CBU140
Compact Booster Unit - single pump
To ensure the quality of potable water according to EN1717
Instructions
32304091-001
Honeywell GmbH 2 Translation of original - EN1H-1377GE23 R1114
GB
Contents
1. Safety Guidelines ...............................................................................3
1.1 Safety instructions in this manual .........................................................3
1.2 General safety instructions ...................................................................3
1.3 Further safety regulations .....................................................................3
1.4 Unauthorised operation types ...............................................................3
1.5 Residual dangers in handling the compact booster unit .......................4
1.5.1 Mechanical residual dangers ......................................................4
1.5.2 Residual dangers pertaining to fluids ..........................................4
1.5.3 Residual electrical hazards .........................................................4
1.5.4 Residual biological hazards ........................................................4
1.5.5 Residual chemical hazards .........................................................4
1.5.6 Consequences and dangers that result from not
observing the manual ..................................................................5
1.6 Basic Safety Measures .........................................................................5
1.6.1 Keep information available ..........................................................5
1.6.2 For environmental protection ......................................................5
1.6.3 Modifications to the compact booster unit ...................................5
1.7 Duty of due care of the operator ...........................................................5
1.8 Safety instructions for the operator/operating personnel ......................5
1.9 Safety instructions for maintenance, inspections and assembly work ..5
1.10Requirements for operating personnel .................................................5
1.10.1Operating personnel ...................................................................5
1.11Personal safety equipment ...................................................................5
2. General information ............................................................................6
2.1 Conformity with the following norms .....................................................6
2.2 Warranty and liability ............................................................................6
2.3 Storage and perfect condition ...............................................................6
2.4 Illustrations ...........................................................................................6
2.5 Symbols ................................................................................................6
2.6 Other applicable documents .................................................................6
2.7 Glossary ...............................................................................................6
3. Description ..........................................................................................7
3.1 Pump Output ........................................................................................7
3.2 Backfeed for 3/4" pipes .........................................................................7
3.3 Noise expectancy values ......................................................................7
3.4 Authorised environmental conditions ....................................................7
3.5 Type label .............................................................................................7
3.6 Version .................................................................................................8
3.7 Overview ...............................................................................................8
3.7.1 Installation type ...........................................................................8
3.8 Intended use .........................................................................................8
3.9 Non-intended use .................................................................................8
3.10Options .................................................................................................8
4. Function ..............................................................................................8
4.1 Construction dimensions ......................................................................8
5. Shipping ..............................................................................................9
5.1 Check condition upon delivery ..............................................................9
5.2 Transportation ......................................................................................9
6. Assembly .............................................................................................9
6.1 General safety instructions ...................................................................9
6.2 Installation according to EN1717 ..........................................................9
6.3 Inspection before assembly ................................................................10
6.3.1 Installation site .........................................................................10
6.4 Installing the compact booster unit .....................................................10
6.5 Installing the pipelines ........................................................................10
6.5.1 Water connection ......................................................................10
6.5.2 Pressure connection .................................................................10
6.5.3 Connecting the overflow ..........................................................10
6.6 Electrical connection ...........................................................................10
6.6.1 Safety instructions .....................................................................10
6.7 Verification of the waterflow ................................................................10
7. Start-up ..............................................................................................11
7.1 Safety instructions for start-up ............................................................11
7.2 Start-up requirements .........................................................................11
7.3 Fill up and vent the pump and tank .....................................................11
7.4 Switching the system on .....................................................................11
7.5 Function check ....................................................................................11
7.5.1 Checking the protection against dry running .............................11
7.6 Start-up checklist ................................................................................11
8. Operation ...........................................................................................11
9. Maintenance ......................................................................................12
9.1 Safety instructions for maintenance ....................................................12
9.2 Overview of inspection tasks ..............................................................12
9.3 Inspection ...........................................................................................12
9.3.1 Check protection against dry running .......................................12
9.3.2 Check pressure hoses ..............................................................12
9.3.3 Check pump control ..................................................................12
9.3.4 Check floating ring seal leakage ...............................................12
9.3.5 Check preload pressure of membrane pressure
expansion vessel ......................................................................12
9.4 Maintenance .......................................................................................12
10. Troubleshooting ...............................................................................13
10.1Measures for elimination of pressure surges ......................................13
10.1.1Enlargement of the inlet line .....................................................13
10.1.2Setting pressure reducing valve ...............................................13
10.1.3Throttle pressure surge .............................................................13
10.1.4Membrane pressure expansion vessel ....................................13
11. Shut-down, disassembly, restart ....................................................14
11.1Shutting down the compact booster unit ............................................14
11.2Restarting the compact booster unit ...................................................14
12. Storage ..............................................................................................14
12.1Short-term storage ..............................................................................14
12.2Storage/Preservation ..........................................................................14
12.3Storage conditions ..............................................................................14
13. Disposal .............................................................................................14
14. Spare Parts ........................................................................................ 14
15. Start-up protocol ...............................................................................15
16. Declaration of no objection .............................................................16
17. Proof of Maintenance .......................................................................17
EN1H-1377GE23 R1114 - Translation of original 3 Honeywell GmbH
GB
1. Safety Guidelines
1.1 Safety instructions in this manual
1.2 General safety instructions
This manual contains basic instructions which are to be observed in transport, assembly, start-up, operation, maintenance, shut-down, storage and
waste disposal.
