KSB IE3 Motor 0,55 - 132 KW
KSB IE3 Motor 0,55 - 132 KW
KSB IE3 Motor 0,55 - 132 KW
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual KSB IE3 Motor
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.
Contents
1 General ..................................................................................................6
1.1 Principles ........................................................................................................... 6
1.2 Target group ..................................................................................................... 6
1.3 Other applicable documents ............................................................................ 6
1.4 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 this manual ......... 8
2.6 Safety awareness .............................................................................................. 8
2.7 Safety information for the user/operator ....................................................... 8
2.8 Safety information for maintenance, inspection and installation work ....... 8
2.9 Unauthorised modes of operation .................................................................. 9
2.10 Electromagnetic compatibility ......................................................................... 9
4 Description ..........................................................................................12
4.1 General description ........................................................................................ 12
4.2 Designation ..................................................................................................... 12
4.3 Name plate ...................................................................................................... 12
4.4 Types of construction ..................................................................................... 12
4.5 Mounting arrangements ................................................................................ 13
4.6 Noise characteristics ....................................................................................... 13
4.7 Balancing ......................................................................................................... 13
6 Commissioning/Start-up/Shutdown ...................................................22
6.1 Checking earth conductor connection .......................................................... 22
6.2 Checking insulation resistance ....................................................................... 22
7 Servicing/Maintenance .......................................................................25
7.1 Safety regulations ........................................................................................... 25
7.2 Maintenance/inspection ................................................................................. 25
7.3 Preparing disassembly .................................................................................... 29
7.4 Dismantling the motor ................................................................................... 30
7.5 Assembling the motor .................................................................................... 31
8 Trouble-shooting ................................................................................33
Index ....................................................................................................36
Glossary
1 General
1.1 Principles
This manual is supplied as an integral part of the type series 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.
1.4 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. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product
2 Safety
All the information contained in this section refers to hazardous situations.
! DANGER
2.1 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.
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 that the product is operated safely as well as to
prevent injury and damage to property.
The safety information in all sections of this manual must be complied with.
The operating manual must be read and fully understood by the specialist personnel/
operators responsible 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 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 manual.
This electric motor has been designed and constructed in accordance with the
requirements of Directive 2006/95/EC ("Low-voltage Directive"). It is intended for use
in industrial plants.
If the motor is used in countries outside the European Community, adhere to the
regulations applicable to the relevant country. Also observe any local and industry-
specific regulations governing erection and safety.
3 Transport/Temporary Storage/Disposal
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 motors weighing more than 25 kg, suspend them from the lifting tackle
as shown.
Fig. 1: Transporting the motor by two lifting lugs attached to sides of motor housing
3.3 Storage/preservation
Exposed metal parts 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 Replace closed rolling element bearings after 48 months of storage.
bearings
Outdoor storage
CAUTION
Damage during storage by 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 product sinking into the ground.
Implement appropriate measures to accommodate extreme climatic conditions, e.g.
salty, dusty or moist atmospheres.
Indoor storage
Storage rooms provide protection against extreme weather conditions and must be
dry, dust-free, frost-free, jolt-free, vibration-free and well-ventilated.
3.4 Disposal/recycling
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
4.2 Designation
Example: 2-45-225M
Table 4: Designation key
Code Description
2 Number of poles
45 Rated power, e. g.: 45 = 45.0 kW
225M Shaft centreline height [mm] = IEC motor size
1) Designations to EN 50347
2) Detachable feet
IM B5
IM B35
IM V1
IM V15
4.7 Balancing
The rotor is balanced dynamically in accordance with the ISO 1940-1 standard. The
rotor is balanced to balance quality grade G 2.5.
The motor complies with vibration class A to IEC 60034-14.
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.
5 Installation at Site
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 have set and must be completely horizontal and
even.
▷ 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.
Ventilation
WARNING
Improper installation
Drive overheated!
