KSB Hya-Solo DSV, Hya-Solo DSV/B 1/2503 V Operating Manual

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Pressure Booster System

Hya-Solo DSV

From series 2015w13

Installation/Operating Manual

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Legal information/Copyright

Installation/Operating Manual Hya-Solo DSV

Original operating manual

All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose, nor otherwise transmitted, published or made available to a third party without the manufacturer's express written consent.

Subject to technical modification without prior notice.

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Contents

Glossary .................................................................................................................................................. 5

1 General.................................................................................................................................................... 6

1.1 Principles ...........................................................................................................................................................6

1.2 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 Key to safety symbols/markings.......................................................................................................................7

3 Software Changes.................................................................................................................................. 8

4 Transport/Temporary Storage/Disposal............................................................................................... 9

4.1 Checking the condition upon delivery............................................................................................................9

4.2 Transport...........................................................................................................................................................9

4.3 Storage/preservation........................................................................................................................................9

4.4 Return to supplier ..........................................................................................................................................10

4.5 Disposal ...........................................................................................................................................................10

5 Description............................................................................................................................................ 11

5.1 General description ........................................................................................................................................11

5.2 Designation.....................................................................................................................................................11

5.3 Name plate......................................................................................................................................................11

5.4 Design details..................................................................................................................................................11

5.5 Configuration and function...........................................................................................................................12

5.6 Noise characteristics .......................................................................................................................................13

5.7 Scope of supply...............................................................................................................................................13

5.8 Dimensions and weights ................................................................................................................................13

6 Installation at Site................................................................................................................................ 14

6.1 Installation to DIN 1988 .................................................................................................................................14

6.2 Checks to be carried out prior to installation...............................................................................................14

6.3 Installing the pressure booster system..........................................................................................................14

6.4 Installing the piping .......................................................................................................................................15

6.4.1 Fitting an expansion joint .................................................................................................................15

6.4.2 Installing a pressure reducer .............................................................................................................16

6.5 Installing unpressurised inlet tanks...............................................................................................................16

6.6 Fitting the dry running protection device ....................................................................................................17

6.7 Connection to power supply..........................................................................................................................17

6.7.1 Sizing the power cable ......................................................................................................................17

6.7.2 Connecting the pressure booster system..........................................................................................17

6.7.3 Digital inputs......................................................................................................................................17

6.7.4 Relay outputs .....................................................................................................................................18

6.7.5 Analog inputs.....................................................................................................................................18

6.7.6 Analog output....................................................................................................................................18

7 Commissioning/Start-up/Shutdown................................................................................................... 19

7.1 Commissioning/Start-up.................................................................................................................................19

7.1.1 Prerequisites for commissioning/start-up .........................................................................................19

7.1.2 Dry running protection......................................................................................................................19

7.1.3 Commissioning/start-up of pressure booster system .......................................................................19

7.2 Switching on the pressure booster system....................................................................................................20

7.3 Checklist for commissioning/start-up ............................................................................................................21

7.4 Shutdown........................................................................................................................................................21

8 Operating the Pressure Booster System............................................................................................. 22

8.1 Graphical control panel..................................................................................................................................22

8.1.1 Graphical display................................................................................................................................22

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Contents

8.1.2 Menu keys ..........................................................................................................................................24

8.2 Service interface and LED traffic light function ...........................................................................................29

8.3 Adjusting the settings ....................................................................................................................................30

8.3.1 Setting the setpoint ...........................................................................................................................30

8.3.2 Changing the controller settings ......................................................................................................30

9 Servicing/Maintenance........................................................................................................................ 31

9.1 General information/Safety regulations .......................................................................................................31

9.1.1 Inspection contract ...........................................................................................................................32

9.2 Servicing/inspection........................................................................................................................................32

9.2.1 Supervision of operation ...................................................................................................................32

9.2.2 Checklist for inspection .....................................................................................................................32

9.2.3 Setting the pre-charge pressure........................................................................................................33

10 Trouble-shooting.................................................................................................................................. 34

10.1 Trouble-shooting: pressure booster system..................................................................................................34

10.2 Trouble-shooting: frequency inverter...........................................................................................................35

11 Related Documents.............................................................................................................................. 37

11.1 List of components .........................................................................................................................................37

11.1.1 Hya-Solo DSV with Movitec 2, 4, 6, 10, 15........................................................................................37

11.1.2 Hya-SoloDSV with Movitec 25, 40, 60, 90........................................................................................38

12 EU Declaration of Conformity............................................................................................................. 39

13 Certificate of Decontamination........................................................................................................... 40

14 Commissioning Report......................................................................................................................... 41

Index ..................................................................................................................................................... 42

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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 as a function of pressure and stopped as a function of flow.

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.

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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 (ðSection5.6,Page13)

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.

1.4 Other applicable documents

Table1: Overview of other applicable documents

Document Contents

Sub-supplier product literature Operating manuals, logic diagram and other

product literature of accessories and integrated machinery components

1.5 Symbols

Table2: Symbols used in this manual

Symbol Description

✓ Conditions which need to be fulfilled before proceeding with the

step-by-step instructions

⊳ Safety instructions

⇨ Result of an action

⇨ Cross-references

Step-by-step instructions

Note Recommendations and important information on how to handle the product

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2 Safety

DANGER

WARNING

CAUTION

2 Safety

All the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table3: Definition of safety symbols/markings

Symbol Description

DANGER

This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury.

WARNING

This signal word indicates a medium-risk hazard which, if not avoided, could result in death or serious injury.

CAUTION

This signal word indicates a hazard which, if not avoided, could result in damage to the machine and its functions.

General hazard

In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or serious injury.

Electrical hazard

In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and identifies information about protection against electrical voltage.

Machine damage In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its functions.

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3 Software Changes

The software has been specially created for this product and thoroughly tested. It is not allowed to make any changes or additions to the software or parts of the software. Software updates supplied by KSB are excluded from this rule.

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4 Transport/Temporary Storage/Disposal

4.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.

2. In the event of in-transit damage, assess the exact damage, document it and

notify KSB or the supplying dealer and the insurer about the damage in writing immediately.

4.2 Transport

NOTE

The pressure booster system is bolted to a pallet and wrapped in plastic 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.

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.

4.3 Storage/preservation

If commissioning is to take place some time after delivery, we recommend that the following measures be taken when storing the pressure booster system:

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4 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.

4.4 Return to supplier

1. Drain the pressure booster system as per operating instructions.

2. Always flush and clean the pressure booster system, particularly if it has been

used for handling noxious, explosive, hot or other hazardous fluids.

3. If the pressure booster system has handled fluids whose residues could lead to

corrosion damage in the presence of atmospheric humidity or could ignite upon contact with oxygen, the pressure booster system must also be neutralised and treated with anhydrous inert gas to ensure drying.

