KSB Delta Solo SVP, Delta Basic SVP Operating Manual

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Pressure Booster System

KSB Delta Solo

KSB Delta Solo SVP

Installation/Operating Manual

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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.

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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

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

1.1 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

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 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 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) 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

3.1 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:

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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-free ▪ Well-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

06/2018 1234567-01

123456789

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 system ▪ Variable speed operation ▪ Baseplate-mounted

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production, consecutive number

14 Order number

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4 Description

▪ Hydraulic components made of stainless steel / brass ▪ Check valve ▪ Discharge-side, direct-flow membrane-type accumulator, approved for drinking

water

▪ Pressure gauge ▪ Integrated dry running protection ▪ Pressure transmitters on the inlet side and discharge side ▪ Vibration damping

Installation

▪ Stationary dry installation

Drive

▪ Electric motor ▪ Efficiency class IE4/IE5 to IECTS60034-30-2:2016 ▪ IP54 enclosure

Automation

▪ Frequency inverter ▪ Control panel (display, keys, LEDs, service interface) ▪ Control unit (IP54 enclosure) ▪ Fault message signalling contact ▪ Operation 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 flange ▪ Powder-coated / epoxy resin-coated steel baseplate ▪ Check valve ▪ Discharge- side gate valve ▪ Suction-side gate valve ▪ Suction-side manifold and discharge-side manifold made of stainless steel ▪ Pressure transmitter on the discharge side ▪ Pressure gauge ▪ Dry running protection on the inlet pressure side ▪ Discharge-side, direct-flow membrane-type accumulator, approved for drinking

water

Control unit

▪ IP54 enclosure ▪ Control panel (display, keys, LEDs, service interface) ▪ Three LEDs signalling the operating status ▪ Lockable 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.

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4 Description

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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5 Installation at Site

5.1 Checks to be carried out prior to installation

WARNING

Installation on mounting surfaces which are unsecured and cannot support the load

Personal injury and damage to property!

▷ Use a concrete of compressive strength class C12/15 which meets the

requirements of exposure class X0 to EN206-1.

▷ The mounting surface must have set and must be completely horizontal and

even.

▷ Observe the weights indicated.

NOTE

The anti-vibration mounts of the pressure booster system provide adequate insulation against solid-borne noise. Thanks to level-adjustable feet (KSB accessory) the pressure booster system can also be installed in a horizontal position on uneven floors.

For pressure booster systems with pumps, Movitec 2, 4, 6, 10, 15 level-adjustable feet are available as accessories.

NOTE

Do not install pressure booster systems next to sleeping or living quarters.

NOTE

The installation room must provide for suitable drainage.

Before beginning with the installation check the following:

▪ All structural work required has been checked and prepared in accordance with

the dimensions in the outline drawing.

▪ The pressure booster system can be operated on the power supply network

according to the data on the name plate.

▪ The place of installation is frost-free. ▪ The place of installation can be locked. ▪ The place of installation is well-ventilated. ▪ A suitably dimensioned drain connection (e.g. leading to a sewer) is available. ▪ If expansion joints are used, take note of their creep resistance. Expansion joints

must be easily replaceable.

1983.844/02-EN

5.2 Installing the pressure booster system

WARNING

Top-heavy pressure booster system

Risk of personal injury by pressure booster system tipping over!

▷ Pressure booster systems awaiting final installation must be secured against

tipping over.

▷ Firmly anchor the pressure booster system.

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5 Installation at Site

1952:116

NOTE

To prevent the transmission of piping forces and solid-borne noise, installing expansion joints with length-limiters is recommended.

ü The pressure booster system’s packaging has been removed. ü A suitable installation site has been selected that meets the requirements. ü Sufficient clearance in all directions is provided for servicing work.

1. Mark out the anchoring holes on the floor as shown in the outline drawing.

2. Drill the holes (max. diameter: 12mm).

3. Insert plug fixings of appropriate size.

4. Place the pressure booster system in its correct installation position.

5. Use suitable bolts to firmly anchor the pressure booster system.

5.3 Mounting the accumulator

CAUTION

Dirt in the pressure booster system

Damage to the pump sets!

▷ Clean the accumulator before filling it.

ü The original operating manual of the pressure booster system is on hand.

1. Mechanically and electrically connect the accumulator in accordance with the original operating manual supplied.

5.4 Connecting the piping

CAUTION

Air pockets in suction line

Pressure booster system cannot prime!

▷ Lay the pipe with a continuously rising slope.

Fig.4: Correct piping connection

1 Suction lift operation

1. Mechanically support the suction head line on site to provide for absorption of mechanical forces.

2. Install the piping without transmitting any stresses and strains.

3. Connect the piping to the distribution lines on the inlet side and discharge side.

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NOTE

For single-pump systems, the shut-off valves must be fitted directly at the system's suction-side connection and discharge-side connection, respectively. This will enable straightforward replacement and servicing.

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5 Installation at Site

5.4.1 Fitting an expansion joint (optional)

DANGER

Sparks and radiant heat

Fire hazard!

▷ Take suitable precautions to protect the expansion joint if any welding work is

carried out.

CAUTION

Leaking expansion joint

Flooding of installation room!

▷ Do not apply any paint to the expansion joint. ▷ Keep the expansion joint clean. ▷ Regularly check for cracks or blisters, exposed fabric or other defects.

ü Sufficient clearance in all directions is provided for checking the expansion joint. ü The expansion joint is not insulated along with the pipeline insulation.

1. The expansion joint has a length limiter with solid-borne sound insulation.

2. Install the expansion joint in the piping free of twist or distortion. Never use the expansion joint to compensate for misalignment or mismatch of the piping.

3. Evenly tighten the bolts crosswise. The ends of the bolts must not protrude from the flange.

Example p

5.4.2 Fitting the pressure reducer (optional)

NOTE

A pipe length of approximately 600 mm must be provided on the inlet side to accommodate a pressure reducer, if necessary.

NOTE

A pressure reducer must be installed if the inlet pressure fluctuation is too high for the pressure booster system to operate as intended or if the total pressure (inlet pressure and shut-off head) exceeds the design pressure.

The inlet pressure (p 5m is required for the pressure reducer to function properly. This means that the pressure reducer must be mounted 5m higher than the pressure booster system. The pressure drops by about 0.1bar per metre of height difference. Alternatively, the pressure reducer can be subjected to a pressure of 0.5 bar.

=4bar

inl

Minimum pressure gradient=5m ≙ 0.5bar Downstream pressure:4bar - 0.5bar = 3.5bar.

ü A minimum pressure gradient of 5m is available.

1. Install the pressure reducer in the pipe on the inlet side.

) varies between 4and 8bar. A minimum pressure gradient of

inl

1983.844/02-EN

5.5 Fitting the dry running protection device

Install the dry running protection device supplied together with the pressure booster system as a separate, non-fitted accessory, or supplied at a later date for retrofitting, in accordance with its operating instructions and connect it to the switchgear and controlgear assembly. The switchgear and controlgear assembly is provided with the requisite inputs.

1. Remove the front cover to access the terminal strip.

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Page 22

400V/ 3~ variant with

L1 L2 L3

LINE

PE U V W

MOTOR

PTC

MOTOR

DI-EN

+24V

GND

DI3

DI2

DI1

+24V

DICOM

AO-GND

AIN2

NO1

+24V

GND

COM1

+24V

B 8

B10

GND

AIN1

+24V

C 3

GND

B2B3B4

B 5

A1A2A3

A5A6A7

A 10

C 4

2relays

5 Installation at Site

Fig.5: Overview of terminal strips for 400V/ 3~ variant with 1relay

1 Connection to power supply

2 Control cables

network and motor

In the case of direct connection (direct connection of the pump system to the drinking water supply line of the public water supply system):

1. Use a wire jumper to connect DI1 (B4) and +24V (B3). ð When this connection type is used, monitoring by the suction-side pressure

sensor protects the pump system against lack of water.

In the case of indirect connection (connection to an unpressurised drinking water reservoir (water tank)):

1. Remove the wire jumper between DI1 (B4) and +24V (B3). Connect an external dry running protection device (e.g. a float switch) in its place.

ð When this connection type is used, the lack-of-water function must be

adjusted.

Adjusting the lack-of-water function:

1. Log in at the frequency inverter using the customer login (standard: 0000). Open parameter 3 "Settings".

2. Open parameter 3-9-11 "Lack-of-water function". Adjust parameters 3-9-11-5 and 3-9-11-6 .

3. If a single-pump pressure booster system is operated with an indirect connection (e.g. water tank), set parameter 3-9-11-4 to "OFF".

5.6 Electrical connection

DANGER

Electrical connection work by unqualified personnel

Danger of death from electric shock!

▷ Always have the electrical connections installed by a trained and qualified

electrician.

▷ Observe regulations IEC60364.

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WARNING

Incorrect connection to the mains

Damage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.

NOTE

Installing a motor protection device is recommended.

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5 Installation at Site

NOTE

If a residual current device is installed, observe the operating manual for the frequency inverter.

