DP Pumps Hydro-Unit Utility Line F Installation instructions

Pressure Booster System
Installation/Operating Manual
Hydro-Unit Utility Line
Hydro-Unit Utility Line F
Hydro-Unit Utility Line VC
Hydro-Unit Utility Line SVP

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Legal information/Copyright
Original operating manual Hydro-Unit Utility Line
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.
© Duijvelaar Pompen, Alphen aan den Rijn, Netherlands 23/11/2021

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Contents
Glossary.............................................................................................................6
1 General...............................................................................................................7
1.1 Principles ............................................................................................................................................. 7
1.2 Software changes ................................................................................................................................ 7
1.3 Installation of partly completed machinery........................................................................................... 7
1.4 Target group ........................................................................................................................................ 7
1.5 Other applicable documents ................................................................................................................ 7
1.6 Symbols ............................................................................................................................................... 7
2 Safety .................................................................................................................8
2.1 Key to safety symbols/markings .......................................................................................................... 9
2.2 General ................................................................................................................................................ 9
2.3 Intended use ........................................................................................................................................ 9
2.4 Personnel qualification and personnel training .................................................................................. 10
2.5 Consequences and risks caused by non-compliance with this manual............................................. 10
2.6 Safety awareness .............................................................................................................................. 10
2.7 Safety information for the operator/user ............................................................................................ 10
2.8 Safety information for maintenance, inspection and installation........................................................ 11
2.9 Unauthorised modes of operation...................................................................................................... 11
2.10 Electromagnetic compatibility (EMC)................................................................................................. 11
2.10.1 Interference emission requirements ...................................................................................... 11
2.10.2 Line harmonics requirements ................................................................................................ 12
2.10.3 Interference immunity requirements...................................................................................... 12
3 Transport/Storage/Disposal...........................................................................14
3.1 Checking the condition upon delivery ................................................................................................ 14
3.2 Transport............................................................................................................................................ 14
3.3 Storage/preservation ......................................................................................................................... 17
3.4 Return to supplier .............................................................................................................................. 18
3.5 Disposal ............................................................................................................................................. 18
4 Description ......................................................................................................20
4.1 General description............................................................................................................................ 20
4.2 Product information as per Regulation No. 1907/2006(REACH)...................................................... 20
4.3 Designation ........................................................................................................................................ 20
4.4 Name plate ........................................................................................................................................ 20
4.5 Design details .................................................................................................................................... 21
4.6 Configuration and function................................................................................................................. 22
4.7 Noise characteristics.......................................................................................................................... 24
4.8 Scope of supply ................................................................................................................................. 24
4.8.1 Inlet conditions, version M..................................................................................................... 25
4.8.2 Inlet conditions, version F...................................................................................................... 26
4.8.3 Inlet conditions, version L...................................................................................................... 27
4.9 Dimensions and weights.................................................................................................................... 28
4.10 Potential equalisation......................................................................................................................... 28
5 Installation at Site ...........................................................................................30
5.1 Installation.......................................................................................................................................... 30
5.2 Installing the pressure booster system .............................................................................................. 30
5.3 Mounting the accumulator ................................................................................................................. 31
5.4 Connecting the piping ........................................................................................................................ 31