4. Always complete and enclose a certificate of decontamination when returning the pressure booster system. (ðSection13,Page40) Always indicate any safety and decontamination measures taken.

NOTE

If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination

4.5 Disposal

WARNING

Fluids, 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.

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5 Description

Werk-Nr.

51w5102.rN-neireS:noitisoPV 3052/1 B/VSD oloS- ayH

Förderstrom 22,0 m3/h Druckbehälter: Motorleistung P2 1 x 5,50 kW Anlagensolldruck (p

) 5,0 bar Vorpreßdruck 4,5 bar Betriebsspannung / Frequenz Hz

Förderhöhe 49,5 m Inhalt Bruttovolumen 8,0 Liter Steuerspannung / Frequenz Hz

05,21mortsnnenrotoMm2,560=Q ieb ehöhredröF

:.rN nalptlahcSrab5,0kcurdroV

Betriebsdruck max. 16,0 bar

! nethcaeb gnutielnasbeirteB emhanbeirtebnI roVynamreG ni edaM ZNI 1448J

9972904032 100

1 2 3

4 5

6 7

8 9

101112

18 17 16

Johann-Klein-Straße 9

Deutschland

67227 Frankenthal

KSB SE & Co. KGaA

5 Description

5.1 General description

▪ Pressure booster system

5.2 Designation

Example: Hya-Solo DSV / 04 05 / 2 - 4

Table4: Designation key

Code Description

Hya-Solo Pressure booster system with one pump

DSV Model with three-phase motor, speed-controlled, pressure-

dependent starting and flow-dependent stopping

04 Pump size

05 Number of stages per pump

2 - 4 Inlet pressure in bar

5.3 Name plate

Fig.2: Name plate (example) of a Hya-Solo DSV

1 Type series, size 2 Order item number

3 Order number 4 Series code

5 Motor power P2 6 Operating voltage/frequency

7 Control voltage/frequency 8 Nominal motor current

9 Circuit diagram 10 Gross vol. content

11 Pre-charge pressure 12 Accumulator

13 Maximum operating pressure 14 Inlet pressure

15 Head at Q=0 16 Head

17 System setpoint pressure 18 Flow rate

5.4 Design details

Design

The pressure booster system consists of a non-self-priming multistage high-pressure centrifugal pump with suction and discharge side shut-off valves. The shut-off valves enable dismantling of the pump or check valve without draining the piping system. The check valve on the discharge side prevents backflow through the pump when the pump is not running and reduces the load on the mechanical seal. An accumulator, a pressure transmitter and a pressure gauge are fitted on the discharge side of the pressure booster system. The PumpDrive speed control system is mounted on and ready-wired to the pump set. The system comes with separate rubber anti-vibration pads.

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Design

Function

Automatic mode

Function

Manual mode

5 Description

5.5 Configuration and function

Fig.3: Illustration of a Hya-Solo DSV

1 Master switch 2 Accumulator

3 Pump 4 Pressure sensor

5 PumpDrive 6 Valves

The fully automatic pressure booster system is equipped with a non-self-priming vertical high-pressure pump (3) for pumping the fluid handled to the consumer installations at a constant pressure.

The pump is started as a function of pressure and stopped as a function of flow by a fully automatic control unit. If the pressure drops below the pre-set pressure, the pump starts up and the frequency inverter controls the pressure booster system to maintain the set pressure, so that the pressure is kept constant. If the demand decreases, the pump stops as soon as the flow rate has fallen below a set minimum value.

A key for manual operation is provided on the control panel. In manual mode the pump operates at the pre-set minimum speed, independently of the automatic system (pressure transmitter) or an External ON/OFF signal.

NOTE

Continuous manual mode is reserved exclusively for emergencies!

Continuous operation of the pressure booster system in manual mode may result in waste of energy and water.

In manual mode, a minimum flow (see table below) is essential to prevent the fluid handled and the pump from overheating when no water is consumed at the consumer installations.

Minimum flow for pump in manual mode

Table5: Minimum flow per pump in manual mode

Pump Minimum flow per pump in manual mode

[l/h]

Movitec 2B 200

Movitec 4B 400

Movitec 6B 600

Movitec 10B 1100

Movitec 15B 1600

Example

Movitec 25B 2800

Movitec 40B 4600

Movitec 60B 6100

Movitec 90B 8500

An open 1/2-inch tap equals a water consumption of approx. 800 to 1,200l/h.

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5 Description

Function

Dry running protection

The dry running protection function is active in automatic mode and manual mode. 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 pressure booster system after approx. 10seconds (factory setting).

5.6 Noise characteristics

For the noise level of the individual pumps please refer to the pump's operating instructions.

5.7 Scope of supply

Depending on the model, the following items are included in the scope of supply:

▪ Pressure booster system

▪ One Movitec vertical high-pressure centrifugal pump

▪ Check valve

▪ Shut-off valves

▪ Membrane-type direct-flow accumulator on the discharge side

▪ Pressure transmitter on the discharge side

▪ Vibration damping

▪ Pressure gauge for pressure indication

PumpDrive

▪ Self-cooling motor-mounted frequency inverter (PumpDrive) for pressure-

controlled starting and demand-based stopping

▪ Plain-text display (for voltage, current, power, speed, frequency)

▪ Control panel with operating keys (manual-0-automatic), navigation and

function keys

▪ LEDs signalling operational availability (green), warning (yellow), alert (red)

▪ Two freely parameterisable relay outputs (operation/fault, alert, etc.)

▪ Two NO contacts 250V AC/1A

▪ Analog input for external setpoint adjustment

▪ Analog output for transmitting the actual value, motor speed, etc.

▪ Lockable master switch (repair switch)

5.8 Dimensions and weights

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

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6 Installation at Site

6.1 Installation to DIN 1988

Install pressure booster systems either in the technical equipment room or in a wellventilated, frost-free, lockable room used for no other purpose. No harmful gases are allowed to enter the place of installation. An adequately sized floor drain (leading to a sewer or equivalent) must be provided.

The system is designed for a maximum ambient temperature of 0°C to +40°C at a relative humidity of 50%.

NOTE

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

If expansion joints (KSB accessory) are used for damping vibrations, their fatigue strength (endurance limit) must be given due consideration. Expansion joints must be installed to allow quick and easy replacement.

6.2 Checks to be carried out prior to installation

Place of installation

WARNING

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

Personal injury and damage to property!

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

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

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

even.

▷ Observe the weights indicated.

NOTE

The anti-vibration mounts of the pressure booster system provide adequate insulation against solid-borne noise.

1. Check the structural requirements. All structural work required must have been prepared in accordance with the dimensions stated in the outline drawing.

