KSB Hya-Solo DV Series Operating Manual

Pressure Booster System

Hya®-Solo DV

from series S-V/1

Installation/Operating Manual

Your contact:

Tel: 01474 832498

Email: technique1988@gmail.com

Web: www.techniquetergravesend.co.uk

Legal information/Copyright

Installation/Operating Manual Hya®-Solo DV Original operating manual

KSB Aktiengesellschaft Frankenthal

All rights reserved. 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 KSB´s express written consent.

Subject to technical modification without prior notice.

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 ............................................................................. 10

4 Transport/Temporary Storage/Disposal ........................................... 11

4.1 As-delivered condition .................................................................................. 11

4.2 Transport ....................................................................................................... 11

4.3 Storage/Preservation ..................................................................................... 11

4.4 Return to supplier ........................................................................................ 12

4.5 Disposal of pressure booster system ............................................................ 12

5 Description ........................................................................................ 13

5.1 General description ....................................................................................... 13

5.2 Designation ................................................................................................... 13

5.3 Name plate .................................................................................................... 13

5.4 Design details ................................................................................................ 13

5.5 Configuration and function ......................................................................... 14

5.6 Noise characteristics ...................................................................................... 15

5.7 Scope of supply ............................................................................................. 15

5.8 Dimensions and weights ............................................................................... 15

5.9 Terminal wiring diagram .............................................................................. 15

6 Installation at Site ............................................................................. 21

6.1 Installation to DIN 1988 ................................................................................ 21

6.2 Checks to be carried out prior to installation ............................................. 21

6.3 Installing the pressure booster system ......................................................... 21

6.4 Installing the piping ...................................................................................... 22

6.5 Installing unpressurised inlet tanks .............................................................. 23

6.6 Fitting the dry running protection device ................................................... 23

6.7 Connection to power supply ........................................................................ 24

7 Commissioning/Start-up/Shutdown ................................................. 26

7.1 Commissioning/start-up ................................................................................ 26

7.2 Switching on the pressure booster system .................................................. 27

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Contents

7.3 Check list for commissioning/start-up .......................................................... 27

7.4 Shutdown ...................................................................................................... 28

8 Operating the Pressure Booster System ........................................... 29

8.1 Control panel functions ................................................................................ 29

8.2 Menu structure .............................................................................................. 32

8.3 Access levels ................................................................................................... 33

8.4 Displaying and changing parameters .......................................................... 34

8.5 Monitoring .................................................................................................... 35

8.6 Description of parameters ............................................................................ 35

8.7 Adjusting the settings ................................................................................... 36

9 Servicing/Maintenance ...................................................................... 43

9.1 General notes/Safety regulations ................................................................. 43

9.2 Servicing/inspection ...................................................................................... 44

10 Trouble-shooting ............................................................................... 46

10.1 Hya-Solo DV ................................................................................................... 46

10.2 PumpDrive ..................................................................................................... 47

11 Related Documents ........................................................................... 49

11.1 List of components ........................................................................................ 49

12 EC Declaration of Conformity .......................................................... 51

13 Certificate of Decontamination ....................................................... 53

14 Commissioning Report ...................................................................... 54

Index .................................................................................................. 55

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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 certifies that the pressure booster system has been properly cleaned and decontaminated 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 system is operated at a selectable speed via the frequency inverter, independently of the control unit.

Noise characteristics

The noise emission to be expected, indicated as sound pressure level LpA in dB(A)

PumpDrive

KSB frequency inverter mounted on the pump set.

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1 General

1.1 Principles

This manual is supplied as an integral part of the type series and variants indicated on the front cover. It 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 clearly 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 (⇨ Section 5.6 Page 15)

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB, please refer to the subsections under Servicing/Maintenance.

1.3 Target group

This manual is aimed at the target group of trained and qualified specialist technical personnel. (⇨ Section 2.1.3 Page 8)

1.4 Other applicable documents

Table 1: Overview of other applicable documents

Document Contents Sub-supplier documentation 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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DANGER

WARNING

CAUTION

DANGER

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

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

CAUTION 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 indicates a hazard which will or could result in death or serious injury.

Electrical hazard identifies information about protection against electrical voltage.

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

2.1.1 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.

2.1.2 Intended use

The pressure booster system must only be operated within the operating limits which are 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.

