Monitoring System

KSB Leakage Sensor

Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual KSB Leakage Sensor

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 27/11/2020

 Contents

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 manual ......................................................... 7
2.5 Safety awareness .............................................................................................................................................. 8
2.6 Software changes ............................................................................................................................................. 8
2.7 Explosion protection ........................................................................................................................................ 8

3 Transport/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 plate...................................................................................................................................................... 11
4.3 Operating limits.............................................................................................................................................. 11
4.4 Fluids handled................................................................................................................................................. 12

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 sensor ....................................................................................................................................... 15
5.3.1 Installing a KSB Leakage Sensor that has been supplied but not fitted ........................................ 16
5.3.2 Installing a pre-mounted KSB Leakage Sensor ................................................................................ 16
5.4 Electrical connection ...................................................................................................................................... 17
5.4.1 Standard design ................................................................................................................................. 17
5.4.2 Variant for use in potentially explosive atmospheres ..................................................................... 18
5.4.3 Connecting the power supply and message signals ........................................................................ 18
5.4.4 DIP switch configuration ................................................................................................................... 19
5.5 Display functions during operation............................................................................................................... 20
5.5.1 Display ................................................................................................................................................ 20
5.5.2 Analog output.................................................................................................................................... 20

6 Commissioning / Start-up.................................................................................................................... 22
6.1 Carrying out a functional test........................................................................................................................ 22
6.2 Measures to be taken for shutdown ............................................................................................................. 23

7 Servicing/Maintenance ........................................................................................................................ 24
7.1 Safety regulations........................................................................................................................................... 24
7.2 Maintenance/inspection................................................................................................................................. 24
7.2.1 Cleaning the drop capillary ............................................................................................................... 24
7.3 Dismantling and reassembly .......................................................................................................................... 25
7.3.1 Dismantling and reassembling the KSB Leakage Sensor................................................................. 25
7.3.2 Rotating the upper half of the sensor housing ............................................................................... 25
7.3.3 Removing and re-mounting the inductive sensor ........................................................................... 25
7.3.4 Resetting the analysing unit ............................................................................................................. 26

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 Contents

8 Trouble-shooting.................................................................................................................................. 27
9 Related Documents .............................................................................................................................. 28
9.1 General assembly drawing with list of components .................................................................................... 28
9.2 Layout / connection diagram ......................................................................................................................... 29
9.2.1 Standard design ................................................................................................................................. 29
9.2.2 Variant for use in potentially explosive atmospheres ..................................................................... 30

10 EU Declaration of Conformity ............................................................................................................. 31

4 of 34 KSB Leakage Sensor

 1 General

1 General

1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The operating 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 facility to
maintain the right to claim under warranty.

1.2 Target group

This operating 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
Sub-supplier product literature Operating manuals and other product literature
describing accessories and integrated machinery
components
For accessories and/or integrated machinery components observe the product
literature of the relevant manufacturer.

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

1.5 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings
Symbol Description
1984.8/02-EN

! 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.

KSB Leakage Sensor 5 of 34

 1 General

Symbol Description
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.

1984.8/02-EN

6 of 34 KSB Leakage Sensor

 2 Safety

2 Safety
All the information contained in this section refers to hazardous situations.
! DANGER
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 operating 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.
▪ Comply with all the safety instructions given in the individual sections of this
operating manual.
▪ The operating manual must be read and understood by the responsible specialist
personnel/operators 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 and markings 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.

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 manual

▪ 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
1984.8/02-EN

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances

KSB Leakage Sensor 7 of 34

 2 Safety

2.5 Safety awareness

In addition to the safety information contained in this operating 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.
Making changes or additions to the software or parts of the software is prohibited.

2.7 Explosion protection

Always observe the information on explosion protection given in this section when
! DANGER operating the product in potentially explosive atmospheres.
The standard design of the KSB Leakage Sensor is not approved for use in potentially
explosive atmospheres.
The KSB Leakage Sensor may be used in potentially explosive atmospheres (II 2G T5-
T1) provided that an inductive sensor1) approved for use in potentially explosive
atmospheres and a switching amplifier1) are used.
In this case, it must be ensured that the switching amplifier and the display unit are
located outside of the potentially explosive atmosphere. (ð Section 9.2.2, Page 30)
This operating manual’s additional sections containing information on use in
potentially explosive atmospheres must be observed. In addition, observe the
operating manuals provided by the manufacturers of components supplied with this
product that are marked as explosion-proof.
The KSB Leakage Sensor does not have its own marking (mechanical part: housing
parts and balance scale without inductive sensor) as it is considered an integral part
of the pump.
KSB Leakage Sensors fitted on pumps of a make other than KSB must not be used in
potentially explosive atmospheres.

