KSB Hya-Solo D Series Installation And Operating Manual
Pressure Booster System
Hya-Solo D
From Series 2014w33
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual Hya-Solo D
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 18/12/2017
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
2 Safety...................................................................................................................................................... 7
2.1 General..............................................................................................................................................................7
2.2 Intended use .....................................................................................................................................................7
2.3 Personnel qualification and personnel training.............................................................................................7
2.4 Consequences and risks caused by non-compliance with this manual .........................................................8
2.5 Safety awareness ..............................................................................................................................................8
2.6 Safety information for the operator/user.......................................................................................................8
2.7 Safety information for maintenance, inspection and installation ................................................................8
2.8 Unauthorised modes of operation..................................................................................................................9
3 Transport/Temporary Storage/Disposal............................................................................................. 10
3.1 Checking the condition upon delivery..........................................................................................................10
3.2 Transport.........................................................................................................................................................10
3.3 Storage/preservation......................................................................................................................................10
3.4 Return to supplier ..........................................................................................................................................11
3.5 Disposal ...........................................................................................................................................................11
4 Description............................................................................................................................................ 12
4.1 General description ........................................................................................................................................12
4.2 Designation.....................................................................................................................................................12
4.3 Name plate......................................................................................................................................................12
4.4 Design details..................................................................................................................................................12
4.5 Configuration and function...........................................................................................................................13
4.6 Noise characteristics .......................................................................................................................................14
4.7 Scope of supply...............................................................................................................................................14
4.8 Dimensions and weights ................................................................................................................................14
4.9 Terminal wiring diagram ...............................................................................................................................15
5 Installation at Site................................................................................................................................ 16
5.1 Installation ......................................................................................................................................................16
5.2 Checks to be carried out prior to installation...............................................................................................16
5.3 Installing the pressure booster system..........................................................................................................16
5.4 Installing the piping .......................................................................................................................................17
5.4.1 Fitting an expansion joint .................................................................................................................17
5.4.2 Installing a pressure reducer .............................................................................................................18
5.5 Installing unpressurised inlet tanks...............................................................................................................18
5.6 Fitting the dry running protection device ....................................................................................................19
5.7 Electrical connection ......................................................................................................................................19
6 Commissioning/Start-up/Shutdown................................................................................................... 20
6.1 Commissioning/Start-up.................................................................................................................................20
6.1.1 Prerequisites for commissioning/start-up .........................................................................................20
6.1.2 Commissioning/start-up of pressure booster system .......................................................................20
6.2 Switching on the pressure booster system....................................................................................................21
6.3 Checklist for commissioning/start-up ............................................................................................................22
6.4 Shutdown........................................................................................................................................................22
Hya-Solo D
3 of 36
Contents
7 Operating the Pressure Booster System............................................................................................. 23
8 Servicing/Maintenance........................................................................................................................ 24
8.1 General information/Safety regulations .......................................................................................................24
8.1.1 Inspection contract ...........................................................................................................................25
8.2 Servicing/inspection........................................................................................................................................25
8.2.1 Supervision of operation ...................................................................................................................25
8.2.2 Checklist for inspection .....................................................................................................................25
8.2.3 Setting the pre-charge pressure........................................................................................................26
9 Trouble-shooting.................................................................................................................................. 27
10 Related Documents.............................................................................................................................. 29
10.1 List of components .........................................................................................................................................29
10.1.1 Hya-SoloD with Movitec 2, 4, 6, 10, 15 ............................................................................................ 29
10.1.2 Hya-SoloD with Movitec 25, 40, 60, 90 ............................................................................................ 30
11 EC Declaration of Conformity ............................................................................................................. 31
12 Certificate of Decontamination........................................................................................................... 32
13 Commissioning Report......................................................................................................................... 33
Index ..................................................................................................................................................... 34
4 of 36
Hya-Solo D
Glossary
Glossary
Accumulator
The accumulator serves to compensate for
pressure losses in the piping system downstream
of the pressure booster system which may be
caused by the consumption of small quantities of
water. As a result, the frequency of starts of the
pressure booster system is minimised.
Automatic mode
The pump is started and stopped as a function of
pressure or via a contact at the wall hydrant.
Certificate of decontamination
A certificate of decontamination is enclosed by the
customer when returning the product to the
manufacturer to certify that the product has been
properly drained to eliminate any environmental
and health hazards arising from components in
contact with the fluid handled.
Dry running protection
Dry running protection devices prevent the pump
from being operated without the fluid to be
handled, which would result in pump damage.
Manual mode
In manual mode, the pressure booster system is
operated directly on mains power, independently
of the control unit.
Hya-Solo D
5 of 36
1 General
1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover. The manual describes the proper and safe use of this
equipment in all phases of operation.
The name plate indicates the type series/size, the main operating data and the order
number. The series/serial number uniquely identifies the pressure booster system and
serves as identification for all further business processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
Noise characteristics see (ðSection4.6,Page14)
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,Page7)
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
⇨ Result of an action
⇨ Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
6 of 36
Hya-Solo D
2 Safety
!
DANGER
2 Safety
All the information contained in this section refers to hazardous situations.
2.1 General
This manual contains general installation, operating and maintenance instructions
that must be observed to ensure safe operation of the pressure booster system and
prevent personal injury and damage to property.
The safety information in all sections of this manual must be complied with.
This manual must be read and completely understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the pressure booster system must always be
complied with and be kept in a perfectly legible condition at all times. This applies
to, for example:
▪ Arrow indicating the direction of rotation
▪ Markings for connections
▪ Name plate
The operator is responsible for ensuring compliance with all local regulations which
are not taken into account in this manual.
2.2 Intended use
▪ The pressure booster system must only be operated within the operating limits
described in the other applicable documents.