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5.4.1 Fitting an expansion joint (optional)....................................................................................... 32
5.4.2 Fitting the pressure reducer (optional) .................................................................................. 32
5.5 Electrical connection.......................................................................................................................... 33
5.5.1 Sizing the power cable .......................................................................................................... 33
5.5.2 Connecting the pressure booster system.............................................................................. 34
5.5.3 Connecting the remote ON/OFF input................................................................................... 34
5.5.4 Connecting the dry running protection device ....................................................................... 34
6 Commissioning/Start-up/Shutdown..............................................................35
6.1 Commissioning/Start-up .................................................................................................................... 35
6.1.1 Prerequisites for commissioning/start-up .............................................................................. 35
6.1.2 Priming and venting the pressure booster system ................................................................ 35
6.1.3 Dry running protection ........................................................................................................... 36
6.1.4 Start-up.................................................................................................................................. 36
6.1.5 Checklist for commissioning/start-up..................................................................................... 37
6.2 Operating limits.................................................................................................................................. 38
6.2.1 Frequency of starts................................................................................................................ 38
6.2.2 Ambient temperatures ........................................................................................................... 38
6.2.3 Maximum operating pressure................................................................................................ 38
6.2.4 Fluid handled......................................................................................................................... 38
6.2.5 Minimum flow rate ................................................................................................................. 39
6.3 Shutdown ........................................................................................................................................... 39
6.3.1 Stopping ................................................................................................................................ 39
6.3.2 Measures to be taken for shutdown ...................................................................................... 40
7 Operation .........................................................................................................41
7.1 Control panel ..................................................................................................................................... 41
7.1.1 Screen ................................................................................................................................... 41
7.1.2 Turn/push button ................................................................................................................... 41
7.1.3 Status LED ............................................................................................................................ 41
7.2 Symbols on the screen ...................................................................................................................... 42
7.2.1 Operating status of the system.............................................................................................. 43
7.2.2 Bluetooth connection............................................................................................................. 43
7.2.3 Locking/unlocking the screen ................................................................................................ 44
7.2.4 Operating status of the pump ................................................................................................ 44
7.2.5 Information on the system ..................................................................................................... 44
7.3 Operating the device via the control panel ........................................................................................ 45
7.3.1 Unlocking the screen............................................................................................................. 46
7.3.2 Changing the operating mode ............................................................................................... 46
7.3.3 Resetting messages.............................................................................................................. 46
7.3.4 Setting the setpoint................................................................................................................ 46
7.3.5 Activating the Bluetooth connection ...................................................................................... 47
7.3.6 Displaying the firmware version ............................................................................................ 47
7.4 Operation via the app ........................................................................................................................ 47
8 Servicing/Maintenance ...................................................................................48
8.1 General information/safety regulations .............................................................................................. 48
8.1.1 Inspection contract ................................................................................................................ 48
8.2 Servicing/Inspection........................................................................................................................... 49
8.2.1 Supervision of operation........................................................................................................ 49
8.2.2 Maintenance schedule .......................................................................................................... 49
8.3 Setting the pre-charge pressure ........................................................................................................ 50
8.4 Resetting dry running protection........................................................................................................ 51
9 Trouble-shooting ............................................................................................52
9.1 Trouble-shooting: pressure booster system ...................................................................................... 52
9.2 Trouble-shooting: frequency inverter ................................................................................................. 54

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10 Related Documents ........................................................................................56
10.1 General drawings with list of components ......................................................................................... 56
10.1.1 Hydro-Unit Utility Line with DPV 2, 4, 6, 10, 15..................................................................... 56
10.1.2 Hydro-Unit Utility Line with DPV 25, 40, 60, 85, 125............................................................. 57
10.2 Parameter lists................................................................................................................................... 59
10.2.1 Configuration ......................................................................................................................... 59
10.2.2 Settings ................................................................................................................................. 71
10.3 Messages........................................................................................................................................... 83
10.3.1 Messages for specific pumps ................................................................................................ 83
10.3.2 Messages for additional devices ........................................................................................... 85
10.3.3 Messages for specific functions ............................................................................................ 86
11 EU Declaration of Conformity........................................................................88
12 Certificate of Decontamination......................................................................89
13 Commissioning Report ..................................................................................90
Index.................................................................................................................91

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Glossary
Accumulator
Pressure losses may occur in the piping
downstream of the pressure booster system as a
result of losses due to leakage. The accumulator
serves to compensate for pressure losses and
minimises the frequency of starts of the pressure
booster system.
Certificate of decontamination
A certificate of decontamination is enclosed by
the customer when returning the product to the
manufacturer to certify that the product has been
properly drained to eliminate any environmental
and health hazards arising from components in
contact with the fluid handled.
Dry running protection
Dry running protection devices prevent the pump
from being operated without the fluid to be
handled, which would result in pump damage.
IE3
Efficiency class to IEC60034-30: 3=Premium
Efficiency (IE = International Efficiency)
IE5
Efficiency class to
IECTS60034-30-2:2016=Ultra Premium
Efficiency (IE= International Efficiency)
Manual mode
Direct operation on the power supply network,
independently of the control unit.
Switchgear and controlgear assembly
Control cabinet with one or several control units/
switchgears and electrical equipment.