1984.8/02-EN

1 Only to be purchased from KSB

8 of 34 KSB Leakage Sensor

 3 Transport/Storage/Disposal

3 Transport/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

DANGER
Improper transport of the pump with fitted KSB Leakage Sensor
Risk of injury from falling parts!
▷ Never use the piping, leakage sensor or its fastening elements as attachment
points.

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 the 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 due to 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.

1984.8/02-EN

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.

KSB Leakage Sensor 9 of 34

 3 Transport/Storage/Disposal

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 operator 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.

1984.8/02-EN

10 of 34 KSB Leakage Sensor

 4 Description

4 Description

4.1 General description

The device is an intelligent leakage sensor for pumps with mechanical seal.
The following information is provided by the device:
▪ The statuses “ready for operation”, warning and alarm are shown as light signals
(LEDs) on the display unit.
▪ An acoustic signal is emitted when the device changes to alarm status.
▪ “Ready for operation”, warning and alarm statuses are output as an open
collector signal (24 V).
▪ The leakage rate is output as an analog signal (4 - 20 mA).

4.2 Name plate

KSB Leakage Sensor

SN V12 01 0001
KSB 5052360

2 1
Fig. 1: Name plate (example)
1 Serial number 2 KSB ident. number

4.3 Operating limits

DANGER
Use in potentially explosive atmospheres
Explosion hazard!
▷ The device in standard design must not be used in potentially explosive
atmospheres.
▷ For use in potentially explosive atmospheres refer to the information in the
corresponding section. (ð Section 2.7, Page 8)

CAUTION
Improper handling
Damage to property!
▷ Only use the device with solids-free fluids handled which are not liable to stick,
encrust, solidify, crystallise or polymerise.
1984.8/02-EN

KSB Leakage Sensor 11 of 34

 4 Description

CAUTION
Leakage temperature in the sensor housing exceeded
Damage to the measurement transmitter!
▷ If the permissible leakage temperature in the sensor housing is exceeded, the
inductive measurement transmitter 69-8 can become damaged and must be
replaced as a precautionary measure. (ð Section 7.3.3, Page 25)

▪ IP65 enclosure2)
▪ Permissible in-service ambient temperature: -10 °C to + 60 °C
▪ Permissible fluid temperature of the pump: -30 °C to +350 °C
▪ Permissible leakage temperature in the sensor housing -20 °C to +100 °C (the
fluid handled must not solidify inside the sensor.)
▪ Resistant to oil mist and alkaline industrial cleaning agents
▪ Free from paint-wetting impairment substances (silicone-free)

4.4 Fluids handled

DANGER
Leakage caused by chemically or mechanically affected material
Hot and/or toxic fluid may escape!
Hazard to persons and the environment!
▷ Only use the equipment for fluids which are neither chemically nor
mechanically aggressive to the equipment materials.
▷ Only use the equipment for the fluids indicated in the operating manual or the
data sheet, or consult KSB.

NOTE
The fluids handled must be clean when entering the leakage sensor. If there is any
risk of the drop capillary in the upper sensor housing becoming clogged (e.g. by
crystallisation), its free passage has to be checked regularly.

Table 5: Overview of fluids handled

Fluid handled Concentration Temperature3)
Minimum Maximum
[%] [°C] [°C]
Alum 3 0 80
Alkaline solution, bottle rinsing 10 0 80
Alcohol – 0 60
Ammonium bicarbonate 10 0 40
Ammonium sulphate 20 0 60
Beer mash, beer wort - 0 80
Calcium acetate 10 0 80
Calcium nitrate 10 0 30
1984.8/02-EN

Ferric sulphate (II) 5 0 80

Emulsion - 0 80
Degreasing solution 10 0 80

2 Applies to the analysing unit incl. inductive sensor, closed service interface (DIP) and external connections (EXT,
IN1, IN2)
3 Permissible temperatures at the inlet into the sensor housing. The fluid temperatures inside the pump have to
comply with the pump's temperature limits.

