Page 1
Break Tank Package Booster Set for Fire
Fighting
Hya-Duo D FL Compact
From Series 2014w33
Installation/Operating Manual
Page 2
Legal information/Copyright
Installation/Operating Manual Hya-Duo D FL Compact
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 03/06/2019
Page 3
Contents
Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Installation of partly completed machinery....................................................................................................6
1.3 Target group.....................................................................................................................................................6
1.4 Other applicable documents............................................................................................................................6
1.5 Symbols .............................................................................................................................................................6
1.6 Key to safety symbols/markings.......................................................................................................................6
2 Safety...................................................................................................................................................... 8
2.1 General..............................................................................................................................................................8
2.2 Intended use .....................................................................................................................................................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 instructions for the operator/user........................................................................................................9
2.7 Safety information for maintenance, inspection and installation ..............................................................10
2.8 Unauthorised modes of operation................................................................................................................10
3 Transport/Temporary Storage/Disposal............................................................................................. 11
3.1 Checking the condition upon delivery..........................................................................................................11
3.2 Transport.........................................................................................................................................................11
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 Designation.....................................................................................................................................................15
4.4 Name plate......................................................................................................................................................15
4.5 Design details..................................................................................................................................................15
4.6 Configuration and function...........................................................................................................................17
4.7 Noise characteristics .......................................................................................................................................18
4.8 Scope of supply...............................................................................................................................................18
4.9 Dimensions and weights ................................................................................................................................18
5 Installation at Site................................................................................................................................ 19
5.1 Checks to be carried out prior to installation...............................................................................................19
5.2 Installing the break tank package booster set for fire fighting..................................................................20
5.3 Mounting the accumulator............................................................................................................................20
5.4 Connecting the piping ...................................................................................................................................21
5.4.1 Connecting the overflow line ...........................................................................................................21
5.4.2 Fitting an expansion joint (optional)................................................................................................22
5.5 Installing operator-supplied valves ...............................................................................................................22
5.6 Setting up the float valve ..............................................................................................................................23
5.7 Electrical connection ......................................................................................................................................23
5.7.1 Sizing the power cable ......................................................................................................................24
5.7.2 On-site protective measures..............................................................................................................24
5.7.3 Connecting the break tank package booster set for fire fighting .................................................24
5.7.4 Connecting the limit switches (remote ON/OFF)..............................................................................25
5.7.5 Connecting the dry running protection device................................................................................25
5.7.6 Connecting the volt-free contacts ....................................................................................................25
5.7.7 Connecting electrical accessories ......................................................................................................25
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Contents
6 Commissioning/Start-up/Shutdown................................................................................................... 26
6.1 Commissioning/Start-up.................................................................................................................................26
6.1.1 Prerequisites for commissioning/start-up .........................................................................................26
6.1.2 Priming and venting the break tank package booster set for fire fighting ..................................27
6.1.3 Setting the dry running protection device.......................................................................................28
6.1.4 Start-up...............................................................................................................................................29
6.1.5 Checklist for commissioning/start-up................................................................................................29
6.2 Operating limits..............................................................................................................................................30
6.2.1 Application limits ...............................................................................................................................30
6.2.2 Frequency of starts.............................................................................................................................31
6.2.3 Ambient conditions ...........................................................................................................................31
6.2.4 Maximum operating pressure ...........................................................................................................31
6.2.5 Fluid handled .....................................................................................................................................31
6.2.6 Drainage capacity ..............................................................................................................................31
6.2.7 Minimum flow rate............................................................................................................................32
6.3 Shutdown........................................................................................................................................................32
6.3.1 Shutdown ...........................................................................................................................................32
6.3.2 Measures to be taken for shutdown ................................................................................................32
7 Operation.............................................................................................................................................. 33
7.1 LED display......................................................................................................................................................33
7.2 Operating modes............................................................................................................................................33
7.2.1 Manual mode .....................................................................................................................................33
7.2.2 Functional check run..........................................................................................................................33
7.3 Functions.........................................................................................................................................................34
7.3.1 Automatic switchover (duty system and back-up system)...............................................................34
7.3.2 Dry running protection......................................................................................................................35
7.3.3 Temperature monitoring...................................................................................................................35
7.3.4 Mains water supply............................................................................................................................35
7.3.5 Drinking water stop...........................................................................................................................35
7.3.6 Flushing ..............................................................................................................................................36
8 Servicing/Maintenance........................................................................................................................ 37
8.1 General information/safety regulations........................................................................................................37
8.2 Inspection contract.........................................................................................................................................38
8.3 Servicing/Inspection........................................................................................................................................38
8.3.1 Supervision of operation ...................................................................................................................38
8.3.2 Maintenance schedule.......................................................................................................................38
8.4 Setting the pre-charge pressure ....................................................................................................................39
9 Trouble-shooting.................................................................................................................................. 40
10 Related Documents.............................................................................................................................. 42
10.1 General assembly drawing with list of components ....................................................................................42
10.2 Wiring diagram (limit switches).....................................................................................................................43
11 EU Declaration of Conformity............................................................................................................. 44
12 Certificate of Decontamination........................................................................................................... 45
13 Commissioning Report......................................................................................................................... 46
Index ..................................................................................................................................................... 47
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Glossary
Glossary
Accumulator
Pressure losses may occur in the piping system
downstream of the break tank package booster
set for fire fighting which may be caused by
leakage of small quantities of water. The
accumulator serves to compensate pressure losses
and minimises the frequency of starts of the break
tank package booster set for fire fighting.
Back-up system
The part of the fire-fighting system / break tank
package booster set for fire-fighting which
ensures the supply of fire-fighting water in the
event of a fire if the duty system fails (see also
duty 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.
DIN 1988
German Standard which stipulates technical rules
for drinking water installations.
Pump activation
Pump activation means that a pump is started up
by a starting signal from the pressure switch, from
a wall hydrant (limit switch) via remote ON/OFF, or
from the broken wire and short-circuit monitoring
relay.
Rainwater storage tank
Tank for collecting rainwater, for buried
installation or above-floor installation
Switchgear and controlgear assembly
Control cabinet with one or several control units/
switchgears and electrical equipment.
DIN14462
The fire-fighting systems/ break tank package
booster sets for fire fighting must comply with the
German standard for water conduits for fire
extinguishing.
Duty system
The active part of the fire-fighting system / break
tank package booster set for fire-fighting which
ensures the supply of fire-fighting water in the
event of a fire (see also back-up system).
Flushing
If the volume of the inlet line exceeds 1.5l and/or
the length of the inlet line ≥10×DN, a flushing
system must be provided. This will prevent
stagnating fluid handled and microbial
contamination of drinking water.
IE3
Efficiency class to IEC60034-30: 3=Premium
Efficiency (IE = International Efficiency)
Manual mode
Direct operation on the power supply network,
independently of the control unit.
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1 General
!
DANGER
!
WARNING
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 Installation of partly completed machinery
To install partly completed machinery supplied by KSB refer to the sub-sections under
Servicing/Maintenance.