6.3 Installing the pressure booster system

WARNING

Top-heavy pressure booster system

Risk of personal injury by pressure booster system tilting!

▷ Pressure booster systems awaiting final installation must be secured against

tipping over.

▷ Firmly anchor the pressure booster system.

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Remove all packaging before installing the pressure booster system. Connect the pressure booster system's inlet line and discharge line to the corresponding site distribution lines.

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6 Installation at Site

NOTE

In order to avoid transmission of piping forces onto the pressure booster system and transmission of solid-borne noise, we recommend installing length-limited expansion joints.

Allow sufficient space for maintenance and repair work.

ü All structural work required has been checked.

ü The dimensions of the concrete foundation are correct, and the concrete has set

firmly.

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

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

3. Insert plug fixings of appropriate size.

4. Set the pressure booster system down in its correct installation position.

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

6.4 Installing the piping

Make sure that piping is installed without transmitting any stresses or strains. The use of length-limited expansion joints (see accessories) is recommended.

CAUTION

Air pockets in suction line

Pressure booster system cannot prime!

▷ Lay piping with a continuously rising slope (as shown).

Suction lift operation

Incorrect Correct

NOTE

For suction lift operation install suitable swing check valves at the suction line ends which are submerged in the fluid handled. Take into account the head losses caused by these swing check valves. Do not exceed the maximum suction lift of the pumps.

6.4.1 Fitting an expansion joint

DANGER

Sparks and radiant heat

Fire hazard!

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

carried out nearby.

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6 Installation at Site

CAUTION

Leaking expansion joint

Flooding of installation room!

▷ Regularly check for cracks or blisters, exposed fabric or other defects.

ü The expansion joint has a length limiter with solid-borne sound insulation so as

to be able to absorb reaction forces.

1. 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.

2. Tighten the bolts evenly and crosswise during assembly. The ends of the bolts must not protrude from the flange.

3. Do not apply paint to the expansion joint. Protect it from any contact with oil.

4. The position of the expansion joint within the pressure booster system must

allow easy access and inspection and it must, therefore, not be insulated along with the piping.

5. Expansion joints are subject to wear.

6.4.2 Installing a pressure reducer

NOTE

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

NOTE

A pressure reducer must be installed

- if the inlet pressure fluctuation is too high for the pressure booster system to operate as intended or

- if the total pressure (inlet pressure plus shut-off head) of the pressure booster system exceeds the design pressure. The maximum pump discharge pressure at zero flow point is reached in manual mode.

A minimum pressure gradient of 5 metres is required for the pressure reducer to fulfill its function. The pressure downstream of the pressure reducer (downstream pressure) is the basic parameter for determining the pump head.

For example:

The inlet pressure fluctuates between 4 and 8 bar. A pressure reducer is needed upstream of the pressure booster system on the inlet side. Min. inlet pressure (p Min. pressure gradient=0.5bar Downstream pressure=3.5bar.

)=4bar

inl

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6.5 Installing unpressurised inlet tanks

Installation and location of an unpressurised inlet tank together with the pressure booster system are governed by the same rules applicable to the pressure booster system.

Install the closed PE inlet tank (under atmospheric pressure) available as a KSB accessory as described in the installation instructions supplied with the tank.

CAUTION

Contamination in the pressure booster system

Damage to the pumps!

▷ Clean the tank before filling it.

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6 Installation at Site

The tank must be connected mechanically and electrically to the pressure booster system prior to commissioning of the system.

6.6 Fitting the dry running protection device

Install the dry running protection device supplied together with the pressure booster system as a separate, non-fitted accessory, or supplied at a later date for retrofitting, in accordance with its operating instructions and connect it to digital input1 (terminals C1 and C2 on terminal stripC) of the PumpDrive. This digital input is assigned exclusively to the Start/Stop function and is bridged if the system is supplied without a dry running protection device. Only dry running protection devices can be used which open a contact when dry running occurs. No cut-out delay can be set.

6.7 Connection to power supply

DANGER

Electrical connection work by unqualified personnel

Danger of death from electric shock!

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

electrician.

▷ Observe regulations IEC60364.

WARNING

Incorrect connection to the mains

Damage to the mains network, short circuit!

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

NOTE

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

The circuit diagrams are included in the control cabinet of the pressure booster system, where they must remain when not in use. The product literature of the switchgear and controlgear assembly supplied with the pressure booster system includes a list of the electrical components installed. When ordering spare parts for electrical components, please always indicate the circuit diagram number.

6.7.1 Sizing the power cable

The cross-section of the power cable must be sized for the total rated power requirement.

6.7.2 Connecting the pressure booster system

Connect the pressure booster system to the power supply via terminals L1, L2, L3 and PE of the terminal strip or the master switch in the connection space of the frequency inverter. To do so, proceed as described in the operating manual of the PumpDrive. Observe the data on the name plate.

6.7.3 Digital inputs

Terminal strip C, terminals C1 to C10

PumpDrive is equipped with six digital inputs. Digital inputs 1 and 6 are factory-defaulted. Digital inputDI-EN is the digital enable input. In as-delivered condition it is linked with terminal C9. If the pressure booster system is equipped with a dry running

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6 Installation at Site

protection device, this device is connected to digital input 1 (C1 and C2). The functions of digital inputs 2 to 5 can be parameterised by the user at the control panel. To connect the inputs use terminal C1 (+24VDC). For setting the parameters see the PumpDrive2 operating manual.

6.7.4 Relay outputs

Terminal strip A, terminals A1 to A10

In as-delivered condition the relay outputs are parameterised as volt-free contacts for "Alarm" (relay1) and "RUN operating status" (relay2). Different messages can be assigned to these relay outputs via the control panel. For setting the parameters see the PumpDrive2 operating manual.

6.7.5 Analog inputs

Terminal strip B, terminals B1 to B8

Analog input1 can be connected to an external setpoint adjustment. Analog input2 is assigned to the pressure transmitter (feedback value transmitter) as standard and connected to the mains-motor-PTC terminal strip. For setting the parameters see the PumpDrive2 operating manual.

6.7.6 Analog output

Terminal strip B, terminals B9 and B10

PumpDrive features an analog output whose output value can be parameterised via the control panel depending on the digital inputs. For setting the parameters see the PumpDrive2 operating manual.

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7 Commissioning/Start-up/Shutdown

7.1 Commissioning/Start-up

7.1.1 Prerequisites for commissioning/start-up

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

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

supply and is equipped with all protection devices.

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

complied with.

▪ The dry running protection device has been installed.

CAUTION

Dry running of pump

Damage to the pump/pressure booster system!

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

place, the pressure booster system will start neither in manual nor in test run mode. If the dry running protection terminal is disabled by means of a bridge, the operator shall assume responsibility for any dry running that might occur.

