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)

3 Transport/Storage/Disposal
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3 Transport/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 KSB 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!
▷Never suspend the pressure booster system by its cable.
▷Observe the applicable local accident prevention regulations.
▷Observe the information on weights, centre of gravity and fastening points.
▷Use suitable and permitted transport equipment, e.g. crane, forklift or pallet
truck.
▷To transport the pressure booster system, suspend it from the lifting tackle as
illustrated.
▷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
üTransport equipment/lifting equipment suitable for the corresponding weight
has been selected and is available.
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.
5. Attach the pressure booster system to the lifting equipment as illustrated.
6. Separate the pressure booster system from the wooden skids with a suitable
tool. Lift the pressure booster system off. Dispose of the wooden skids.
7. Carefully place down the pressure booster system at the place of installation.

3 Transport/Storage/Disposal
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3.3 Storage/preservation
CAUTION
Damage during storage due to frost, moisture, dirt, UV radiation or vermin
Corrosion/contamination of pressure booster system!
▷Store the pressure booster system in a frost-proof room. Do not store outdoors.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage of the pressure booster system!
▷Only open the openings of the pressure booster system at the time of
installation.
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken:
Store the pressure booster system in a dry, protected room where the atmospheric
humidity is as constant as possible.
Table4: 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
treated with anhydrous inert gas to ensure drying.
4. Always complete and enclose a certificate of decontamination when returning
the pressure booster system. (ðSection12,Page39)
Always indicate any safety and decontamination measures taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the
following web site: www.ksb.com/certificate_of_decontamination

3 Transport/Storage/Disposal
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3.5 Disposal
WARNING
Fluids handled, consumables and supplies which are hot and/or pose a health
hazard
Hazard to persons and the environment!
▷Collect and properly dispose of flushing fluid and any 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.
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.

4 Description
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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 https://
www.ksb.com/ksb-en/About-KSB/Corporate-responsibility/reach/ .
4.3 Designation
Example: Hya-Solo D 1 / 0405 / 2 B
Table5: Designation key
Code Description
Hya-Solo Type series
D Three-phase current
1 Number of pumps
04 Pump size
05 Number of stages
2 Inlet pressure [bar]
B Design status
4.4 Name plate
Auftrags-Nr.:
93w1202.rN-neireS:noitisoP6040/1 B/D oloS ayH
Förderstrom 4,0 m3/h Druckbehälter: Motorleistung P2 1 x 1,10 kW
Einschaltdruck (pE) 3,4 bar Vorpreßdruck 3,1 bar Betriebsspannung / Frequenz 400V 50 HZ Hz
Ausschaltdruck (pA) 4,8 bar Inhalt Bruttovolumen 8,0 Liter Steuerspannung / Frequenz 230 V 50HZ Hz
mortsnnenrotoMm3,43ehöhredröF 2,4 A
:.rN nalptlahcSm4,250=Q ieb ehöhredröF BD 706 990
Vordruck 0,0 bar
Betriebsdruck max. 16,0 bar
Ident Nr: xx xxx xxx Vor Inbetriebnahme Betriebsanleitung beachten ! ZNI 1448J
200
9972XXXXXX
6
4
8
7
12
3
5
9
10
11
12
13
14
15
16
17
18
19
Made in Germany
Fig.2: Name plate (example)
1 Type series, size 11 Gross vol. content
2 Order number 12 Accumulator
3 Order item number 13 Maximum operating pressure
4 Year/ calender week of construction 14 Inlet pressure
5 Motor power P2 15 Head at Q=0
6 Operating voltage, frequency 16 Maximum head
7 Control voltage, frequency 17 Stop pressure
8 Nominal motor current 18 Start-up pressure
9 Wiring diagram number 19 Maximum flow rate
10 Pre-charge pressure

4 Description
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4.5 Design details
Design
▪Fully automatic pressure booster package system
▪Discharge-side, direct-flow membrane-type accumulator, approved for drinking
water
▪Pressure gauge
Installation
▪Stationary dry installation
Drive
▪Three-phase asynchronous squirrel-cage motor
▪Efficiency class IE3 to IEC60034-30
▪220 – 240V/ 380 – 420V, 380 – 420V/ 660 – 720V
▪Enclosure IP55
▪Thermal class F
▪DOL starting up to and including 4kW
▪Star-delta starting ≥ 5.5kW
Automation
▪Control unit for pressure-controlled starting and stopping
▪Control unit (IP54 enclosure)
▪LEDs indicate faults and lack of water
▪Motor protection switch
▪Manual-0-automatic selector switch
▪Timer for 24-hour functional check run
▪Terminal strip with markings for all connections
▪Volt-free contacts for operation, fault, lack of water
▪Lockable master switch (repair switch)