The following safety instructions have to be observed while operating the
compact booster unit:
• When using the compact booster unit, the data, operation and usage
conditions specifically authorised in the technical data sheet and the
operating manual have to be observed.
• Never exceed the permissible limits pertaining to pressure, temperature,
etc. as stated in the documentation.
• Observe all safety instructions as well as the operating instructions of the
manual.
• Instructions that are directly attached to the system have to be observed
and must be kept completely legible. This applies for example to:
- Safety instructions
- Arrow for rotation direction
- Connection labels
- Type label
• Before assembly and start-up, the manual has to be read by the operator
as well as by the responsible technical/operating personnel and has to be
stored at the site of the compact booster unit at all times.
• Installation and maintenance work may only be performed by authorised
specialist personnel with the appropriate tools.
• The technical condition of the compact booster unit has to be checked
regularly (at least once a year) by the operating company.
• The local safety and accident regulations have to be observed when
operating the compact booster unit.
• The general technical rules must be observed when planning the usage
and operating the device.
• Modification of the compact booster unit is not permitted and leads to the
loss of warranty.
• After an interruption of the electrical or fluid supply, a defined or controlled
re-run of the process must be ensured.
• The operator is responsible for complying with local regulations that are
not covered by the manual.
1.3 Further safety regulations
Besides the safety instructions presented in this manual and its intended
use, the following safety regulations are valid:
• Accident prevention regulations, safety and operating regulations
• Safety regulations for handling hazardous substances
• Applicable standards and laws
1.4 Unauthorised operation types
The limits that are stated in the documentation have to always be complied
with. The delivered system is only guaranteed to operate reliably when it is
used as intended.
Danger
Places with this sign signify that death, severe bodily injury or significant
property damage will occur if the appropriate precautionary measures
are not followed!
Warning
Places with this sign signify that death, severe bodily injury or significant
property damage may occur if the appropriate precautionary measures
are not followed!
Caution
Places with this sign signify that small bodily injury or slight property damage may occur if the appropriate precautionary measures are not followed!
Places with this sign provide technical information and tips on usage
that damage to the machine must be avoided.This symbol is not a safety indication.
Places with this sign provide information about possible hazards to the
environment
Please notice that a safety symbol never can replace the text of the
safety instruction itself - the text of the safety instruction must be read
entirely!
Honeywell GmbH 4 Translation of original - EN1H-1377GE23 R1114
GB
1.5 Residual dangers in handling the compact booster unit
Danger and adverse effects may result from use of the compact booster unit
• for the body and life of the operator or third person
• for the compact booster unit itself
• to other property.
The basis for safe and error-free operation of the compact booster unit is knowledge of the instructions for safety and operation in this manual.
1.5.1 Mechanical residual dangers
During normal operation, no danger is threatened from mechanical components.
1.5.2 Residual dangers pertaining to fluids
During normal operation, no danger is threatened by hydraulic components.
Hazards might result solely under the following conditions.
1.5.3 Residual electrical hazards
During normal operation, no danger results from the electrical equipment of the compact booster unit.
Hazards might result solely under the following conditions.
1.5.4 Residual biological hazards
During normal operation, no biological danger results from the compact booster unit.
Hazards might result solely under the following conditions.