Lightning protection

▪ Electrical installations must be protected against overvoltage (compulsory since

14December2018) (see DINVDE0100-443 (IEC60364-4-44:2007/A1:2015, modified) and DIN VDE 0100-534 (IEC 60364-5-53:2001/A2:2015, modified). Whenever modifications are made to existing installations, retrofitting a surge protective device (SPD) in accordance with VDE is mandatory.

▪ A maximum cable length of 10metres should not be exceeded between the

surge protective device (usually type 1, internal lightning protection) installed at the service entrance and the equipment to be protected. For longer cables, additional surge protective devices (type 2) must be provided in the subdistribution board upstream of the equipment to be protected or directly in the equipment itself.

▪ The associated lightning protection concept must be provided by the operator or

by a suitable provider commissioned by the operator. Surge protective devices can be offered for the control units on request.

Wiring diagram

The wiring diagrams are located in the control cabinet, which is where they must be stored. The product literature of the switchgear and controlgear assembly supplied with the system includes a list of the electrical components installed. When ordering spare parts for electrical components, always indicate the number of the wiring diagram.

Terminal assignment

For the terminal assignment refer to the wiring diagram.

5.6.1 Sizing the power cable

Determine the cross-section of the power cable based on the total rated power required.

5.6.2 Connecting the pressure booster system

Plug the mains plug into a suitable socket. Observe the data on the name plate.

5.6.2.1 Fitting an expansion joint (optional)

DANGER

Sparks and radiant heat

Fire hazard!

▷ Take suitable precautions to protect the expansion joint if any welding work is

carried out.

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5 Installation at Site

CAUTION

Leaking expansion joint

Flooding of installation room!

▷ Do not apply any paint to the expansion joint. ▷ Keep the expansion joint clean. ▷ Regularly check for cracks or blisters, exposed fabric or other defects.

ü Sufficient clearance in all directions is provided for checking the expansion joint. ü The expansion joint is not insulated along with the pipeline insulation.

1. The expansion joint has a length limiter with solid-borne sound insulation.

2. Install the expansion joint in the piping free of twist or distortion. Never use the expansion joint to compensate for misalignment or mismatch of the piping.

3. Evenly tighten the bolts crosswise. The ends of the bolts must not protrude from the flange.

5.6.2.2 Fitting the pressure reducer (optional)

NOTE

Example p

A pipe length of approximately 600 mm must be provided on the inlet side to accommodate a pressure reducer, if necessary.

NOTE

=4bar

inl

Minimum pressure gradient=5m ≙ 0.5bar Downstream pressure:4bar - 0.5bar = 3.5bar.

ü A minimum pressure gradient of 5m is available.

1. Install the pressure reducer in the pipe on the inlet side.

5.6.3 Connecting the dry running protection device

ü The original operating manual of the dry running protection device is on hand.

1. Fit the dry running protection device in accordance with the supplied original operating manual. Connect it in the control unit in accordance with the supplied original operating manual.

) varies between 4and 8bar. A minimum pressure gradient of

inl

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1983.844/02-EN

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6 Commissioning/Start-up/Shutdown

6.1 Commissioning/Start-up

6.1.1 Prerequisites for commissioning/start-up

Before commissioning/start-up of the pressure booster system make sure that the following requirements are met:

▪ The pressure booster system has been properly connected to the electric power

supply and is equipped with all protection devices.

▪ All relevant VDE standards and/or regulations applicable in the country of use are

complied with.

▪ The dry running protection device has been installed.

CAUTION

Dry running of pump

Damage to the pump/pressure booster system!

▷ If no dry running protection device is connected when commissioning takes

place, pressure booster systems in manual or test run mode will be stopped automatically after approx. 10 seconds. If the dry running protection terminal is disabled by means of a bridge, the operator shall assume responsibility for any dry running that might occur.

NOTE

The competent authorities must be informed in due time prior to commissioning/ test running the system.

6.1.2 Dry running protection

Pressure booster systems are fitted with a dry running protection device. A float switch whose volt-free contact closes the circuit in upper float position can be

connected to the control system as dry running protection. Follow the float switch manufacturer's instructions on how to set the float switch levels.

6.1.3 Commissioning/start-up of pressure booster system

NOTE

Prior to its delivery, the pressure booster system will be tested hydraulically with water and then drained again. For technical reasons the presence of some residual water is unavoidable.

Prior to commissioning/start-up observe EN806. After prolonged standstill periods, flushing or professional disinfection is recommended. For extensive or branched piping systems, flushing the pressure booster system can be restricted to a limited area.

CAUTION

1983.844/02-EN

Foreign matter in the piping

Damage to the pump / pressure booster system!

▷ Before commissioning/starting up or functional check running the pressure

booster system, make sure that there is no foreign matter in the pressure booster system or piping.

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Page 26

6 Commissioning/Start-up/Shutdown

NOTE

Commissioning of the pressure booster system - even test running - shall only be carried out in full compliance with all pertinent VDE (German Association of Electrical Engineers) regulations.

CAUTION

Operation without the fluid to be handled

Damage to the pump sets!

▷ Prime the pressure booster system with the fluid to be handled.

ü The pipe unions between the pump and the piping have been re-tightened. ü Flange connections have been firmly tightened. ü The cooling air inlet openings and cooling air outlet openings at the motor are

unobstructed.

ü All shut-off valves of the pressure booster system are open. ü The pre-charge pressure of the membrane-type accumulator has been checked.

1. Disconnect the mains plug from the power supply.

2. Provide connection to power supply.

3. Open/loosen the vent plugs on the pump (refer to the pump's installation/ operating manual).

4. Slowly open the inlet-side shut-off element and prime the pressure booster system until the fluid to be handled escapes through all vent holes.

5. Close and slightly tighten the pump vent plugs.

6. Switch on all motor protection switches.

7. Set the manual-0-automatic selector switch (if any) to Automatic.

8. Switch on the master switch.

9. Open the discharge-side shut-off element.

10. After the pump set has been run once, switch it off and loosen the vent plugs again to let any remaining air escape.

11. Tighten the vent plug firmly.

12. Verify that the pump is running smoothly.

13. Close the discharge-side shut-off element for a short period in order to verify that the pump reaches the shut-off head.

14. Close the discharge-side shut-off element, causing the pump to stop.

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NOTE

Minor leakage of the mechanical seals during commissioning is normal and will cease after a short period of operation.

6.2 Start-up

NOTE

The pressure booster system is factory-set to the data indicated on the name plate.

Standard design

ü The pressure booster system has been primed and vented.

1. Switch on the master switch.

ð The green LED lights up and signals the system's readiness for operation.

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6 Commissioning/Start-up/Shutdown

Additional instruments

ü The pressure booster system has been primed and vented.

1. Set the manual-0–automatic selector switch to automatic.

ð The green LED lights up and signals the system's readiness for operation.

6.3 Checklist for commissioning/start-up

Table9: Checklist

Actions Done

1 Read the operating manual. 2 Compare the power supply data against the name plate data. 3 Check the earthing system (taking measurements). 4 Check the mechanical connection to the water mains.

Re-tighten the flange bolting and pipe unions. 5 Check the pre-charge pressure. 6 Prime and vent the pressure booster system from the inlet side. 7 Check inlet pressure. 8 Check whether all cables are still firmly connected to the terminals inside the control unit. 9 Check the start and stop pressure; re-adjust if necessary. 10 Test the proper function of the lack-of-water and dry-running protection equipment. If not

fitted, make a relevant note in the acceptance report. 11 Vent the pump for a second time after it has been running for 5 to 10 minutes. 12 Set all switches to automatic. 13 Record all system conditions that do not correspond to our specifications or to the purchase

order in the commissioning report (i.e. no dry running protection or inlet pressure + max.

pressure of pressure booster system higher than 16bar). 14 Complete the commissioning report together with the operator/user and instruct the operator/

user as to the function of the unit.

1983.844/02-EN

6.4 Shutdown

NOTE

As long as the pressure booster system is out of operation, water is supplied directly at p

through the pressure booster system.

inl

Set the master switch to "0".

NOTE

Drain the pressure booster system for prolonged shutdown.

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Page 28

7 Operation

AUTO

1/min

OFFOFF

MAN

AUTO

1/min

m h kW

A V Hz

% °C bar

1 2

7 Operation

7.1 Standard control panel

Fig.6: Standard control panel

Table10: Description of standard control panel

Item Description Function

1 Service interface Optical interface 2 LED traffic light function The traffic light function provides information about the system's

operating status. 3 Display Displays information on frequency inverter operation 4 Operating keys Toggling operating modes 5 Navigation keys Navigation and parameter setting

7.1.1 Display

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Fig.7: Main screen (example)

1 Operating point display 2 Type of control 3 Display of the current operating mode

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7 Operation

AUTO

bar

AUTO

bar

AUTO

1/min

4 Units 5 Menu, parameter number, parameter values 6 Log in as customer 7 Active wireless connection

The wireless icon illuminates when the Bluetooth module is inserted. The

wireless icon flashes when communication takes place. 8 Single/dual pump 9 Rotational speed 0-100%

Table11: Menu, parameter number, parameter values, messages

Display Function

Menu example: Open-loop Control (1-3):

▪ The letter S is used as the first character to identify a menu.