1.3 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (ðSection2.3,Page9)
1.4 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Sub-supplier product literature Operating manuals, logic diagram and other
product literature of accessories and integrated
machinery components
1.5 Symbols
Table2: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨
⇨ Cross-references
1.
2.
Result of an action
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
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1.6 Key to safety symbols/markings
Table3: Definition of safety symbols/markings
Symbol Description
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
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1 General
CAUTION
Symbol Description
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EU Directive
2014/34/EU (ATEX).
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:
– Flow direction arrow
– 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 break tank package booster set for fire fighting must only be operated
within the operating limits described in the other applicable documents.
▪ Only operate break tank package booster sets for fire fighting which are in
perfect technical condition.
▪ Do not operate partially assembled break tank package booster sets for fire
fighting.
▪ Only use the break tank package booster set for fire fighting to handle the fluids
described in the product literature of the respective design variant.
▪ Never operate the break tank package booster set for fire fighting 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 break tank package
booster set for fire fighting (to prevent cavitation damage).
▪ Consult the manufacturer about any other modes of operation not described in
the product literature.
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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 break tank package booster set for fire fighting 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
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 instructions 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.
▪ Provide the personnel with protective equipment and make sure it is used.
▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪ Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
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2 Safety
2.7 Safety information for maintenance, inspection and installation
▪ Modifications or alterations of the break tank package booster set for fire
fighting require the manufacturer's prior consent.
▪ Use only original spare parts or parts/components authorised by the
manufacturer. The use of other parts/components 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 break tank package booster set for fire fighting during
standstill only.
▪ The pump (set) must have cooled down to ambient temperature.
▪ Pump pressure must have been released and the pump must have been drained.
▪ When taking the break tank package booster set for fire fighting out of service
always adhere to the procedure described in the manual.
▪ Decontaminate break tank package booster sets for fire fighting which handle
fluids posing a health hazard. (ðSection8.1,Page37)
▪ As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ðSection6.1,Page26)
▪ Make sure the break tank package booster set for fire fighting cannot be
accessed by unauthorised persons (e.g. children).
▪ Prior to opening the break tank package booster set for fire fighting, pull the
mains plug and wait for at least 10minutes.
2.8 Unauthorised modes of operation
▪ Always observe the limits stated in the product literature.
▪ The warranty relating to the operating reliability and safety of the break tank
package booster set for fire fighting supplied is only valid if the break tank
package booster set for fire fighting is used in accordance with its intended use.
(ðSection2.2,Page8)
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3 Transport/Temporary Storage/Disposal
3 Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer and the insurer about the damage in writing
immediately.
3.2 Transport
DANGER
Tilting break tank package booster set for fire fighting
Risk of injury from falling break tank package booster set for fire fighting!
▷ Never suspend the break tank package booster set for fire fighting by its cable.
▷ 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
truck.
▷ Attach the break tank package booster set for fire fighting to crane lifting
tackle as shown, or use a forklift or pallet truck to move the pallet.
Transporting the separated
break tank package booster
set for fire fighting
The break tank package booster set for fire fighting can be separated into three
parts to facilitate transport.
▪ Control cabinet with hydraulic unit (pump sets with valves and piping)
▪ Tank
▪ Baseplate
Fig.1: Transporting the separated parts of the break tank package booster set for
fire fighting
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. Disconnect the plug-type connection between the tank and the control cabinet.
4. Undo the flanged connections between the hydraulic unit and the tank.
5. Remove the hydraulic unit from the tank.
6. Unbolt the tank from the baseplate.
7. Transport the three modules to the place of installation.
8. Suspend the tank, hydraulic unit and baseplate as illustrated.
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Transporting the complete
break tank package booster
set for fire fighting
3 Transport/Temporary Storage/Disposal
9. Lift each of the three modules with suitable lifting equipment and carefully
place the modules down at the place of installation.
10. Mount the tank and hydraulic unit on the baseplate. Flange the hydraulic unit
to the tank.
11. Re-connect the plug-type connection between the tank and the control cabinet.
Fig.2: Transporting the complete break tank package booster set for fire fighting
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 break tank package booster set for fire fighting to the place of
installation.
4. Attach the break tank package booster set for fire fighting to the lifting
equipment as shown. Lift it off the wooden skids. Dispose of the wooden skids.
5. Carefully place down the break tank package booster set for fire fighting at the
site of installation.
3.3 Storage/preservation
CAUTION
Damage during storage due to frost, humidity, dirt, UV radiation or vermin
Corrosion/contamination of the break tank package booster set for fire fighting!
▷ Store the break tank package booster set for fire fighting in a frost-proof,
roofed area.
CAUTION
Wet, contaminated or damaged openings and connections
Leaking or damaged break tank package booster set for fire fighting!
▷ Only remove caps/covers from the openings of the break tank package booster
set for fire fighting at the time of installation.
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for storing the break tank package booster set for fire
fighting:
Store the break tank package booster set for fire fighting in a dry, protected room
where the atmospheric humidity is as constant as possible.
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3 Transport/Temporary Storage/Disposal
Table4: 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 break tank package booster set for fire fighting as per operating
instructions.
2. Flush and clean the break tank package booster set for fire fighting, particularly
if it has been used for handling noxious, explosive, hot or other hazardous
fluids.
3. If the break tank package booster set for fire fighting has handled fluids whose
residues could lead to corrosion damage in the presence of atmospheric
humidity or could ignite upon contact with oxygen, the break tank package
booster set for fire fighting must also be neutralised, and anhydrous inert gas
must be blown through the break tank package booster set for fire fighting to
ensure drying.
4. Always complete and enclose a certificate of decontamination when returning
the break tank package booster set for fire fighting. (ðSection12,Page45)
Always indicate any safety measures 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 break tank package booster set for fire fighting.
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
1
2
4
3
6
5
8
7
Johann-Klein-Straße 9
Deutschland
67227 Frankenthal
KSB SE & Co. KGaA
Hmax: 74,4 m
Qmax: 48,2 m³/h
Made in Germany
29134528
ZNI1448 P
Hya-Duo D FL 2/4003 B Compact
2019w04
400 V 3~ 19,5 A
50 Hz 11,0 kW IP 54
4 Description
4.1 General description
▪ Break tank package booster set for fire fighting
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 Designation
Example: Hya-Duo D FL 2/ 1506 B Compact
Table5: Designation key
Code Description
Hya-Duo Type series
D FL Break tank package booster set for fire fighting with three-phase motor
2 Number of pump sets
15 Pump size
06 Number of stages
B Design status
Compact Compact design
4.4 Name plate
Fig.3: Name plate (example)
1 Type series, size 5 Year,calender week of construction
2 Rated voltage 6 Maximum current input
3 Frequency, power 7 Enclosure
4 Maximum head 8 Maximum permissible flow rate
4.5 Design details
Design
▪ Fully automatic break tank package booster set for fire fighting to EN1717
▪ Baseplate-mounted
▪ Modular design (comprising 3 modules):
1) Supplied fitted and electrically connected, with default settings
– Control cabinet with hydraulic unit (two pump sets with redundant function,
valves, piping, pressure switch1) and temperature sensor1))
– Baseplate
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4 Description
– Tank with inlet device and flushing device, overflow monitoring and dry
running monitoring
2)
▪ Vibration damping
Installation
▪ Stationary dry installation
Drive
▪ Three-phase asynchronous motor
▪ 380 / 420V, 50Hz
▪ 2 poles
▪ Enclosure IP55
▪ Efficiency class IE3 to IEC60034-30
▪ Soft starter for each pump
▪ Pressure-controlled starting and flow-controlled stopping
Automation
▪ Electro-mechanical control system, IP54
▪ Timer
▪ Manual-automatic selector switch
▪ Phase monitoring relay
▪ In automatic mode, the motor protection circuit only outputs an alert.
