KSB Delta Solo SVP, Delta Basic SVP Operating Manual

Pressure Booster System
KSB Delta Solo
KSB Delta Solo SVP
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual KSB Delta Solo
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 B.V., Alphen aan den Rijn, Nederland 03/09/2019

Contents

Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Software changes .............................................................................................................................................6
1.3 Installation of partly completed machinery....................................................................................................6
1.4 Target group.....................................................................................................................................................6
1.5 Other applicable documents............................................................................................................................6
1.6 Symbols .............................................................................................................................................................6
1.7 Key to safety symbols/markings.......................................................................................................................7
2 Safety...................................................................................................................................................... 8
2.1 General..............................................................................................................................................................8
2.2 Intended use .....................................................................................................................................................8
2.2.1 Prevention of foreseeable misuse.......................................................................................................8
2.3 Personnel qualification and personnel training.............................................................................................9
2.4 Consequences and risks caused by non-compliance with this manual .........................................................9
2.5 Safety awareness ..............................................................................................................................................9
2.6 Safety information for the operator/user.......................................................................................................9
2.7 Safety information for maintenance, inspection and installation ................................................................9
2.8 Unauthorised modes of operation................................................................................................................10
2.9 Electromagnetic compatibility (EMC)............................................................................................................10
2.9.1 Interference emission requirements .................................................................................................10
2.9.2 Line harmonics requirements............................................................................................................11
2.9.3 Interference immunity requirements ...............................................................................................11
3 Transport/Temporary Storage/Disposal............................................................................................. 12
3.1 Checking the condition upon delivery..........................................................................................................12
3.2 Transport.........................................................................................................................................................12
3.3 Storage/preservation......................................................................................................................................12
3.4 Return to supplier ..........................................................................................................................................13
3.5 Disposal ...........................................................................................................................................................13
4 Description............................................................................................................................................ 15
4.1 General description ........................................................................................................................................15
4.2 Product information as per Regulation No. 1907/2006(REACH).................................................................15
4.3 Description......................................................................................................................................................15
4.4 Name plate......................................................................................................................................................15
4.5 Design details..................................................................................................................................................15
4.6 Configuration and function...........................................................................................................................16
4.7 Scope of supply...............................................................................................................................................17
4.8 Dimensions......................................................................................................................................................17
4.9 Terminal diagram ...........................................................................................................................................17
4.10 Potential equalisation ....................................................................................................................................18
5 Installation at Site................................................................................................................................ 19
5.1 Checks to be carried out prior to installation...............................................................................................19
5.2 Installing the pressure booster system..........................................................................................................19
5.3 Mounting the accumulator............................................................................................................................20
5.4 Connecting the piping ...................................................................................................................................20
5.4.1 Fitting an expansion joint (optional)................................................................................................21
5.4.2 Fitting the pressure reducer (optional) ............................................................................................21
5.5 Fitting the dry running protection device ....................................................................................................21
5.6 Electrical connection ......................................................................................................................................22
5.6.1 Sizing the power cable ......................................................................................................................23
5.6.2 Connecting the pressure booster system..........................................................................................23
5.6.3 Connecting the dry running protection device................................................................................24
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Contents
6 Commissioning/Start-up/Shutdown................................................................................................... 25
6.1 Commissioning/Start-up.................................................................................................................................25
6.1.1 Prerequisites for commissioning/start-up .........................................................................................25
6.1.2 Dry running protection......................................................................................................................25
6.1.3 Commissioning/start-up of pressure booster system .......................................................................25
6.2 Start-up ...........................................................................................................................................................26
6.3 Checklist for commissioning/start-up ............................................................................................................27
6.4 Shutdown........................................................................................................................................................27
7 Operation.............................................................................................................................................. 28
7.1 Standard control panel ..................................................................................................................................28
7.1.1 Display ................................................................................................................................................28
7.1.2 Main screen ........................................................................................................................................31
7.1.3 Settings menu ....................................................................................................................................32
7.1.4 Service interface and LED traffic light function...............................................................................35
8 Servicing/Maintenance........................................................................................................................ 36
8.1 General information/Safety regulations .......................................................................................................36
8.1.1 Inspection contract ............................................................................................................................37
8.2 Servicing/Inspection........................................................................................................................................37
8.2.1 Supervision of operation...................................................................................................................37
8.2.2 Maintenance schedule.......................................................................................................................37
8.2.3 Setting the pre-charge pressure........................................................................................................38
8.2.4 Replacing the non-return valve ........................................................................................................39
9 Trouble-shooting.................................................................................................................................. 42
9.1 Faults/malfunctions: Trouble-shooting .........................................................................................................42
9.2 Alerts ...............................................................................................................................................................43
9.3 Warnings.........................................................................................................................................................46
9.4 Information messages ....................................................................................................................................49
10 Related Documents.............................................................................................................................. 50
10.1 General assembly drawings/exploded views with list of components........................................................50
10.1.1 KSB Delta Solo SVP.............................................................................................................................50
10.2 Alerts ...............................................................................................................................................................50
10.3 Warnings.........................................................................................................................................................53
10.4 Information messages ....................................................................................................................................55
11 EU Declaration of Conformity............................................................................................................. 56
12 Certificate of Decontamination........................................................................................................... 57
13 Commissioning Report......................................................................................................................... 58
Index ..................................................................................................................................................... 59
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Glossary

