KSB Hya-Solo D Installation instructions

Pressure Booster System
Hya-Solo D
From Series 2021w39
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual Hya-Solo D
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 04/01/2022

Contents
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Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Installation of partly completed machinery....................................................................................................6
1.3 Target group.....................................................................................................................................................6
1.4 Other applicable documents............................................................................................................................6
1.5 Symbols .............................................................................................................................................................6
1.6 Key to safety symbols/markings.......................................................................................................................7
2 Safety...................................................................................................................................................... 8
2.1 General..............................................................................................................................................................8
2.2 Intended use .....................................................................................................................................................8
2.3 Personnel qualification and personnel training.............................................................................................8
2.4 Consequences and risks caused by non-compliance with this manual .........................................................9
2.5 Safety awareness ..............................................................................................................................................9
2.6 Safety information for the operator/user.......................................................................................................9
2.7 Safety information for maintenance, inspection and installation ................................................................9
2.8 Unauthorised modes of operation................................................................................................................10
3 Transport/Storage/Disposal ................................................................................................................ 11
3.1 Checking the condition upon delivery..........................................................................................................11
3.2 Transport.........................................................................................................................................................11
3.3 Storage/preservation......................................................................................................................................12
3.4 Return to supplier ..........................................................................................................................................12
3.5 Disposal ...........................................................................................................................................................13
4 Description............................................................................................................................................ 14
4.1 General description ........................................................................................................................................14
4.2 Product information as per Regulation No. 1907/2006(REACH).................................................................14
4.3 Designation.....................................................................................................................................................14
4.4 Name plate......................................................................................................................................................14
4.5 Design details..................................................................................................................................................15
4.6 Configuration and function...........................................................................................................................16
4.7 Noise characteristics .......................................................................................................................................17
4.8 Scope of supply...............................................................................................................................................17
4.9 Dimensions and weights ................................................................................................................................17
5 Installation at Site................................................................................................................................ 18
5.1 Checks to be carried out prior to installation...............................................................................................18
5.2 Installing the pressure booster system..........................................................................................................19
5.3 Mounting the accumulator............................................................................................................................20
5.4 Connecting the piping ...................................................................................................................................20
5.4.1 Fitting an expansion joint (optional)................................................................................................21
5.4.2 Fitting the pressure reducer (optional) ............................................................................................21
5.5 Electrical connection ......................................................................................................................................22
5.5.1 Sizing the power cable ......................................................................................................................23
5.5.2 Connecting the pressure booster system..........................................................................................23
5.5.3 Connecting the dry running protection device................................................................................23
6 Commissioning/Start-up/Shutdown................................................................................................... 24
6.1 Commissioning/Start-up.................................................................................................................................24
6.1.1 Prerequisites for commissioning/start-up .........................................................................................24
6.1.2 Priming and venting the pressure booster system...........................................................................24
6.1.3 Setting the dry running protection device.......................................................................................25
6.1.4 Start-up...............................................................................................................................................26
6.1.5 Checklist for commissioning/start-up................................................................................................26

Contents
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6.2 Operating limits..............................................................................................................................................27
6.2.1 Frequency of starts.............................................................................................................................27
6.2.2 Ambient conditions ...........................................................................................................................27
6.2.3 Maximum operating pressure ...........................................................................................................27
6.2.4 Fluid handled .....................................................................................................................................28
6.2.5 Minimum flow rate............................................................................................................................28
6.3 Shutdown........................................................................................................................................................29
6.3.1 Shutdown ...........................................................................................................................................29
6.3.2 Measures to be taken for shutdown ................................................................................................29
7 Operation.............................................................................................................................................. 30
7.1 LED display......................................................................................................................................................30
7.2 Operating modes............................................................................................................................................30
7.2.1 Manual mode .....................................................................................................................................30
7.2.2 Functional check run..........................................................................................................................30
7.3 Functions.........................................................................................................................................................30
7.3.1 Dry running protection......................................................................................................................30
8 Servicing/Maintenance........................................................................................................................ 31
8.1 General information/safety regulations........................................................................................................31
8.2 Inspection contract.........................................................................................................................................31
8.3 Servicing/Inspection........................................................................................................................................32
8.3.1 Supervision of operation ...................................................................................................................32
8.3.2 Maintenance schedule.......................................................................................................................32
8.4 Setting the pre-charge pressure ....................................................................................................................33
9 Trouble-shooting.................................................................................................................................. 34
10 Related Documents.............................................................................................................................. 36
10.1 List of components .........................................................................................................................................36
10.1.1 Hya-SoloD with Movitec 2, 4, 6, 10, 15 ............................................................................................36
10.1.2 Hya-SoloD with Movitec 25, 40, 60, 90 ............................................................................................37
11 EU Declaration of Conformity............................................................................................................. 38
12 Certificate of Decontamination........................................................................................................... 39
13 Commissioning Report......................................................................................................................... 40
Index ..................................................................................................................................................... 41

Glossary
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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)
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.

1 General
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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 KSB service facility to
maintain the right to claim under warranty.
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB refer to the sub-sections under
Servicing/Maintenance.
1.3 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (ðSection2.3,Page8)
1.4 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Sub-supplier product literature Operating manuals, logic diagram and other
product literature of accessories and integrated
machinery components
1.5 Symbols
Table2: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product

1 General
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1.6 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.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EU Directive
2014/34/EU (ATEX).
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 Safety
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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.
2.1 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:
– Flow direction arrow
– Markings for connections
– Name plate
▪The operator is responsible for ensuring compliance with all local regulations not
taken into account.
2.2 Intended use
▪The pressure booster system must only be operated within the operating limits
described in the other applicable documents.
▪Only operate pressure booster systems which are in perfect technical condition.
▪Do not operate partially assembled pressure booster systems.
▪The pressure booster system must only handle the fluids described in the product
literature of the respective design variant.
▪Never operate the pressure booster system without the fluid to be handled.
▪Observe the information on minimum flow rates specified in the product
literature (to prevent overheating, bearing damage, etc).
▪Observe the 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.
2.3 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 Safety
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2.4 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
2.5 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
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws
2.6 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.
2.7 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the pressure booster system are only permitted
with the manufacturer's prior consent.
▪Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪The operator ensures that maintenance, inspection and installation 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 Safety
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2.8 Unauthorised modes of operation
Always observe the limits stated in the product literature.
The warranty relating to the operating reliability and safety of the pressure booster
system supplied is only valid if the equipment is used in accordance with its intended
use. (ðSection2.2,Page8)