▪ Terminal strip/terminals with identification for all connections
▪ Pressure switch or remote ON/OFF, monitored for broken wires and short circuit
▪ Circuit diagram to VDE and parts list for electric parts
Indication via indicator lamps:
▪ Colour LED indicating lack of water (red)
▪ Colour LED indicating a fault (amber)
▪ Colour LED indicating readiness for operation (green)
▪ Colour LED indicating operation started by pressure switch or remote ON/OFF
(white)
Indication via volt-free isolating terminals:
▪ Lack of water
▪ Overflow
▪ Position of manual-automatic selector switch
▪ Pump control via pressure switch or remote ON/OFF
▪ General fault message
▪ Drinking water stop
Monitoring for broken wires and monitoring for short circuit:
▪ >10.3kΩ: broken wire
▪ 10kΩ: good state
▪ 1kΩ: pump start through actuation of limit switch
▪ < 300Ω: short circuit
2) Supplied assembled and pre-set. The electrical components can be connected and disconnected at the control cabinet via
plug-type connections.
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4 Description
1
2
3
4
5
4.6 Configuration and function
Fig.4: Illustration of the break tank package booster set for fire fighting
1 Control cabinet 4 Tank
2 High-pressure centrifugal pump 5 Baseplate
3 Inlet
Design Fully automatic, ready-to-connect break tank package booster set for fire fighting
comprising two high-pressure centrifugal pumps (2) with redundant function, a
control cabinet (1) and a tank (4) for the hygienic separation of drinking water and
fire-fighting water. The modular design allows separating the break tank package
booster set for fire fighting into three modules (control cabinet with hydraulic unit,
tank and baseplate). Anti-vibration mounts are fitted at the pump feet and baseplate
(5).
Function The pump sets are started and stopped as a function of pressure via the electro-
mechanical control system. If the pressure drops below the set start-up pressure pE,
the pump sets are started up via the pressure switch. When consumption decreases
again, the pump sets are stopped as a function of pressure after the set after-run
period (up to 10minutes). Independently of the pressure switch, the break tank
package booster set for fire fighting can also be controlled via remote ON/OFF (e.g. a
switch in the wall hydrant). The pressure switch and remote ON/OFF input are
monitored for broken wires and short circuit. If a broken wire or short circuit are
detected, the break tank package booster set for fire fighting is started up
automatically and a fault is indicated.
In the event of a fire, pumping the fluid handled is of top priority. In automatic
mode, the protective features (dry running protection, motor protection) cannot be
enabled. If the motor protection switch trips, the motor will keep running on the
power supply network without further monitoring. A fault message is output.
The required quantity of the fluid handled is supplied via the float valve.
The float valve at the drinking water inlet is opened and closed fully automatically as
a function of the fill level in the tank. A float switch monitors for lack-of-water and
overflow, and signals such events to the control system. Power supply of the flushing
system and water level monitoring equipment is effected via terminals in the control
cabinet.
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4 Description
4.7 Noise characteristics
For the noise characteristics refer to the operating manual of the pump (set).
4.8 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪ Break tank package booster set for fire fighting
– Two vertical Movitec high-pressure centrifugal pumps
– Discharge-side piping
– Check valve
– Shut-off valves
– Discharge-side, direct-flow membrane-type accumulator
– Two pressure switches on the discharge side
– Pressure gauge
– Base frame
– Drain connection with integrated odour trap
– Temperature sensor
– Automatic flushing
– Tank with typeAB air gap to EN1717
– Float valve for mains water supply to DVGW
▪ Control unit
– Two power supply connections
– Two motor protection switches
– Two master switches
– Two relays for broken wire monitoring/ short-circuit monitoring
– Two manual-automatic selector switches
– Two timers
– Two phase monitoring relays
– Two soft starters
– Two control transformers
– Terminal strip with markings for all connections
– Plug-type connection for the control cabinet and tank
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4.9 Dimensions and weights
For dimensions and weights refer to the outline drawing.
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5 Installation at Site
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 EN206-1.
▷ The mounting surface must have set and must be completely horizontal and
even.
▷ Observe the weights indicated.
NOTE
The anti-vibration mounts provide adequate insulation against solid-borne noise.
NOTE
Do not operate the break tank package booster set for fire fighting near living
quarters and/or sleeping quarters.
NOTE
Observe the installation requirements to DIN14462.
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 break tank package booster set for fire fighting can be operated on the
power supply network according to the data on the name plate.
(ðSection4.4,Page15)
▪ 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 the system is installed below the flood level, the country-specific drainage
regulations must be complied with.
▪ If expansion joints are used, take note of their creep resistance. Expansion joints
must be easily replaceable.
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5 Installation at Site
5.2 Installing the break tank package booster set for fire fighting
DANGER
Microbial contamination of drinking water
Danger to life!
▷ If the volume of the inlet line exceeds 1.5l and/or the length of the inlet line
≥10×DN, flush the inlet line at least 1× per week. (ðSection7.3.6,Page36)
CAUTION
Dirt in the break tank package booster set for fire fighting
Damage to the pump set!
▷ Clean the tank before filling it.
▷ Clean the tank and the integrated odour trap at least once a year.
NOTE
DIN1988 permits the installation of an unpressurised tank. The tank made of
polyethylene meets the requirements of EN1717 and EN13077, (overflow typeAB
air gap).
ü The packaging of the break tank package booster set for fire fighting has been
removed.
ü Sufficient clearance in all directions is provided for servicing work.
ü All structural work required has been checked.
ü The dimensions of the foundation are correct, and the concrete has set firmly.
ü The foundation is level.
1. Align the break tank package booster set for fire fighting horizontally.
ð Standard design: If necessary, insert shims, wedges or other supports under
baseplate sections designed to contact the floor.
ð Version with feet (optional): Adjust the feet height.
2. Connect the mains water supply line and discharge line to the corresponding
distribution lines on the inlet side and discharge side. See DIN1988.
3. Mark the fastening hole positions on the foundation in accordance with the
outline drawing (other applicable documents).
4. Drill the holes (maximum diameter: 12mm).
5. Insert plug fixings of appropriate size.
6. Place the break tank package booster set for fire fighting in its correct
installation position.
7. Use suitable bolts to firmly anchor the break tank package booster set for fire
fighting.
8. Clean the tank.
20 of 48
5.3 Mounting the accumulator
CAUTION
Dirt in the break tank package booster set for fire fighting
Damage to the pump set!
▷ Clean the accumulator before filling it.
ü The original operating manual of the accumulator is on hand.