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1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front cover.
The operating manual describes the proper and safe use of this equipment in all phases of
operation.
The name plate indicates the type series, the main operating data and the serial number.
The serial number uniquely describes the product and is used as identification in all further
business processes.
In the event of damage, immediately contact your nearest DP service facility to maintain the
right to claim under warranty.
1.2 Software changes
The software has been specially created for this product and thoroughly tested.
Making changes or additions to the software or parts of the software is prohibited. This does
not, however, apply to software updates supplied by DP.
1.3 Installation of partly completed machinery
To install partly completed machinery supplied by DP refer to the sub-sections under
Servicing/Maintenance.
1.4 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. [ðSection2.4,Page10]
1.5 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Sub-supplier product literature Operating manuals and other product literature describing
accessories and integrated machinery components
1.6 Symbols
Table2: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the step-by-step
instructions
⊳ Safety instructions
⇨Result of an action
⇨ Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle the product

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2 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
In addition to the present general safety information the action-related safety information
given in the other sections must be observed.

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2.1 Key to safety symbols/markings
Table3: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided, will result in
death or serious injury.
!WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not avoided, could
result in death or serious injury.
CAUTION
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.
2.2 General
– This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and prevent
personal injury and damage to property.
– Comply with all the safety instructions given in the individual sections of this operating
manual.
– The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
– The contents of this operating manual must be available to the specialist personnel at
the site at all times.
– Information and markings attached directly to the product must always be complied with
and kept in a perfectly legible condition at all times. This applies to, for example:
– Arrow indicating the direction of rotation
– Markings for connections
– Name plate
– The operator is responsible for ensuring compliance with all local regulations not taken
into account.
2.3 Intended use
– The pressure booster system must only be operated within the operating limits
described in the other applicable documents.
– Only operate pressure booster systems which are in perfect technical condition.
– Do not operate partially assembled pressure booster systems.
– The pressure booster system must only handle the fluids described in the product
literature of the respective design variant.
– Never operate the pressure booster system without the fluid to be handled.
– Observe the information on minimum flow rates specified in the product literature (to
prevent overheating, bearing damage, etc).

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– Observe the maximum flow rates indicated in the data sheet or product literature (to
prevent overheating, cavitation damage, bearing damage, etc).
– Do not throttle the flow rate on the suction side of the pressure booster system (to
prevent cavitation damage).
– Consult the manufacturer about any other modes of operation not described in the
product literature.
2.4 Personnel qualification and personnel training
– All personnel involved must be fully qualified to install, operate, maintain and inspect
the product this manual refers to.
– The responsibilities, competence and supervision of all personnel involved in transport,
installation, operation, maintenance and inspection must be clearly defined by the
operator.
– Deficits in knowledge must be rectified by means of training and instruction provided by
sufficiently trained specialist personnel. If required, the operator can commission the
manufacturer/supplier to train the personnel.
– Training on the pressure booster system must always be supervised by specialist
technical personnel.
2.5 Consequences and risks caused by non-compliance with this
manual
– Non-compliance with these operating instructions will lead to forfeiture of warranty cover
and of any and all rights to claims for damages.
– Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical effects and
explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.6 Safety awareness
In addition to the safety information contained in this operating manual and the intended
use, the following safety regulations shall be complied with:
– Accident prevention, health regulations and safety regulations
– Safety regulations for handling hazardous substances
– Applicable standards, directives and laws
2.7 Safety information for the operator/user
– Fit protective equipment (e.g. contact guards) supplied by the operator for hot, cold or
moving parts, and check that the equipment functions properly.
– Do not remove any protective equipment (e.g. contact guards) during operation.
– Eliminate all electrical hazards. (In this respect refer to the applicable national safety
regulations and/or regulations issued by the local energy supply companies.)
– If stopping the pump does not increase potential risk, fit an emergency-stop control
device in the immediate vicinity of the pump (set) during pump set installation.