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EtaLine Pro

1168.87/01-EN

10.2 Exploded view and list of components

Fig. 38:

Exploded view

Table 36:

List of components

Part No.

Description

Part No.

Description

102

Volute casing

920

Hexagon nut

161

Casing cover

930

Safety device

160

Cover

940

Key

210

Shaft

960

Operating element

230

Impeller

59-2

Fan impeller

411.01/.02/.03

Joint ring

68-3

Cover plate

412

O-ring

79-10

Frequency inverter

433

Mechanical seal

81-43

Connection disc

741

Vent valve

801

KSB motor

Auxiliary
connections

900.01/.02/.03/.04/.
05

Bolt/screw

Fluid drain

903.01/02

Screw plug

Fluid priming and venting

914

Hexagon socket head cap screw

Fluid venting (vertical installation)

Summary of Contents for EtaLine Pro

Page 1: ...Fully Integrated In line Water Pump EtaLine Pro Installation Operating Manual...

Page 2: ...ents 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 manufact...

Page 3: ...Description 16 4 1 General description 16 4 2 Product information 16 4 2 1 Product information as per Ecodesign for Energy Related Products Regulations 2010 16 4 2 2 Product information as per Regula...

Page 4: ...nstant speed open loop control 48 7 3 Functions 49 7 3 1 Protective functions 49 7 3 2 Saving data 49 7 3 3 Fault messages 50 7 3 4 External analog 0 10 V DC signal 51 7 3 5 Bluetooth 52 7 3 6 Externa...

Page 5: ...ock 66 8 7 1 Ordering spare parts 66 8 7 2 Recommended spare parts stock for 2 years operation to DIN 24296 67 9 Trouble shooting 68 10 Related Documents 70 10 1 Installation types 70 10 2 Exploded vi...

Page 6: ...ch the kinetic energy is converted into pressure energy IE5 Efficiency class to IEC TS 60034 30 2 2016 Ultra Premium Efficiency IE International Efficiency In line design A pump whose suction and disc...

Page 7: ...aim under warranty 1 2 Target group This operating manual is aimed at the target group of trained and qualified specialist technical personnel Section 2 3 Page 10 1 3 Other applicable documents Table...

Page 8: ...ous 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 volt...

Page 9: ...n arrow Markings for connections Name plate The operator is responsible for ensuring compliance with all local regulations not taken into account 2 2 Intended use The pump set must only be operated in...

Page 10: ...ny 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 Failu...

Page 11: ...nected from the power supply de energised The pump set 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 o...

Page 12: ...pplicable local occupational safety regulations and accident prevention regulations Use tested and approved lifting accessories WARNING Insufficient stability Risk of crushing hands and feet During as...

Page 13: ...mp set and accessories with waterproof material and protect against condensation CAUTION Wet contaminated or damaged openings and connections Leakage or damage to the pump Clean and cover pump opening...

Page 14: ...coming into contact with atmospheric humidity or which might ignite when coming into contact with oxygen the pump set must be neutralised and anhydrous inert gas must be blown through the pump for dr...

Page 15: ...and any fluid residues 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 a...

Page 16: ...of a pump with a trimmed impeller is usually lower than that of a pump with the full impeller diameter 1 Trimming of the impeller will adapt the pump to a fixed duty point leading to reduced energy co...

Page 17: ...Optional component O None 4 4 Name plate Made in Germany KSB SE Co KGaA Johann Klein Str 67227 Frankenthal Germany EtaLine Pro ESCCI 065 065 090 3 380 480 V AC 10 50 60 Hz Qmax 42 m hHmax 12m TFluid_m...

Page 18: ...or Variable speed version Pump casing Radially split volute casing In line design Drive Surface cooled synchronous motor TEFC designed for operation in a compact pump set Efficiency class IE5 to IEC 6...

Page 19: ...essure energy The fluid is pumped to the discharge nozzle 2 where it leaves the pump The clearance gap 1 prevents any fluid from flowing back from the casing into the suction nozzle At the rear side o...

Page 20: ...pe of supply Depending on the model the following items are included in the scope of supply Pump set Sealing elements Installation operating manual 4 9 Dimensions and weight For dimensions and weights...

Page 21: ...of outdoor installation fit a protective roof to protect the pump set from the weather e g sun rain snow 5 2 Checks to be carried out prior to installation Foundation Check the structural requirement...

Page 22: ...ent until it has reached the required position Compare it against the permissible installation positions Adjust the position if required 3 Tighten two hexagon socket head cap screws with a suitable to...

Page 23: ...spirit level on the discharge nozzle to align the pump set 5 4 1 Installation types Horizontal installation Fig 7 Horizontal installation of pump set direction of flow from bottom to top Fig 8 Horizon...

Page 24: ...n of rolling element bearings pitting effect Never earth the electric welding equipment on the pump or baseplate Prevent current flowing through the rolling element bearings NOTE Installing check and...