▪ The second character identifies the first menu level, i.e. Operation S1-x-x-x,

Diagnosis S2-x-x-x, Settings S3-x-x-x and Information S4-x-x-x.

▪ The wrench icon shows that you have logged in as a customer.

Menu example: Open-loop Control

Parameter number example: Setpoint (Closed-loop Control) (1-3-2):

▪ The letter P is used as the first character to identify a parameter number.

▪ The following characters show the parameter number.

▪ The wrench icon shows that you have logged in as a customer.

Parameter number example: Setpoint (Closed-loop Control)

Parameter value example: Setpoint (Closed-loop Control)

Message example: Dry running

Parameter value example: Setpoint (Closed-loop Control) (1-3-2) set to 4 bar:

▪ If a parameter value can be edited, the digit flashes.

▪ The wrench icon shows that you have logged in as a customer.

Message example: Dry running (E13):

▪ A message is identified by the letter E (Error) and a unique number.

1983.844/02-EN

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Table12: Assignment of keys

ESC

MAN

OFF

AUTO

MAN

ESC

Key Function

Arrow keys:

▪ Move up/down in the menu options. ▪ Increase/decrease a numerical value. (When an arrow key is pressed and held down, the

response repeats in ever shorter intervals.)

Escape key:

▪ Delete/reset entry

(the entry is not saved).

▪ Move up one menu level.

OK key:

▪ Confirm settings. ▪ Confirm menu selection. ▪ Move to the next digit when entering numerals. ▪ Message display: Acknowledge alert. ▪ Measured value display: Go to Favourites menu.

MAN operating key:

▪ Starts the frequency inverter in manual operating mode.

7 Operation

OFF operating key:

▪ Stops the frequency inverter.

AUTO operating key:

▪ Switches to automatic operating mode.

Manual mode via control panel

NOTE

After a power failure, the frequency inverter reverts to the OFF operating mode. Manual mode must be restarted.

Table13: Assignment of keys for manual mode

Key Function

MAN operating key:

▪ When switching the operating mode from AUTO to MAN, the current operating speed is

used as control value (Manual) 1-3-4 and is displayed accordingly. The control point 1-3-10 must be set to Local.

▪ When switching the operating mode from OFF to MAN, the frequency inverter operates

at minimum speed. The control point 1-3-10 must be set to Local.

▪ If the control value (Manual) 1-3-4 is defined via an analog input, the analog input speed

is accepted.

Arrow keys:

▪ Pressing the arrow keys changes and immediately accepts the control value (Manual)

1-3-5. Making a change using the arrow key has a direct effect even when not confirmed with OK. The speed can only be changed between the set minimum speed and the maximum speed.

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ESC/OK key:

▪ Press the OK or ESC key to go from digit to digit. Press the ESC key to go back. Changes

are rejected. Pressing the OK key for the right-hand digit takes you back to the main screen.

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7 Operation

AUTO

1/min

AUTO

1/min

AUTO

A Hz

ESC

1 2

7.1.2 Main screen

The main screen shows factory default operating values.

Fig.8: Selecting and displaying operating values on the main screen

1 Parameter number for speed (1-2-1-1) 2 Current speed [rpm] 3 Parameter number for motor input power (1-2-1-2)

1983.844/02-EN

4 Current power input of motor in kW 5 Parameter number for motor current (1-2-1-5) 6 Current motor current in A

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7 Operation

AUTO

1/min

AUTO

ESC

OKESC

AUTO

1/min

1 2

7 Parameter number for output frequency (1-2-1-7) 8 Current output frequency in Hz

If a message (alert, warning or information) is currently active, it will be displayed on the main screen.

Fig.9: Message display A message is identified by the letter E (Error) and a unique number (see list of all

messages in the Annex). The traffic light function shows whether the message is an alert (red LED), a warning (amber LED) or just information (green LED).

Messages are acknowledged by pressing OK. Acknowledged and gone messages are listed in the message history in Menu 2 – Diagnosis.

NOTE

If the motor standstill heater has been switched on, the display alternates between the measured value and the letter H.

7.1.3 Settings menu

NOTE

The standard control panel is designed to be used for simple settings only (e.g. setting the setpoint). We recommend using the KSB ServiceTool for more extensive configuration tasks.

Opening the Settings menu: Press and hold the ESC key and press OK.

Fig.10: Switch to the settings menu

1 Main screen 2 Settings menu

The wrench icon indicates that the settings menu is called up and a value can be edited.

The parameter numbers identify the navigation path, which helps you find a particular parameter quickly and easily. The first digit of the parameter number indicates the first menu level, which is called up directly via the four menu keys.

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Page 33

7 Operation

7.1.3.1 Menu: Operation

The Operation section contains all information required for operating the machine and the process. This includes:

▪ Login to device with password ▪ Operating and measured values for motor, frequency inverter, pump and system ▪ Setpoints and control values ▪ Energy meter and operating hours

7.1.3.1.1 Access levels

Three access levels have been defined to prevent unintentional or unauthorised access to frequency inverter parameters:

Table14: Access levels

Access level Description

Standard (No Login) Access without password entry. Customer Access level for the expert user with access to all parameters required for

commissioning

Customer service Access level for service personnel.

If a parameter's access level is not explicitly specified, the parameter is always assigned the Customer access level.

Table15: Access level parameters

Parameter Description Possible settings Factory setting

1-1-1 Customer Login

Customer service parameters can only be accessed using the KSBServiceTool and the appropriate dongle.

0000...9999 0000

NOTE

If no keys are pressed for five minutes, the system will automatically return to the Standard access level.

The password can be changed after entering the factory default password.

Table16: Parameter for changing the password (requires use of the KSBServiceTool)

Parameter Description Possible settings Factory setting

1-1-5 Customer Access ID

Changing the customer access ID

7.1.3.2 Menu: Diagnosis

In the Diagnosis section, the user is provided with information about faults and warning messages that pertain to the pump set or process. The frequency inverter can be in fault (standstill) or warning (operational) status. The user can also find previous messages in the history.

0000...9999 -

1983.844/02-EN

Messages

All monitoring and protective functions trigger warnings or alerts. These are signalled via the amber or red LED of the LED traffic light function.

A corresponding message is output on the control panel display. If more than one message is output, the last one is displayed. Alerts have priority over warnings.

Pending messages If a message has occurred and been acknowledged but has not gone, this message

will be listed in the Pending Messages menu. All current messages can be displayed in the Diagnosis menu under Pending Messages (2-1). Active warnings and alerts can also be connected to the relay outputs.

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7 Operation

Message history Only messages that have come, been acknowledged, and gone are listed in the

message history. The message history can be viewed by selecting the Message History parameter 2-2. The last 100 messages are listed here. You can use the arrow keys and the OK key to select an entry from the list.

Acknowledging and resetting messages

NOTE

Depending on the combination of settings, the frequency inverter could conceivably restart automatically after acknowledgement/reset or when the cause of the malfunction or fault has been eliminated.

Acknowledgement Messages can be acknowledged once the cause has been rectified. Messages can be

acknowledged individually in the Diagnosis menu. A message can also be acknowledged via a digital input. Digital input 2 is defaulted for this purpose.

Overview of warnings and alerts (ðSection9,Page42) Messages can be acknowledged as follows:

Table17: Acknowledgement types for messages

Property of message Type of acknowledgement

Self-acknowledging Message is automatically acknowledged if condition for message no longer applies. Automatic

acknowledgement (configurable)

Partially automatic acknowledgement

No automatic acknowledgement

Time stamp If a message is not acknowledged and its condition comes and goes several times in

Users can choose between automatic acknowledgement and manual acknowledgement.

Alerts that are partially acknowledged automatically carry out automatic acknowledgement in increasingly large intervals after the alert condition no longer applies. If the alert occurs repeatedly within a specific time window, automatic acknowledgement is suspended.

As soon as the alarm condition of a pending alert no longer exists, the time interval is started. When this interval expires, automatic acknowledgement takes place.

If the alert occurs again within 30seconds after the time interval has started, the interval is extended by one increment. Should this not be the case, the previous (shorter) time interval is reverted to and corresponding action is taken again in 30seconds. The time intervals are 1second, 5seconds, 20seconds, and endless (i.e. manual acknowledgement is required). When the 20-second interval is extended, automatic acknowledgement no longer takes place.

Must be acknowledged manually.

this time window, the first occurrence of the message is always used for the Message Come time stamp. The Message Condition Gone time stamp, however, always shows the last time the message condition was no longer active.

7.1.3.3 Menu: Settings

General settings can be made or the settings for the process optimised in the Settings section.

Locking operating keys

Table18: Parameters for setting the control panel

Parameter Description Possible settings Factory setting

3-1-2-2 Control Keys Require Login

The MAN, OFF, AUTO and FUNC keys are locked without a valid login (customer).