1. Mechanically and electrically connect the accumulator in accordance with the
original operating manual supplied.
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5 Installation at Site
2
1
3
5.4 Connecting the piping
Fig.5: Connecting the piping
1 Inlet line connection 3 Overflow line connection
2 Discharge line connection
1. Install the piping without transmitting any stresses and strains.
2. Connect the piping to the distribution lines on the inlet side and discharge side.
Connect the inlet line in a rigid horizontal position.
3. Connect the overflow. (ðSection5.4.1,Page21)
5.4.1 Connecting the overflow line
CAUTION
Overflow not connected
Flooding of installation room!
▷ Lay the overflow line to a sewer of sufficient drainage capacity.
NOTE
The overflow with typeAB air gap separates the drinking water from the firefighting water (service water) in compliance with the standard, also if the siphon is
clogged or closed.
ü The break tank package booster set for fire fighting has been properly installed.
ü The sewer has sufficient drainage capacity.
ü The drainage capacity required for the break tank package booster set for fire
fighting is met. (ðSection6.2.6,Page31)
1. Design the overflow line as short as possible.
2. Connect the overflow line to the overflow (connection DN150).
3. Lay the overflow line with a continuously falling slope to the sewer.
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5 Installation at Site
5.4.2 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. Sufficient clearance in all directions is provided for checking the expansion joint.
2. Only fit an expansion joint upstream of the float valve if a rigid, supported pipe
section is fitted between the float valve and the expansion joint.
3. 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.
4. Evenly tighten the bolts crosswise. The ends of the bolts must not protrude from
the flange.
5.5 Installing operator-supplied valves
1. Any additional valves used (e.g. gate valve, water meter and lift check valve)
must comply with the local water supplier's requirements.
22 of 48
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5 Installation at Site
1
5.6 Setting up the float valve
Fig.6: Access to the float valve
1 Cover
ü The original operating manual of the float valve is on hand.
ü The inlet line has been installed properly. (ðSection5.4,Page21)
1. Undo the six bolts of the cover at the top of the tank with a suitable tool. Store
the bolts.
2. Remove the retaining tabs of the float valve.
3. Loosen the fastening screw of the floating ball with a suitable tool.
4. Move the floating ball along the lever arm as required.
ð Floating ball close to the valve = maximum fill level.
ð Floating ball at the end of the lever arm = maximum tightness and reliable
closing at high inlet pressure.
5. Fasten the fastening screw of the floating ball with a suitable tool. The floating
ball must be able to move freely.
6. Fit the cover on the top of the tank. Fasten it with the six bolts.
5.7 Electrical connection
DANGER
Electrical connection work by unqualified personnel
Risk of fatal injury due to electric shock!
▷ Always have the electrical connections installed by a trained and qualified
electrician.
▷ Observe regulations IEC 60364 and, for explosion-proof models, EN60079.
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷ Observe the technical specifications of the local energy supply companies.
NOTE
For the electrical connection comply with the requirements to DIN14462.
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5 Installation at Site
Lightning protection
▪ Electrical installations must be protected against overvoltage (compulsory since
14December2018) (see DINVDE0100-443 (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 10metres 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.
5.7.1 Sizing the power cable
Determine the cross-section of the power cable based on the total rated power
required.
5.7.2 On-site protective measures
For protective measures on site observe DIN14462 for the electrical connection.
5.7.3 Connecting the break tank package booster set for fire fighting
NOTE
If the connection for emergency back-up power supply is connected to the second
terminal, the power supply must be switched between the two power supply
options at the site. The terminals for the power supply options are wired in the
control cabinet. The control cabinet must only be supplied by one of the power
supply options at a time.
ü Prior to connecting the system to the power supply network, the operator has
made sure that the applicable VDE and country-specific regulations are complied
with.
ü The power cable has been connected by an approved company.
1. Connect the limit switches (remote ON/OFF). (ðSection5.7.4,Page25)
2. Connect the dry running protection device. (ðSection5.7.5,Page25)
3. Connect the volt-free contacts. (ðSection5.7.6,Page25)
4. Connect the electrical accessories. (ðSection5.7.7,Page25)
24 of 48
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5 Installation at Site
5.7.4 Connecting the limit switches (remote ON/OFF)
1. Connect one or several limit switches in accordance with the wiring diagram
(limit switches). When connecting several limit switches, connect the
terminating resistor behind the last limit switch. (ðSection10.2,Page43)
The terminals for connecting limit switches (remote ON/OFF) are marked in the
switchgear and controlgear assembly. A terminating resistor of 10kΩ is connected at
the terminals. The relay for broken wire monitoring and the relay for short-circuit
monitoring analyse the following resistance values:
▪ 10kΩ: no fault
▪ >10.3kΩ: broken wire
▪ < 300Ω: short circuit
▪ 1kΩ: pump start through actuation of limit switch
5.7.5 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.
5.7.6 Connecting the volt-free contacts
1. Establish the connection in accordance with the wiring diagram. The terminals
are marked in the switchgear and controlgear assembly.
2. If fault information of volt-free individual fault message is to be transmitted as
a volt-free general fault message, loop through the volt-free individual fault
messages.
Volt-free contacts are provided for the following messages:
▪ General fault message
– Motor protection warning
– No control voltage
– Short circuit/ broken wire
– Mains fault
– Excessive pump temperature
▪ General fault message
– Tank overflow
– Pump activated
– Lack of water/ dry running
– Switch position of manual-automatic selector switch
– Drinking water stop
5.7.7 Connecting electrical accessories
1. Connect the electrical accessories in accordance with the wiring diagram.
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6 Commissioning/Start-up/Shutdown
6 Commissioning/Start-up/Shutdown
6.1 Commissioning/Start-up
6.1.1 Prerequisites for commissioning/start-up
CAUTION
Pump set running dry
Damage to the pump set/ break tank package booster set for fire fighting!
▷ Use a dry running protection device. 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.
Ensure that the following requirements are met prior to commissioning/start-up:
▪ The break tank package booster set for fire fighting 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 owner or the owner's representative must had the system's readiness for
operation and connection conditions checked by the responsible authorities (e.g.
local water provider or the office for industrial safety and product safety).
▪ The dry running protection device has been installed. (ðSection5.7.5,Page25)
26 of 48
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6 Commissioning/Start-up/Shutdown
6.1.2 Priming and venting the break tank package booster set for fire fighting
CAUTION
Foreign matter in the piping
Damage to the pump set/ break tank package booster set for fire fighting!
▷ Before commissioning/starting up or test running the break tank package
booster set for fire fighting, make sure that there is no foreign matter in the
break tank package booster set for fire fighting or piping.
CAUTION
Operation without the fluid to be handled
Damage to the pump set!
▷ Prime the break tank package booster set for fire fighting with the fluid to be
handled.
NOTE
Prior to delivery, the break tank package booster set for fire fighting is hydraulically
tested with water and then drained again. For technical reasons the presence of
some residual water is unavoidable.
Prior to commissioning/start-up observe EN806. After prolonged standstill periods,
flushing or professional disinfection is recommended. For extensive or branched
piping systems flushing the break tank package booster set for fire fighting can be
restricted to a limited area.