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2 Safety

▪ Observe the minimum flow rates indicated in the product literature (to prevent

overheating, bearing damage, etc.).

▪ Observe the maximum flow rates indicated 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 use or mode of operation not described in

the product literature.

Preve n t i on of f o resee a b l e mis u s e

▪ Never exceed the permissible operating limits specified in the product literature

regarding pressure, temperature, etc..

▪ Observe all safety information and instructions in this manual.

2.1.3 Personnel qualification and 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 sufficiently trained specialist personnel training and instructing the personnel who will carry out the respective tasks. If required, the operator can commission the manufacturer/supplier to train the personnel.

Training on the pressure booster system must always be supervised by technical specialist personnel.

2.1.4 Consequences and risks caused by non-compliance with these operating instructions

▪ Non-compliance with these operating instructions will lead to forfeiture 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

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2.1.5 Safety awareness

In addition to the safety instructions contained in this manual and the intended use, the following safety instructions shall be complied with:

▪ Accident prevention, health and safety regulations

▪ Explosion protection regulations

▪ Safety regulations for handling hazardous substances

▪ Applicable standards and laws

2.1.6 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.

▪ Never remove a contact guard while the pump is running.

▪ Eliminate all electrical hazards.

Hya®-Solo DV

2 Safety

2.1.7 Safety information for maintenance, inspection and installation work

▪ 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 all maintenance, inspection and installation work 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 is completed, re-install and/or re-activate any safety-relevant

and protective devices. Before returning the product to service, observe all instructions on commissioning. (⇨ Section 7.1 Page 26)

▪ Make sure the pressure booster system cannot be accessed by unauthorised

persons (e.g. children).

2.1.8 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. (⇨ Section 2.1.2 Page 7)

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3 Software Changes

The software has been specially created for this product and thoroughly tested. It is impermissible 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 As-delivered condition

NOTE

Prior to dispatch, the pressure booster system was tested and inspected to ensure full compliance with the specifications and should therefore be in perfect electrical and mechanical condition upon arrival at its destination. It is recommended that the pressure booster system be inspected for in-transit damage immediately upon receipt. If there are any complaints or objections, the recipient and carrier must jointly draw up a damage report.

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 local accident prevention regulations.

▷ Use suitable, approved transport equipment, e.g. crane, forklift or pallet trucks.

▷ 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

✓ The pressure booster system has been checked for in-transit damage.

Make sure the transport equipment is suitable for safely carrying the indicated

1. 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 by frost, moisture, dirt, UV radiation or vermin Corrosion/contamination of pressure boosting system!

▷ Store the pressure booster system in a frost-proof room. Do not store the unit

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.

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

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

3. If the fluids handled by the system leave residues which might lead to corrosion when coming into contact with atmospheric humidity, or which might ignite when coming into contact with oxygen, the pressure booster system must also be neutralised and blown through with anhydrous inert gas for drying purposes.

4. Always complete and enclose a certificate of decontamination when returning the pressure booster system. It is imperative to indicate any safety and decontamination measures taken.

NOTE

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

4.5 Disposal of pressure booster system

WARNING

Fluids posing a health hazard Hazardous to persons and the environment!

▷ Collect and properly dispose of flushing liquid and any fluid residues.

▷ Wear safety clothing and a protective mask, if required.

▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Dismantle the pressure booster system. Collect greases and other lubricants during dismantling.

2. Separate and sort the pump materials, e.g. by:

- Metals

- Plastics

- Electronic waste

- Greases and other lubricants

3. Dispose of materials in accordance with local regulations or in another controlled manner.

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Hya®-Solo DV

Hya-Solo DV 1808 S-U

ZNI1448 P

29 132 276 Made by KSB

400 V 3~ 15,50 A

max

: 115 m Q

max

: 23 m3/h

50 Hz IP 55

Aktiengesellschaft D-67225 Frankenthal

1 2

5 Description

5.1 General description

The fully automatic pressure booster package system

▪ with one vertical high-pressure pump

▪ with a motor-mounted PumpDrive frequency inverter ensuring a constant supply

pressure at the consumer installations

complies with DIN 1988 in configuration and function.