NOTE

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

7.1.2 Dry running protection

Pressure booster systems can be factory-equipped with pressure switches as dry running protection devices. Such dry running protection devices will be factory-set to the inlet pressure values specified in the purchase order.

If the factory settings should not match the site data, set the start and stop pressure as described in the operating manual of the pressure switch.

Table6: Recommended settings

Stop pressure Start-up pressure

Pressure switch 0.5barbelow p

7.1.3 Commissioning/start-up of pressure booster system

inl

0.2barbelow p

inl

NOTE

The pressure booster systems undergo hydraulic testing with water at the factory and are drained carefully before shipment. However, for technical reasons the presence of some residual water is unavoidable. The hydraulic connections are closed in as-supplied condition. They must only be opened immediately before installation. Refer to EN806 before commissioning/starting up the pressure booster system. After an extended pre-installation period, in particular, flushing or even professional disinfection is recommended. For extensive or branched piping systems the pressure booster system should preferably be flushed either before installation, or flushing should be restricted to a limited area.

Commissioning should be carried out by specialist KSB staff.

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7 Commissioning/Start-up/Shutdown

CAUTION

Foreign matter in the piping

Damage to the pump/pressure booster system!

▷ Before commissioning/starting (or even test running) the pressure booster

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

NOTE

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

ü The pipe unions between the pump and the piping have been re-tightened.

ü The flange bolting has been checked for firm seating.

ü The cooling air inlet and outlet openings on the motor are unobstructed.

ü All shut-off valves of the pressure booster system are open.

ü The pre-charge pressure of the membrane-type accumulator has been checked.

(ðSection9.2.3,Page33)

1. Set the master switch to "0".

2. Provide connection to power supply.

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

operating instructions).

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

5. Close and slightly tighten the pump vent plugs.

6. Switch on the master switch.

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

8. Loosen the vent plug again to let any remaining air escape.

9. Then re-tighten the vent plugs firmly.

10. Verify that the pump is running smoothly.

11. Close the discharge-side shut-off element for a short period in order to verify

that the pump reaches the shut-off head.

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

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NOTE

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

7.2 Switching on the pressure booster system

Switch on the master switch to energise the pressure booster system. The green LED on the control panel lights up, indicating the system's readiness for operation.

NOTE

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

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7 Commissioning/Start-up/Shutdown

7.3 Checklist for commissioning/start-up

Table7: Checklist

Operations Done

1 Read the operating instructions.

2 Check power supply and compare against the name plate data.

3 Check the earthing system (by measuring).

4 Check the mechanical connection to the water mains.

Re-tighten the flange bolting and pipe unions.

5 Prime and vent the pressure booster system from the inlet side.

6 Check inlet pressure.

7 Check whether all cables are still firmly connected to the terminals inside the control unit.

8 Check the setpoint, re-adjust if necessary.

9 Test the proper function of the lack-of-water and dry running protection equipment. If not

fitted, make a relevant note in the commissioning report.

10 Vent the pump for a second time after it has been running for 5 to 10 minutes.

11 Check the pre-charge pressure.

12 Record all system conditions that do not correspond to our specifications or to the purchase

order in the commissioning report (i.e. no dry running protection or inlet pressure + max. pressure of pressure booster system higher than 16 bar).

13 Complete the commissioning report together with the operator/user and instruct the operator/

user as to the function of the system.

7.4 Shutdown

NOTE

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

through the pressure booster system.

inl

Set the master switch to "0".

NOTE

Drain the pressure booster system for prolonged shutdown.

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8 Operating the Pressure Booster System

MAN

ESC

AUTO FUNC

OFF

8 Operating the Pressure Booster System

CAUTION

Incorrect operation

Water supply is not assured!

▷ Make sure to comply with all local regulations, particularly the EC Machinery

Directive and the EC Directive on Low-Voltage Equipment.

The pressure booster system is factory-set to the operating data indicated on the name plate. The settings can be modified via the control panel, if necessary.

8.1 Graphical control panel

Fig.4: Graphical control panel

Table8: Description of graphical control panel

Position Description Function

1 Graphical display Displays information on frequency inverter operation

2 Menu keys Accessing the elements of the first menu level (Operation,

Diagnosis, Settings and Information)

3 Navigation keys Navigation and parameter setting

4 Operating keys Toggling operating modes

8.1.1 Graphical display

The main screen breaks down into 6areas.

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8 Operating the Pressure Booster System

C M

1-2-1-1

2893

rpm

17.48 m³/h

4.62 bar 642.9 V

RUN

AUTO

Speed

ESC

Fig.5: Main screen (example)

1 Motor standstill heater is switched on

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

wireless icon flashes when communication takes place.

3 Display of the master and login level

4 Display of up to four (4)operating values: One operating value is displayed in

large format. Three (3) operating values are displayed in small format. The operating values scroll through cyclically.

5 Display of operating status

6 Display of the current operating mode

7 Parameter number of the operating value displayed in the centre

8 Name of the operating value displayed in the centre

Table9: Assignment of keys

Key Function

Operation menu key

Diagnosis menu key

Settings menu key

Information menu key

Arrow keys:

▪ Move up/down in the menu options.

▪ Increase/decrease the value displayed when you are entering numerals. (When an arrow

key is pressed and held down, the response repeats in ever shorter intervals.)

Escape key:

▪ Delete/reset entry

(the entry is not saved).

▪ Move up one menu level.

OK key:

▪ Confirm settings.

▪ Confirm menu selection.

▪ Move to the next digit when entering numerals.

▪ Message display: Acknowledge alert.

▪ Measured value display: Go to Favourites menu.

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Key Function

MAN

OFF

AUTO

FUNC

MAN

ESC

Help key:

▪ Displays a help text for each selected menu option.

MAN operating key:

▪ Starts the frequency inverter in manual operating mode.

OFF operating key:

▪ Stops the frequency inverter.

AUTO operating key:

▪ Switches to automatic operating mode.

FUNC operating key:

▪ Parameterisable function key

8 Operating the Pressure Booster System

Manual mode via control panel

NOTE

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

Table10: Assignment of keys for manual mode

Key Function

MAN operating key:

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

used as control value (Manual) 1-3-4 and is displayed accordingly. The control point 3-6-2 must be set to Local.

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

at minimum speed. The control point 3-6-2 must be set to Local.

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

is accepted.

Arrow keys:

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

1-3-4. Making a change using the arrow key has a direct effect even when not confirmed with OK. The speed can only be changed between the set minimum speed and the maximum speed.

ESC/OK key:

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

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

8.1.2 Menu keys

The menu keys allow you to directly access the first menu level (Operation 1-x-x-x, Diagnosis 2-x-x-x, Settings 3-x-x-x, and Information 4-x-x-x).