Locking operating keys The operating keys of the control panel can be locked via the 3-1-2-2 parameter to

prevent unauthorised operation or unauthorised acknowledgement of alerts.

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▪ 0 = OFF ▪ 1 = ON

0 = OFF

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Page 35

7 Operation

7.1.3.4 Menu: Information

All direct information about the frequency inverter is provided in the Information section. Important details regarding the firmware version are listed here.

7.1.4 Service interface and LED traffic light function

Service interface The service interface allows a PC/notebook to be connected via a special cable (USB –

optical). The following action can be taken:

▪ Configuring and parameterising the frequency inverter with the service software ▪ Software update ▪ Saving and documenting set parameters

LED traffic light function The LED traffic light function provides information about the current operating

status of the frequency inverter.

Table19: LED description

LED Description

Red Amber Green

One or more than one alert is active One or more than one warning is active Steady light: Trouble-free operation

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Page 36

8 Servicing/Maintenance

8.1 General information/Safety regulations

DANGER

Unintentional start-up of pressure booster system

Danger to life!

▷ De-energise the pressure booster system for any repair work or servicing work. ▷ Ensure that the pressure booster system cannot be re-energised unintentionally.

DANGER

Voltage at the pressure booster system

Danger to life!

▷ Prior to opening the device, wait at least 10minutes for any residual voltage to

dissipate.

WARNING

Improper lifting/moving of heavy assemblies or components

Personal injury and damage to property!

▷ Use suitable transport devices, lifting equipment and lifting tackle to move

heavy assemblies or components.

WARNING

Unintentional start-up of pressure booster system

Risk of injury by moving parts!

▷ Make sure the pressure booster system has been de-energised before

commencing work on the pressure booster system.

▷ Make sure that the pressure booster system cannot be started up

unintentionally.

WARNING

Unqualified personnel performing work on the pressure booster system

Risk of personal injury!

▷ Always have repair and maintenance work performed by specially trained,

qualified personnel.

CAUTION

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Incorrectly serviced pressure booster system

Function of pressure booster system not guaranteed!

▷ Regularly service the pressure booster system. ▷ Prepare a maintenance schedule for the pressure booster system, with special

emphasis on lubricants, shaft seals and pump couplings.

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8 Servicing/Maintenance

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

▪ Observe the safety instructions and information. ▪ For any work on the pump (set) observe the operating manual of the pump (set). ▪ In the event of damage you can always contact KSB Service . ▪ A regular maintenance schedule will help avoid expensive repairs and contribute

to trouble-free, reliable operation with a minimum of maintenance expenditure and work.

▪ Never use force when dismantling and reassembling the equipment.

8.1.1 Inspection contract

For all inspection work and servicing work to be carried out at regular intervals we recommend taking out the KSB inspection contract. Contact your service partner for details.

8.2 Servicing/Inspection

8.2.1 Supervision of operation

CAUTION

Increased wear due to dry running

Damage to the pump set!

▷ Never operate the pump set without liquid fill. ▷ Never close the shut-off element in the suction line and/or supply line during

pump operation.

CAUTION

Impermissibly high temperature of fluid handled

Damage to the pump!

▷ Prolonged operation against a closed shut-off element is not permitted

(heating up of the fluid).

▷ Observe the temperature limits in the data sheet and in the section on

operating limits.

While the pump is in operation, observe and check the following:

▪ If activated, check the functional check run. ▪ Measure the actual start-up pressure and stop pressure of the pump sets with a

pressure gauge. Compare the values with the specifications on the name plate.

▪ Compare the pre-charge pressure of the accumulator with the recommended

data.

▪ Check the rolling element bearings for running noises.

Vibrations, noise and an increase in current input occurring during unchanged operating conditions indicate wear.

▪ Monitor the functions of auxiliary connections, if any.

8.2.2 Maintenance schedule

1983.844/02-EN

Table20: Overview of maintenance work

Maintenance interval Servicing/maintenance work

At least once a year Check the pump sets for smooth running and the mechanical seal for integrity.

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8 Servicing/Maintenance

Maintenance interval Servicing/maintenance work

At least once a year Check the shut-off elements, drain valves and check valves for proper functioning and

tightness. If fitted, clean the strainer in the pressure reducer. If fitted, check the expansion joints for any wear. Verify the pre-charge pressure. Check the accumulator for integrity. Check the automatic switching functionality. Check the cut-in levels and cut-out levels. Check the inflow, inlet pressure, dry running protection, flow monitoring and pressure

reducer.

8.2.3 Setting the pre-charge pressure

WARNING

Wrong gas

Danger of poisoning!

▷ Use only nitrogen to charge the accumulator.

CAUTION

Pre-charge pressure too high

Damage to the accumulator!

▷ Observe the manufacturer's product literature (see name plate or operating

manual of the accumulator).

The accumulator’s pre-charge pressure (p) must be lower than the set start-up pressure (pE) of the pressure booster system.

The best storage volumes are achieved with the following settings (mean value):

▪ Value0.9 at start-up pressure > 3bar ▪ Value0.8 at start-up pressure < 3bar

Example 1 pE=5bar

5bar×0.9=4.5bar With a start-up pressure of 5bar the pre-charge pressure of the accumulator must be

4.5 bar.

Example 2 pE=2bar

2bar ×0.8=1.6bar With a start-up pressure of 2bar the pre-charge pressure of the accumulator must be

1.6 bar.

Checking the pre-charge pressure

1. Close the shut-off elements fitted underneath the membrane-type accumulator.

2. Drain the membrane-type accumulator via the drain valve.

3. Remove and store the protective cap of the membrane-type accumulator valve.

4. Check the pre-charge pressure using suitable equipment (e.g. tyre pressure gauge).

5. Fit the protective cap of the membrane-type accumulator valve.

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Filling the membrane-type accumulator

1. Remove and store the protective cap of the membrane-type accumulator valve.

2. Add nitrogen through the valve.

3. Fit the protective cap of the membrane-type accumulator valve.

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1983.844/02-EN

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8 Servicing/Maintenance

8.2.4 Replacing the non-return valve

DANGER

Voltage at the pressure booster system

Danger to life!

▷ Prior to opening the device, wait at least 10minutes for any residual voltage to

dissipate.

1. De-energise the pump set and secure it against unintentional start-up. Comply with the local regulations.

2. Close the shut-off valve of the pump.

3. Place a suitable container under the drain connection.

4. Open the drain connections. To do so, observe the pump's operating manual.

Fig.11: Removing the screw

5. Remove the screw.

Fig.12: Screwing the valve's body parts into each other

6. Use a suitable tool to screw the body parts of the non-return valve into each other to shorten the length of the body.

1983.844/02-EN

Fig.13: Removing the body

7. Remove the body of the non-return valve.

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8 Servicing/Maintenance

8. Remove the insert check valve including O-rings.

9. Remove excessive contamination or deposits with a clean cloth.

10. Re-insert the insert check valve into the body. Apply lubricant to new O-rings. See table below.

Fig.14: Mounting the body

11. Mount the body of the non-return valve.

Fig.15: Loosening the screwed connection of the body parts

12. Use a suitable tool to loosen the screwed connection of the body parts of the non-return valve to extend the body length.

Fig.16: Verifying the alignment

13. Verify the correct alignment.

1983.844/02-EN

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Fig.17: Fitting the screw

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8 Servicing/Maintenance

14. Fit and tighten the screw.

15. Close the drain plugs of the pump. Properly dispose of the fluid collected.

16. Slowly open the shut-off valve and check for any leakage.

Table21: Spare parts for servicing non-return valves, per pump

Material number Description Non-return valve O-rings O-ring lubricant

(non-water soluble)

71630405 ER non-return valve

DN32

71630410 ER non-return valve

DN50

Watts Industries IN 032 DN 32

Watts Industries IN 050 DN 50

1xEriks 12711456 Molykote® G-5511 2xEriks 12711457 1xEriks 12192264 2xEriks 12711459

1983.844/02-EN

3) Sealant for taps

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9 Trouble-shooting

DANGER

Unintentional start-up

Risk of fatal injury due to electric shock!

▷ Disconnect the frequency inverter from the mains before carrying out any

maintenance and installation work.

▷ Prevent the frequency inverter from being re-started unintentionally when

carrying out any maintenance and installation work.

DANGER

Contact with live components

Risk of fatal injury due to electric shock!

▷ Any work on the product shall only be performed when it has been

disconnected from the power supply (de-energised).

▷ Never remove the centre housing part from the heat sink. ▷ Mind the capacitor discharge time.

After switching off the frequency inverter, wait 10minutes until dangerous voltages have discharged.

NOTE

Depending on the combination of settings, the frequency inverter could conceivably restart automatically after acknowledgement/reset or when the cause of the malfunction or fault has been eliminated.

The operator ensures that trouble-shooting is performed by authorised, qualified specialist personnel who are thoroughly familiar with the operating manual.

Reset the frequency inverter to the default factory settings before engaging in any fault rectification measures.