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 4 Description

Fluid handled Concentration Temperature3)

Minimum Maximum
[%] [°C] [°C]
Condenser water (sugar production) - 0 60
Antifreeze on ethylene glycol basis or propylene 30 -10 80
glycol basis with inhibitors, closed or open system
Beverages, alcoholic - 0 80
Beverages containing carbon dioxide - 0 40
Glycerine 90 10 80
Glycols, pure - 0 80
Potassium hydroxide 10 -10 80
Potassium nitrate 5 0 60
Potassium sulphate 3 0 20
Cooling lubricants - 20 60
Copper sulphate 5 10 30
Magnesium sulphate 10 10 20
Sodium carbonate 6 0 60
Sodium hydrogen carbonate 6 0 20
Sodium hydroxide 20 20 80
Sodium nitrate 10 20 90
Sodium sulphate 5 20 60
Oil, mineral-based thermal oil - -10 90
Oil, synthetic-based thermal oil - -10 90
Oil, hydraulic oil - 0 80
Oil, mineral oil - 0 80
Oil, cutting oil - 0 80
Oil, silicone oil - 0 80
Oil, vegetable oil - 0 90
Oil, lubricating oil - 20 80
Paraffin - 20 40
Kerosene - 20 60
Acid, butanoic acid - 10 30
Acid, citric acid 25 10 30
Acid, acetic acid 10 0 30
Acid, tannic acid 50 0 30
Acid, maleic acid 10 0 30
Acid, lactic acid 50 0 30
Acid, oxalic acid 10 0 40
Acid, tartaric acid 50 0 40
Trisodium phosphate 4 20 85
Water, desalinated - 0 90
Water, fire-fighting water - 0 40
Water, heating water - 0 90
1984.8/02-EN

Water, hot water - 0 90

Water, boiler feed water - 0 90
Water, condensate - 0 90
Water, seawater, brackish water - 0 25
Water, surface water - 0 40
Water, process water - 0 90
Water, rainwater - 0 40

KSB Leakage Sensor 13 of 34

 4 Description

Fluid handled Concentration Temperature3)

Minimum Maximum
[%] [°C] [°C]
Water, raw water - 0 40
Water, swimming pool water, bathing water - 0 50
Water, drinking water, tap water - 0 50

1984.8/02-EN

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 5 Installation at site

5 Installation at site

5.1 Safety regulations

WARNING
Sensor housing and piping take on the same temperature as the fluid handled
Risk of burns!
▷ Fit protective equipment/devices if necessary.

WARNING
Mechanical loads acting on the connections between pump (set) and sensor
Fluid could spurt out!
Burns, scalding!
▷ Never subject the connections and piping between the pump (set) and sensor
housing to mechanical loads.
▷ Verify proper installation of the sensor.

NOTE
Comply with all safety regulations of the corresponding pump (set).

5.2 Checks to be carried out prior to installation

NOTE
The KSB Leakage Sensor can be supplied pre-mounted on the pump (set) or
supplied but not fitted.
Observe the operating conditions of the pump (set).
Always contact the manufacturer if the device is to be used under ambient
conditions other than specified.

5.3 Installing the sensor

Observe the following:
▪ No forces must act on the sensor housing via the leakage lines.
▪ Do not insulate the piping to the leakage sensor. Ensure sufficient leakage
cooling.
▪ The inside diameter of the leakage drain line must be equal to or greater than
that of the leakage inlet line. Otherwise large quantities of leakage can cause
backflow in the sensor housing and a malfunction of the sensor.
▪ The inside diameter of the leakage lines must not be smaller than 6 mm.
▪ Never cover the vents in the upper housing half.
1984.8/02-EN

KSB Leakage Sensor 15 of 34

 5 Installation at site

5.3.1 Installing a KSB Leakage Sensor that has been supplied but not fitted
ü The operating manual for the pump (set) is available.
ü Assembly tools are available.
ü All safety instructions have been observed and carried out.
ü The pump (set) has been taken out of service and secured against unintentional
re-start.
ü The pump (set) has cooled down to room temperature.
1. Position sensor housing 105 on a level surface next to the pump, e.g. on the
baseplate of the pump.
ð Select a sensor housing position that keeps the line leading from the pump
to the sensor as short as possible.
ð Select a sensor housing position that keeps the distance to any hot pump
components and system components as large as possible.
ð If the leakage inlet 8E is positioned on the same side as the leakage drain 8B,
the upper half of the sensor housing can be taken off, rotated by 180° and
mounted in this position. (ð Section 7.3.2, Page 25)
2. Mark the position of the drilled holes at the two lower recesses of sensor
housing 105 on the pump baseplate.
3. Carefully place aside sensor housing 105. Drill holes (M5) into the pump
baseplate.
4. Position the sensor housing again. Fasten it to the pump baseplate with
hexagon socket head cap screws 914.2.
5. Verify the levelling of sensor housing 105 with measuring instrument 690
(bullseye level). If necessary, undo hexagon socket head cap screws 914.2 and
level the sensor housing with suitable shims. Re-tighten hexagon socket head
cap screws 914.2.
6. Use the supplied compression fittings and L-pipe to connect the leakage drain
hole of the pump (set) with leakage inlet 8E of the sensor housing.
ð If necessary, shorten the leakage line (pipe) accordingly.
7. Use the supplied compression fittings and L-pipe to connect the leakage drain
hole 8B of the sensor housing to the site-supplied leakage collector.
ð Fit the leakage line with a continuously falling slope towards the site-
supplied leakage collector.