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

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8 Operating the Pressure Booster System

C M

STOP

3-6-1

AUTO

OFF (Open-loop Control) Discharge Pressure Suction Pressure Differential Pressure Flow Rate Temperature (Cooling)

Type of Control

Fig.6: Menu display

1 Name of current menu/parameter

2 Parameter number of parameter selected in selection list

3 Display of the current operating mode

4 Display of the master and login level

5 Parameter/submenu selection list

6 Display of operating status

8.1.2.1 Menu: Operation

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

▪ Login to device with password

▪ Operating and measured values for motor, frequency inverter, pump and system

▪ Setpoints and control values

▪ Energy meter and operating hours

8.1.2.1.1 Access levels

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

Table11: Access levels

Access level Description

Standard (No Login) Access without password entry.

Customer Access level for the expert user with access to all parameters required for

commissioning

Customer service Access level for service personnel.

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

Table12: Access level parameters

Parameter Description Possible settings Factory setting

1-1-1 Customer Login

1-1-2 Service Login

1-1-4 Logout

Log out of all access levels

NOTE

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

0000...9999 0000

0000...9999 -

Run -

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8 Operating the Pressure Booster System

AUTO

17.48 m³/h

4.62 bar2893 rpm

W57

rpm

C M

RUN

Low flow

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

Table13: Parameters for changing passwords

Parameter Description Possible settings Factory setting

1-1-5 Customer Access ID

Changing the customer access ID

1-1-6 Service Access ID

Changing the service access ID

8.1.2.1.2 Operating values for input and output signals

The status of the digital inputs/relay outputs is displayed via the Digital Inputs (1-2-4-6) and Digital Outputs (1-2-4-7) parameters.

Table14: Example of status of digital inputs (1-2-4-6). 24V is applied to digital input 1: System Start

Optional IO card Standard

Digital input DI8 DI7 DI6 DI5 DI4 DI3 DI2 DI1

Bit pattern on display 0 0 0 0 0 0 0 I

Table15: Example of status of digital outputs (1-2-4-7). The following is reported via relay output 1: General fault message (configurable)

Optional IO card Standard

Digital output R8 R7 R6 R5 R4 R3 DO2 D01 R2 R1

Bit pattern on display

0 0 0 0 0 0 0 0 0 I

0000...9999 -

8.1.2.2 Menu: Diagnosis

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

Messages

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

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

Fig.7: Message display

1 Name of the message displayed in the centre

2 Display of the master and login level

3 Display of the message: The most recently received message is displayed in

4 Display of operating status

5 Displays the current operating mode

large format on the main screen. Three operating values are displayed in small format.

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8 Operating the Pressure Booster System

Pending messages

Message history

If a message has occurred and been acknowledged but has not gone, this message will be listed in the Pending Messages menu. All current messages can be displayed in the Diagnosis menu under Pending Messages (2-1). Active warnings and alerts can also be connected to the relay outputs.

Only messages that have come, been acknowledged, and gone are listed in the message history. The message history can be viewed by selecting the Message History parameter 2-2. The last 100 messages are listed here. You can use the arrow keys and the OK key to select an entry from the list.

Acknowledging and resetting messages

NOTE

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

Acknowledgement

Table16: Acknowledgement types for messages

Property of message Type of acknowledgement

Self-acknowledging Message self-acknowledges if condition for message has gone.

Self-acknowledging (configurable)

Partially selfacknowledging

Non-self-acknowledging Must be acknowledged manually.

Time stamp

You can acknowledge the message once the cause has been rectified. Messages can be acknowledged separately in the Diagnosis menu. A message can also be acknowledged via a digital input. Digital input 2 is defaulted for this purpose.

Overview of warnings and alerts

Messages can be acknowledged as follows:

Users can choose between self-acknowledging and acknowledging manually.

Alerts that are partially self-acknowledging carry out self-acknowledgement in increasingly large intervals after the alarm condition has gone. If the alert occurs repeatedly within a specific time window, no additional self-acknowledgement is carried out.

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

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

If a message is not acknowledged and its condition comes and goes several times in this time window, the first occurrence of the message is always used for the Message Come time stamp. The Message Condition Gone time stamp, however, always shows the last time the message condition was no longer active.

8.1.2.3 Menu: Settings

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

8.1.2.3.1 Setting the display language

The display ships from the factory with support for 4languages (language package). A language package can be changed using the KSB Service Tool:

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8 Operating the Pressure Booster System

Table17: Parameters for display language

Parameter Description Possible settings Factory setting

3-1-1 Language

Configurable display language

8.1.2.3.2 Setting the control panel

Table18: Parameters for setting the control panel

Parameter Description Possible settings Factory setting

3-1-2-1 Operating Values on Main Screen

Display of current operating values on the main screen

3-1-2-2 Control Keys Require Login

Direct access to the MAN, OFF, AUTO and FUNC operating keys can be disabled via this parameter.

3-1-2-3 Function Key Assignment

Assigning a freely selectable function to the FUNC key

3-1-2-4 Display Contrast

Configurable contrast for the display

3-1-2-5 Display Backlight

Configuring the display backlight

3-1-2-6 Display Backlight Duration

Duration of display backlight on period in automatic mode

Operating Values on Main

Screen

Up to 4operating values are simultaneously displayed on the main screen. An operating value is displayed in large format with the associated parameter name, parameter number and unit. Three (3) operating values are displayed in smaller format with the associated unit. The arrow keys can be used to cycle through the operating values. Each operating value passes through all display areas. Up to

Depending on the language package:

▪ English, German, French, Italian

▪ English, French, Dutch, Danish

▪ English, Spanish, Portuguese, Turkish

▪ English, Norwegian, Swedish, Finnish

▪ English, Estonian, Latvian, Lithuanian

▪ English, Polish, Hungarian, Czech

▪ English, Slovenian, Slovakian, Croatian

▪ English, Russian, Romanian, Serbian

Main screen selection list -

▪ OFF

▪ ON

▪ No Function

▪ System Start / Stop

▪ Setpoint (Closed-loop

Control)

▪ Control Value (Open-loop

Control)

▪ Alternative Setpoint (Closed-

loop Control)

▪ Alternative Control Value

(Open-loop Control)

▪ Immediate Pump

Changeover

▪ Immediate Functional Check

Run

▪ Language

▪ Fixed Speed 1

▪ PumpMeter Upload

▪ Remote/Local Control Point

0...100 50

▪ OFF

▪ ON

▪ Automatic

0...600 30

English, German, French, Italian

OFF

Language

Automatic

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8 Operating the Pressure Booster System

C M

RUN

AUTO

3-1-2-1 Speed

Motor Input Power Motor Current Output Frequency Pump Suction Pressure Pump Discharge Pressure

Operating Values on Main Scr...