NOTE
Minor leakage of the mechanical seals during commissioning is normal and will
cease after a short period of operation.
Have commissioning carried out by specialist KSB staff. Start-up the duty system prior
to starting up the stand-by system.
ü The original operating manual of the pump set is on hand.
ü The original operating manual of the pressure switch is on hand.
ü The original operating manual of the timer is on hand.
ü The pipe unions between the pump set and the piping have been re-tightened.
ü The flange bolting has been checked for firm seating.
ü The cooling air inlet openings and outlet openings at the motor are
unobstructed.
ü All shut-off valves are open.
ü The pre-charge pressure of the accumulator has been checked.
(ðSection8.4,Page39)
ü The minimum flow rate has been observed. (ðSection6.2.7,Page32)
1. Set the master switch to 0 and the manual-automatic selector switch to
automatic.
2. Provide connection to power supply.
3. Connect the water mains for the mains water supply.
4. Open the vent plugs at the pump set in accordance with the supplied original
operating manual of the pump set.
5. Slowly open the inlet-side valve and slowly prime the break tank package
booster set for fire fighting until the fluid to be handled escapes through the
vent holes.
ð The tank starts to fill up.
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6 Commissioning/Start-up/Shutdown
6. Check that the float valve functions properly. (ðSection5.6,Page23)
7. Close and slightly tighten the pump vent plugs.
8. Switch on the master switch.
9. Set the manual-automatic selector switch to manual. Check the direction of
rotation of the pump sets. Compare the direction of rotation to the arrow
indicating the direction of rotation on the motor. If the direction of rotation
does not match, interchange the phases at the terminal board of the motor.
10. Set the manual-automatic selector switch to automatic.
11. Slowly open the discharge-side valve. Check the set start-up pressure with a
pressure gauge. If necessary, adjust the start-up pressure in accordance with the
supplied original operating manual of the pressure switch.
12. Slowly close the discharge-side valve. Check the set stop pressure with a pressure
gauge. If necessary, adjust the stop pressure in accordance with the supplied
original operating manual of the pressure switch.
13. Slowly open the discharge-side valve.
14. Set the after-run time of the pump set to a value between 3 and 10minutes
using the timer in accordance with the supplied original operating manual.
Observe the maximum permissible frequency of starts.
(ðSection6.2.2,Page31)
15. When all pump sets are running, loosen the vent plugs again to let any
remaining air escape.
16. Close the vent plugs.
17. Check that the pump sets are running smoothly.
18. Close the discharge-side valve in order to verify whether the pump sets reach
the maximum shut-off head.
19. Open the discharge-side valve.
20. Set the time and duration of the test run in the switchgear and controlgear
assembly (first channel of the timer) in accordance with the supplied original
operating manual.
21. Set the flushing system. (ðSection7.3.6,Page36)
22. Check the minimum inlet pressure with a pressure gauge. If the inlet pressure is
too low, contact the public utility company. (ðSection6.2.1,Page30)
23. Set the dry running protection device. (ðSection6.1.3,Page28)
24. Set the mains water supply. (ðSection7.3.4,Page35)
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6.1.3 Setting the dry running protection device
NOTE
Dry running protection is only enabled in manual mode and test run mode. In
automatic mode an alarm message is indicated by the (red) indicator lamp; the
pump sets continue to run.
In the switchgear and controlgear assembly the digital input for dry running
protection is directly connected to the float switch in the tank. If the connection
opens, the control system stops the break tank package booster set for fire fighting
after approximately 10seconds (factory setting). The stop delay of 5 to 100seconds
can be set at the timer.
ü The dry running protection device has been properly connected.
(ðSection5.7.5,Page25)
ü The original operating manual of the timer is on hand.
1. Set the timer in accordance with the supplied original operating manual.
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6 Commissioning/Start-up/Shutdown
6.1.4 Start-up
NOTE
The pressure booster system is factory-set to the operating data indicated on the
name plate.
ü The break tank package booster set for fire fighting has been primed and
vented.
1. Switch on the master switch.
ð The green LED lights ups and signals the system's readiness for operation.
6.1.5 Checklist for commissioning/start-up
Table6: Checklist
Action Completed
Steps to be
carried out
1 Read the operating manual.
2 Compare the power supply data against the name plate data.
3 Check/measure the earthing system.
4 Check the mechanical connection to the water supply system. Re-tighten the flanges and pipe
unions.
5 Prime and vent the break tank package booster set for fire fighting from the inlet side.
6 Check the mains water supply.
7 Check that all cables are firmly connected to the terminals inside the control unit.
8 Check the direction of rotation.
9 Check the start pressure and stop pressure; re-adjust if necessary.
10 Test the proper function of the dry running protection equipment. If not fitted, make a
relevant note in the commissioning report.
11 After the pump set has been running for 5 to 10minutes, vent it again.
12 Check the pre-charge pressure.
13 Enter any deviations from the name plate or order documentation in the commissioning
report.
14 Complete the commissioning report together with the operator/ user and instruct the
operator/ user as to the function of the unit.
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6 Commissioning/Start-up/Shutdown
6.2 Operating limits
DANGER
Non-compliance with operating limits
Damage to the pump set!
▷ Comply with the operating data indicated in the data sheet.
▷ Avoid operation against a closed shut-off element.
▷ Never operate the pump set outside the limits specified below.
DANGER
Non-compliance with operating limits for the fluid handled
Explosion hazard!
▷ Never use the pump to handle different fluids which might react chemically
with each other.
▷ Never use the pump to handle a flammable fluid with a fluid temperature
above the ignition temperature.
6.2.1 Application limits
NOTE
On-site conditions deviating from the test conditions may have a negative impact
on the operating reliability. Regardless of the effective volume of the tank, the
operating reliability of the system must be checked in an on-site acceptance
inspection in accordance with DIN14462.
The effective volume of the tank is selected to DIN1988-500 as standard. Mains
water is refilled via a float valve.
To ensure a sufficient supply of fire-fighting water and when using a tank with
reduced effective volume observe the following application limits:
Table7: Application limits
Flow rate Float switch
connection
[m3/h] [bar] [bar]
≤ 18 G 1 1/
≤ 36 G 2 1,5 8
≤ 48 G 2 3 8
4
Minimum inlet
pressure
1,5 8
3)
Maximum static
pressure
3) Minimum flow pressure at the float switch depending on the nominal flow rate
30 of 48
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6 Commissioning/Start-up/Shutdown
6.2.2 Frequency of starts
To prevent high temperature increases in the motor and excessive loads on the
pump, motor, seals and bearings, the frequency of starts shall not exceed the
following number of starts per hour.
Table8: Frequency of starts
Motor rating Maximum frequency of starts
[kW] [Starts/hour]
≤ 7,5 20
11 - 22 10
≥ 30 6
6.2.3 Ambient conditions
Observe the following parameters and values during operation:
Table9: Permissible ambient conditions
Ambient condition Value
Ambient temperature 0 °C to +40°C
Relative humidity 50 % maximum
6.2.4 Maximum operating pressure
CAUTION
Permissible operating pressure exceeded
Damage to connections and seals!