9.1 Faults/malfunctions: Trouble-shooting

WARNING

Improper work to remedy faults

Risk of injury!

▷ For any work performed to remedy faults, observe the relevant information

given in this instruction manual and/or in the product literature provided by the accessories manufacturer.

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

A Mains fuse rating too small for the nominal mains current.

B Motor does not start. C Motor running unevenly.

D Max. speed not reached.

E Motor running at maximum speed only.

F Motor running at minimum speed only. G No/faulty 24V supply. H Wrong direction of rotation of the motor.

I Fault message/protective tripping.

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9 Trouble-shooting

Table22: Trouble-shooting

A B C D E F G H I Possible cause Remedy

- ✘ - - - - ✘ - - No voltage applied Check the mains voltage. Check the mains fuses.

- ✘ - - - - - - - No enable Check enable via DIGIN-EN and system start.

✘ - - - - - - - - Mains fuse rating too low for

frequency inverter input current

- - - ✘ - - - - - No setpoint signal or setpoint set too low / drive overloaded and in i²t control mode

- - - - ✘ - - - - Process-related persistent control deviation (actual value smaller than setpoint) / no actual value (e.g. due to broken wire)

- ✘ --- - - - - ✘ Permissible voltage range undershot/exceeded

Check configuration/selection of mains fuse.

Check setpoint signal and operating point.

Check setpoint/actual value signal; check operating point; check controller setting.

Check mains voltage; supply frequency inverter with required voltage.

- - - - - - - ✘ - Wrong direction of rotation setting.

- - ✘ ✘ - - - - ✘ Frequency inverter overloaded Reduce the power input by lowering the speed;

- ✘ - - - - - - ✘ Short circuit in control cable/ pump blocked

- - ✘ ✘ - - - - ✘ Temperature of power electronics or motor winding too high

- - - - - - ✘ - ✘ 24 V voltage supply overloaded

- - - - - - - - ✘ Dry running of pump Check the hydraulic system and rectify the fault on

- - - ✘ - ✘ - - ✘ Sensor signal error (e.g. broken wire)

- ✘ ✘ - - - - - ✘ Phase failure (drive) Check motor connection and motor winding.

Change the direction of rotation.

check the motor/pump for blockages. Check/replace control cable connections. Remove the

pump blockage manually.

▪ Reduce the ambient temperature by improving

ventilation.

▪ Improve cooling by cleaning the cooling fins. ▪ Ensure that the intake opening for the fans is

not blocked.

▪ Ensure that the fans are working properly. ▪ Reduce the power input by changing the

operating point (system-specific).

▪ Check the permissible load and, if necessary, use

external cooling.

Disconnect frequency inverter from the power supply and eliminate the cause of the overload.

the frequency inverter. Check sensor and sensor cable.

9.2 Alerts

Table23: Alerts

Message code

E1 Thermal motor protection PTC has tripped Self-acknowledging

E2 Overvoltage Impermissible overvoltage (mains) Partially self-

E3 Undervoltage Impermissible undervoltage (mains) Partially self-

1983.844/02-EN

E4 Phase failure (motor) Phase failure (motor) Non-self-

Message Description Behaviour

(configurable)

acknowledging

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9 Trouble-shooting

Message

Message Description Behaviour

code

E5 Short circuit Motor short-circuited (defective motor winding) Partially self-

acknowledging

E6 Hardware error Hardware defective Non-self-

acknowledging

E7 Heat sink temperature high Power electronics overtemperature Non-self-

acknowledging

E8 PCB temperature high Control electronics overtemperature Non-self-

acknowledging

E9 Overcurrent Impermissible overcurrent Partially self-

acknowledging

E10 Braking resistor Internal overcurrent (for example, if the ramp is

too steep)

Non-selfacknowledging

E11 Dynamic overload protection Impermissible overcurrent Partially self-

acknowledging

E12 Firmware update required Firmware update required Non-self-

acknowledging

E13 Dry running Dry running of pump Non-self-

acknowledging

E14 Dry running (external) Dry running of pump Self-acknowledging

(configurable)

E15 Hydraulic blockage Pumping against closed piping Non-self-

acknowledging

E16 No master control Failure of actual value sensor/ Broken wire/ Local/

Self-acknowledging

No redundancy

E18 No matching motor data

available

The extended KSB SuPremE motor data could not be determined.

Self-acknowledging

E19 No motor data available The motor data is not set Self-acknowledging E20 AMA fault The extended motor data could not be

Self-acknowledging

determined. E76 24V overload Internal 24V power supply unit overloaded Self-acknowledging E77 PumpMeter communication Incorrect PumpMeter communication Self-acknowledging E83 Overflow - Non-self-

acknowledging E84 Setpoint/control value failure - Self-acknowledging E98 HMI hardware test not

passed.

Control panel is defective. Non-self-

acknowledging E99 IO hardware test not passed. Control electronics or M12 module defective. Non-self-

acknowledging

Table24: Alerts

Alert Possible causes Remedy

Short circuit Motor short-circuited (defective motor

winding)

Check motor winding, perform dielectric test. Check motor for blockage.

4)5)

Power supply connected incorrectly Check the cabling; connect the mains power

supply to L1, L2, L3, PE. Parallel operation of motors Impermissible operating range Motor terminal board wired incorrectly (delta/

Wire motor terminal board correctly. star)

Motor power cable short circuit Check motor power cable.

4) Disconnect the frequency inverter from the power supply to rectify faults on current-carrying components. Observe the safety information!

5) Restore the frequency inverter’s default settings.

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9 Trouble-shooting

Alert Possible causes Remedy

4)5)

Short circuit Sensor cable shielding connected incorrectly Connect sensor cable shielding to PE on one

end only.

24 V DC cabling short circuit Check cabling.

Thermal motor protection

PTC thermistor connected incorrectly Check PTC sensor connection. Incorrect motor data set Match motor data settings to motor used. Wrong direction of rotation of the pump Adjust the direction of rotation of the motor

via the phase sequence. Hydraulic overload Reduce the hydraulic load. Pump blocked mechanically/runs sluggishly Check pump. Motor terminal board wired incorrectly (delta/

Wire motor terminal board correctly. star)

Frequency inverter power < motor power and/ or

Wrong device ordered, mount larger frequency

inverter. output current < motor current

Carrier frequency of frequency inverter set

Set carrier frequency to permissible range. too high

Fluctuating DC link voltage when pump is not

Check mains voltage quality. running

Fluctuating DC link voltage when pump

Check mains voltage quality. operates at nominal values

Incorrect motor current measurement Measure current using suitable snap-on

ammeter and compare with the information

displayed on the control panel.

NOTE!Approx. 10% tolerance is permissible. Pump runs in reverse when motor is not

Check swing check valve. supplied with current.

Heat sink temperature high/ PCB temperature high

Motor voltage output is too low at nominal load, <380V at nominal load

Ambient temperature of frequency inverter >50°C

Dirt in external fans Clean fans. Heat sink/cooling fins dirty Clean heat sink/cooling fins. Carrier frequency of frequency inverter set

Check line input voltage; enter motor current

at 380V mains voltage; fit larger-sized motor.

Impermissible operating range; mind power

derating.

Set carrier frequency to permissible range. too high

Frequency inverter power < motor power and/ or

Wrong device ordered, mount larger frequency

inverter. output current < motor current

Frequency inverter mounted incorrectly External fans must point upwards; on the wall-

mounted model, the back of the heat sink must

be closed.

Undervoltage Line input voltage too low Check the mains voltage.

Fluctuating DC link voltage when pump is not

Check mains voltage quality. running

Mains fuse has tripped Fit new mains fuse. Brief interruption of mains voltage Check the mains voltage.

Overvoltage Line input voltage too high Check the mains voltage.

Fluctuating DC link voltage when pump is not

Check mains voltage quality. running

Ramp times too short Select longer ramp times.

1983.844/02-EN

Overcurrent/ dynamic overload protection

Pump runs in reverse when motor is not supplied with current.

Mains power supply connected incorrectly Connect mains power supply to L1, L2, L3, PE. Motor terminal board wired incorrectly (delta/

star)

Check swing check valve.

Wire motor terminal board correctly.

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9 Trouble-shooting

Alert Possible causes Remedy

Overcurrent/ dynamic overload protection

Incorrect motor data set (3-3-2) Match motor data settings to motor used. Parallel operation of motors This mode of operation is not permissible. Sensor cable shielding connected incorrectly Connect sensor cable shielding to PE on one

4)5)

end only. Frequency inverter power < motor power and/

Wrong device ordered, mount larger frequency

inverter. output current < motor current

Ramp times too short Select longer ramp times. Wrong direction of rotation of the pump Adjust the direction of rotation of the motor

via the phase sequence. Pump blocked mechanically/runs sluggishly Check pump. Carrier frequency of frequency inverter set

Set carrier frequency to permissible range. too high

Incorrect motor current measurement Measure current using suitable snap-on

ammeter and compare with the information

displayed on the control panel.