5.2 Designation

Examp l e : Hya- S o l o DV / 0 4 05 / 2 - 4

Table 4: Key to the designation

Code Description Hya-Solo Pressure booster system with one pump DV Model with three-phase motor, speed-controlled, pressure-

dependent starting and flow-dependent stopping 04 Pump size 05 Number of pump stages 2 - 4 Inlet pressure in bar

5.3 Name plate

Fig. 2: Hya-Solo DV name plate

1 Type series/size 2 Rated voltage 3 Frequency 4 Maximum head 5 Series number 6 Max. current consumption 7 Enclosure 8 Maximum flow rate

Key t o t he se r i e s num b e r

Calendar year 2009 2010 2011 2012 2013 1st half of the year S-U S-W S-Y S-A S-C 2nd half of the year S-V S-X S-Z S-B S-D

5.4 Design details

Desig n

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

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5 Description

set. The system comes with separate rubber anti-vibration pads.

Design

Function

Automatic mode

Function

Manual mode

5.5 Configuration and function

Fig. 3: Hya-Solo DV

1 Master switch 2 Accumulator 3 Pump 4 Pressure transmitter 5 PumpDrive 6 Valves

The fully automatic pressure booster system is equipped with a non-self-priming vertical high-pressure pump (1) 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 unit to maintain the set pressure, so that the pressure is kept constant. As the consumption decreases, the speed is reduced. At zero flow, the pressure booster system stops after a set after-run period (45 to 360 seconds).

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.

Example

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.

Minim u m flow f o r pump i n manu a l mode

Table 5: Minimum consumption per pump in manual mode

Pump Minimum consumption per pump in manual mode

[l/h] Movitec 2 300 Movitec 4 600 Movitec 10 1200 Movitec 18 2400 Movitec 32 4000 Movitec 45 4600 Movitec 65 6100 Movitec 90 8000

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

Pressure booster system

PumpDrive

The dry running protection function is active in automatic mode and manual mode. A digital input is provided for connecting dry running protection equipment. 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:

▪ One Movitec vertical high-pressure centrifugal pump

▪ One check valve and shut-off valves

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

▪ Pressure transmitter for the discharge side

▪ Vibration damping

▪ Pressure indication via pressure gauge

▪ Shut-off valves

▪ Self-cooling motor-mounted frequency inverter

▪ 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.),

2x 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 please refer to the outline drawings of the pressure booster system.

5.9 Terminal wiring diagram

5.9.1 Power terminals

NOTE

The PumpDrive is wired to the master switch, the motor and the pressure sensor at the factory. Work at the power terminals is only required if the PumpDrive needs to be removed.

The power terminals are located underneath the V-shaped cover.

DANGER

Electrical connection work by unqualified personnel Danger of death from electric shock!

▷ Always have the electrical connections installed by a trained electrician.

▷ Observe regulations IEC 30364 (DIN VDE 0100) and, for explosion-proof models,

IEC 60079 (DIN VDE 0164).

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5 Description

Removing the L-shaped cover.

Removing the V-shaped cover.

Route the power/motor cable through the cable glands (as shown in table 20, section

NOTE

The housing cover must not be opened. Non-compliance will result in forfeiture of any and all warranty claims.

Remove the cross-head screws on the L-shaped cable cover for the control cables and remove the cover.

Remove the cross-head screws on the V-shaped cover for the mains and motor connection and remove the cover.

6.4.6) and connect them to the appropriate terminals (see Fig. 10 and Fig. 11). When closing the covers, make sure that the sealing elements are properly seated.

NOTE

The screws fastening the cover of the mains and motor terminal box must be tightened to a torque of 1.2 Nm to ensure that the device has IP55 enclosure protection.

DANGER

Open terminals and connectors of brake resistor. Danger to life!

▷ Do not open the terminals and connectors of the brake resistor.

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Hya®-Solo DV

+24VIN 0

PTC

PE L1 L2 L3

L1 L2

1 2 3 4 5 6

U V W

M 3~

+24VIN 0

PTC

PE L1 L2 L3

L1 L2

1 2 3 4 5 6

U V W

M 3~

5 Description

Fig. 4: Power supply and motor wiring up to 7.5 kW

A Analog input 2 B Brake resistor

Fig. 5: Power supply and motor wiring from 11 kW

A Analog input 2 B Brake resistor

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+ 39 hidden pages

KSB Hya-Solo DV Series 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 As-delivered condition

4.2 Transport

4.3 Storage/Preservation

4.4 Return to supplier

4.5 Disposal of pressure booster system

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

5.9 Terminal wiring diagram