5.3.2 Installing a pre-mounted KSB Leakage Sensor

ü The operating manual for the pump (set) is available.
ü Assembly tools are available.
ü All safety instructions have been observed and carried out.
ü The pump (set) has been taken out of service and secured against unintentional
re-start.
ü The pump (set) has cooled down to room temperature.
1. After the pump set has been installed, verify the levelling of sensor housing 105
with measuring instrument 690 (bullseye level). If necessary, loosen hexagon
socket head cap screws 914.2 and level the sensor housing with suitable shims.
Re-tighten hexagon socket head cap screws 914.2.
1984.8/02-EN

2. Use the supplied compression fittings and L-pipe to connect the leakage drain
hole 8B of the sensor housing to the site-supplied leakage collector.
ð Fit the leakage line with a continuously falling slope towards the site-
supplied leakage collector.

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 5 Installation at site

5.4 Electrical connection

CAUTION
Improper electrical connections
Damage to the device!
▷ Check the electrical connection.
▷ Observe the wiring diagrams.

5.4.1 Standard design

The KSB Leakage Sensor is supplied with two pre-configured cables of 10 m length
each.
▪ The power cable (connection EXT) is supplied with an open cable end.
▪ The sensor cable is supplied with two M12 connectors.
Optionally, a third cable is supplied for transmitting the leakage rate to an external
analysis device. (10 m length, 4-core, open cable end and M12 connector, KSB
material number 05059190)

Table 6: Pin assignment of the display unit

Illustration Power supply and signals to external device
M12 connector EXT
1: Power supply 24 V DC (+VB-IN)
2: Signal 1 red (open collector signal)
3: GND (-VB-IN)
4: Signal 2 yellow (open collector signal)
5: Signal 3 green (open collector signal)

M12 socket IN1

1: Power supply 24 V DC (+VB-OUT)
2: Signal sensor
3: GND(-VB-OUT)
4: (not connected)
5: (not connected)

M12 socket IN2

1: OUT 4 - 20 mA (+) leakage rate
2: (not connected)
3: OUT 4 - 20 mA (-) leakage rate
4: (not connected)
5: (not connected)

Colour coding of the power 1: BN = brown

cable cores 2: WH = white
3: BU = blue
4: BK = black
5: GY = grey
1984.8/02-EN

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 5 Installation at site

5.4.2 Variant for use in potentially explosive atmospheres

DANGER
Use in potentially explosive atmospheres
Explosion hazard!
▷ The device in standard design must not be used in potentially explosive
atmospheres.
▷ For use in potentially explosive atmospheres refer to the information in the
corresponding section. (ð Section 2.7, Page 8)

The KSB Leakage Sensor is supplied with three pre-configured cables.

▪ The power cable (connection EXT) is supplied with an open cable end, cable
length 10 m.
▪ The blue sensor cable from the switching amplifier (blue terminals) to the
inductive sensor in potentially explosive atmospheres is supplied with open cable
ends, cable length 25 m.
▪ The black sensor cable from the display unit (connection INT1) to the switching
amplifier (green terminals) is supplied with an open cable end, cable length
10 m.
Optionally, a third cable is supplied for transmitting the leakage rate to an external
analysis device. (10 m length, 4-core, open cable end and M12 connector, KSB
material number 05059190)

Pin assignment
Pin assignment of the display unit see (ð Table 6)

Table 7: Terminal configuration of the switching amplifier

Switching amplifier Connection cable
Terminal colour Terminal Core colour Cable
Blue 1 Brown Blue sensor cable, 2-pole connection to inductive
2 Blue sensor
Green 5 White Black sensor cable, 4-pole connection to display unit
6 Not connected
9 Brown
10 Blue
The DIP switches of the switching amplifier remain in their factory-set position
(switches 1, 2, 3 and 4 in position I).