▷ Never exceed the operating pressure specified in the data sheet.
The maximum operating pressure equals 16, 25 or 40bar, depending on the design
variant.
6.2.5 Fluid handled
6.2.5.1 Permissible fluids to be handled
▪ Fire-fighting water
▪ Liquids not containing aggressive, abrasive or solid substances
6.2.5.2 Fluid temperature
Table10: Temperature limits of the fluid handled
Permissible fluid temperature Value
Maximum +70°C
Minimum 0°C
6.2.6 Drainage capacity
Table11: Drainage capacity depending on the effective volume of the tank
Effective volume of the tank Drainage capacity
[l] [m3/h]
540 25
1080 50
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6 Commissioning/Start-up/Shutdown
1
6.2.7 Minimum flow rate
Table12: Minimum flow rate per pump in manual mode
Size Minimum flow rate per pump
[l/h]
Movitec 15B 1600
Movitec 25B 2800
Movitec 40B 4600
6.3 Shutdown
6.3.1 Shutdown
1. Close the valves in the inlet line.
2. Set the master switch to 0.
6.3.2 Measures to be taken for shutdown
Fig.7: Draining the break tank package booster set for fire fighting
1 Drain plug
ü The break tank package booster set for fire fighting has been shut down.
(ðSection6.3.1,Page32)
1. Open the drain plug at the tank with a suitable tool.
ð The break tank package booster set for fire fighting is drained.
2. Close the drain plug at the tank with a suitable tool.
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7 Operation
7 Operation
CAUTION
Incorrect operation
Damage to the pump system!
▷ Make sure to comply with all local regulations, particularly the EC Machinery
Directive and the EC Directive on Low-Voltage Equipment.
▷ Check all electric cables prior to commissioning/start-up.
7.1 LED display
The LED display provides information about the operating status.
Table13: LED description
LED Description
Green Trouble-free operation
Yellow One or more warnings are active.
Red Fire-fighting operation active, one or more alarm messages active.
7.2 Operating modes
7.2.1 Manual mode
Manual mode is reserved for emergencies. Continuous manual operation would lead
to waste of energy and water and cause the fluid handled and/or the pump sets to
overheat. A manual-automatic selector switch for each pump set is provided at the
switchgear and controlgear assembly. When the switch is set to manual the pump
sets are operated on the power supply network, independently of the automatic
system (pressure switch, remote ON/OFF).
7.2.2 Functional check run
The switchgear and controlgear assembly is fitted with a timer per pump set. During
the functional check run the pump sets are operated directly on the power supply
network, independently of the automatic system (pressure switch, remote ON/OFF).
The functional check run parameters can be set via the timer (see supplied original
operating manual).
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7 Operation
7.3 Functions
7.3.1 Automatic switchover (duty system and back-up system)
If the duty system fails (motor protection switch or phase monitoring tripped, 24V
supply interrupted or control transformer failed), operation automatically switches
from the duty system to the back-up system.
Table14: Response in the event of a failure
Duty system fault Back-up system fault Response of pressure booster system
Motor protection switch tripped Motor protection switch tripped Back-up system ready for operation
24V supply interrupted Back-up system starts up
Control voltage interrupted Switchover back to duty system
Duty system ready for operation
Failure phase monitoring Switchover back to duty system
Duty system ready for operation
24V supply interrupted Motor protection switch tripped Back-up system ready for operation
24V supply interrupted Back-up system starts up
Control voltage interrupted Switchover back to duty system
Duty system starts up
Failure phase monitoring Switchover back to duty system
Duty system starts up
Control voltage interrupted Motor protection switch tripped Back-up system ready for operation
24V supply interrupted Back-up system starts up
Control voltage interrupted Switchover back to duty system
Pressure booster system no longer ready for
operation
Failure phase monitoring Switchover back to duty system
Pressure booster system no longer ready for
operation
Failure phase monitoring Motor protection switch tripped Back-up system ready for operation
24V supply interrupted Back-up system starts up
Control voltage interrupted Switchover back to duty system
Pressure booster system no longer ready for
operation
Failure phase monitoring Switchover back to duty system
Pressure booster system no longer ready for
operation
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7 Operation
7.3.2 Dry running protection
In the following cases, dry running protection is active in manual mode and during a
test run:
▪ The discharge-side pressure is not below the start-up pressurep
E .
▪ The break tank package booster set for fire fighting is started up via the remote
ON/OFF contact.
Both cases are interpreted as an event of fire. In the event of fire, the system's
protective features must be disabled.
A digital input is provided for connecting the dry running protection device. When
the input is open, the control unit detects dry running and stops the break tank
package booster set for fire fighting after approx. 10seconds (factory setting).
7.3.3 Temperature monitoring
To protect the pump sets against overheating during operation without minimum
flow rate a temperature sensor is fitted on the pump shroud. The temperature sensor
opens the solenoid valve in the by-pass line when a specific fluid temperature
(factory-set to 65°C) is exceeded. Temperature monitoring is enabled in automatic
mode and manual mode.
7.3.4 Mains water supply
The tank is automatically re-filled with mains water via the float valve. During
operation the fill level is maintained by the water supply balancing out the water
consumed. The float switch monitors for lack-of-water and dry running, and signals
such events to the switchgear and controlgear assembly as faults.
ü The application limits of the float switch and tank are observed.
(ðSection6.2.1,Page30)
ü The sewer has sufficient drainage capacity.
1. Set the flow rate by means of throttle valves or pressure reducers so that the
tank, when the valve closes automatically, fills up until just under the float
valve.
The peak flow rate in an inlet line must not exceed the flow velocity of 5m/s
(DIN1988-600).
7.3.5 Drinking water stop
If a drinking water supply branch is provided at the site, this branch can be closed off
by the volt-free message drinking water stop. A time delay applies to this message
(factory setting 30seconds) when activated via pressure switch or limit switch
(remote ON/OFF).
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7 Operation
0
1
2
3
4
5
6
7
8
0 1 2
Q [l/s]
pzul [bar]
0
1
2
3
4
5
0 0,1 0,2 0,3 0,4 0,5
DN 80
DN 50
DN 65
V [m/s]
pzul [bar]
7.3.6 Flushing
NOTE
According to DIN1988-600 automatic flushing must be effected once a week, if the
supply line exceeds a length of 10xDN and a volume of 1.5l. The flushing system
must be set to replace three times the water volume in the supply line. During the
flushing process the minimum flow velocity for DN50 is 0.2m/s; for larger nominal
diameters the minimum flow velocity is 0.1m/s.
The break tank package booster set for fire fighting is fitted with a discharge-side
flushing system (solenoid valve 1/2inch).
For flushing the inlet line provide a flushing system (e.g. solenoid valve) at the site.
The flushing duration of the inlet line must be determined and set using the timer in
the switchgear and controlgear assembly.
Determining the flushing duration
1. Determine the flow rate (Q) of the solenoid valve at minimum available inlet
pressure (p
).
Inl
36 of 48
Fig.8: Flow diagram, solenoid valve: flow rate (Q) as a function of inlet pressure (p
2. Determine the flow velocity (V) at minimum available inlet pressure (p
).