10operating values can be selected from the predefined list for the display. The sequence of the selection list determines the sequence of the operating values on the main screen. If more than 4parameters are selected, the hidden parameters are also cycled through in the background.

Selecting operating values for the main screen

1. Open parameter 3-1-2-1 in the Settings menu.

2. Using the arrow keys, select the operating value to be displayed from the list.

3. Press OK key.

4. Select additional, required operating values from the list and confirm by

pressing the OK key.

Locking operating keys

Function key assignment

Favourites menu

Fig.8: Selecting multiple parameters from the selection list

The operating keys of the control panel can be locked via the 3-1-2-2 parameter to prevent unauthorised operation or unauthorised acknowledgement of alerts.

The FUNC operating key can be preassigned a function from a selection list.

NOTE

When the FUNC operating key is used in the System Start / Stop role, the system must be restarted via the FUNC operating key every time the voltage is reset.

Press the OK key on the main screen to call up the favourites menu, where you can select various parameters and quickly adapt their configuration settings.

8.1.2.4 Menu: Information

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

8.2 Service interface and LED traffic light function

Item Description Function

1 Service interface Optical interface

2 LED traffic light function The traffic light function provides information about the

Fig.9: Service interface and traffic light LEDs

system's operating status.

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8 Operating the Pressure Booster System

Service interface

LED traffic light function

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

The following action can be taken:

▪ Configuring and parameterising the frequency inverter with the service software

▪ Software update

▪ Saving and documenting set parameters

The LED traffic light function provides information about the current PumpDrive operating status.

Table19: LED description

LED Description

Red

Amber

Green

One or more than one alert is active

One or more than one warning is active

Steady light: Trouble-free operation

8.3 Adjusting the settings

8.3.1 Setting the setpoint

The pressure booster system is factory-set to the setpoint indicated on the rating plate. If the setpoint needs to be adjusted to site conditions, parameter 1-3-2 has to be changed as required. First, enter the customer password. Then change the setpoint.

8.3.2 Changing the controller settings

The PI controller of the frequency inverter is optimised when leaving the factory, therefore no changes are required. Should a process-related adjustment of the PI controller be necessary, check/change the factory settings in accordance with the PumpDrive operating manual.

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9 Servicing/Maintenance

9.1 General information/Safety regulations

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

DANGER

Unintentional start-up of pressure booster system

Danger to life!

▷ The pressure booster system must be de-energised before repair or

maintenance work is carried out. Switching off the motor protection switch will not de-energise the motor

power cables reliably.

WARNING

Improper lifting/moving of heavy assemblies or components

Personal injury and damage to property!

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

heavy assemblies or components.

WARNING

Unintentional start-up of pressure booster system

Risk of injury by moving parts!

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

commencing work on the pressure booster system.

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

unintentionally.

WARNING

Unqualified personnel performing work on the pressure booster system

Risk of personal injury!

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

qualified personnel.

CAUTION

Incorrectly serviced pressure booster system

Function of pressure booster system not guaranteed!

▷ Regularly service the pressure booster system.

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

emphasis on lubricants, shaft seals and pump couplings.

Observe the general safety instructions and information.

Observe the operating manual of the pump when performing work on the pumps.

In the event of damage you can always contact our service staff.

A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation of the pressure booster system with a minimum of maintenance expenditure and work.

Never use force when dismantling and re-assembling the pressure booster system.

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9 Servicing/Maintenance

9.1.1 Inspection contract

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

9.2 Servicing/inspection

9.2.1 Supervision of operation

CAUTION

Increased wear due to dry running

Damage to the pump set!

▷ Never operate the pump set without liquid fill.

▷ Never close the shut-off element in the suction line and/or supply line during

pump operation.

CAUTION

Impermissibly high temperature of fluid handled

Damage to the pump!

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

(heating up of the fluid).

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

operating limits.

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

▪ Check the test run (if activated).

▪ Compare the start and stop pressures of the pumps with the data on the name

plate (using the pressure gauge).

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

data. (ðSection9.2.3,Page33) Close the shut-off elements under the accumulator and drain the accumulator via the drain valve. Remove the protective cap of the accumulator valve and check the pre-charge pressure with the aid of a tyre pressure gauge. Add nitrogen as necessary.

WARNING

Wrong gas

Danger of poisoning!

▷ Use only nitrogen to charge the accumulator.

▪ 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 correct functioning of any auxiliary connections.

9.2.2 Checklist for inspection

In the event that you decide to conduct your own inspections, proceed according to the following checklist at least once a year:

1. Check the pump and drive for smooth running and the mechanical seal for

integrity.

2. Check the shut-off, drain and check valves for proper functioning and tightness.

3. Clean the strainer in the pressure reducer (if applicable).

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9 Servicing/Maintenance

4. Check expansion joints for wear (if applicable).

5. Verify the pre-charge pressure level and check the accumulator for integrity if required. (ðSection9.2.3,Page33)

6. Check the automatic switching functionality.

7. Check the start and stop points of the pressure booster system.

8. Check the water inflow, inlet pressure, lack-of-water monitoring, flow

monitoring and pressure reducer.

9. Check the inlet tank and the float valve (if applicable). Check the overflow for integrity and cleanliness.

9.2.3 Setting the pre-charge pressure

WARNING

Wrong gas

Danger of poisoning!

▷ Use only nitrogen to charge the accumulator.

The pre-charge pressure in the accumulator should be set to a value below the set start-up pressure. The setting can be effected via a valve located under the cover at the top of the accumulator.

Example: Pre-charge pressure 10% lower than start-up pressure

Pre-charge pressure of accumulator p=0.9xp p

= start-up pressure of pressure booster system

start

Recommendation

The stated values are average values. Tests on accumulators have shown that the best storage volumes are achieved with the following factors: pressures >3bar: factor0.9 and pressures <3bar: factor0.8

Example:

= 5 bar: pre-charge pressure 5x0.9=4.5bar

start

=2bar: pre-charge pressure 2x0.8=1.6bar

start

CAUTION

Pre-charge pressure too high

Damage to accumulator!

▷ Observe data provided by accumulator manufacturer (see name plate or

operating manual of accumulator).

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10 Trouble-shooting

10.1 Trouble-shooting: pressure booster system

WARNING

Improper work to remedy faults

Risk of injury!

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

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

NOTE

Before performing any work on the pump's internal parts during the warranty period please always consult the manufacturer. Our after-sales service will be at your disposal. Non-compliance 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 customer service is required.

Pressure booster system cuts out.

Pressure fluctuations on the discharge side.

Pressure booster system does not start up.

Pump running but not delivering water.