1.5.5 Residual chemical hazards
During normal operation, no chemical danger results from the compact booster unit.
Hazards might result solely under the following conditions.
Danger area Type of hazard Reduction of hazard
Pipelines Injury through high pressure Clear pipelines of pressure and medium prior to assem-
bly, maintenance, shut-down!
Danger area Type of hazard Reduction of hazard
Injury from cables Danger to life !
Electric shock of 230/400V from electric voltage
Connect up protective earth system!
Always switch off power supply and secure against swit-
ching on again during maintenance and servicing work!
Comply with the valid accident prevention and safety re-
gulations for electrical devices!
Electrostatically endangered
components / subassemblies
The device contains electronic componental elements that react
sensitively to electrostatic discharge (ESD). Contact with electrostatically charged persons or objects endangers these componental elements. Worst case scenario: they will be immediately
destroyed or fail after start-up.
Comply with requirements according to EN 100 015 - 1,
in order to minimise or avoid damage through shock-type
electrostatic discharge!
Do not touch electronic componental elements when the
power supply is on!
Danger area Type of hazard Reduction of hazard
Buffer tank Danger of microbial contamination Clean the buffer tank regularly!
Danger area Type of hazard Reduction of hazard
Use of detergents Danger through contact with or breathing in dangerous fluids, ga-
ses, fumes, vapours or dust
Wear personal safety equipment!
Pay attention to the safety specifications sheet of deter-
gent manufacturers!
EN1H-1377GE23 R1114 - Translation of original 5 Honeywell GmbH
GB
1.5.6 Consequences and dangers that result from not observing the manual
• Not observing this manual will lead to loss of the warranty and make
damage claims invalid.
• Failure to observe the manual can lead, for example, to the following
dangers:
- Hazard to persons caused by electrical, thermal, mechanical, and
chemical influences
- Loss of important product functions
- Failure to perform required maintenance and service measures
- Environmental hazard caused by leakage of hazardous substances
1.6 Basic Safety Measures
1.6.1 Keep information available
This manual has to be stored. It has to be ensured that all persons who
operate the compact booster unit have access to the manual at all times.
1.6.2 For environmental protection
1.6.3 Modifications to the compact booster unit
When using externally procured parts, there is no guarantee that these are
designed and constructed to tolerate demands made upon them or whether
they comply with safety regulations.
For safety reasons, no unauthorised modifications may be made to the
compact booster unit.
Parts and special equipment not delivered by Honeywell are also not authorised by Honeywell for use.
1.7 Duty of due care of the operator
This compact booster unit was designed and constructed according to a risk
assessment and after careful selection of the harmonised standards that
apply, as well as according to further technical specifications. It thus
complies with best practice and guarantees the highest safety standard.
This level of safety can only be attained during operational practice if all
required safety measures have been taken. It is the duty of care of the
operator of the compact booster unit to plan these measures and enforce
their implementation.
In particular, the operator must ensure that
• the compact booster unit is only operated as intended
• the compact booster unit is only operated in perfect working condition.
• the manual has to be kept legible at all times and stored on-site with the
compact booster unit.
• the compact booster unit is assembled, commissioned, maintained, and
shut down solely by sufficiently qualified and authorised personnel.
• this personnel is regularly instructed on all relevant questions of work
safety and environmental protection, and has also read and understood
the manual and particularly the safety instructions it contains.
• none of the safety and warning signs attached to the compact booster unit
are removed and all remain legible.
• a hazard assessment (according to the Safety at Work Act § 5) is
conducted to detect further hazards that may arise from the particular
working conditions on-site where the compact booster unit is operated.
• all further information and safety instructions which arise from the hazard
assessment process shall be summarised in operating instructions
(according to the work equipment regulation § 6).
• the drain output lines are sufficiently dimensioned
1.8 Safety instructions for the operator/operating personnel
• Eliminate hazards caused by electrical energy (for details refer to the
country specific regulations and/or local power supply companies).
1.9 Safety instructions for maintenance, inspections and
assembly work
• Alterations or modifications of the system are only permitted with the
consent of the manufacturer.
• Use only original parts or parts authorised by the manufacturer.
• Use of parts other than those authorised may lead to loss of liability for
any damage they may cause.
• Perform service on the system only when the machine is off.