Glossary
Accumulator
Pressure losses may occur in the piping downstream of the pressure booster system as a result of losses due to leakage. The accumulator serves to compensate for pressure losses and minimises the frequency of starts of the pressure booster system.
Certificate of decontamination
A certificate of decontamination is enclosed by the customer when returning the product to the manufacturer to certify that the product has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled.
Dry running protection
Dry running protection devices prevent the pump from being operated without the fluid to be handled, which would result in pump damage.
Switchgear and controlgear assembly
Control cabinet with one or several control units/ switchgears and electrical equipment.
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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 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. This does not, however, apply to software updates supplied by KSB.

1.3 Installation of partly completed machinery

To install partly completed machinery supplied by KSB refer to the sub-sections under Servicing/Maintenance.

1.4 Target group

This operating manual is aimed at the target group of trained and qualified specialist technical personnel. (ðSection2.3,Page9)

1.5 Other applicable documents

Table1: Overview of other applicable documents
Document Contents
Sub-supplier product literature Operating manuals, logic diagram and other
product literature of accessories and integrated machinery components

1.6 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
⇨ ⇨ Cross-references
1.
2.
Result of an action
Step-by-step instructions
Note Recommendations and important information on how to handle the product
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1 General
!
DANGER
!
WARNING
CAUTION

1.7 Key to safety symbols/markings

Table3: Definition of safety symbols/markings
Symbol Description
DANGER
This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury.
WARNING This signal word indicates a medium-risk hazard which, if not avoided, could result in death or serious injury.
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.
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2 Safety

!
DANGER
2 Safety
All the information contained in this section refers to hazardous situations. 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:
– Arrow indicating the direction of rotation – Markings for connections – Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account.

2.2 Intended use

The pressure booster system must only be operated within the operating limits
described in the other applicable documents.
Only operate pressure booster systems which are in perfect technical condition.Do not operate partially assembled pressure booster systems.The pressure booster system must only handle the fluids described in the product
literature of the respective design variant.
Never operate the pressure booster system without the fluid to be handled.Observe the information on minimum flow rates specified in the product
literature (to prevent overheating, bearing damage, etc).
Observe the maximum flow rates indicated in the data sheet or product
literature (to prevent overheating, cavitation damage, bearing damage, etc).
Do not throttle the flow rate on the suction side of the pressure booster system
(to prevent cavitation damage).
Consult the manufacturer about any other modes of operation not described in
the product literature.

2.2.1 Prevention of foreseeable misuse

Never exceed the permissible application and operating limits specified in the
product literature regarding pressure, temperature, etc.
Observe all safety information and instructions in this manual.
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2 Safety

2.3 Personnel qualification and personnel training

All personnel involved must be fully qualified to install, operate, maintain and
inspect the product 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 pressure booster system 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 – Failure of important product functions – Failure of prescribed maintenance and servicing practices – Hazard to the environment due to leakage of hazardous substances
1983.844/02-EN

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 regulationsExplosion protection regulationsSafety regulations for handling hazardous substancesApplicable standards, directives and laws

2.6 Safety information for the operator/user

Fit protective equipment (e.g. contact guards) supplied by the operator for hot,
cold or moving parts, and check that the equipment functions properly.
Do not remove any protective equipment (e.g. contact guards) during operation.Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply companies.)
If shutting down the pump does not increase potential risk, fit an emergency-
stop control device in the immediate vicinity of the pump (set) during pump set installation.