Insufficient delivery of pressure booster system.

Discharge-side pressure too low.

Discharge-side pressure too high.

Leakage at mechanical seal.

Motor/pump overheated.

Motor protection switch triggered.

Pressure booster system does not stop.

Excessive starting/stopping of pressure booster system.

Motor overheated.

Table20: Trouble-shooting

A B C D E F G H I J K L M Possible cause Remedy

✘ - ✘ - - - - - - - - - - Dry-running protection device not

connected.

✘ - ✘ - - - - - - - - - - Mains supply interrupted Check and remedy defect.

✘ - ✘ - - - - - - ✘ - - ✘ Phase failure Check individual phases/fuse.

✘ - ✘ - - - - - - ✘ - - ✘ Motor protection switch triggered

or set incorrectly, or pump seized

✘ - ✘ - - - - - - - - - - Control current fuse tripped. Check fuse and replace as

- - ✘ - - - - - - - - - - Lack of water Check inlet pressure.

- - ✘ - - - ✘ - - - - - - Inlet pressure higher than stated in the purchase order

1) The pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.

Disconnect the pump from the power supply!

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Connect or bridge.

Compare setting with the motor's rating plate data and set accordingly. Press reset/fault acknowledgement key.

necessary.

Fit pressure reducer; contact KSB.

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10 Trouble-shooting

A B C D E F G H I J K L M Possible cause Remedy

- - - - ✘ ✘ ✘ - ✘ ✘ ✘ - - Incorrect power supply; wrong speed.

- ✘ ✘ ✘ ✘ ✘ - - ✘ - - ✘ ✘ Shut-off valves (partially) closed Check, open as necessary.

- - - ✘ ✘ - - - ✘ - ✘ - ✘ Pump and/or piping are not completely vented or primed.

- - - ✘ ✘ ✘ - - ✘ ✘ ✘ - ✘ Check valve in bypass line defective Replace.

- - - - - ✘ - - - - - - - Insufficient inflow Restore required inflow; connect

- - - - - ✘ - - ✘ ✘ - - ✘ Pump runs sluggishly. Have pump repaired by a

- - - - - - - ✘ - - - - - Defective mechanical seal Replace.

- - ✘ - - - - - ✘ - - - ✘ Incorrect pre-charge pressure of accumulator

✘ - ✘ ✘ - - - - - ✘ ✘ - - Inlet-side pressure switch defective

or set incorrectly.

- - - - - - - - ✘ - ✘ ✘ ✘ Defective time-lag relay or time set incorrectly.

- - - - - - - - - - - ✘ - System leaking. Restore system integrity.

- - ✘ - - ✘ ✘ - - - ✘ ✘ - Discharge-side pressure switch defective or set incorrectly.

✘ - - - - - - - - ✘ - - - Intermittent voltage fluctuations Press reset/fault acknowledgement

- - - ✘ - - - - ✘ ✘ - - ✘ Defective check valve in the pressure booster system

- - - ✘ ✘ ✘ - - ✘ - ✘ - - Pump running in the wrong direction of rotation.

- - - ✘ - ✘ - - - - ✘ ✘ - Inlet pressure lower than stated in the purchase order

- ✘ - - - ✘ - - - ✘ ✘ - - Water extraction higher than stated in the purchase order

Check power supply.

Vent and/or prime.

inlet tank.

specialist.

Set correct pre-charge pressure; replace membrane.

Check/correct the value set at the pressure switch.

Check time-lag relay/correct minimum operating time.

Check/correct the value set at the pressure switch.

key.

Check; fit new valve if required.

Interchange two phases of the power cable.

Connect inlet tank, contact KSB.

Contact KSB.

10.2 Trouble-shooting: frequency inverter

WARNING

Improper work to remedy faults

Risk of injury!

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

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

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

Mains fuse rating too small for the nominal mains current.

Motor does not start.

Motor running unevenly.

Max. speed not reached.

Motor running at maximum speed only.

Motor running at minimum speed only.

No/faulty 24V supply.

Wrong direction of rotation of the motor.

Fault message/protective tripping.

Hya-Solo DSV

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Page 36

10 Trouble-shooting

Table21: Trouble-shooting

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

- ✘ - - - - ✘ - - No voltage Check the mains voltage; check the mains fuses.

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

✘ - - - - - - - - Mains fuse rating too small for

frequency inverter input current

- - - ✘ - - - - - No setpoint signal or setpoint

set too low / drive overloaded and in i²t control mode

- - - - ✘ - - - - Process-related persistent

control deviation (actual value smaller than setpoint) / no actual value (e.g. due to broken wire)

- ✘ --- - - - - ✘ Permissible voltage range

undershot/exceeded

Check design configuration of mains fuse.

Check setpoint signal and operating point.

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

Check mains voltage; supply frequency inverter with required voltage.

- - - - - - - ✘ - Wrong direction of rotation

setting

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

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

pump blocked

- - ✘ ✘ - - - - ✘ Temperature of power

electronics or motor winding too high

- - - - - - ✘ - ✘ 24 V supply overloaded Disconnect PumpDrive from the power supply and

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

- - - ✘ - ✘ - - ✘ Sensor signal error (e.g.

broken wire)

- ✘ ✘ - - - - - ✘ Phase failure, drive side Check motor connection and motor winding.

Change the direction of rotation.

check the motor/pump for blockages.

Check/replace control cable connections. Remove the blockage manually.

Reduce the ambient temperature by improving ventilation. Improve cooling by cleaning the cooling fins. Ensure the intake opening for the motor fans is not blocked. Ensure that the motor fans are working properly. Reduce the power input by changing the operating point (system-specific). Check the permissible load and, if necessary, use external cooling.

eliminate the cause of the overload.

PumpDrive.

Check sensor and sensor cable.

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Hya-Solo DSV

Page 37

11 Related Documents

82-1 655

591

79-2

743.02

691 743.01742743.01

11 Related Documents

11.1 List of components

11.1.1 Hya-Solo DSV with Movitec 2, 4, 6, 10, 15

Fig.10: General assembly drawing of Hya-Solo DSV with Movitec 2, 4, 6, 10, 15

Table22: Spare parts for Hya-Solo DSV with Movitec 2, 4, 6, 10, 15

Part No. Description Ident. No.

591 Accumulator 01 079 764

655 Pump

691 Pressure gauge, discharge side 00 401 413

742 Lift check valve1 (Movitec 2, 4) 01 149 253

742 Lift check valve11/4 (Movitec 6) 01 149 254

742 Lift check valve11/2 (Movitec 10) 01 149 255

742 Lift check valve2 (Movitec 15) 01 149 256

743.01 Ball valve1 (Movitec 2, 4) 01 057 427

743.01 Ball valve11/4 (Movitec 6) 01 057 428

743.01 Ball valve11/2 (Movitec 10) 01 057 429

743.01 Ball valve2 (Movitec 15) 01 057 430

743.02 Ball valve (make Reflex) 01 079 765

79-2 Measuring transducer 0-16bar 01 112 649

82-1 PumpDrive On request

For electric parts refer to the circuit diagram in the Annex.

