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 30/09/2020

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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/Temporary 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.................................................................................................................................. 37
6.2.1 Frequency of starts................................................................................................................ 37
6.2.2 Ambient temperatures ........................................................................................................... 37
6.2.3 Maximum operating pressure................................................................................................ 38
6.2.4 Fluid handled......................................................................................................................... 38
6.2.5 Minimum flow rate ................................................................................................................. 38
6.3 Shutdown ........................................................................................................................................... 39
6.3.1 Stopping ................................................................................................................................ 39
6.3.2 Measures to be taken for shutdown ...................................................................................... 39
7 Operating the Pressure Booster System......................................................40
7.1 Hydro-Unit Utility Line F/VC/SVP....................................................................................................... 40
7.1.1 Control panel ......................................................................................................................... 40
7.1.2 Menu structure ...................................................................................................................... 42
7.1.3 Access levels......................................................................................................................... 43
7.1.4 Displaying and changing parameters .................................................................................... 43
7.1.5 Displaying messages ............................................................................................................ 44
7.1.6 Description of parameters ..................................................................................................... 44
7.1.7 Quick menu ........................................................................................................................... 49
7.1.8 Saving and restoring settings ................................................................................................ 49
7.1.9 Alerts and warnings............................................................................................................... 50
7.1.10 Connecting the remote ON/OFF input................................................................................... 50
7.1.11 Connecting the fire alert ........................................................................................................ 50
7.1.12 Filling the accumulator .......................................................................................................... 51
7.1.13 Energy-saving mode ............................................................................................................. 51
7.1.14 Setting flow detection ............................................................................................................ 52
7.1.15 Setting the ambient temperature monitoring device (optional).............................................. 52
7.1.16 Enabling digital inputs (optional) ........................................................................................... 52
8 Servicing/Maintenance ...................................................................................53
8.1 General information/safety regulations .............................................................................................. 53
8.1.1 Inspection contract ................................................................................................................ 53
8.2 Servicing/Inspection........................................................................................................................... 54
8.2.1 Supervision of operation........................................................................................................ 54
8.2.2 Maintenance schedule .......................................................................................................... 54
8.3 Setting the pre-charge pressure ........................................................................................................ 55
8.4 Resetting dry running protection........................................................................................................ 55
9 Trouble-shooting ............................................................................................57
9.1 Trouble-shooting: pressure booster system ...................................................................................... 57
9.2 Trouble-shooting: frequency inverter ................................................................................................. 58
10 Related Documents ........................................................................................60

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10.1 General drawings with list of components ......................................................................................... 60
10.1.1 Hydro-Unit Utility Line with DPV 2, 4, 6, 10, 15..................................................................... 60
10.1.2 Hydro-Unit Utility Line with DPV 25, 40, 60, 85, 125............................................................. 61
11 EU Declaration of Conformity........................................................................62
12 Certificate of Decontamination......................................................................63
13 Commissioning Report ..................................................................................64
Index.................................................................................................................65

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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.
Energy-saving mode
Setting designed to avoid the energetically
inefficient operation of a pump at minimum water
consumption.
Filling the accumulator
Function to fill a (discharge-side) accumulator; it
prevents pump sets from starting if only a very
small amount of water (e.g. caused by leakage)
is required.
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 shutting down the pump does not increase potential risk, fit an emergency-stop control
device in the immediate vicinity of the pump (set) during pump set installation.

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2.8 Safety information for maintenance, inspection and installation
– Modifications or alterations of the pressure booster system are only permitted with the
manufacturer's prior consent.
– Use only original spare parts or parts authorised by the manufacturer. The use of other
parts can invalidate any liability of the manufacturer for resulting damage.
– The operator ensures that maintenance, inspection and installation are performed by
authorised, qualified specialist personnel who are thoroughly familiar with the manual.
– Carry out work on the pressure booster system during standstill only.
– The pump casing must have cooled down to ambient temperature.
– Pump pressure must have been released and the pump must have been drained.
– When taking the pressure booster system out of service always adhere to the procedure
described in the manual.
– Decontaminate pressure booster systems which handle fluids posing a health hazard.
– As soon as the work has been completed, re-install and/or re-activate any safety-
relevant and protective devices. Before returning the product to service, observe all
instructions on commissioning.
– Make sure the pressure booster system cannot be accessed by unauthorised persons
(e.g. children).
– Prior to opening the device, pull the mains plug and wait for at least 10minutes.
2.9 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.
[ðSection2.3,Page9]
2.10 Electromagnetic compatibility (EMC)
2.10.1 Interference emission requirements
The EN61800-3 EMC product standard is relevant for electric variable speed drives/control
systems. It specifies all pertinent requirements and refers to the relevant generic standards
for complying with the EMC Directive.
Frequency inverters are commonly used by operators as a part of a system, plant or
machine assembly. It should be noted that the operator bears all responsibility for the final
EMC properties of the equipment, plant or installation.
A prerequisite or requirement for complying with the relevant standards or the limit values
and inspection/test levels referenced by them is that all information and descriptions
regarding EMC-compliant installation be observed and followed.
In accordance with the EMC product standard, the EMC requirements to be met depend on
the purpose or intended use of the frequency inverter. Four categories are defined in the
EMC product standard:

