump flange to the pipe flange by means of screws.
4. Tighten the screws hand tight with an assembly tool (e.g. wrench).
5. Accurately insert the seal element on the opposite side.
6. Connect the pump flange to the pipe flange by means of screws. Tighten the
screws hand tight.
5.4 Connecting the piping
DANGER
Excessive loads acting on the pump nozzles
Danger to life from leakage of hot fluids!
▷Do not use the pump as an anchorage point for the piping.
▷Anchor the pipelines in close proximity to the pump and connect them without
transmitting any stresses or strains.
▷Take appropriate measures to compensate thermal expansion of the piping.
NOTE
It is recommended to install check and shut-off elements in the system, depending
on the type of plant and pump. However, such elements must not obstruct proper
drainage or hinder disassembly of the pump.
✓The suction lift line has been laid with a rising slope, the suction head line with a
downward slope towards the pump.
✓The nominal diameters of the pipelines are equal to or greater than the nominal
diameters of the pump nozzles.
✓The pipelines have been anchored in close proximity to the pump and connected
without transmitting any stresses or strains.
Screw-ended pumps
Flanged pumps
5 Installation at Site
16 of 30 Rio-Therm N

1. Thoroughly clean, flush and blow through all vessels, pipelines and connections
(especially of new installations).
CAUTION
Welding beads, scale and other impurities in the piping
Damage to the pump!
▷Free the piping from any impurities.
5.5 Casing/insulation
WARNING
The pump takes on same temperature as the fluid pumped
Risk of burns!
▷Insulate the volute casing.
▷Fit protective equipment.
5.6 Electrical connection
DANGER
Work on the pump set by unqualified personnel
Danger of death from electric shock!
▷Always have the electrical connections installed by a trained electrician.
▷Observe regulations IEC 30364 (DIN VDE 0100) and, for explosion-proof pump
sets, IEC 60079 (DIN VDE 0165).
DANGER
Work performed on an energised terminal box
Danger of death from electric shock!
▷Switch off the supply voltage at least 5 minutes prior to commencing work and
ensure that it cannot be switched on again unintentionally.
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷Observe the technical specifications of the local energy supply companies.
1. Check the available mains voltage against the data on the name plate.
2. Select an appropriate start-up method.
The pumps must be connected in accordance with the applicable regulations. The
electrical data is printed on the name plate of the pump. A wiring diagram is
provided under the cover of the terminal box. PG cable glands are fitted at the
terminal box for connecting the cables.
Pumps of sizes 25-30 S to 25-60 T do not require any external motor protection.
Pumps of sizes 25-60 T and larger require an external overload protection.
NOTE
If a conventional motor protection switch is used, the overload setting must be
adjusted to the current indicated on the name plate of the pump. When changing
the speed level, this setting must be adjusted accordingly.
For three-phase pumps ("Rio-Therm N xx-xx T" models) the direction of rotation of
the pump should be checked after the electrical connection. To do so, use a suitable
screwdriver to remove the vent plug in the centre of the name plate. This will open
5 Installation at Site
Rio-Therm N 17 of 30

up a view of the motor shaft. If the direction of rotation is incorrect, interchange any
two phases. Prior to commissioning, the vent plug must be re-inserted and tightened
with a suitable screwdriver.
If the piping is not filled with water, the pump should only be operated for a short
period of time to prevent any damage to the pump bearings (lubricated by the
product pumped).
5 Installation at Site
18 of 30 Rio-Therm N

6 Commissioning/Start-up/Shutdown
6.1 Commissioning/start-up
6.1.1 Prerequisites for commissioning/start-up
Before commissioning/starting up the pump set, make sure that the following
conditions are met:
▪The pump set has been properly connected to the power supply and is equipped
with all protection devices.
▪The pump has been primed with the fluid to be pumped.
▪After prolonged standstill of the pump (set) the pump rotor has been rotated by
means of a screwdriver to make sure the motor is not locked.
6.1.2 Priming and venting the pump
CAUTION
Increased wear due to dry running
Damage to the pump set!
▷Never operate the pump set without liquid fill.
▷Never close the shut-off element in the suction line and/or supply line during
pump operation.
1. Vent the pump and suction line and prime both with the fluid to be pumped.
2. Fully open the shut-off element in the suction line.
3. During operation (at top speed) loosen the screw plug until some air escapes.
4. Close the screw plug again.
5. Repeat this procedure several times until all air has escaped.
DANGER
Hot fluid spraying out of the pump
Risk of burns!
▷Wear protective clothing.
6.1.3 Start-up
DANGER
Non-compliance with the permissible pressure and temperature limits if the pump is
operated with the suction and discharge lines closed.
Leakage of hot fluids!
▷Never operate the pump with the shut-off elements in the suction line and/or
discharge line closed.
▷Only start up the pump set against a slightly or completely open discharge-side
shut-off element.
DANGER
Excessive temperatures due to dry running
Damage to the pump set!
▷Never operate the pump set without liquid fill.
▷Prime the pump as per operating instructions.
▷Always operate the pump within the permissible operating range.
6 Commissioning/Start-up/Shutdown
Rio-Therm N 19 of 30

CAUTION
Abnormal noises, vibrations, temperatures or leakage
Damage to the pump!
▷Switch off the pump (set) immediately.
▷Eliminate the causes before returning the pump set to service.
✓The system piping has been cleaned.
✓Pump, suction line and inlet tank, if any, have been vented and primed with the
fluid to be pumped.
✓The lines for priming and venting have been closed.
1. Fully open the shut-off element in the suction head/suction lift line.
2. Close or slightly open the shut-off element in the discharge line.
3. Start up the motor.
6 Commissioning/Start-up/Shutdown
20 of 30 Rio-Therm N