2.7 Safety information for maintenance, inspection and installation

Modifications or alterations of the pressure booster system are only permitted
with the manufacturer's prior consent.
Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
The operator ensures that maintenance, inspection and installation are
performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual.
Carry out work on the pressure booster system during standstill only.The pump casing must have cooled down to ambient temperature.Pump pressure must have been released and the pump must have been drained.
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2 Safety
When taking the pressure booster system out of service always adhere to the
procedure described in the manual.
Decontaminate pressure booster systems which handle fluids posing a health
hazard.
As soon as the work has been completed, re-install and/or re-activate any safety-
relevant and protective devices. Before returning the product to service, observe all instructions on commissioning.
Make sure the pressure booster system cannot be accessed by unauthorised
persons (e.g. children).
Prior to opening the device, pull the mains plug and wait for at least 10minutes.

2.8 Unauthorised modes of operation

Always observe the limits stated in the product literature. The warranty relating to the operating reliability and safety of the pressure booster
system supplied is only valid if the equipment is used in accordance with its intended use. (ðSection2.2,Page8)

2.9 Electromagnetic compatibility (EMC)

2.9.1 Interference emission requirements

The EN61800-3 EMC product standard is relevant for electric variable speed drives/ control systems. It specifies all pertinent requirements and refers to the relevant generic standards for complying with the EMC Directive.
Frequency inverters are commonly used by operators as a part of a system, plant or machine assembly. It should be noted that the operator bears all responsibility for the final EMC properties of the equipment, plant or installation.
A prerequisite or requirement for complying with the relevant standards or the limit values and inspection/test levels referenced by them is that all information and descriptions regarding EMC-compliant installation be observed and followed.
In accordance with the EMC product standard, the EMC requirements to be met depend on the purpose or intended use of the frequency inverter. Four categories are defined in the EMC product standard:
Table4: Categories of intended use
Category Definition Limits to EN55011
C1 Frequency inverters with a supply voltage under 1000V installed in the
Class B
first environment (residential and office areas).
C2 Frequency inverters with a supply voltage under 1000V installed in the
Class A, Group 1 first environment (residential and office areas) that are neither ready to be plugged in/connected nor are mobile and must be installed and commissioned by specialist personnel.
C3 Frequency inverters with a supply voltage under 1000V installed in the
Class A, Group 2 second environment (industrial environments).
C4 Frequency inverters with a supply voltage over 1000V and a nominal
current over 400A installed in the second environment (industrial
No borderline/
boundary
environments) or that are envisaged for use in complex systems.
The following limit values and inspection/test levels must be complied with if the generic standard on interference emissions applies:
1)
1) An EMC plan must be devised.
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2 Safety
Table5: Classification of installation environment
Environment Generic standard Limits to EN55011
First environment (residential and office areas) EN/IEC61000-6-3
for private, business and commercial environments
Second environment (industrial environments) EN/IEC61000-6-4
for industrial environments
The frequency inverter meets the following requirements:
Table6: EMC properties of the frequency inverter
Power
[kW]
≤ 11 ≤5 C1 Class B
The EN61800-3 standard requires that the following warning be provided for drive systems that do not comply with category C1 specifications: This product can produce high-frequency interference emissions that may necessitate targeted interference suppression measures in a residential or office environment.