▷ Maintain the specified minimum distances to neighbouring assemblies.
▷ Never restrict the ventilation ducting to/from the drive.
▷ Prevent exhaust air from neighbouring assemblies from being drawn in directly.
NOTE
Maintain the vibration levels to ISO 10816-1 during operation.
NOTE
Lifting lugs that have been screwed in must either be tightened or removed after
installation.
DANGER
Hazardous voltage
Danger of death from electric shock!
▷ Have all work performed only by qualified specialist personnel and only when
the drive is at a standstill and secured against unintentional start-up. This also
applies to auxiliary circuits (e.g. standstill heater).
▷ The drive must not be electrically connected at any point in time when work is
performed on the open terminal box.
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷ Observe the technical specifications of the local energy supply companies.
NOTE
Always protect three-phase motors with a current-dependent overload protection
device with additional phase failure protection.
Select the motor connection cables in accordance with IEC 60364, taking into account
the current load of the cable at the given ambient temperature and the requisite
heat dissipation to IEC / EN 60204-1 as a result of cable routing.
U1 V1 W1
PE
W2 U2 V2
Star configuration
U1 V1 W1
PE
W2 U2 V2
Delta configuration
The terminal boards of motors with shaft centreline heights of 80 mm and
90 mm may differ from the schematic shown. In this case, star or delta
configuration is selected by setting jumpers.
4. Connect the earth conductor (PE).
WARNING
Parts flying off
Personal injury and damage to property!
▷ When checking the direction of rotation with the coupling removed, secure the
respective keys to protect them from being thrown off.
The motors are configured for clockwise and anti-clockwise rotation as standard.
Select the drive's direction of rotation to match the direction of rotation required by
the driven centrifugal pump.
Clockwise rotation Connecting the power cables in the phase sequence U1, V1, W1 to L1, L2, L3 of the
power supply network results in clockwise rotation (looking at the drive shaft end).
Anti-clockwise rotation Interchanging two connections, e.g. V1, U1, W1 to L1, L2, L3 results in anti-clockwise
rotation.
6 Commissioning/Start-up/Shutdown
DANGER
Hazardous voltage
Danger of death from electric shock!
▷ Have all work performed only by qualified specialist personnel and only when
the drive is at a standstill and secured against unintentional start-up. This also
applies to auxiliary circuits (e.g. standstill heater).
▷ The drive must not be electrically connected at any point in time when work is
performed on the open terminal box.
Before commissioning and whenever returning the product to service, perform the
electrical safety checks stipulated by EN 60204-1.
NOTE
If windings have been dried after having been repaired or cleaned, bear in mind
that the insulation resistance of warm windings is lower. The insulation resistance
can only be correctly evaluated after converting to the reference temperature of
25 °C.
6.4 Start-up
WARNING
High sound pressure level > 70 dB(A) can occur during operation
Injury to the ear and hearing impairment. Hardness of hearing, tinnitus and hearing
loss can be caused!
▷ Wear ear protection!
▷ Observe the applicable local occupational health and safety regulations.
The motor must only be started from a standstill.
1. Re-check the direction of rotation immediately after starting. (⇨ Section 5.3.2
Page 19)
CAUTION
Operation outside the permissible ambient temperature
Damage to the pump (set)!
▷ Observe the specified limits for permissible ambient temperatures.
Observe the following parameters and values during operation:
Table 14: Permissible ambient temperatures
Permissible ambient temperature Value
Maximum 40 °C
Minimum - 20 °C
6.5.4 Altitude
▪ ≤ 1000 m above MSL: without power derating
▪ > 1000 m above MSL: installation at altitudes of up to 4000 m above MSL is
possible with power derated by 3.8 % per 500 m.
6.6 Shutdown
The motor is only regarded as being shut down if it has been de-energised and the
shaft has stopped rotating.