▪ Only operate pressure booster systems which are in perfect technical condition.
▪ Do not operate partially assembled pressure booster systems.
▪ The pressure booster system must only handle the fluids described in the product
literature of the respective design variant.
▪ Never operate the pressure booster system without the fluid to be handled.
▪ Observe the information on minimum flow rates specified in the product
literature (to prevent overheating, bearing damage, etc).
▪ Observe the information on maximum flow rates specified in the product
literature (to prevent overheating, mechanical seal damage, cavitation damage,
bearing damage, etc).
▪ Do not throttle the flow rate on the suction side of the pressure booster system
(to prevent cavitation damage).
▪ Consult the manufacturer about any other modes of operation not described in
the product literature.
Prevention of foreseeable misuse
▪ Never exceed the permissible operating limits (pressure, temperature, etc.)
specified in the product literature.
▪ Observe all safety information and instructions in this manual.
2.3 Personnel qualification and personnel training
All personnel involved must be fully qualified to install, operate, maintain and
inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
installation, operation, maintenance and inspection must be clearly defined by the
operator.
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.
Hya-Solo D
7 of 36
2 Safety
Training on the pressure booster system must always be supervised by technical
specialist personnel.
2.4 Consequences and risks caused by non-compliance with this manual
▪ Non-compliance with this operating manual will lead to forfeiture of warranty
cover and of any and all rights to claims for damages.
▪ Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.5 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪ Accident prevention, health and safety regulations
▪ Explosion protection regulations
▪ Safety regulations for handling hazardous substances
▪ Applicable standards, directives and laws
2.6 Safety information for the operator/user
▪ The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
▪ Do not remove any contact guards during operation.
▪ Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
▪ If shutting down the pump does not increase potential risk, fit an emergency-
stop control device in the immediate vicinity of the pump (set) during pump set
installation.
2.7 Safety information for maintenance, inspection and installation
▪ Modifications or alterations of the pressure booster system are only permitted
with the manufacturer's prior consent.
▪ Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪ The operator ensures that maintenance, inspection and installation is performed
by authorised, qualified specialist personnel who are thoroughly familiar with
the manual.
▪ Carry out work on the pressure booster system during standstill only.
▪ The pump casing must have cooled down to ambient temperature.
▪ Pump pressure must have been released and the pump must have been drained.
▪ When taking the pressure booster system out of service always adhere to the
procedure described in the manual.
▪ Decontaminate pressure booster systems which handle fluids posing a health
hazard.
▪ As soon as the work has been completed, re-install and/or re-activate any safety-
relevant and protective devices. Before returning the product to service, observe
all instructions on commissioning.
▪ Make sure the pressure booster system cannot be accessed by unauthorised
persons (e.g. children).
▪ Prior to opening the device, pull the mains plug and wait for at least 10minutes.
8 of 36
Hya-Solo D
2 Safety
2.8 Unauthorised modes of operation
Always observe the limits stated in the product literature.
The warranty relating to the operating reliability and safety of the pressure booster
system supplied is only valid if the equipment is used in accordance with its intended
use. (ðSection2.2,Page7)
Hya-Solo D
9 of 36
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 (as applicable) and the insurer about the
damage in writing immediately.
3.2 Transport
NOTE
The pressure booster system is bolted to a pallet and wrapped in plastic foil for
shipping and temporary storage. All connecting points are capped.
DANGER
Pressure booster system tipping over
Risk of injury by falling pressure booster system!
▷ Never suspend the pressure booster system by its power cable.
▷ Observe the applicable local accident prevention regulations.
▷ Pay attention to the weight data and the centre of gravity.
▷ Use suitable and permitted transporting equipment, e.g. crane, forklift or
elevating platform truck.
▷ Attach the pressure booster system to crane lifting tackle as shown, or use a
forklift or pallet truck to move the pallet.
10 of 36
Fig.1: Transporting the pressure booster system
ü The pressure booster system has been checked for in-transit damage.
1. Make sure the transport equipment is suitable for safely carrying the indicated
load.
2. Transport the pressure booster system to the place of installation.
3. Attach the pressure booster system to the lifting tackle as shown, lift it off the
pallet and dispose of the pallet.
4. Use suitable lifting equipment to lift the pressure booster system and carefully
put it down at the place of installation.
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken when storing the pressure booster system:
Hya-Solo D
3 Transport/Temporary Storage/Disposal
CAUTION
Damage during storage due to frost, moisture, dirt, UV radiation or vermin
Corrosion/contamination of pressure booster system!
▷ Store the pressure booster system in a frost-proof room. Do not store outdoors.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage of the pressure booster system!
▷ Only open the openings of the pressure booster system at the time of
installation.
Store the pressure booster system in a dry, protected room where the atmospheric
humidity is as constant as possible.
3.4 Return to supplier
1. Drain the pressure booster system as per operating instructions.
2. Always flush and clean the pressure booster system, particularly if it has been
used for handling noxious, explosive, hot or other hazardous fluids.
3. If the pressure booster system has handled fluids whose residues could lead to
corrosion damage in the presence of atmospheric humidity or could ignite upon
contact with oxygen, the pressure booster system must also be neutralised and
treated with anhydrous inert gas to ensure drying.
4. Always complete and enclose a certificate of decontamination when returning
the pressure booster system. (ðSection12,Page32)
Always indicate any safety and decontamination measures taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the
following web site: www.ksb.com/certificate_of_decontamination
3.5 Disposal
WARNING
Fluids, 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 residues of the fluid
handled.
▷ Wear safety clothing and a protective mask if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Dismantle the pressure booster system.
Collect greases and other lubricants during dismantling.
2. Separate and sort the pump materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another
controlled manner.
Hya-Solo D
11 of 36
Loading...