5.4.3 Connecting the power supply and message signals

1
1984.8/02-EN

2 3 4
Fig. 2: Connection to the analysing unit
1 Analysing unit
2 M12 socket IN1

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 5 Installation at site

3 M12 socket IN2

4 M12 connector EXT
▪ The analysing unit is connected via a 5-pin M12 plug-type connection for the
power supply and message signals.
– Use the M12 connector EXT.
▪ The leakage sensor is connected via a 3-pin M12 plug-type connection.
– Use the M12 socket IN1.
▪ The optional analog output signal “leakage rate” can be connected via a 3-pin
M12 plug-type connection.
– Use the M12 socket IN2.
1. Precisely align the M12 plug-type connections and completely screw them into
the analysing unit.
2. Tighten the screwed connections hand-tight. Observe a tightening torque of
0.4 - 0.6 Nm.
3. Fasten the analysing unit to a level surface with an M5 screw, screw length =
8 mm. Observe a tightening torque ≤ 2 Nm.

5.4.4 DIP switch configuration

NOTE
Behind the service interface a leakage rate for analysis can be configured using the
four micro switches. After this configuration, securely close the access with the
screw plug. Enclosure IP65 only applies when the service interface is closed and the
sensors are connected correctly.

NOTE
The setting of the DIP switches must only be adjusted after the analysing unit has
been de-energised.

Table 8: Setting 8 fixed warning levels and alarm levels using the DIP switches:
ON_ECE Level Warning threshold Alarm threshold
1 2 3 4 g/h g/h
X 1 0,1 2

X 2 0,2 3

X 3 0,3 3

X 44) 0,3 5

X 5 0,3 8

X 6 0,5 8

X 7 1 12

X 8 2 30
1984.8/02-EN

X X X Mute Acoustic signal deactivated

4 Factory setting

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 5 Installation at site

5.5 Display functions during operation

5.5.1 Display
The display of the analysing unit indicates the status of the leakage sensor with light
signals (LEDs).

Table 9: Overview of light signals and open collector signals

Display Light signal (LED) Open collector signal Description
GREEN lit continuously Signal 3, green, Ready for operation, leakage
connected monitoring active

GREEN lit continuously Signal 3, green, Warning, set warning threshold

YELLOW lit continuously connected exceeded
Signal 2, yellow,
connected

RED lit continuously Signal 1, red, connected Alarm, set alarm threshold
Acoustic warning exceeded

BLUE lit for 1 second - Inductive sensor triggered

BLUE lit continuously Signal 2, yellow, flashing Warning, contact to inductive

YELLOW flashing frequency applied sensor interrupted
or balance scale jammed / in
incorrect position

5.5.2 Analog output

The analog output supplies a 4 - 20 mA signal, indicating the averaged leakage rate
depending on the sensitivity level set via the DIP switches (ð Section 5.4.4, Page 19)
as per the following table.

Table 10: Calculation factors

Level Leakage rate at Leakage rate at Calculation factors
4 mA 20 mA
[g/h] [g/h] A B
1 ≤ 0,02 ≥4 269730 13432,5
1984.8/02-EN

2 ≤ 0,04 ≥6 134820 6705

3 ≤ 0,06 ≥6 89820 4455
5)
4 ≤ 0,06 ≥ 10 89892 4473
5 ≤ 0,06 ≥ 16 89932,5 4483,125
6 ≤ 0,1 ≥ 16 53932,5 2683,125

5 Factory setting

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 5 Installation at site

Level Leakage rate at Leakage rate at Calculation factors

4 mA 20 mA
[g/h] [g/h] A B
7 ≤ 0,2 ≥ 24 26955 1338,75
8 ≤ 0,4 ≥ 60 13482 670,5
The following formula can be used to calculate the leakage rates based on the
analog signal.
Select the calculation factors from the Calculation factors table depending on the set
sensitivity level.

4320
L=
A - (BxI)
Fig. 3: Formula for calculating the leakage rate in [g/h]
A Calculation factor A [-]
B Calculation factor B [-]
I Analog signal [mA]
L Leakage rate [g/h]
1984.8/02-EN

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 6 Commissioning / Start-up

6 Commissioning / Start-up

DANGER
Carrying out work on a running pump
Risk of injury: Limbs can be pulled into or crushed by machinery!
▷ De-energise the motor.
▷ Take steps to ensure that the motor cannot be switched on again
unintentionally.

DANGER
Electric shock
Danger to life!
▷ De-energise the mains connections of all devices (e.g. pump, PumpDrive,
PumpMeter, leakage sensor).
▷ Ensure that the mains connections cannot be re-energised unintentionally.