Page 25: ...that the inside of the pump is free from any foreign objects Remove any foreign objects 4 If required install a filter in the piping see figure Filter in the piping 1 2 Fig 11 Filter in the piping 1 D...

Page 26: ...N N Nm Nm Nm 040 040 090 40 400 450 350 696 450 320 370 050 050 090 50 530 580 470 916 500 350 400 065 065 090 65 650 740 600 1153 530 390 420 5 5 3 Vacuum balance line NOTE Where fluid has to be pump...

Page 27: ...isk of injury from escaping fluid Risk of burns Malfunction of the pump Refer to the general arrangement drawing the piping layout and pump markings if any for the quantity dimensions and locations of...

Page 28: ...pecialist personnel Observe the technical specifications of the local and national energy supply companies DANGER Unintentional start up Danger to life from electric shock Disconnect the pump set from...

Page 29: ...on and installation EN 50310 and EN 50174 2 must be taken into account The most important points are summarised here Induction loops must be avoided when laying cables Maintain a sufficient distance o...

Page 30: ...es either do not trip at all or trip incorrectly as a result of possible DC components The residual current device should have a rated current of 150 mA If a long shielded cable is used for the mains...

Page 31: ...tor No fluid must pass through the pump until the electronic system of the pump set has been fitted on the motor 1 De energise the pump set and wait for the DC link capacitor to discharge for 1 minute...

Page 32: ...nsors single ended 30 mA Maximum output current 10 mA Short circuit current downward current characteristic Voltage input 10 V Measuring range 11 V Overload range 30 V Maximum input voltage 100 k Inpu...

Page 33: ...the power cable 1 Prepare the power cable for connection Fig 17 11 Fig 18 Connecting the power cable 2 Route the power cable for the power supply network through the cable gland and connect the cable...

Page 34: ...protection against electric shock in the case of indirect contact or direct contact with a limited direct contact area The PELV supply is not earthed in the electronic system of the pump set and must...

Page 35: ...on and potential equalisation connections have been made correctly All fastening bolts screws connecting elements and electrical connections have been tightened to the specified tightening torques Mea...

Page 36: ...nd or supply line during pump operation 1 Vent the pump and suction line and prime both with the fluid to be handled Connection 6D can be used for venting see drawing of auxiliary connections For vert...

Page 37: ...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 The pump suction line and inlet tank if any have been v...

Page 38: ...onditions and system regulations are considered and observed For prolonged shutdown periods 1 Close the shut off element in the suction line 2 Close any auxiliary lines If the fluid to be handled is f...

Page 39: ...n must be prevented Atmospheric pressure 70 KPa to 106 KPa 6 2 2 Maximum operating pressure CAUTION Permissible operating pressure exceeded Damage to connections and seals Never exceed the operating p...

Page 40: ...ient fluid is supplied for the functional check run of the pump 1 For prolonged shutdown periods start up the pump set regularly between once a month and once every three months for approximately five...

Page 41: ...all servicing maintenance operations before returning the pump set to service Section 8 Page 58 WARNING Failure to re install or re activate protective devices Risk of injury from moving parts or esca...

Page 42: ...te the selected settings 7 1 1 Control element Table 13 Configuration via control element Menu Time to open menu Details Operating modes setpoint Press and hold the control button for 3 seconds Sectio...

Page 43: ...play shows the electric power Head Symbol lights up Display shows the head Flow rate Symbol lights up Display shows the flow rate Speed Symbol lights up Display shows the actual speed Operating modes...

Page 44: ...trol operating mode p v The setting of the discharge head setpoint depends on the piping curve of the system and on the heat requirements As standard the pump set is pre set to Proportional pressure C...

Page 45: ...ate the higher the system s resistance This is corrected by the pump set automatically increasing the head setpoint When setting the setpoint ensure that the selected control curve is suitable for the...

Page 46: ...low rate setpoint Increase or decrease the flashing setpoint by changing the control element or Press the control button OK to confirm the setpoint The selected setpoint lights up It has been saved 7...

Page 47: ...teristic curve is unknown the noise at the thermostatic valves is reduced If the system characteristic curve is known e g hydraulic balancing Set the setpoint manually Select a control curve that is m...

Page 48: ...flashing head setpoint by changing the control element or Press the control button OK to confirm the setpoint The selected setpoint lights up It has been saved Step 4 Changing the flow rate setpoint I...

Page 49: ...hing setpoint by changing the control element or The speed setpoint is increased or decreased in 200 rpm increments Press the control button OK to confirm the setpoint The selected setpoint lights up...

Page 50: ...e When the alert is no longer active the display will revert to the set operating mode The settings of the pump set can then be changed again Table 21 Warnings Error code Cause Response 40 Pump unit r...

Page 51: ...Verify the available supply voltage against the data on the name plate Measure the supply voltage 63 Mains voltage phase failure Check the power supply and fuse elements 70 Test alert Disconnect the p...