Please note: Approx. 10% tolerance is

permissible. Pump runs in reverse when motor is not

Check swing check valve. supplied with current.

No master control KSB device bus wired incorrectly (interruption,

Re-wire properly. short circuit)

Sensor connected incorrectly (actual value

Connect sensor correctly. failure)

No main pump recognised in system Define role in multiple pump system.

Braking resistor Stop ramp time too short Increase ramp time.

Pump runs in reverse when motor is not

Check swing check valve. supplied with current.

Generator operation of pump Impermissible operating range

Dry running/ dry running (external)

Dry running of pump Check piping.

Check the pump valves.

Hydraulic blockage Piping clogged Check piping.

Check the pump valves.

9.3 Warnings

Table25: Warnings

Message code

E30 External message External message present. Self-acknowledging

E50 Dynamic overload

E51 Overvoltage Overvoltage Self-acknowledging E52 Undervoltage Undervoltage Self-acknowledging E53 Resonance range Resonance range Self-acknowledging E54 Broken wire Broken wire Self-acknowledging E55 Actual value failure Failure of actual value Self-acknowledging E56 Hydraulic blockage Pumping against closed piping Self-acknowledging E56 Hydraulic blockage Pumping against closed piping Self-acknowledging E57 Low flow Low flow Self-acknowledging E58 Hydraulic overload Hydraulic overload Self-acknowledging

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Message Description Behaviour

(configurable)

Impermissible overcurrent Self-acknowledging

protection

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9 Trouble-shooting

Message code

E59 Heat sink temperature

E60 PCB temperature high Control electronics overtemperature Self-acknowledging E61 Current high Motor current high Self-acknowledging E62 Current low Motor current low Self-acknowledging E63 Speed monitoring Limit value violation, speed Self-acknowledging E64 Setpoint monitoring Limit value violation, setpoint Self-acknowledging E65 Actual value monitoring Limit value violation, actual value Self-acknowledging E66 Flow rate monitoring Limit value violation, flow rate Self-acknowledging E67 Suction pressure

E68 Discharge pressure

E69 Differential pressure

E70 Temperature monitoring Limit value violation, temperature Self-acknowledging E71 Frequency high Frequency high Self-acknowledging E72 Frequency low Frequency low Self-acknowledging E73 Power high Power high Self-acknowledging E74 Power low Power low Self-acknowledging E75 Limited stop ramp Set stop ramp time exceeded Self-acknowledging E76 24V overload Internal 24V power supply unit overloaded Self-acknowledging E77 PumpMeter

E78 Firmware update for field

E79 Firmware update for HMI

E83 Overflow - Non-self-acknowledging E84 Setpoint/control value

E99 General settings loaded General settings loaded Self-acknowledging

Message Description Behaviour

Power electronics overtemperature Self-acknowledging

high

Limit value violation, suction pressure Self-acknowledging

monitoring

Limit value violation, discharge pressure Self-acknowledging

monitoring

Limit value violation, differential pressure Self-acknowledging

monitoring

Incorrect PumpMeter communication Self-acknowledging

communication

Module incompatible with main module Self-acknowledging

bus required

Module incompatible with main module Self-acknowledging

required

- Self-acknowledging

failure

Table26: Warnings

Warning Possible causes Remedy

Dynamic overload protection

1983.844/02-EN

Incorrect motor data set Match motor data to motor used. Wrong direction of rotation of the pump Adjust the direction of rotation of the motor via

Hydraulic overload Reduce the hydraulic load. Pump blocked mechanically/runs sluggishly Check pump. Motor terminal board wired incorrectly

(delta/star) Frequency inverter power < motor power

and/or output current < motor current

Frequency inverter carrier frequency set too high

Ambient temperature of frequency inverter > 50 °C

Fluctuating DC link voltage when pump is not running

KSB Delta Solo

the phase sequence

Wire motor terminal board correctly.

Wrong device ordered, mount larger frequency inverter.

Set carrier frequency to permissible range.

Impermissible operating range; mind power derating.

Check mains voltage quality.

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9 Trouble-shooting

Warning Possible causes Remedy

Dynamic overload protection

Broken wire Cable integrity monitoring Replace defective sensor with new one. Low flow/overload The driven pump is operated under low

24V overload 24 V DC voltage supply overload Reduce current draw on 24 V DC supply; compare

Dynamic overload protection Incorrect motor data set Match motor data to motor used.

Incorrect motor current measurement Measure current using suitable snap-on ammeter

and compare with the information displayed on the control panel.

NOTE!Approx. 10% tolerance is permissible.

Pump runs in reverse when motor is not supplied with current

Motor voltage output is too low at nominal load, < 380V at nominal load

flow/overload conditions.

Short circuit of consumers connected to 24VDC voltage supply

Control terminal wiring errors (DigIn, AnIn) Re-wire properly.

Wrong direction of rotation of the pump

Hydraulic overload Reduce the hydraulic load. Pump blocked mechanically/runs

sluggishly Motor terminal board wired

incorrectly (delta/star) Frequency inverter power < motor

power and/or output current < motor current

Frequency inverter carrier frequency set too high

Ambient temperature of frequency inverter > 50 °C

Fluctuating DC link voltage when pump is not running

Incorrect motor current measurement

Pump runs in reverse when motor is not supplied with current

Motor voltage output is too low at nominal load, < 380V at nominal load

Check swing check valve.

Check line input voltage; enter motor current at 380V mains voltage; fit larger-sized motor.

Impermissible operating range; operate the pump within the permissible range.

the number of electrical connections with the maximum permissible current load of the 24 V DC supply.

Disconnect defective 24VDC consumers.

Adjust the direction of rotation of the motor via the phase sequence

Check pump.

Wire motor terminal board correctly.

Wrong device ordered, mount larger frequency inverter.

Set carrier frequency to permissible range.

Impermissible operating range; mind power derating.

Check mains voltage quality.

Measure current using suitable snap-on ammeter and compare with the information displayed on the control panel.

NOTE!Approx. 10% tolerance is permissible.

Check swing check valve.

Check line input voltage; enter motor current at 380V mains voltage; fit larger-sized motor.

48 of 60

1983.844/02-EN

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9 Trouble-shooting

9.4 Information messages

Table27: Information messages

Message code

E100 Pump maintenance/

E101 Drive disabled ▪ The motor is disabled while AMA is being

E102 Pipe flushing mode active Performing the pipe flushing function Self-acknowledging E103 Pipe filling mode active Performing the pipe filling function Self-acknowledging E104 Maintenance interval,

E105 Factory-set defaults

E106 User settings 1 loaded User settings 1 were loaded. Non-self-acknowledging E107 User settings 2 loaded User settings 2 were loaded. Non-self-acknowledging

Message Description Behaviour

Service interval set for pump expired. Self-acknowledging

service interval

Self-acknowledging

carried out.

▪ If the Overcurrent alert is output that

causes the drive to be stopped, the drive remains disabled as long as this event is active.

▪ In the event of a stop via the DI-EN digital

input, the motor is not stopped by the stop ramp, but coasts to a standstill. The amount of time this process takes depends on the mass moment of inertia of the system. The drive remains disabled during coasting.

Maintenance interval set for motor expired. Self-acknowledging

motor bearings

Factory-set defaults are being loaded. Self-acknowledging

loaded

1983.844/02-EN

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Page 50

10 Related Documents

595

655

742.01

742.02

591

79-2

743.90

691

79-2

10 Related Documents

10.1 General assembly drawings/exploded views with list of components

10.1.1 KSB Delta Solo SVP

Fig.18: KSB Delta Solo SVP

Table28: List of components

Part No. Description Part No. Description

79-2 Measuring transducer 691 Pressure gauge 591 Accumulator 742.01/.02 Lift check valve 595 Anti-vibration pad 743.90 Ball valve 655 Pump

The individual parts of the pump set are shown in the product literature of the pump set.

10.2 Alerts

Table29: Alerts

Message number

A1 Thermal motor protection PTC has tripped Self-acknowledging

A2 Overvoltage Impermissible overvoltage (mains) Partially self-

Message Description Behaviour

A3 Undervoltage Impermissible undervoltage (mains) Partially self-

A4 Phase failure (motor) Phase failure (motor) Non-self-

(configurable)

acknowledging

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10 Related Documents

Message number

A5 Short circuit Motor short-circuited (defective motor winding) Partially self-

A6 Hardware error Hardware defective Non-self-

A7 Heat sink temperature high Power electronics overtemperature Non-self-

A8 PCB temperature high Control electronics overtemperature Non-self-

A9 Overcurrent Impermissible overcurrent Partially self-

A10 Braking resistor Internal overcurrent (for example, if the ramp is too

A11 Dynamic overload protection Impermissible overcurrent Partially self-

A12 Firmware update required Firmware update required Non-self-

A13 Dry running Dry running of pump Non-self-

A14 Dry running (external) Dry running of pump Self-acknowledging

A15 Hydraulic blockage Pumping against closed piping Non-self-

A16 No master control Failure of actual value sensor/ Broken wire/ Local/ No

A18 No matching motor data

A19 No motor data available The motor data is not set: Self-acknowledging A20 AMA fault The extended motor data could not be determined: Self-acknowledging A98 HMI hardware test not passed Control panel defective Non-self-

A99 IO hardware test not passed Control electronics or M12 module defective Non-self-

Message Description Behaviour

acknowledging

acknowledging Non-self-

acknowledging

(configurable)

acknowledging Self-acknowledging

Self-acknowledging

acknowledging

available

steep)

redundancy The extended KSB SuPremE motor data could not be

determined.