Inl
)
Inl
Multiply the result with three times the volume of the inlet line.
ð Nominal size ≤DN50: minimum flow velocity (V) = 0.2m/s
ð Nominal size >DN50: minimum flow velocity (V) = 0.1m/s
Fig.9: Flushing process in the inlet line: flow velocity (V) as a function of inlet
pressure (p
)
Inl
3. Calculate the flushing duration.
Setting the discharge-side flushing system
ü The overflow has been properly connected.
ü The required flushing duration has been determined.
1. Set the timers in the duty system and in the stand-by system. Set the time and
duration for flushing in the switchgear and controlgear assembly (second
channel of the timer) in accordance with the supplied original operating
manual.
ð The flushing water is discharged via the overflow.
Hya-Duo D FL Compact
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8 Servicing/Maintenance
8 Servicing/Maintenance
8.1 General information/safety regulations
DANGER
Unintentional starting of the break tank package booster set for fire fighting
Danger to life!
▷ De-energise the break tank package booster set for fire fighting for any repair
work or servicing work.
▷ Ensure that the break tank package booster set for fire fighting cannot be re-
energised unintentionally.
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
Work on the break tank package booster set for fire fighting by unqualified
personnel
Risk of injury!
▷ Always have repair work and maintenance work performed by specially trained,
qualified personnel.
CAUTION
Use after event of fire/ failure
Malfunction; functions not working!
▷ Completely check the break tank package booster set for fire fighting after it
has been operated in an event of fire.
CAUTION
Incorrectly serviced break tank package booster set for fire fighting
Function of break tank package booster set for fire fighting not guaranteed!
▷ Regularly service the break tank package booster set for fire fighting.
▷ Create a maintenance schedule. Observe the information on lubricant, shaft
seal and coupling of the pump sets.
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.
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Page 38
8 Servicing/Maintenance
8.2 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.
8.3 Servicing/Inspection
8.3.1 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. (ðSection8.4,Page39)
▪ 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.
8.3.2 Maintenance schedule
Table15: Overview of maintenance work
Maintenance interval Servicing/maintenance work
At least once a year Check the pump set for smooth running. Check the mechanical seal for integrity.
If applicable, check the feet for any wear.
Check the shut-off valves, drain valves and check valves for proper functioning and
tightness.
If applicable, clean the strainer in the pressure reducer.
If applicable, check the expansion joints for any wear.
Verify the pre-charge pressure. Check the accumulator for integrity.
Check the automatic switching functionality.
Check if the functional check run is running.
Check the cut-in levels and cut-out levels.
Check the inlet, inlet pressure, dry running protection and, if applicable, the pressure
reducer.
Check the tank, float switch and float valve. Check the overflow for integrity and
cleanliness.
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Hya-Duo D FL Compact
Page 39
8 Servicing/Maintenance
8.4 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 pre-charge pressure of the accumulator (p) must be below the set start-up
pressure (pE) of the break tank package booster set for fire fighting.
The best storage volumes are achieved at the following settings (average value):
▪ Factor0.9 at pre-charge pressure >3bar
▪ Factor0.8 at pre-charge pressure <3bar
Example 1 pE=5bar
5bar×0.9=4.5bar
At a start-up pressure of 5bar the pre-charge pressure of the accumulator must be
set to 4.5bar.
Example 2 pE=2bar
2bar ×0.8=1.6bar
At a start-up pressure of 2bar the pre-charge pressure of the accumulator must be
set to 1.6bar.
Checking the pre-charge pressure
1. Close the valve under the accumulator.
2. Drain the accumulator via the drain valve.
3. Remove and store the protective cap of the accumulator valve.
4. Check the pre-charge pressure with a suitable pressure gauge (e.g. tyre pressure
gauge).
5. Fit the protective cap of the accumulator valve.
Filling the accumulator
1. Remove and store the protective cap of the accumulator valve.
2. Re-fill nitrogen through the valve.
3. Fit the protective cap of the accumulator valve.
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Page 40
9 Trouble-shooting
9 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.
NOTE
Prior to commissioning and maintenance work during the warranty period,
consultation with KSB Service is required. Non-compliance with this instruction will
lead to forfeiture of any and all rights to claims for damages.
If problems occur that are not described in the following table, consultation with the
KSB service is required.
A Pump cuts out shortly after start-up in manual mode. Red indicator lamp signals lack
of water.
B The break tank package booster set for fire fighting does not start.
C Pump running but not delivering water
D Insufficient flow rate of the break tank package booster set for fire fighting
E Discharge-side pressure too low.
F Discharge-side pressure too high.
G Leakage at mechanical seal.
H Motor/pump overheated.
I Motor protection switch triggered. Yellow indicator lamp is on.
J Pump does not stop.
K Pump starts too often (more than 30 starts per hour).
L Broken wire and short-circuit monitoring relay indicates a broken wire.
M Broken wire and short-circuit monitoring relay indicates a short circuit.
N Green lamp and yellow lamp light up simultaneously and pump is running.
O Yellow lamp and red lamp are lit.
P Drain connection overflows.
Table16: Trouble-shooting
A B C D E F G H I J K L M N O P Possible cause Remedy
- - ✘ ✘ - - - ✘ - ✘ - - - - - - Pump/ piping not vented
and/or primed
✘ ✘ ✘ ✘ ✘ - - ✘ - - - - - - - - Shut-off valves fully or
partially closed
✘ - - ✘ ✘ - - - - ✘ - - - - - - Strainer / dirt trap clogged Clean.
- - ✘ ✘ ✘ ✘ - - - - - - - - - - Inlet-side shut-off valve closed Check, open as necessary.
- - - - - - - ✘ - ✘ - - - - - - Discharge-side shut-off valve
closed or defective
✘ ✘ - ✘ ✘ ✘ - ✘ - ✘ - - - - - - Pressure switch set incorrectly Check setting.
- - - - - - - - - ✘ - - - - - - Start-up pressure set too high Check setting.
- - - - - - - ✘ - - ✘ - - - - - Pre-charge pressure of the
accumulator too low
- - - - - - - ✘ - - ✘ - - - - - Accumulator defective Check integrity. Replace if
4) Before any work on pressure-retaining components, release the pump set pressure and de-energise the pump set.
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Hya-Duo D FL Compact
Vent and/or prime.
Check, open as necessary.
Check, open as necessary.
Restore nitrogen cushion.
necessary.
4)
Page 41
9 Trouble-shooting
A B C D E F G H I J K L M N O P Possible cause Remedy
4)
- - - - - - ✘ - - - - - - - - - Defective mechanical seal Replace.
✘ - - - - - - - - - - - - - - - Tank / accumulator not filled Check the water level in the
tank/ accumulator.
- - ✘ ✘ ✘ - - ✘ ✘ ✘ - - - - - - Check valve defective Check. Replace sealing
element if necessary.
✘ - - - ✘ - - - ✘ ✘ ✘ - - - - - Water consumption higher
Contact the manufacturer.
than stated in the purchase
order
- - - - - - - - ✘ - - - - - - - Motor protection switch
triggered or set incorrectly/
Compare setting with the
motor's rating plate data.
pump seized
- - - - - - - - - - ✘ - - - - - Delay setting too short Check the setting.