WARNING
Fluid may escape!
Risk of burns!
▷ Make sure that any leakage that occurs is collected in the site-supplied leakage
collector.

CAUTION
Incorrect commissioning/start-up
Damage to property!
▷ Ensure that all local applicable regulations and directives – particularly the EC
Machinery Directive and EC Directive on Low-voltage Equipment – are fulfilled.
▷ Before commissioning/start-up, check all connected cables against the wiring
diagram.

6.1 Carrying out a functional test

Carry out a functional test for every commissioning/start-up.
(ð Section 9.2, Page 29)
ü The mechanical and electrical connection have been completed as described in
(ð Section 5.3, Page 15) and (ð Section 5.4, Page 17) .
ü At the analysing unit the green LED is lit. At inductive sensor 69-8 the orange
indicator lamp is lit.
1. Turn measuring instrument 690 (bullseye level) anti-clockwise to remove it from
the upper housing half 105.01 of the KSB Leakage Sensor.
ð The free tapped hole in the upper housing half 105.01 allows indicator 620
(balance scale) to tip. To do so, apply several shorts bursts of compressed air
through the tapped hole. Alternatively, a liquid can be dripped through the
1984.8/02-EN

tapped hole. This liquid has to be clean and compatible with the fluid
handled.
ð Every time the balance scale tips the orange indicator lamp is extinguished
briefly and the blue LED lights up.
ð The sensor input is then locked for one second. This is signalled by the blue
LED being lit for an extended time.
ð If the scale tips again during the locking period, this will be ignored by the
analysing unit.

22 of 34 KSB Leakage Sensor

 6 Commissioning / Start-up

ð After the balance scale has tipped four to five times, the alarm of the display
unit is triggered. The red LED lights up, and an acoustic signal is emitted.
2. To acknowledge the alarm, place the supplied magnetic clip on the KSB logo at
the display unit. (ð Section 7.3.4, Page 26)
ð The acoustic signal stops.
ð The green LED lights up.
ð The KSB Leakage Sensor is ready for operation.
▪ Analog signal option: After a reset with the magnetic clip or after power has
returned, the analog output supplies a 4 mA current signal.

6.2 Measures to be taken for shutdown

NOTE
Observe the original operating manual of the pump (set).
Comply with the safety regulations specified for the pump (set).
Comply with the instructions for shutdown of the pump (set).

1. Perform the shutdown procedure described in the original operating manual.

2. Undo the M12 connector from connection EXT at the analysing unit.
ð The analysing unit has been de-energised.
3. Disconnect the sensor cable IN1 and the cable for analog signal IN2 from the
analysing unit.
ð The KSB Leakage Sensor can be removed from the pump casing.
1984.8/02-EN

KSB Leakage Sensor 23 of 34

 7 Servicing/Maintenance

7 Servicing/Maintenance

7.1 Safety regulations

The operator ensures that maintenance, inspection and installation are performed by
authorised, qualified specialist personnel who are thoroughly familiar with the
manual.

DANGER
Electric shock
Danger to life!
▷ De-energise the mains connections of all devices (e.g. pump, PumpDrive,
PumpMeter, leakage sensor).
▷ Ensure that the mains connections cannot be re-energised unintentionally.

Never use force when dismantling and reassembling the pump set.

NOTE
All maintenance work, service work and installation work can be carried out by KSB
Service or authorised workshops. For contact details please refer to the enclosed
"Addresses" booklet or visit "www.ksb.com/contact" on the Internet.

7.2 Maintenance/inspection
The KSB Leakage Sensor is essentially maintenance-free.
Carry out the functional test once per year as a minimum. (ð Section 6.1, Page 22)
When using a fluid that can lead to clogging of the drop capillary in the sensor
housing, regularly check the free passage of the drop capillary. This applies especially
to fluids handled containing solids and fluids handled liable to resinify or crystallise.

7.2.1 Cleaning the drop capillary

WARNING
Hot surface
Burns, scalding!
▷ Allow the pump set and sensor housing to cool down to ambient temperature.