Table30: Alerts

Alert Possible causes Remedy

Short circuit Motor short-circuited (defective motor

winding)

Check motor winding, perform dielectric test.

Check motor for blockage.

6)7)

Power supply connected incorrectly Check the cabling; connect the mains power

supply to L1, L2, L3, PE. Parallel operation of motors Impermissible operating range Motor terminal board wired incorrectly (delta/

Wire motor terminal board correctly. star)

Motor power cable short circuit Check motor power cable. Sensor cable shielding connected incorrectly Connect sensor cable shielding to PE on one

end only. 24 V DC cabling short circuit Check cabling.

Thermal motor protection

via the phase sequence. Hydraulic overload Reduce the hydraulic load.

1983.844/02-EN

6) Disconnect the frequency inverter from the power supply to rectify faults on current-carrying components. Observe the safety information!

7) Restore the frequency inverter’s default settings.

Pump blocked mechanically/runs sluggishly Check pump.

KSB Delta Solo

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10 Related Documents

Alert Possible causes Remedy

Thermal motor protection

Motor terminal board wired incorrectly (delta/ star)

Frequency inverter power < motor power and/ or

Wire motor terminal board correctly.

Wrong device ordered, mount larger frequency inverter.

6)7)

output current < motor current Carrier frequency of frequency inverter set

Set carrier frequency to permissible range.

too high Fluctuating DC link voltage when pump is not

Check mains voltage quality.

running Fluctuating DC link voltage when pump

Check mains voltage quality.

operates at nominal values Incorrect motor current measurement Measure current using suitable snap-on

ammeter and compare with the information displayed on the control panel.

NOTE!Approx. 10% tolerance is permissible.

Pump runs in reverse when motor is not

Check swing check valve.

supplied with current.

Heat sink temperature high/ PCB temperature high

Motor voltage output is too low at nominal load, <380V at nominal load

Ambient temperature of frequency inverter >50°C

Dirt in external fans Clean fans. Heat sink/cooling fins dirty Clean heat sink/cooling fins. Carrier frequency of frequency inverter set

Check line input voltage; enter motor current at 380V mains voltage; fit larger-sized motor.

Impermissible operating range; mind power derating.

Set carrier frequency to permissible range.

too high Frequency inverter power < motor power and/

Wrong device ordered, mount larger frequency inverter.

output current < motor current Frequency inverter mounted incorrectly External fans must point upwards; on the wall-

mounted model, the back of the heat sink must be closed.

Undervoltage Line input voltage too low Check the mains voltage.

Fluctuating DC link voltage when pump is not

Check mains voltage quality.

running Mains fuse has tripped Fit new mains fuse. Brief interruption of mains voltage Check the mains voltage.

Overvoltage Line input voltage too high Check the mains voltage.

Fluctuating DC link voltage when pump is not

Check mains voltage quality.

running Ramp times too short Select longer ramp times. Pump runs in reverse when motor is not

Check swing check valve.

supplied with current.

Overcurrent/ dynamic overload protection

Mains power supply connected incorrectly Connect mains power supply to L1, L2, L3, PE. Motor terminal board wired incorrectly (delta/

Wire motor terminal board correctly.

star) Incorrect motor data set (3-3-2) Match motor data settings to motor used. Parallel operation of motors This mode of operation is not permissible. Sensor cable shielding connected incorrectly Connect sensor cable shielding to PE on one

end only.

Frequency inverter power < motor power and/ or

Wrong device ordered, mount larger frequency inverter.

output current < motor current Ramp times too short Select longer ramp times. Wrong direction of rotation of the pump Adjust the direction of rotation of the motor

via the phase sequence.

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10 Related Documents

Alert Possible causes Remedy

Overcurrent/ dynamic overload protection

Pump blocked mechanically/runs sluggishly Check pump. Carrier frequency of frequency inverter set

Set carrier frequency to permissible range.

too high

6)7)

Incorrect motor current measurement Measure current using suitable snap-on

ammeter and compare with the information displayed on the control panel. Please note: Approx. 10% tolerance is permissible.

Pump runs in reverse when motor is not

Check swing check valve.

supplied with current.

No master control KSB device bus wired incorrectly (interruption,

Re-wire properly.

short circuit) Sensor connected incorrectly (actual value

Connect sensor correctly.

failure) No main pump recognised in system Define role in multiple pump system.

Braking resistor Stop ramp time too short Increase ramp time.

Pump runs in reverse when motor is not

Check swing check valve.

supplied with current. Generator operation of pump Impermissible operating range

Dry running/ dry running (external)

Dry running of pump Check piping.

Check the pump valves.

Hydraulic blockage Piping clogged Check piping.

Check the pump valves.

10.3 Warnings

Table31: Warnings

Message number

A30 / W30 External message External message present Self-acknowledging

W50 Dynamic overload

W51 Overvoltage Overvoltage Self-acknowledging W52 Undervoltage Undervoltage Self-acknowledging W53 Resonance range Resonance range Self-acknowledging W54 Broken wire Broken wire Self-acknowledging W55 Actual value failure Failure of actual value Self-acknowledging W56 Hydraulic blockage Pumping against closed piping Self-acknowledging W57 Low flow Low flow Self-acknowledging W58 Hydraulic overload Hydraulic overload Self-acknowledging W59 Heat sink temperature

W60 PCB temperature high Control electronics overtemperature Self-acknowledging W61 Current high Motor current high Self-acknowledging W62 Current low Motor current low Self-acknowledging W63 Speed monitoring Limit value violation, speed Self-acknowledging W64 Setpoint monitoring Limit value violation, setpoint Self-acknowledging

1983.844/02-EN

W65 Actual value monitoring Limit value violation, actual value Self-acknowledging W66 Flow rate monitoring Limit value violation, flow rate Self-acknowledging W67 Suction pressure

Message Description Behaviour

(configurable)

Impermissible overcurrent Self-acknowledging

protection

Power electronics overtemperature Self-acknowledging

high

Limit value violation, suction pressure Self-acknowledging

monitoring

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Message number

W68 Discharge pressure

W69 Differential pressure

W70 Temperature monitoring Limit value violation, temperature Self-acknowledging W71 Frequency high Frequency high Self-acknowledging W72 Frequency low Frequency low Self-acknowledging W73 Power high Power high Self-acknowledging W74 Power low Power low Self-acknowledging W75 Limited stop ramp Set stop ramp time exceeded Self-acknowledging W76 24V overload Internal 24V power supply unit overloaded Self-acknowledging W77 PumpMeter

W80 Low flow velocity Lower limit for flow velocity undershot Self-acknowledging W81 Field bus communication Defective field bus module Self-acknowledging W83 Overflow Overflow trip via external signal Non-self-acknowledging W84 Setpoint/control value

W99 General settings loaded General settings loaded Self-acknowledging

Table32: Warnings

Warning Possible causes Remedy

Dynamic overload protection

Broken wire Cable integrity monitoring Replace defective sensor with new one. Low flow/overload The driven pump is operated under low

24V overload 24 V DC voltage supply overload Reduce current draw on 24 V DC supply; compare

Message Description Behaviour

Limit value violation, discharge pressure Self-acknowledging

monitoring

Limit value violation, differential pressure Self-acknowledging

monitoring

Incorrect PumpMeter communication Self-acknowledging

communication

Failure of setpoint/control value via external

failure

Incorrect motor data set Match motor data to motor used. Wrong direction of rotation of the pump Adjust the direction of rotation of the motor via

Hydraulic overload Reduce the hydraulic load. Pump blocked mechanically/runs sluggishly Check pump. Motor terminal board wired incorrectly

(delta/star) Frequency inverter power < motor power

and/or output current < motor current

Frequency inverter carrier frequency set too high

Ambient temperature of frequency inverter > 50 °C

Fluctuating DC link voltage when pump is not running

Incorrect motor current measurement Measure current using suitable snap-on ammeter

Pump runs in reverse when motor is not supplied with current

Motor voltage output is too low at nominal load, < 380V at nominal load

flow/overload conditions.

signal

the phase sequence

Wire motor terminal board correctly.

Wrong device ordered, mount larger frequency inverter.

Set carrier frequency to permissible range.

Impermissible operating range; mind power derating.

Check mains voltage quality.

and compare with the information displayed on the control panel.

NOTE!Approx. 10% tolerance is permissible. Check swing check valve.

Check line input voltage; enter motor current at 380V mains voltage; fit larger-sized motor.