- ✘ - - - - - - - - - - - - - - Mains supply interrupted Check. Remedy defect. Check
fuse.
- ✘ - - - - - - ✘ - - - - - - - Main fuse on (ownersupplied) distribution board
loose or blown; fuses possibly
Check fuses and replace as
necessary. Measure the motor
current.
too small or too fast
- ✘ - - - - - - - - - - - - - - Phase failure Check individual phases;
replace fuse if necessary.
- - - - - - - - - ✘ - ✘ - ✘ - - Broken wire in the input line
of the pressure switch
- - - - - - - - - ✘ - ✘ - ✘ - - Broken wire in the input line
of the remote ON/OFF system
- - - - - - - - - ✘ - - ✘ ✘ - - Short circuit in the input line
of the pressure switch
- - - - - - - - - ✘ - - ✘ ✘ - - Short circuit in the input line
of the remote ON/OFF system
- - - - - - - ✘ - - - - - - - - Solenoid valve for minimum
flow not actuated
Check. Remedy defect if
applicable.
Check. Remedy defect if
applicable.
Check. Remedy defect if
applicable.
Check. Remedy defect if
applicable.
Check. Remedy defect if
applicable.
- - - - - - - - - - ✘ - - - - - Leakage on the discharge side Check.
- - - - - - - - - - - - - - ✘ - Power supply disconnected Check. Re-connect if required.
- - - - - - - - - - - - - - - ✘ Excessive mains water supply.
Siphon clogged.
Check mains water supply.
Check siphon for free passage
and clean it if required.
Hya-Duo D FL Compact
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Page 42
10 Related Documents
81-45
591.02
655
79-1
591.01
741.02
691.01
691.02
743.02
741.01
735
747
740
746.01
UG1494557
10 Related Documents
10.1 General assembly drawing with list of components
Fig.10: General assembly drawing
Table17: List of components
Part No. Description Ident. No.
591.01 Accumulator 01079764
591.02 Break tank On request
655 Pump set On request
691.01 Pressure gauge 00401413
691.02 Pressure switch MCS 22 01049356
735 Expansion joint (Movitec 15) 01349542
735 Expansion joint (Movitec 25, 40) 01349543
740 Float valve 1 1/
4
01511210
740 Float valve 2 01511211
741.01 Solenoid valve 1/
741.02 Solenoid valve 1/
743.01 Ball valve 3/
743.02 Ball valve 1/
4
2
2
2
01357811
01228626
01079765
01349946
746.01 Butterfly valve DN50 (Movitec 15) 42087765
746.01 Butterfly valve DN65 (Movitec 25) 40982350
746.01 Butterfly valve DN80 (Movitec 40) 40982351
747 Swing check valve DN50 (Movitec 15) 01056738
747 Swing check valve DN65 (Movitec 25) 01086243
747 Swing check valve DN80 (Movitec 40) 01056931
79-1 Control unit On request
81-45 Float switch 01048585
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Hya-Duo D FL Compact
Page 43
10 Related Documents
-X2 4
-R2
5
1
-R2
2
354
1k
4-X2
a)
b)
1
-X2 4
2 3
5
4
1k
1
-R2
2 3 4
1k
1
-X2 4
2
354
1k
1 2 3 4
1k
1
-R2
2 3 4
1k
a) b)
c)
10.2 Wiring diagram (limit switches)
Fig.11: Wiring without limit switch
Fig.12: Wiring with one limit switch
Fig.13: Wiring with two limit switches
a) First limit switch b) Last limit switch
Fig.14: Wiring with more than two limit switches
a) First limit switch c) Last limit switch
b) Following limit switches
Hya-Duo D FL Compact
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Page 44
11 EU Declaration of Conformity
11 EU Declaration of Conformity
Manufacturer: KSB SE & Co. KGaA
Johann-Klein-Straße 9
67227 Frankenthal (Germany)
The manufacturer herewith declares that the product:
Hya-Duo D FL Compact, Hya-Solo D FL Compact
KSB order number: ...................................................................................................
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Pump set: EC Machinery Directive 2006/42/EC
– Pump set: Electromagnetic Compatibility Directive 2014/30/EU
The manufacturer also declares that
▪ the following harmonised international standards have been applied:
– ISO 12100
– EN 809
– EN 60204-1
▪ Applied national technical standards and specifications, in particular:
– DIN 14462
– EN 1717
– EN 13077
Person authorised to compile the technical file:
Name
Function
Address (company)
Address (street, No.)
Address (post or ZIP code, city) (country)
The EU Declaration of Conformity was issued in/on:
Place, date
..............................5).............................
Name
Function
Company
Address
5) A signed, legally binding EU Declaration of Conformity is supplied with the product.
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Hya-Duo D FL Compact
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12 Certificate of Decontamination
R
12 Certificate of Decontamination
Type: ................................................................................................................................
Order number/
Order item number6): ................................................................................................................................
Delivery date: ................................................................................................................................
Applications: ................................................................................................................................
Fluid handled6): ................................................................................................................................
Please tick where applicable6):
Corrosive Oxidising Flammable Explosive Hazardous to health
Seriously hazardous to
health
Toxic Radioactive Bio-hazardous Safe
Reason for return6): ................................................................................................................................
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
6) Required fields
Hya-Duo D FL Compact
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Page 46
13 Commissioning Report
13 Commissioning Report
The break tank package booster set for fire fighting specified below was today commissioned by the
undersigned, authorised KSB customer service engineer who created this report.
Information on the break tank package booster set for fire fighting
Type series ........................................................................................................................................
Size ........................................................................................................................................
Serial number ........................................................................................................................................
Order number ........................................................................................................................................
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]
Special information
If, in addition, the system is operated with accumulators of GroupsIII/ IV to the Pressure Equipment Directive, the
responsible technical inspection body must be informed about commissioning of the system.
The system operator/operator's representative herewith confirms to have received instructions on how to operate
and service the break tank package booster set for fire fighting. The relevant circuit diagrams and the operating
manual 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
Index
A
After-run time28
Applications8
Automation16
C
Certificate of Decontamination45
Commissioning/start-up26
D
Design15
Designation15
Disposal13
Drive16
Dry running protection35
Connecting the dry running protection device25
Setting the dry running protection device28
E
Event of damage6
F
Faults
Causes and remedies40
Float valve23
Flushing36
Frequency of starts31
Functions
Automatic switchover (duty system and back-up
system)34
O
Operating modes
Functional check run33
Manual mode33
Other applicable documents6
P
Partly completed machinery6
Personnel9
Pump activated25
Q
Qualification9
R
Return to supplier13
S
Safety8
Safety awareness9
Scope of supply18
Setting the start-up pressure28
Setting the stop pressure28
W
Warnings6
Warranty claims6
I
Installation16
Installation at site19
Intended use8
K
Key to safety symbols/markings6
L
LED display33
List of components42
M
Maintenance work38
N
Name plate15
Hya-Duo D FL Compact
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Page 48
KSB SE & Co. KGaA
Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0
www.ksb.com
1968.81/05-EN (01351580)
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