2.9.2 Line harmonics requirements

The product is a device for professional applications as defined by EN 61000-3-2. The following generic standards apply when establishing a connection to the public power grid:
EN 61000-3-2
EN 61000-3-12
Cable length
[m]
for symmetric, three-phase devices (professional devices with a total power of up to 1kW)
for devices with a phase current of between 16A and 75A and professional devices from 1kW up to a phase current of 16 A.
Category to EN 61800-3 Limits to EN55011
Class B
Class A, Group 1
1983.844/02-EN

2.9.3 Interference immunity requirements

In general, the interference immunity requirements for a frequency inverter hinge on the specific environment in which the inverter is installed.
The requirements for industrial environments are therefore higher than those for residential and office environments.
The frequency inverter is designed such that the immunity requirements for industrial environments and, thus, the lower-level requirements for residential and office environments, are met and fulfilled.
The following relevant generic standards are used for the interference immunity test:
EN 61000-4-2: Electromagnetic compatibility (EMC)
– Part 4-2: Testing and measurement techniques – Electrostatic discharge
immunity test
EN 61000-4-3: Electromagnetic compatibility (EMC)
– Part 4-3: Testing and measurement techniques – Radiated, radio-frequency,
electromagnetic field immunity test
EN 61000-4-4: Electromagnetic compatibility (EMC)
– Part 4-4: Testing and measurement techniques – Electrical fast transient/burst
immunity test
EN 61000-4-5: Electromagnetic compatibility (EMC)
– Part 4-5: Testing and measurement techniques – Surge immunity test
EN 61000-4-6: Electromagnetic compatibility (EMC)
– Part 4-6: Testing and measurement techniques – Immunity to conducted
disturbances, induced by radio-frequency fields
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3 Transport/Temporary Storage/Disposal

3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and notify KSB or the supplying dealer and the insurer about the damage in writing immediately.

3.2 Transport

DANGER
Pressure booster system tipping over
Danger to life from falling pressure booster system!
Never suspend the pressure booster system by its power cable.Do not lift the pressure booster system by its manifold.Observe the applicable local accident prevention regulations.Observe the information on weights, centre of gravity and fastening points.Use suitable and permitted transport equipment, e.g. crane, forklift or pallet
jack.
ü Transport equipment/ lifting equipment suitable for the corresponding weight
has been selected and is on hand.
1. Remove the packaging. Remove the caps from the connection openings.
2. Check for any in-transit damage.
3. Transport the pressure booster system to the place of installation.
4. Detach the pressure booster system from the pallet using a suitable tool.
5. Attach the pressure booster system to the lifting equipment as illustrated.
6. Lift it off the wooden skids. Dispose of the wooden skids.
7. Carefully place down the pressure booster system at the site of installation.

3.3 Storage/preservation

CAUTION
Damage during storage due to frost, moisture, dirt, UV radiation or vermin
Corrosion/contamination of pressure booster system!
Store the pressure booster system in a frost-proof room. Do not store outdoors.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage of the pressure booster system!
Only open the openings of the pressure booster system at the time of
installation.
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NOTE
Rotate the shaft by hand every three months, e.g. via the motor fan.
1983.844/02-EN
If commissioning is to take place some time after delivery, the following measures are recommended when storing the pressure booster system:
KSB Delta Solo
3 Transport/Temporary Storage/Disposal
Store the pressure booster system in a dry, protected room where the atmospheric humidity is as constant as possible.
Table7: Ambient conditions for storage
Ambient condition Value
Relative humidity 50% maximum Ambient temperature 0°C to +40°C
Frost-freeWell-ventilated

3.4 Return to supplier

1. Drain the pressure booster system as per operating instructions.
2. Always flush and clean the pressure booster system, particularly if it has been used for handling noxious, explosive, hot or other hazardous fluids.
3. If the pressure booster system has handled fluids whose residues could lead to corrosion damage in the presence of atmospheric humidity or could ignite upon contact with oxygen, the pressure booster system must also be neutralised and treated with anhydrous inert gas to ensure drying.
4. Always complete and enclose a certificate of decontamination when returning the pressure booster system. (ðSection12,Page57) Always indicate any safety and decontamination measures taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination

3.5 Disposal

WARNING
Fluids handled, consumables and supplies which are hot and/or pose a health hazard
Hazard to persons and the environment!
Collect and properly dispose of flushing fluid and any fluid residues.Wear safety clothing and a protective mask if required.Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Dismantle the pressure booster system. Collect greases and other lubricants during dismantling.
2. Separate and sort the pump materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another controlled manner.
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3 Transport/Temporary Storage/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.
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4 Description

ID PN Prod. IP RDP PO U Kalkovenweg 13 F Alphen a/d Rijn, NL Imax www.ksb.com
KSB B. V.
Made in NL
KSB Delta Solo 1/1508
SVP
12345678
33A
50Hz
3x400V
PT
06/2018 1234567-01
123456789
54
10
1
14
13
12
6
11
10
9
8
7
2
5
43
4 Description

4.1 General description

Pressure booster system
4.2 Product information as per Regulation No. 1907/2006(REACH)
For information as per chemicals Regulation (EC) No. 1907/2006 (REACH), see http://
www.ksb.com/reach.