Impermissible operating range; operate the pump within the permissible range.

the number of electrical connections with the maximum permissible current load of the 24 V DC supply.

Self-acknowledging

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10 Related Documents

Warning Possible causes Remedy

24V overload Short circuit of consumers connected to

24VDC voltage supply Control terminal wiring errors (DigIn, AnIn) Re-wire properly.

Disconnect defective 24VDC consumers.

10.4 Information messages

Table33: Information messages

Message number

I100 Pump maintenance/

I101 Drive disabled ▪ The motor is disabled while AMA is being

I102 Pipe flushing mode active Performing the pipe flushing function Self-acknowledging I103 Pipe filling mode active After the system has been started, the pipe

I104 Maintenance interval,

I105 Factory-set defaults

I106 User settings 1 loaded User settings 1 were loaded Non-self-acknowledging I107 User settings 2 loaded User settings 2 were loaded Non-self-acknowledging

Message Description Behaviour

service interval

motor bearings

loaded

Maintenance/service interval set for pump expired

carried out.

▪ If the Overcurrent alert is output that

causes the drive to be stopped, the drive remains disabled as long as this event is active.

▪ In the event of a stop via the DI-EN digital

input, the drive is not stopped via the stop ramp, but coasts to standstill. The amount of time this process takes depends on the mass moment of inertia of the system. The drive remains disabled during coasting.

filling function is carried out. Maintenance/service interval set for motor

bearings expired Factory-set defaults are being loaded Self-acknowledging

Self-acknowledging

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Page 56

11 EU Declaration of Conformity

Manufacturer: KSB B.V.

Kalkovenweg 13

2401 LJ Alphen aan den Rijn (The Netherlands)

The manufacturer herewith declares that the product:

KSB Delta Solo SVP

Serial numbers: 06/2018 0000000-0001 - 52/2020 9999999-9999

▪ is in conformity with the provisions of the following Directives as amended from time to time:

– Pump set: 2006/42/EC Machinery Directive

– Electrical components8): 2011/65/EU Restriction of the use of certain hazardous substances in electrical and

electronic equipment (RoHS)

– 2014/30/EU: Electromagnetic Compatibility (EMC)

The manufacturer also declares that

▪ the following harmonised international standards have been applied:

– ISO 12100 – EN 809 – EN 60204-1 – EN 806-2

Person authorised to compile the technical file:

Menno Schaap Manager Competence Centre Products KSB B.V. (Subsidiary D.P. Industries B.V.) Kalkovenweg 13 2401 LJ Alphen aan den Rijn (The Netherlands)

The EU Declaration of Conformity was issued in/on:

Alphen aan den Rijn, 01.06.2018

8) Where applicable

56 of 60

Menno Schaap

Manager Competence Centre Products

KSB B.V.

Kalkovenweg 13

2401 LJ Alphen aan den Rijn

KSB Delta Solo

Page 57

12 Certificate of Decontamination

Type: ................................................................................................................................

Order number/

Order item number9): ................................................................................................................................

Delivery date: ................................................................................................................................

Applications: ................................................................................................................................

Fluid handled9): ................................................................................................................................

Please tick where applicable9):

    

Corrosive Oxidising Flammable Explosive Hazardous to health

    

Seriously hazardous to

health

Toxic Radioactive Bio-hazardous Safe

Reason for return9): ................................................................................................................................

Comments: ................................................................................................................................

................................................................................................................................

The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/ placing at your disposal.

We herewith declare that this product is free from hazardous chemicals, biological and radioactive substances.

For mag-drive pumps, the inner rotor unit (impeller, casing cover, bearing ring carrier, plain bearing, inner rotor) has been removed from the pump and cleaned. In cases of containment shroud leakage, the outer rotor, bearing bracket lantern, leakage barrier and bearing bracket or intermediate piece have also been cleaned.

For canned motor pumps, the rotor and plain bearing have been removed from the pump for cleaning. In cases of leakage at the stator can, the stator space has been examined for fluid leakage; if fluid handled has penetrated the stator space, it has been removed.

 No special safety precautions are required for further handling.  The following safety precautions are required for flushing fluids, fluid residues and disposal:

...............................................................................................................................................................

We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with the relevant legal provisions.

.................................................................. ....................................................... .......................................................

Place, date and signature Address Company stamp

1983.844/02-EN

9) Required fields

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13 Commissioning Report

The pressure booster system specified below has been commissioned today by the undersigned, authorised KSB Service who created this report.

Pressure booster system details

Type series ........................................................................................................................................

Size ........................................................................................................................................

Serial number ........................................................................................................................................

Order No. ........................................................................................................................................

Purchaser/place of installation

Purchaser Place of installation

Name .................................................... ..........................................................................

Address .................................................... ..........................................................................

.................................................... ..........................................................................

Operating data For further data refer to the wiring diagram.

Start-up pressure pE bar ....................................................

Inlet pressure monitoring p (setting of inlet pressure switch)

Stop pressure pA bar ....................................................

Inlet pressure p Pre-charge pressure

of accumulator p

- x

....................................................

inl

[bar] ....................................................

inl

pre-charge

....................................................

[bar]

The operator or operator’s representative herewith confirms to have received instructions on how to operate and service the pressure booster system. The relevant circuit diagrams and operating instructions have been handed over.

Non-conformities found during commissioning Deadline for remedial action

Non-conformity

..........................................................................

1 ............................................................................................

............................................................................................................. ..........................................................................

Name of KSB representative Name of purchaser or representative

............................................................................................................. ..........................................................................

Place Date

............................................................................................................. ..........................................................................

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Index

Access levels33 Alerts43, 50 Analog input22 Arrow keys30 Automation16

Certificate of Decontamination57 Commissioning25

Design15 Designation15 Disposal13 Drive16 Dry running protection21, 25

Connecting the dry running protection device24

EMC Directive10 Escape key30 Event of damage6

Faults

Causes and remedies43

Partly completed machinery6 Personnel9

Qualification9

Return to supplier13

Safety8 Safety awareness9 Scope of supply17 Service interface35 Standard control panel28

Terminal strip22 Traffic light35

Warnings7, 46, 53

Graphical control panel35

Warranty claims6

Information message55 Installation16 Installation at site19 Intended use8 Interference emissions10

Key to safety symbols/markings7

LED display35

Main screen28 Maintenance work37

1983.844/02-EN

OK key30 Operating limits8 Other applicable documents6

KSB Delta Solo

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KSB B.V.

Kalkovenweg 13 2401 LJ Alphen aan den Rijn (Netherlands)

1983.844/02-EN

KSB Delta Solo SVP, Delta Basic SVP Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Glossary

1 General

1.1 Principles

1.2 Software changes

1.3 Installation of partly completed machinery

1.4 Target group

1.5 Other applicable documents

1.6 Symbols

1.7 Key to safety symbols/markings

2 Safety

2.1 General

2.2 Intended use

2.2.1 Prevention of foreseeable misuse

2.3 Personnel qualification and personnel training

2.4 Consequences and risks caused by non-compliance with this manual

2.5 Safety awareness

2.6 Safety information for the operator/user

2.7 Safety information for maintenance, inspection and installation

2.8 Unauthorised modes of operation

2.9 Electromagnetic compatibility (EMC)

2.9.1 Interference emission requirements

2.9.2 Line harmonics requirements

2.9.3 Interference immunity requirements

3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

3.2 Transport

3.3 Storage/preservation

3.4 Return to supplier

3.5 Disposal

4 Description

4.1 General description

4.3 Description

4.4 Name plate

4.5 Design details

4.6 Configuration and function

4.7 Scope of supply

4.8 Dimensions

4.9 Terminal diagram

4.10 Potential equalisation

5 Installation at Site

5.1 Checks to be carried out prior to installation

5.2 Installing the pressure booster system

5.3 Mounting the accumulator

5.4 Connecting the piping

5.4.1 Fitting an expansion joint (optional)

5.4.2 Fitting the pressure reducer (optional)

5.5 Fitting the dry running protection device

5.6 Electrical connection

5.6.1 Sizing the power cable

5.6.2 Connecting the pressure booster system

5.6.2.1 Fitting an expansion joint (optional)

5.6.2.2 Fitting the pressure reducer (optional)

5.6.3 Connecting the dry running protection device

6 Commissioning/Start-up/Shutdown

6.1 Commissioning/Start-up

6.1.1 Prerequisites for commissioning/start-up

6.1.2 Dry running protection

6.1.3 Commissioning/start-up of pressure booster system

6.2 Start-up

6.3 Checklist for commissioning/start-up

6.4 Shutdown

7 Operation

7.1 Standard control panel

7.1.1 Display

7.1.2 Main screen

7.1.3 Settings menu

7.1.3.1 Menu: Operation

7.1.3.1.1 Access levels

7.1.3.2 Menu: Diagnosis

7.1.3.3 Menu: Settings

7.1.3.4 Menu: Information

7.1.4 Service interface and LED traffic light function

8 Servicing/Maintenance

8.1 General information/Safety regulations

8.1.1 Inspection contract