4 Description
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4.6 Configuration and function
1
5
2
3
6
4
Fig.3: Illustration of the pressure booster system
1 Pump 4 Pressure gauge
2 Accumulator 5 Control unit
3 Check valve 6 Shut-off valve
Design 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 in the set pressure range.
Function The pump set is started and stopped as a function of pressure via the electro-
mechanical control system. If the pressure drops below the set start-up pressure pE ,
the pump is started up via the pressure switch. When consumption decreases again,
the pump set is stopped as a function of pressure after the set after-run period (up to
3minutes). The integrated dry running protection is enabled in manual mode and
automatic mode. In the event of dry running the pressure booster system stops after
approx.10seconds (factory setting).

4 Description
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4.7 Noise characteristics
For the noise characteristics refer to the operating manual of the pump (set).
4.8 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪Pressure booster system
– 1 vertical Movitec high-pressure centrifugal pump
– Discharge-side piping
– Check valve
– Shut-off valves
– Discharge-side, direct-flow membrane-type accumulator
– Pressure switch on the discharge side
– Pressure gauge
– Vibration damping
▪Control unit
– Power supply connection
– Motor protection switch
– Manual-0-automatic selector switch
– Terminal strip with markings for all connections
– Volt-free contacts for operation, fault, lack of water
– Colour LED indicating lack of water (red)
– Colour LED indicating a fault (amber)
4.9 Dimensions and weights
For dimensions and weights refer to the outline drawing.

5 Installation at Site
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5 Installation at Site
5.1 Checks to be carried out prior to installation
WARNING
Installation on mounting surfaces which are unsecured and cannot support the
load
Personal injury and damage to property!
▷Use a concrete of compressive strength class C12/15 which meets the
requirements of exposure class X0 to EN206-1.
▷The mounting surface must have set and must be completely horizontal and
even.
▷Observe the weights indicated.
NOTE
The anti-vibration mounts provide adequate insulation against solid-borne noise.
NOTE
Do not operate the pressure booster system near living quarters and/or sleeping
quarters.
Before beginning with the installation check the following:
▪All structural work required has been checked and prepared in accordance with
the dimensions in the outline drawing.
▪The data on the name plate of the pressure booster system has been checked.
The pressure booster system must be suitable for operation on the available
power supply network.
▪The place of installation is frost-free.
▪The place of installation can be locked.
▪The place of installation is well-ventilated.
▪A suitably dimensioned drain connection (e.g. leading to a sewer) is available.
▪If expansion joints are used, take note of their creep resistance. Expansion joints
must be easily replaceable.

5 Installation at Site
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5.2 Installing the pressure booster system
WARNING
Top-heavy pressure booster system
Risk of personal injury by pressure booster system tipping over!
▷Pressure booster systems awaiting final installation must be secured against
tipping over.
▷Firmly anchor the pressure booster system.
NOTE
To prevent the transmission of piping forces and solid-borne noise, installing
expansion joints with length-limiters is recommended.
üThe pressure booster system’s packaging has been removed.
üA suitable installation site has been selected that meets the requirements.
üSufficient clearance in all directions is provided for servicing work.
1. Mark out the anchoring holes on the floor as shown in the outline drawing.
2. Drill the holes (max. diameter: 12mm).
3. Insert plug fixings of appropriate size.
4. Place the pressure booster system in its correct installation position.
5. Use suitable bolts to firmly anchor the pressure booster system.

5 Installation at Site
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5.3 Mounting the accumulator
CAUTION
Dirt in the pressure booster system
Damage to the pump sets!
▷Clean the accumulator before filling it.
üThe original operating manual of the pressure booster system is on hand.
1. Mechanically and electrically connect the accumulator in accordance with the
original operating manual supplied.
5.4 Connecting the piping
CAUTION
Air pockets in suction line
Pressure booster system cannot prime!
▷Lay the pipe with a continuously rising slope.
1952:116
1
Fig.4: Correct piping connection
1 Suction lift operation
1. Mechanically support the suction head line on site to provide for absorption of
mechanical forces.
2. Install the piping without transmitting any stresses and strains.
3. Connect the piping to the distribution lines on the inlet side and discharge side.