KSB Delta Primo Series, Delta Primo K, Delta Primo VP, Delta Primo SVP Installation And Operating Manual
Pressure Booster System
KSBDeltaPrimo
KSB Delta Primo K
KSB Delta Primo VP
KSB Delta Primo SVP
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual KSBDeltaPrimo
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 13/09/2018
Contents
Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Installation of partly completed machinery....................................................................................................6
1.3 Target group.....................................................................................................................................................6
1.4 Other applicable documents............................................................................................................................6
1.5 Symbols .............................................................................................................................................................6
1.6 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.............................................................................................8
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
3 Software Changes................................................................................................................................ 11
4 Transport/Temporary Storage/Disposal............................................................................................. 12
4.1 Checking the condition upon delivery..........................................................................................................12
4.2 Transport.........................................................................................................................................................12
4.3 Storage/preservation......................................................................................................................................12
4.4 Return to supplier ..........................................................................................................................................13
4.5 Disposal ...........................................................................................................................................................13
5 Description............................................................................................................................................ 14
5.1 General description ........................................................................................................................................14
5.2 Designation.....................................................................................................................................................14
5.3 Name plate......................................................................................................................................................14
5.4 Design details..................................................................................................................................................15
5.5 Configuration and function...........................................................................................................................16
5.6 Noise characteristics .......................................................................................................................................17
5.7 Scope of supply...............................................................................................................................................17
5.8 Dimensions and weights ................................................................................................................................18
5.9 Terminal wiring diagram ...............................................................................................................................18
5.10 Potential equalisation ....................................................................................................................................18
6 Installation at Site................................................................................................................................ 19
6.1 Installation ......................................................................................................................................................19
6.2 Checks to be carried out prior to installation...............................................................................................19
6.3 Installing the pressure booster system..........................................................................................................19
6.4 Connecting the piping ...................................................................................................................................20
6.4.1 Fitting an expansion joint .................................................................................................................20
6.4.2 Installing a pressure reducer .............................................................................................................20
6.5 Connection to power supply..........................................................................................................................21
6.5.1 Sizing the power cable ......................................................................................................................21
6.5.2 Connecting the pressure booster system..........................................................................................22
6.5.3 Volt-free contacts...............................................................................................................................22
7 Commissioning/Start-up/Shutdown................................................................................................... 23
7.1 Commissioning/Start-up.................................................................................................................................23
7.1.1 Prerequisites for commissioning/start-up .........................................................................................23
7.1.2 Dry running protection......................................................................................................................23
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Contents
7.1.3 Commissioning/start-up of pressure booster system .......................................................................23
7.2 Switching on the pressure booster system....................................................................................................24
7.3 Checklist for commissioning/start-up ............................................................................................................25
7.4 Shutdown........................................................................................................................................................25
8 Operating the Pressure Booster System............................................................................................. 26
8.1 KSB Delta Primo K, VP, SVP............................................................................................................................26
8.1.1 Control panel .....................................................................................................................................26
8.1.2 Menu structure...................................................................................................................................28
8.1.3 Access levels........................................................................................................................................29
8.1.4 Displaying and changing parameters ...............................................................................................30
8.1.5 Displaying messages ..........................................................................................................................31
8.1.6 Description of parameters.................................................................................................................31
8.1.7 Quick menu ........................................................................................................................................36
8.1.8 Saving and restoring settings............................................................................................................36
8.1.9 Alerts and warnings...........................................................................................................................36
8.1.10 Connecting the Remote OFF contact................................................................................................37
8.1.11 Connecting the fire alert ...................................................................................................................37
8.1.12 Charging the accumulator.................................................................................................................38
8.1.13 Energy-saving mode ..........................................................................................................................38
8.1.14 Flow detection ...................................................................................................................................38
8.1.15 Connecting the ambient temperature monitoring device (option) ...............................................38
8.1.16 Digital inputs for remote reset, setpoint changeover and check run (option)..............................39
9 Servicing/Maintenance........................................................................................................................ 40
9.1 General information/Safety regulations .......................................................................................................40
9.1.1 Inspection contract ...........................................................................................................................41
9.2 Servicing/Inspection........................................................................................................................................41
9.2.1 Supervision of operation ...................................................................................................................41
9.2.2 Checklist for inspection work............................................................................................................42
9.2.3 Setting the pre-charge pressure........................................................................................................42
9.2.4 Replacing the non-return valve ........................................................................................................43
9.2.5 Mounting the manifold in a mirrored position ...............................................................................45
10 Trouble-shooting.................................................................................................................................. 49
11 Related Documents.............................................................................................................................. 51
11.1 General assembly drawings/exploded views with list of components ........................................................51
11.1.1 KSB Delta Primo K..............................................................................................................................51
11.1.2 KSB Delta Primo VP............................................................................................................................52
11.1.3 KSB Delta Primo SVP ..........................................................................................................................53
12 EU Declaration of Conformity............................................................................................................. 54
13 Certificate of Decontamination........................................................................................................... 55
14 Commissioning report ......................................................................................................................... 56
Index ..................................................................................................................................................... 57
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Glossary
Glossary
Accumulator
The accumulator serves to compensate for
pressure losses in the piping system downstream
of the pressure booster system which may be
caused by the consumption of small quantities of
water. As a result, the frequency of starts of the
pressure booster system is minimised.