WARNING
High sound pressure level > 70 dB(A) can occur during operation
Injury to the ear and hearing impairment. Hardness of hearing, tinnitus and hearing
loss can be caused!
▷ Wear ear protection!
▷ Observe the applicable local occupational health and safety regulations.
Also follow the instructions for maintenance/inspection before you return a drive to
service after storage.
7 Servicing/Maintenance
DANGER
Improperly serviced/maintained motor
Damage to the motor!
▷ Service the motor regularly.
▷ Prepare and adhere to a maintenance schedule.
The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly familiar
with the manual.
WARNING
Unintentional starting of the motor
Risk of injury by moving components and shock currents!
▷ Always make sure the electrical connections are de-energised before carrying
out work on the motor. In addition to the main circuits, ensure that
supplementary and auxiliary circuits are also de-energised.
▷ Ensure that the motor cannot be switched on unintentionally.
WARNING
Insufficient stability
Risk of crushing hands and feet!
▷ Secure the motor against overturning or tipping over during assembly/
dismantling.
A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the motor with a minimum of maintenance
expenditure and work.
NOTE
All maintenance, service and installation work can be carried out by KSB Service or
authorised workshops. Find your contact in the attached "Addresses" booklet or on
the Internet at "www.ksb.com/contact".
Never use force when dismantling and reassembling the motor.
Five safety rules in accordance with EN 50110-1 ensuring work is only performed
after the equipment has been disconnected from the power supply (de-energised)
Observe the following safety rules:
1. Disconnect the equipment from the power supply.
2. Secure the equipment against unintentional start-up.
3. Verify that the equipment is de-energised.
4. Earth and short-circuit.
5. Cover or cordon off adjacent live parts.
7.2 Maintenance/inspection
KSB recommends the following regular maintenance schedule:
DANGER
Rotating or live parts
Death, serious injury or damage to property!
▷ If covers have to be removed, de-energise the motor beforehand.
▷ Avoid touching live or rotating parts.
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.
WARNING
Condensing air humidity inside the motor if the motor and/or ambient
temperatures frequently change
Risk of corrosion by condensation!
▷ Always observe the information provided on ambient conditions.
While the system is in operation, observe and check the following:
▪ Deviations from normal operation such as increased power consumption,
temperatures or vibrations, unusual noises or odours, tripping of monitoring
devices, etc.
▪ If rough running or abnormal noises are detected, switch off the motor and find
the cause of the problem as the motor coasts down.
– If mechanical operation improves immediately after the motor is switched
off, the causes are magnetic or electrical phenomena.
– If mechanical operation does not improve after the motor is switched off, it
can be assumed that the cause is mechanical, e.g. unbalance of the electric
motor or the driven machine, poor alignment between the motor and the
driven machine or operation of the motor at system resonance (system =
motor + base frame + foundation, etc.)
7.2.2 Inspection
Initial inspection
Inspection interval After about 500 operating hours, or 6 months at the latest
Procedure Check the following during operation:
▪ The specified electrical characteristics are complied with.
▪ Permissible temperatures at the rolling element bearings are not exceeded.
▪ The smooth running characteristics and running noise of the drive have not
deteriorated.
Check the following when the drive is at a standstill:
▪ Depressions and cracks are visible in the foundation or not.
Immediately correct impermissible deviations that are detected during inspection
work.
NOTE
Further inspections/tests may be required in accordance with the additional
operating manuals or in accordance with the particular system-specific conditions.
General inspection
Inspection interval Once annually
Procedure Check the following during operation:
▪ The specified electrical characteristics are complied with.
▪ Permissible temperatures at the rolling element bearings are not exceeded.
Check the following when the drive is at a standstill:
▪ Depressions and cracks are visible in the foundation or not.
▪ The drive alignment is within the specified tolerance.
▪ All the fastening bolts/screws for the mechanical and electrical connections have
been securely tightened.
▪ The insulation resistances of the windings are sufficient.