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Table4: Categories of intended use
Category Definition Limits to EN55011
C1 Frequency inverters with a supply voltage under 1000V installed in the first
environment (residential and office areas).
Class B
C2 Frequency inverters with a supply voltage under 1000V installed in the first
environment (residential and office areas) that are neither ready to be plugged in/
connected nor are mobile and must be installed and commissioned by specialist
personnel.
Class A, Group 1
C3 Frequency inverters with a supply voltage under 1000V installed in the second
environment (industrial environments).
Class A, Group 2
C4 Frequency inverters with a supply voltage over 1000V and a nominal current
over 400A installed in the second environment (industrial environments) or that
are envisaged for use in complex systems.
No borderline/
boundary1)
The following limit values and inspection/test levels must be complied with if the generic
standard on interference emissions applies:
Table5: Classification of installation environment
Environment Generic standard Limits to EN55011
First environment (residential and office areas) EN/IEC61000-6-3
for private, business and commercial
environments
Class B
Second environment (industrial environments) EN/IEC61000-6-4
for industrial environments
Class A, Group 1
The frequency inverter meets the following requirements:
Table6: EMC properties of the frequency inverter
Power
[kW]
Cable length
[m]
Category to EN 61800-3 Limits to EN55011
≤ 11 ≤5 C1 Class B
The EN61800-3 standard requires that the following warning be provided for drive systems
that do not comply with category C1 specifications:
This product can produce high-frequency interference emissions that may necessitate
targeted interference suppression measures in a residential or office environment.
2.10.2 Line harmonics requirements
The product is a device for professional applications as defined by EN 61000-3-2. The
following generic standards apply when establishing a connection to the public power grid:
– EN 61000-3-2
for symmetric, three-phase devices (professional devices with a total power of up to
1kW)
– EN 61000-3-12
for devices with a phase current of between 16A and 75A and professional devices
from 1kW up to a phase current of 16 A.
2.10.3 Interference immunity requirements
In general, the interference immunity requirements for a frequency inverter hinge on the
specific environment in which the inverter is installed.
The requirements for industrial environments are therefore higher than those for residential
and office environments.
The frequency inverter is designed such that the immunity requirements for industrial
environments and, thus, the lower-level requirements for residential and office
environments, are met and fulfilled.
1An EMC plan must be devised.

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The following relevant generic standards are used for the interference immunity test:
– EN 61000-4-2: Electromagnetic compatibility (EMC)
– Part 4-2: Testing and measurement techniques – Electrostatic discharge immunity
test
– EN 61000-4-3: Electromagnetic compatibility (EMC)
– Part 4-3: Testing and measurement techniques – Radiated, radio-frequency,
electromagnetic field immunity test
– EN 61000-4-4: Electromagnetic compatibility (EMC)
– Part 4-4: Testing and measurement techniques – Electrical fast transient/burst
immunity test
– EN 61000-4-5: Electromagnetic compatibility (EMC)
– Part 4-5: Testing and measurement techniques – Surge immunity test
– EN 61000-4-6: Electromagnetic compatibility (EMC)
– Part 4-6: Testing and measurement techniques – Immunity to conducted
disturbances, induced by radio-frequency fields

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3 Transport/Temporary Storage/
Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and notify DP
or the supplying dealer and the insurer about the damage in writing immediately.
3.2 Transport
DANGER
Pressure booster system tipping over
Risk of injury by falling pressure booster system!
ØNever suspend the pressure booster system by its power cable.
ØObserve the applicable local accident prevention regulations.
ØObserve the information on weights, centre of gravity and fastening points.
ØUse suitable and permitted transport equipment, e.g. crane, forklift or pallet
truck.
ØTo transport the pressure booster system, suspend it from the lifting tackle
as illustrated.
üTransport equipment/ lifting equipment suitable for the corresponding weight has been
selected and is on hand.
üIf the control cabinet and pressure booster system need to be lifted separately from
each other: Disconnect the power cables before lifting the pressure booster system/
control cabinet.
1. Remove the packaging. Remove the caps from the connection openings.
2. Check for any in-transit damage.
3. Transport the pressure booster system to the place of installation.
4. Detach the pressure booster system from the pallet using a suitable tool.