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.
Charging the accumulator
Option offered by speed-controlled pressure
booster systems of filling a discharge-side
accumulator before the last pump stops.
Energy-saving mode
Setting designed to avoid the energetically
inefficient operation of a pump at minimum water
consumption.
IE3
Efficiency class to IEC60034-30: 3=Premium
Efficiency (IE = International Efficiency)
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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 manual describes the proper and safe use of this equipment in all phases of
operation.
The name plate indicates the type series, the main operating data and the serial
number. The serial number uniquely describes the product and is used as
identification in all further business processes.
In the event of damage, immediately contact your nearest KSB Service centre to
maintain the right to claim under warranty.
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB refer to the sub-sections under
Servicing/Maintenance.
1.3 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (ðSection2.3,Page8)
1.4 Other applicable documents
Table1: 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
1.5 Symbols
Table2: 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
1.6 Key to safety symbols/markings
Table3: 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.
The safety information in all sections of this manual must be complied with.
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 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 in this operating manual.
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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2.3 Personnel qualification and personnel training
All personnel involved must be fully qualified to install, operate, maintain and
inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
installation, operation, maintenance and inspection must be clearly defined by the
operator.
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2 Safety
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 technical
specialist 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
2.5 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪ Accident prevention, health regulations and safety regulations
▪ Explosion protection regulations
▪ Safety regulations for handling hazardous substances
▪ Applicable 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 is 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.
▪ 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.
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2 Safety
▪ 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 10minutes.
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. (ðSection2.2,Page8)
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3 Software Changes
3 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.
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4 Transport/Temporary Storage/Disposal
4 Transport/Temporary Storage/Disposal
4.1 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.
4.2 Transport
NOTE
The pressure booster system is bolted to a pallet and wrapped in plastic film for
shipping and temporary storage. All connecting points are capped.
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 The pressure booster system has been checked for in-transit damage.
1. Make sure the transport equipment is suitable for safely carrying the indicated
load.
2. Transport the pressure booster system to the place of installation.
3. Attach the pressure booster system to the lifting tackle. Lift it off the pallet.
Dispose of the pallet.
4. Use suitable lifting equipment to lift the pressure booster system and carefully
place it down at the place of installation.
4.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken when storing the pressure booster system:
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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Store the pressure booster system in a dry, protected room where the atmospheric
humidity is as constant as possible.
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4 Transport/Temporary Storage/Disposal
4.4 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. (ðSection13,Page55)
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
4.5 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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5 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 Primo 3/1508
SVP
48278756
56.1A
50 Hz
3x400V
PT
01/2018 1234567-01
123456789
54
16
1
14
13
12
6
11
10
9
8
7
2
5
4
3
5 Description
5.1 General description
▪ Pressure booster system
5.2 Designation
Example: KSB Delta Primo 3/1508 SVP
Table4: Designation key
Code Description
KSB Delta Primo Type series
3 Number of pumps
15 Pump size
08 Number of pump stages
SVP Design
K Fixed speed pressure booster system
VP Pressure booster system with cabinet-mounted variable speed
SVP Pressure booster system with variable speed system and
system
KSB SuPremE motor
5.3 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
production, consecutive number
14 Order number
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5 Description
5.4 Design details
Design
▪ Compact system mounted on a common base frame
▪ One or more vertical high-pressure pumps with variable speed system
▪ Hydraulic components made of stainless steel/ brass for high operating reliability
Multiple pump system:
▪ Check valve per pump
▪ Discharge-side gate valve per pump
▪ Suction-side gate valve per pump
KSB Delta Primo K:
▪ Power contactor per pump
KSB Delta Primo VP, SVP:
▪ One frequency inverter per pump
Installation
▪ Stationary dry installation
Drive
KSB Delta Primo K, VP:
▪ Electric motor
▪ Efficiency class IE3 to IEC60034-30
KSB Delta Primo SVP:
▪ Magnetless synchronous reluctance motor
▪ Efficiency class IE5 to IEC60034-30
▪ KSB SuPremE
Automation
▪ Control cabinet IP54
– Sheet steel housing: colour RAL7035
– BoosterControl Advanced
– Graphical display with operating panel
– Three LEDs signalling the operating status
– Lockable master switch (repair switch)
– Motor protection switch per pump
– Service interface for KSB ServiceTool
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5 Description
1
2
3
4
5
6
1
2
3
4
5
6
5.5 Configuration and function
Fig.2: KSB Delta Primo
1 Control cabinet
2 Control unit
3 Vertical high-pressure pumps
4 Membrane-type accumulator
5 Manifold
6 Baseplate
Design Fully automatic pressure booster system with two or three vertical high-pressure
pumps (3) for ensuring the required supply pressure
Function KSB Delta Primo K:
Either 2 or 3 pumps are controlled and monitored by a micro-processor control unit
(BoosterControl Advanced). The first pump is started up when the pressure falls
below the set start-up pressure. Additional pumps are sequenced in automatically in
line with actual demand. When demand decreases, the pumps are sequenced out
again as the stop pressure (start-up pressure+ deltap) is reached. The pump that has
been started up first will be stopped first. The pumps are automatically started up in
a different order for each new cycle. The actual pressure is measured by an analog
pressure measuring device (pressure transmitter). The function of this pressure
transmitter is monitored (live-zero).