Regularly check the free passage of the drop capillary in the sensor housing.
ü The mains connection has been de-energised and secured against being
energised.
1. Turn measuring instrument 690 (bullseye level) to remove it from the upper
sensor housing.
2. Insert a suitable long, thin cleaning tool (e.g. pipe cleaner or solid probe with a
diameter of 2.5 mm maximum) approx. 2.5 cm into the tapped hole of the
measuring instrument. Then pull it out again.
3. Repeat this process several times.
1984.8/02-EN

4. In the case of severe incrustation remove the upper sensor housing 105.1 and
clean it.

24 of 34 KSB Leakage Sensor

 7 Servicing/Maintenance

7.3 Dismantling and reassembly

7.3.1 Dismantling and reassembling the KSB Leakage Sensor

ü All power cables as well as the electrical devices connected to them have been
de-energised.
1. Disconnect the M12 connector from connection EXT at the analysing unit.
2. Disconnect the sensor cable IN1 and the cable for analog signal IN2 from the
analysing unit.
3. Remove the KSB Leakage Sensor from the pump set.
4. Fit the KSB Leakage Sensor again in the required position.
5. Re-connect the sensor cable IN1 and the cable for analog signal IN2 to the
analysing unit.
6. Re-connect the M12 connector EXT to the analysing unit.
ð The KSB Leakage Sensor is now connected.
7. Return the KSB Leakage Sensor to service.

7.3.2 Rotating the upper half of the sensor housing

If the leakage inlet 8E is to be positioned on the same side as the leakage drain 8B,
the upper half of the sensor housing can be taken off, rotated by 180° and mounted
in this position.
ü All power cables as well as the electrical devices connected to them have been
de-energised.
1. Undo the hexagon socket head cap screws 914.2 at the upper housing half
105.01.
2. Remove the upper housing half, turn it by 180°, and mount it in this position.
3. Screw in hexagon socket head cap screws 914.2 and tighten them hand-tight.
4. Carry out a functional test. (ð Section 6.1, Page 22)

7.3.3 Removing and re-mounting the inductive sensor

Inductive sensor 69-8 is supplied fitted in the upper housing half with the required
distance to indicator 620 (balance scale). The position of the measurement
transmitter must not be changed by turning it.
If it has been turned or if the measurement transmitter is to be replaced, carry out
the following steps to position it correctly:
1. Undo hexagon socket head cap screws 914.2 at the upper housing half 105.01.
2. Remove the upper housing half 105.01.
3. Undo the locknut of inductive sensor 69-8.
4. Unscrew inductive sensor 69-8 from the upper housing half 105.01.
5. Place the upper housing half in a level work area with measuring instrument
690 (bullseye level) on top. Fasten it with suitable clamping equipment.

2
1984.8/02-EN

UG1840447_CDK_D01/01

Fig. 4: Mounting the inductive sensor

KSB Leakage Sensor 25 of 34

 7 Servicing/Maintenance

6. Screw inductive sensor 69-8 in from the top (2), until it touches the work area
(1).
7. The lower edge of upper housing half 105.01 and the active face of inductive
sensor 69-8 are now on the same level.

NOTE
The lengths of the inductive sensors in the standard design differ from those of the
variant for use in potentially explosive atmospheres. For this reason, the sensors
protrude from the upper housing half at different lengths.

8. Screw the locknut on from the top and tighten it. The inductive sensor must not
be turned during this process.
9. Place upper housing half 105.01 on lower housing half 105.02. Observe the
position of leakage inlet 8B in relation to leakage drain 8E.
10. Screw in hexagon socket head cap screws 914.2 and tighten them hand-tight.
11. Carry out a functional test. (ð Section 6.1, Page 22)

7.3.4 Resetting the analysing unit

The alarm status can be reset with the supplied magnetic clip.
UG1838101_002/01

Fig. 5: Triggering a reset with the magnetic clip

1. Place the magnetic clip on the KSB logo until the LEDs change from red to
green.
ð The analysing unit immediately starts to monitor the leakage rate again.

NOTE
The warning status cannot be reset with the magnetic clip.
If the leakage rates sink below the warning threshold the analysing unit clears the
warning status automatically. 1984.8/02-EN

26 of 34 KSB Leakage Sensor

 8 Trouble-shooting

8 Trouble-shooting

DANGER
Carrying out work on a running pump
Risk of injury: Limbs can be pulled into or crushed by machinery!
▷ De-energise the motor.
▷ Take steps to ensure that the motor cannot be switched on again
unintentionally.

WARNING
Improper work to remedy faults
Risk of injury!
▷ For any work performed to remedy faults, observe the relevant information
given in this operating manual and/or in the product literature provided by the
accessories manufacturer.

If problems occur that are not described in the following table, consultation with the
KSB service is required.