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A
A
Fig.1: Lifting the pressure booster system off the pallet
5. Undo the bolts (A) between the pressure booster system and the pallet.
6. Attach lifting equipment to the pressure booster system.
7. Separate the pressure booster system from the wooden skids with a suitable tool. Lift
the pressure booster system off. Dispose of the wooden skids.
8. Carefully place down the pressure booster system at the site of installation.
Example: Lifting the pressure booster system and control cabinet separately
If the control cabinet is too large and cannot be placed on the baseplate of the pressure
booster system, the pressure booster system and control cabinet have to be lifted
separately.

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C
B
Fig.2: Lifting the pressure booster system and control cabinet separately
üBefore lifting the pressure booster system and control cabinet, disconnect the power
cables.
1. Attach lifting beams to the lifting lugs (B) provided at the baseplate.
2. Use an anti-tilting device (C).

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Example: Lifting the pressure booster system and control cabinet together
on one baseplate
C
Fig.3: Lifting the pressure booster system and control cabinet together on one baseplate
1. Use an anti-tilting device (C).
3.3 Storage/preservation
CAUTION
Damage during storage due to frost, moisture, dirt, UV radiation or
vermin
Corrosion/contamination of pressure booster system!
ØStore 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!
ØOnly open the openings of the pressure booster system at the time of
installation.
If commissioning is to take place some time after delivery, we recommend that the following
measures be taken :

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Store the pressure booster system in a dry, protected room where the atmospheric humidity
is as constant as possible.
Table7: Ambient conditions for storage
Ambient condition Value
Relative humidity 50% maximum
Ambient temperature 0°C to +40°C
– Frost-free
– Well-ventilated
3.4 Return to supplier
1. Drain the 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 anhydrous inert
gas must be blown through the pressure booster system to ensure drying.
4. Always complete and enclose a certificate of decontamination when returning the
pressure booster system. [ðSection12,Page63]
Always 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.dp-pumps.com/certificates-of-decontamination
3.5 Disposal
WARNING
Fluids handled, consumables and supplies which are hot and/or pose a
health hazard
Hazard to persons and the environment!
ØCollect and properly dispose of flushing fluid and any fluid residues.
ØWear safety clothing and a protective mask if required.
ØObserve 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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Electrical or electronic equipment marked with the adjacent symbol must not be disposed of
in household waste at the end of its service life.
Contact your local waste disposal partner for returns.
If the used electrical or electronic equipment contains personal data, the operator is
responsible for deleting it before the equipment is returned.

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4 Description
4.1 General description
– Pressure booster system
4.2 Product information as per Regulation No. 1907/2006(REACH)
For information as per chemicals Regulation (EC) No. 1907/2006 (REACH), see http://
www.dp.nl/reach.
4.3 Designation
Example: HU3 Utility Line DPV15 /8 B SVP
Table8: Designation key
Code Description
Utility Line Type series
HU3 Number of pumps
DPV 15 Pump size
8 B Number of pump stages
SVP Design
F Fixed speed pressure booster system
VC Variable speed pressure booster system with Megacontrol pump control
system, frequency inverter in the control cabinet
SVP Variable speed pressure booster system with Megacontrol pump control
system, frequency inverter mounted on the (IE5) motor
4.4 Name plate
ID PN
Prod. IP
RDP PO
UKalkovenweg 13
FAlphen a/d Rijn, NL
Imax www.dp-pumps.com
Made in NL
HU3 Utility Line DPV15/8 B SVP
M
SDAUL30150805SMD
56.1A
50 Hz
3x400V
PT
10/2019 1234567=01
123456789
54
16
1
15
14
13
7
12
11
10
9
8
2 43
6
5
Fig.4: Name plate (example)
1 Number of pumps 9 Dry running protection
2 Type series 10 Power supply voltage
3 Size 11 Power supply frequency
4 Number of pump stages 12 Maximum current input
5 Design 13 Max. operating pressure