NOTE

Pump spare parts correspond to Movitec in standard design (with oval flange).

Hya-Solo DSV

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Page 38

11 Related Documents

82-1

655

591

743

746

79-2

691 747

746

11.1.2 Hya-SoloDSV with Movitec 25, 40, 60, 90

Fig.11: General assembly drawing of Hya-Solo DSV with Movitec 25, 40, 60, 90

Table23: Spare parts for Hya-SoloDSV with Movitec 25, 40, 60, 90

Part No. Description Ident. No.

591 Accumulator 01 079 764

655 Pump

691 Pressure gauge, discharge side 00 401 413

743 Ball valve (make Reflex) 01 079 765

746 Butterfly valve DN65 (Movitec 25) 40 982 350

746 Butterfly valve DN80 (Movitec 40) 40 982 351

746 Butterfly valve DN100 (Movitec 60, 90) 40 982 352

747 Swing check valve DN65 (Movitec 25) 01 086 243

747 Swing check valve DN80 (Movitec 40) 01 056 931

747 Swing check valve DN100 (Movitec 60, 90) 01 087 142

79-2 Measuring transducer 0-16bar 01 112 649

82-1 PumpDrive On request

For electric parts refer to the circuit diagram in the Annex.

Non-documented parts on request (please indicate serial No. or order No.)

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NOTE

Pump spare parts correspond to Movitec in standard design (with round flange).

Hya-Solo DSV

Page 39

12 EU Declaration of Conformity

Manufacturer: KSB SE & Co. KGaA

Johann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

Hya-Solo DV, Hya-Solo DSV

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 1988-500

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

..............................2).............................

Name

Function

Company

Address

2) A signed, legally binding EU Declaration of Conformity is supplied with the product.

Hya-Solo DSV

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Page 40

13 Certificate of Decontamination

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

Order number/

Order item number3): ................................................................................................................................

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

Field of application: ................................................................................................................................

Fluid handled3): ................................................................................................................................

Please tick where applicable3):

   

Radioactive Explosive Corrosive Toxic

   

Harmful Bio-hazardous Highly flammable Safe

Reason for return3): ................................................................................................................................

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

3) Required fields

40 of 44

Hya-Solo DSV

Page 41

14 Commissioning Report

The KSB pressure booster system specified below was today commissioned by the undersigned authorised KSB customer service engineer who created this report.

Pressure booster system details

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

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

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

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

Purchaser/place of installation Purchaser Place of installation

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

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

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

Operating data For further details please refer to the circuit diagram. Start-up pressure p Inlet pressure monitoring p

(setting of inlet pressure switch) Stop pressure p Inlet pressure p Pre-charge pressure of

accumulator p

bar ....................................................

start

- x

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

inl

bar ....................................................

stop

bar ....................................................

inl

pre-charge

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

bar

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

Non-conformities found during commissioning Deadline for remedial action

Non-conformities 1 ........................................................................... ..........................................................................

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

Name of KSB representative Name of purchaser or representative

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

Place Date

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

Hya-Solo DSV

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Page 42

Index

Access levels25 Arrow keys23, 24

Certificate of decontamination40 Commissioning/Start-up19

Design11 Disposal10

Escape key23

Faults

Causes and remedies34, 36

Graphical control panel22 Graphical display22

Warnings

Graphical control panel30

Help key24

Installation at site14

LED display30 List of spare parts37, 38

OK key23, 24 Operating values for input and output signals26 Other applicable documents6

Partly completed machinery6

Return to supplier10

Safety7 Scope of supply13 Service interface30

Traffic light30

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Hya-Solo DSV

Page 43

Page 44

KSB SE & Co. KGaA

Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)

Tel. +49 6233 86-0

www.ksb.com

1951.89/03-EN (01650730)

KSB Hya-Solo DSV, Hya-Solo DSV/B 1/2503 V Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Glossary

1 General

1.1 Principles

1.2 Installation of partly completed machinery

1.3 Target group

1.4 Other applicable documents

1.5 Symbols

2 Safety

2.1 Key to safety symbols/markings

3 Software Changes

4 Transport/Temporary Storage/Disposal

4.1 Checking the condition upon delivery

4.2 Transport

4.3 Storage/preservation

4.4 Return to supplier

4.5 Disposal

5 Description

5.1 General description

5.2 Designation

5.3 Name plate

5.4 Design details

5.5 Configuration and function

5.6 Noise characteristics

5.7 Scope of supply

5.8 Dimensions and weights

6 Installation at Site

6.1 Installation to DIN 1988

6.2 Checks to be carried out prior to installation

6.3 Installing the pressure booster system

6.4 Installing the piping

6.4.1 Fitting an expansion joint

6.4.2 Installing a pressure reducer

6.5 Installing unpressurised inlet tanks

6.6 Fitting the dry running protection device

6.7 Connection to power supply

6.7.1 Sizing the power cable

6.7.2 Connecting the pressure booster system

6.7.3 Digital inputs

6.7.4 Relay outputs

6.7.5 Analog inputs

6.7.6 Analog output

7 Commissioning/Start-up/Shutdown

7.1 Commissioning/Start-up

7.1.1 Prerequisites for commissioning/start-up

7.1.2 Dry running protection

7.1.3 Commissioning/start-up of pressure booster system

7.2 Switching on the pressure booster system

7.3 Checklist for commissioning/start-up

7.4 Shutdown

8 Operating the Pressure Booster System

8.1 Graphical control panel

8.1.1 Graphical display

8.1.2 Menu keys

8.1.2.1 Menu: Operation

8.1.2.1.1 Access levels

8.1.2.1.2 Operating values for input and output signals

8.1.2.2 Menu: Diagnosis

8.1.2.3 Menu: Settings

8.1.2.3.1 Setting the display language

8.1.2.3.2 Setting the control panel

8.1.2.4 Menu: Information

8.2 Service interface and LED traffic light function

8.3 Adjusting the settings

8.3.1 Setting the setpoint

8.3.2 Changing the controller settings

9 Servicing/Maintenance

9.1 General information/Safety regulations

9.1.1 Inspection contract

9.2 Servicing/inspection

9.2.1 Supervision of operation

9.2.2 Checklist for inspection

9.2.3 Setting the pre-charge pressure

10 Trouble-shooting

10.1 Trouble-shooting: pressure booster system

10.2 Trouble-shooting: frequency inverter