▪ Cables and insulating parts are in good condition and there is no evidence of
discolouring.
Immediately correct impermissible deviations that are detected during inspection
work.
CAUTION
Damage to paintwork
Risk of corrosion!
▷ Immediately correct damage to paintwork to ensure sufficient corrosion
protection.
It is recommended that you contact your nearest KSB service centre for important
information about proper layering as well as paint repair instructions.
Extended storage periods decrease the service life of the lubricating grease. This in
turn reduces the service life of the bearings.
▪ The rolling element bearings should be completely replaced after a storage
period of more than 4 years.
▪ After a storage period of more than 12 months, it is advisable to change the
bearing grease in rolling element bearings that are not greased for life.
NOTE
The bearing service life is reduced e.g. for vertical installations, high vibration and
shock loads, frequent reversing duty, higher ambient temperature and higher
rotating speeds.
7.2.2.2.1.2 Intervals
The rolling element bearings of the motor are grease-packed and maintenance-free.
Motors with axially reinforced bearings are excluded. These drive-end rolling element
bearings must be re-lubricated as part of the maintenance routine.
NOTE
On some pump designs the rolling element bearings are lubricated for life. These
pumps are not provided with a lubricating nipple on the bearing bracket.
NOTE
If re-lubrication intervals are short, we recommend that the grease be completely
replaced once a year.
Otherwise, the grease fill must be replaced completely every two years. To do so,
remove the rolling element bearings, clean and pack with new grease.
Motors with lubricating nipple must be re-lubricated every 2000 hours.
7.2.2.2.1.3 Re-lubrication
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing seals
Fire hazard!
Damage to the motor!
▷ Regularly check the condition of the lubricant.
▷ Regularly check the rolling element bearings for running noises.
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.
Grease quality Optimum grease properties for rolling element bearings
▪ High melting point lithium soap base grease
▪ Free of resin and acid
▪ Rust-preventive characteristics
Grease quantity ▪ 15 g per rolling element bearing
CAUTION
Contaminated lubricating nipples
Contamination of the lubricating grease!
▷ Clean the grease lubricating nipples before re-lubricating them.
1. Clean the lubricating nipples, if contaminated.
2. Position the grease gun on the lubricating nipple.
3. Press in the grease.
CAUTION
Incomplete re-lubrication
Bearing damage!
▷ Always re-lubricate the bearings while the motor is running.
DANGER
Work on the motor/drive by unqualified personnel
Danger of death from electric shock!
▷ Have motors/drives modified and dismantled by authorised personnel only.
▷ Observe regulations IEC 60364 and, for explosion-proof models, IEC 60079.
✓ General safety rules are adhered to. (⇨ Section 7.1 Page 25)
1. Disconnect all electrical connections and remove all cables.
2. Drain, collect and properly dispose of all liquids.
3. Remove all motor fastening elements.
4. Transport the motor to a clean dismantling area. (⇨ Section 3.2 Page 10)
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.
WARNING
Improper lifting/moving of heavy assemblies or components
Personal injury and damage to property!
▷ Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.
Always observe the safety instructions and information.
For dismantling and reassembly, refer to the general assembly drawing.
In the event of damage, you can always contact our service department.
Prior to dismantling, label the respective assignment of fastening elements as well as
the arrangement of internal connections required for reassembling.
Switching connections ▪ Replace any corroded bolts.
▪ Never damage the insulation of live parts.
▪ Document position of any rating and additional plates to be removed.
▪ Avoid damaging the centring spigots.
Protect rolling element bearings against the ingress of contamination and moisture.
WARNING
Improper lifting/moving of heavy assemblies or components
Personal injury and damage to property!
▷ Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.
CAUTION
Incorrect assembly
Damage to windings!
▷ When installing the bearing cover, take care not to damage the windings
protruding out of the motor housing.
General ▪ The motor should be assembled on a marking-out plate if possible. This will
ensure that the foot areas of the motor are properly aligned.