• The pump housing has to be at ambient temperature.
• The pump housing has to be depressurised and empty.
• The procedures described in the manual for shutting down the system
have to be observed under all circumstances.
• Reinstall safety equipment and protective devices and activate them
again immediately after work on the system has been completed. Before
starting up again, observe the start-up checklist.
• Keep unauthorised persons (e.g. children) away from the system.
1.10Requirements for operating personnel
1.10.1 Operating personnel
This compact booster system may only be asembled, started, maintained,
and shut down by persons who have been trained, instructed and authorised
to do so.
In some cases, training can be arranged by the manufacturer if asked by the
operator.
Training or personnel to operate system may only be conducted under the
supervision of specialised technicians.
The relevant authorisations of the personnel are to be specified by the
operating company in the form of an operating instruction.
Over and above this, special qualifications are required for the following
tasks:
• Only electricians may perform work on electrical equipment.
• Assembly, maintenance, servicing and repair work may only be
performed by qualified, specialist personnel
The basic regulations on work safety and accident prevention are to be
observed.
1.10.1.1Qualified personnel
Qualified personnel are persons who on account of their training, experience
and instruction also their knowledge of the relevant norms, regulations, accident prevention regulations and operating conditions, including those
persons responsible for the safety of the system, have been authorised to
perform the relevant and required tasks, meanwhile being able to recognise
and avoid dangers. This includes required knowledge of First Aid measures
and the local ambulance services and facilities.
1.11Personal safety equipment
No personal safety equipment is required to operate the compact booster
unit.
When operating or servicing the compact booster unit, the regulations
concerning waste avoidance and the proper recycling or disposal of waste must be observed.
Particular attention must be paid that materials and agents dangerous
to the groundwater such as fats, oils, coolants, solvent-based liquid detergents, etc. do not pollute the ground or access the sewage system.
These materials must be caught in suitable tanks, stored, transported
and properly disposed of.
Honeywell GmbH 6 Translation of original - EN1H-1377GE23 R1114
GB
2. General information
The manual is a part of the series and the versions as mentioned on the title
page. The manual describes the safe and proper use in all modes of operation.
The type label indicates the series and size, the most important operating
data and the order number. The factory number/serial number describes the
identifies the system uniquely and serves this purpose for all further business transactions.
In order to maintain the warranty, in the event of damage immediately
contact the nearest Honeywell service centre.
2.1 Conformity with the following norms
Pump unit: Machinery Directive 2006/42/EG
Pump unit: EMC Directive 2004/108/EG
Frequency inverter: EMC Directive 2004/108/EG
Frequency inverter: Low voltage directive 2006/95/EG
2.2 Warranty and liability
As a matter of principle, the general sales and delivery terms of the Honeywell Company apply. Warranty and liability claims for injury to persons and
damage to property are ruled out if they arise from one or more of the following causes.
• Non-intended use of the compact booster unit
• Improper assembly, start-up, operation and maintenance of the compact
booster unit
• Failure to comply with the instructions in the manual concerning transport,
storage, assembly, start-up, operation, maintenance, and service of the
compact booster unit
• Unauthorised constructional modifications of the compact booster unit
• Improperly performed repairs
• Catastrophes through effect of a foreign object or force majeure
2.3 Storage and perfect condition
This instruction manual is a part of the compact booster unit and has to be
complete and accessible at all times. Any instruction or page that is missing
has to be replaced immediately.
2.4 Illustrations
The illustrations used are examples of one possible version of the compact
booster unit and might differ in individual cases from the actual compact
booster unit version.
2.5 Symbols
1. Start of a task description
2. Next work step
- Result of an action
• List of several options
Reference to other documents
2.6 Other applicable documents
Operating manuals, circuit diagram and further documentation of auxilia-
ry equipment and integrated machine parts
Product data sheet CBU140
Operating instructions of the operating company
Data sheets
Declaration of Conformity
2.7 Glossary
EN 1717
European standard that specifies technical regulations for potable water
installations.
Noise expectancy values
The expected noise emission, stated here as sound pressure level (SPL) in
dB(A).
Certificate of no objection
A certificate of no objection is a declaration that the system has been
cleaned properly so that parts that have been in contact with medium are not
dangerous for health and environment.
Pictogram Danger classification
Danger source
ª Consequence of non-compliance
Avoidance
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