4.3 Description

Example: KSB Delta Solo 1/1508 SVP
Table8: Designation key
Code Description
KSB Delta Solo Type series 1 Number of pumps 15 Size 08 Number of stages SVP Design
SVP Pressure booster system with variable speed system and KSB
SuPremE motor

4.4 Name plate

Fig.1: Name plate (example)
1 Type series 8 Dry running protection 2 Design 9 Power supply voltage 3 Number of pumps 10 Power supply frequency 4 Size 11 Maximum current input 5 Number of pump stages 12 Max. operating pressure 6 Serial number 13 Enclosure 7 Month of production/ year of

4.5 Design details

1983.844/02-EN
Design
Fully automatic pressure booster systemVariable speed operationBaseplate-mounted
KSB Delta Solo
production, consecutive number
14 Order number
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4 Description
1
2
3
4
Hydraulic components made of stainless steel / brassCheck valveDischarge-side, direct-flow membrane-type accumulator, approved for drinking
water
Pressure gaugeIntegrated dry running protectionPressure transmitters on the inlet side and discharge sideVibration damping
Installation
Stationary dry installation
Drive
Electric motorEfficiency class IE4/IE5 to IECTS60034-30-2:2016IP54 enclosure
Automation
Frequency inverterControl panel (display, keys, LEDs, service interface)Control unit (IP54 enclosure)Fault message signalling contactOperation signalling contact

4.6 Configuration and function

Fig.2: Configuration
1 Control unit 3 Membrane-type accumulator 2 Pump 4 Baseplate
Design The fully automatic pressure booster system pumps the fluid to the consumer
installations in the set pressure range with a vertical high-pressure pump (2) (variable speed version).
1983.844/02-EN
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4 Description
Function The pump (2) is controlled and monitored by a motor-mounted frequency inverter.
As the demand increases or decreases, the pump is started and stopped automatically. The standard setting is for the pressure booster system to start automatically as a function of pressure; the actual pressure is measured by an analog pressure measuring device (pressure transmitter). As long as the pressure booster system is in operation, the pump is started and stopped as a function of demand (standard setting). In this way it is ensured that the pump operates only in line with actual demand. The use of this variable speed pump reduces wear as well as the frequency of pump starts. A fault is output, which can be reported via volt-free contacts (e.g. to the control station). If the demand drops towards 0, the pressure booster system slowly runs down to the stop point.
The pressure booster system is designed with integrated electronic dry running protection. A digital lack-of-water display can be connected at the corresponding contacts.
During commissioning and after every power failure, the pressure booster system fills the piping system slowly to prevent any damage to the piping by surge pressure.
If the pump has not been in operation for 24 hours, a test run is initiated.

4.7 Scope of supply

Depending on the model, the following items are included in the scope of supply:
Pressure booster system
1 vertical high-pressure centrifugal pump with oval flangePowder-coated / epoxy resin-coated steel baseplateCheck valveDischarge- side gate valveSuction-side gate valveSuction-side manifold and discharge-side manifold made of stainless steelPressure transmitter on the discharge sidePressure gaugeDry running protection on the inlet pressure sideDischarge-side, direct-flow membrane-type accumulator, approved for drinking
water
Control unit
IP54 enclosureControl panel (display, keys, LEDs, service interface)Three LEDs signalling the operating statusLockable master switch (repair switch)Frequency inverter
1983.844/02-EN
2) Multiple pump systems only

4.8 Dimensions

For dimensions refer to the outline drawings of the pressure booster system.

4.9 Terminal diagram

For the terminal assignment refer to the circuit diagram.
2)
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4 Description
1
2

4.10 Potential equalisation

A terminal marked with the earth symbol is provided at the power connection for connecting a PE conductor.
Fig.3: PE connection
1 Earthing terminal 2 Location of power connection
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