Page 52: ...mode Table 24 Starting and stopping 0 10 V Step 1 Activating the functions 0 10 V Press and hold the control button OK for 6 seconds The functions setting mode is active Step 2 Selecting 0 10 V Set t...

Page 53: ...3 Activating deactivating Bluetooth 1 Connect the pump set to the smartphone while the Bluetooth symbol is flashing Once successfully connected the Bluetooth symbol lights up for as long as a connect...

Page 54: ...nputs Damage to the printed circuit board Always use a volt free contact for the digital inputs The pump set is started or stopped by an external signal at digital input 2 Table 27 Pump start and stop...

Page 55: ...es Step 2 Activating the setting mode Press the control button OK The current status of the control panel is shown Step 3 Locking unlocking the control panel Select the desired status by changing the...

Page 56: ...functions setting mode is active The symbol flashes Step 2 Selecting test alert Set the desired function at the control element or The symbol flashes Step 3 Activating the setting mode Press the contr...

Page 57: ...current firmware version are briefly shown on the display The display then changes automatically to its normal operating display 7 5 Resetting to factory settings Resetting to factory settings compris...

Page 58: ...al WARNING Unintentional starting of the pump set Risk of injury by moving components and shock currents Ensure that the pump set cannot be started unintentionally Always make sure the electrical conn...

Page 59: ...ers have to be removed de energise the motor beforehand Avoid touching live or rotating parts DANGER Incorrectly serviced shaft seal Fire hazard Hot fluids escaping Damage to the pump set Regularly se...

Page 60: ...noise and an increase in current input occurring during unchanged operating conditions indicate wear Monitor the correct functioning of any auxiliary connections Monitor the stand by pump To make sure...

Page 61: ...nitor contamination of filter with suitable means e g differential pressure gauge Clean filter at appropriate intervals 8 2 2 2 Checking the drive Carry out the following measures Check that the elect...

Page 62: ...1 General information Safety regulations DANGER Insufficient preparation of work on the pump set Risk of injury Properly shut down the pump set Section 6 1 7 Page 38 Close the shut off elements in th...

Page 63: ...te puller 8 4 2 Preparing the pump set 1 De energise the pump set and secure it against unintentional start up 2 Reduce pressure in the piping by opening a consumer installation 3 Disconnect and remov...

Page 64: ...ng ring seat 8 5 Reassembling the pump set 8 5 1 General information Safety regulations WARNING Improper lifting moving of heavy assemblies or components Personal injury and damage to property Use sui...

Page 65: ...faces have been cleaned 1 Clean the mating ring seat in casing cover 161 CAUTION Elastomers in contact with oil grease Shaft seal failure Use water as assembly lubricant Never use oil or grease as ass...

Page 66: ...2 4 Tighten hexagon socket head cap screws 914 with connection discs 81 43 on motor flange 801 Observe the tightening torques Section 8 6 Page 66 8 6 Tightening torques Table 33 Tightening torques for...

Page 67: ...le 34 Quantity of spare parts for recommended spare parts stock Part No Description Number of pumps including stand by pumps 2 3 4 5 6 and 7 8 and 9 10 and more 230 Impeller 1 1 1 2 2 2 20 412 O ring...

Page 68: ...gh pressure Re adjust to duty point Check system for impurities Fit larger impeller 6 Increase the speed frequency inverter Pump and or piping are not completely vented or primed Vent or prime Supply...

Page 69: ...Re tighten the bolts Worn shaft seal Fit new shaft seal Dismantle to find out Remedy Fit new shaft seal if required Vibrations during pump operation Correct the suction conditions Increase the pressu...

Page 70: ...g and or pull out unit by 180 so that the electronic system and the control element remain in their current position on top and are easy to read Fig 36 Horizontal installation for example under the ce...

Page 71: ...930 Safety device 160 Cover 940 Key 210 Shaft 960 Operating element 230 Impeller 59 2 Fan impeller 411 01 02 03 Joint ring 68 3 Cover plate 412 O ring 79 10 Frequency inverter 433 Mechanical seal 81...

Page 72: ...uipment Safety Regulations 2016 are observed Ecodesign for Energy Related Products Regulations 2010 Radio Equipment Regulations 2017 The safety objectives set out in the Electromagnetic Compatibility...

Page 73: ...otection 28 37 38 58 F Faults Causes and remedies 68 Filter 25 61 Fluid handled Density 40 Function 19 I Impeller type 18 Installation altitude 40 Installation at Site 21 Intended use 9 IT mains 30 K...

Page 74: ...taLine Pro 1168 87 01 EN Spare part Ordering spare parts 66 Spare parts stock 67 Start up 37 Storage 13 40 Symbols 43 T Technical data 30 Tightening torques 66 TN mains 30 Transport 12 W Warnings 8 Wa...

Page 75: ......

Page 76: ...KSB SE Co KGaA Johann Klein Stra e 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 1168 87 01 EN...

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