This ensures equal distribution of pump operating hours.
If a duty pump fails, the next pump is started up immediately. A fault is output,
which can be reported via volt-free contacts (e.g. to the control station).
The operating status is displayed via LEDs.
▪ Green: system ready for operation
▪ Yellow: warning
▪ Red: alert
2 volt-free contacts on terminals are provided for reporting warnings and alerts.
KSB Delta Primo VP, SVP:
Either 1 or more pumps are controlled and monitored by a micro-processor control
unit (BoosterControl Advanced). Each pump is operated on a frequency inverter and
controlled by the control unit so as to ensure a constant discharge pressure of the
pressure booster system.
As the demand increases or decreases, peak load pumps are started and stopped
automatically. As soon as the demand increases again after one pump has been
stopped, another pump which has not been in operation before is started up. When
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5 Description
the last pump has been stopped and the demand increases again, the next pump in
line is started up on a frequency inverter. The stand-by pump is also included in the
alternating cycle.
The standard setting is for the pressure booster system to start automatically as a
function of pressure. As long as the pressure booster system is in operation, the
pumps are started and stopped as a function of demand (standard setting). In this
way it is ensured that the individual pumps operate only in line with actual demand.
If the demand drops towards 0, the pressure booster system slowly runs down to the
stop point.
The operating status is displayed via LEDs.
▪ Green: system ready for operation
▪ Yellow: warning
▪ Red: alert
2 volt-free contacts on terminals are provided for reporting warnings and alerts.
5.6 Noise characteristics
The pressure booster systems are available with different numbers of pumps and
different pump sizes.
Therefore, the expected total sound pressure level in dB(A) needs to be calculated.
1. Refer to the pumps' operating manual for the noise characteristics of the
individual pumps.
2. Calculate the expected total sound pressure level.
Table5: Calculating the expected total sound pressure level
Number of pumps Expected total sound pressure level
Single pump See pump operating manual
2 pumps +3dB(A)
3 pumps +4,5dB(A)
Total dB(A)
Table6: Example of calculating the expected total sound pressure level
Number of pumps Expected total sound pressure level
Single pump 48dB(A)
2 pumps +3dB(A)
Total 51dB(A)
The expected total sound pressure level of 51dB(A) for this configuration may
develop when both pumps are running under full-load conditions.
5.7 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪ 2 or 3 vertical high-pressure centrifugal pumps with oval flange
▪ Powder-coated / epoxy resin-coated steel baseplate
▪ Integrated check valve per pump
▪ Discharge-side gate valve per pump
▪ Suction-side gate valve per pump
▪ Suction-side manifold and discharge-side manifold made of stainless steel
▪ Pressure transmitter on the discharge side
▪ Pressure gauge
▪ Dry running protection switch on the inlet pressure side
▪ Membrane-type accumulator on the discharge side, approved for drinking water
▪ Control cabinet IP54
– Sheet steel housing: colour RAL7035
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5 Description
1
2
– Parameterisable BoosterControl Advanced control unit
– Graphical display with operating panel
– Three LEDs signalling the operating status
– Lockable master switch (repair switch)
– Motor protection switch per pump
– One frequency inverter per pump
– Service interface for KSB ServiceTool
5.8 Dimensions and weights
For dimensions and weights refer to the outline drawings of the pressure booster
system.
5.9 Terminal wiring diagram
For the terminal assignment refer to the circuit diagram.
5.10 Potential equalisation
A terminal marked with the earth symbol is provided on the baseplate for connecting
a PE conductor.
Fig.3: Earth symbol
Fig.4: PE terminal
1 Earthing terminal 2 Baseplate
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