▪ Always reassemble the motor in accordance with the corresponding exploded
view.
▪ Clean all dismantled components and check them for signs of wear.
▪ Damaged or worn components must be replaced by new ones.
▪ Always use new tolerance rings.
▪ Make sure that sealing surfaces are clean and that O-rings or gaskets are properly
fitted.
Tightening torques For reassembly, tighten all screws and bolts as specified in this manual.
CAUTION
Incorrect assembly
Damage to the shaft seal ring!
▷ Ensure correct centring when installing the rotor in the motor housing.
CAUTION
Incorrect assembly
Damage to the shaft seal ring!
▷ Ensure correct centring when installing the rotor in the motor housing.
1. Apply liquid sealant to the centring spigot of the bearing cover and the motor
housing.
2. Stand the motor housing upright (drive end up) and guide the bearing cover
and rotor into the motor housing using suitable lifting equipment.
3. Tighten the bolts on the drive-end bearing cover .
4. Insert non-drive-end key.
8 Trouble-shooting
WARNING
Improper work to remedy faults
Risk of injury!
▷ For any work to remedy faults observe the relevant information in this manual
or in the relevant accessory manufacturer's product literature.
If problems occur that are not described in the following table, consultation with
KSB’s customer service is required.
A Drive does not start.
B Rumbling noise during start-up
C Rubbing noises
D Radial vibrations
E Axial vibrations
F Wrong direction of rotation
Table 17: Trouble-shooting
A B C D E F Possible cause Remedy
✘ - - - - - No voltage Check mains fuses, mains voltage and
operating status of the frequency inverter.
✘ - - - - - Mains cables connected incorrectly/ Check wiring.
Fault in supply line
✘ ✘ - - - - Driven machine is blocked Manually clear the blockage from the driven
machine, observing the operating manual of
the driven machine!
- - ✘ - - - Bearings defective Check bearings and replace if necessary.
- - ✘ - - - Rubbing contact between rotor and stator Check bearings and replace if necessary.
Check rotor and replace if necessary.
- - - ✘ - - Rotor unbalance Check key convention applicable to the shaft
and output element; remove rotor and re-
balance if required.
- - - ✘ - - Improper installation Check the foundation, the place of installation
and the mounting surface.
- - - - ✘ - Incorrect connection of pump/load Check correct alignment between motor and
driven machine, check coupling.
- - - - - ✘ Wrong direction of rotation setting Change the direction of rotation by altering
the parameters of the frequency inverter or
interchanging two phase conductors.
9 Related Documents
10 EC Declaration of Conformity
KSB-IE3-Motor
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Motor: Low-voltage Directive 2006/95/EC
– Motor: Directive 2009/125/EC ("Ecodesign Directive"), Regulation No. 640/2009
The manufacturer also declares that
▪ the following harmonised international standards have been applied:
– EN 60034
The product must not be put into service for its intended use until the final product has been declared in
conformity with the Machinery Directive.
The EC Declaration of Conformity was issued in/on:
Frankenthal, 10 April 2015
Joachim Schullerer
Head of Product Development Pump Systems and Drives
KSB Aktiengesellschaft
Johann-Klein-Straße 9
67227 Frankenthal
Index
C O
Commissioning/start-up 22 Other applicable documents 6
D P
Designation 12 Personnel 8
Dismantling 30 Personnel qualification 8
Disposal 11 Product code 34
E S
Event of damage 6 Safety 7
Safety awareness 8
Servicing/Maintenance 25
F Specialist personnel 8
Fan 30, 32
Faults
Causes and remedies 33 T
Tightening torques 20
Training 8
I Transport 10
Installation at site 15
Intended use 7
W
Warranty claims 6
M
Maintenance work 26
N
Name plate 6
KSB Aktiengesellschaft
67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0 • Fax +49 6233 86-3401
www.ksb.com