Table 11: Trouble-shooting

Error / defect description Possible cause Remedy
None of the four LEDs are lit. No power supply Check power supply at EXT pin 1 and
3 (10 - 30 V DC).
KSB Leakage Sensor defective Contact KSB.
Blue LED not lit despite tipped The inductive sensor in the sensor Check the length of engagement of
indicator housing does not recognise the the inductive sensor. Adjust it if
tipping movement. required.
The blue LED lights up for 3 seconds Balance scale in sensor housing is Clean the sensor housing.
and then starts flashing together jammed.
with the yellow LED. Sensor cable at IN1 defective Replace the sensor cable.
Inductive sensor defective Replace the inductive sensor.
The orange indicator lamp at the The sensor cable is not correctly Check the plug-type cable connection
inductive sensor is not lit during connected to connection IN1. at IN1. Correct it if required.
standstill. The sensor cable is not correctly Check the plug-type connection at the
connected to the inductive sensor. inductive sensor. Correct it if required.
Inductive sensor defective Replace the inductive sensor.
Balance scale in sensor housing is Clean the sensor housing.
jammed.
The red LED is lit but no acoustic DIP switch 4 is set to ON. Set DIP switch 4 to OFF.
alarm is emitted.
1984.8/02-EN

KSB Leakage Sensor 27 of 34

 9 Related Documents

9 Related Documents

9.1 General assembly drawing with list of components

69-8

690

914.01

105.01

620

105.02

914.02

Fig. 6: General assembly drawing of the KSB Leakage Sensor

Table 12: List of components

Part No. Description
105.01 Upper housing half
105.02 Lower housing half
69-8 Measurement transmitter (inductive sensor)
620 Indicator (balance scale)
690 Measuring device (bullseye level)
914.01 Hexagon socket head cap screw
914.02 Hexagon socket head cap screw

1984.8/02-EN

28 of 34 KSB Leakage Sensor

 9 Related Documents

9.2 Layout / connection diagram

9.2.1 Standard design

3
1

8E
2

11
8B

10 8 7 6
12

Fig. 7: Connection diagram of the KSB Leakage Sensor (standard design)

1 Leakage line from the pump
2 Indicator lamp, orange
3 Sensor cable
4 Analysing unit
5 Magnetic clip (for resetting the analysing unit)
6 Power cable
7 Screw plug (access to the DIP switches)
8 Connection for analog output signal (leakage rate)
9 Site-supplied leakage collector
10 Leakage line from the sensor housing
11 Leakage sensor
12 Vent opening
8B Leakage drain
8E Leakage inlet
1984.8/02-EN

KSB Leakage Sensor 29 of 34

 9 Related Documents

9.2.2 Variant for use in potentially explosive atmospheres

4 5
UG1839893_ZDK_D02_001/03

3
1

13
8E
2
11

8B
10
12
8 7

14 6

A B
Fig. 8: Connection diagram of the KSB Leakage Sensor (variant for use in potentially explosive atmospheres)
A = potentially explosive atmosphere
B = non-potentially explosive atmosphere
1 Leakage line from the pump
2 Indicator lamp, orange
3 Blue sensor cable
4 Analysing unit
5 Magnetic clip (for resetting the analysing unit)
6 Power cable
7 Screw plug (access to the DIP switches)
8 Connection for analog output signal (leakage rate)
9 Site-supplied leakage collector
10 Leakage line from the sensor housing
11 Leakage sensor
12 Vent opening
13 Switching amplifier
1984.8/02-EN

14 Black sensor cable

8B Leakage drain
8E Leakage inlet

30 of 34 KSB Leakage Sensor

 10 EU Declaration of Conformity

10 EU Declaration of Conformity

Manufacturer: KSB SE & Co. KGaA

Johann-Klein-Straße 9
67227 Frankenthal (Germany)
The manufacturer herewith declares that the product:

KSB Leakage Sensor

Serial number range: SN V13 01 0001 to SN V13 99 9999
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Electromagnetic Compatibility Directive 2014/30/EU
▪ Applied national technical standards and specifications, in particular:
– EN 61326-1
– EN 55011
▪ Applied national technical standards and specifications, in particular:
– ISO 14121-1
– IEC 61000-4-2
– IEC 61000-4-3
– IEC 61000-4-4
– IEC 61000-4-5
– IEC 61000-4-6
The EU Declaration of Conformity was issued in/on:
Frankenthal, 19 March 2020

Thomas Heng
Head of Product Development Series Pumps & Large Pumps
KSB SE & Co. KGaA
Johann-Klein-Straße 9
67227 Frankenthal

KSB Leakage Sensor 31 of 34

 (05058108)
1984.8/02-EN

KSB SE & Co. KGaA

Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0
www.ksb.com