KSB Hya-Solo DV Installation instructions

Pressure Booster System
Hya-Solo DV
From series 2014w33
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual Hya-Solo DV
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 Aktiengesellschaft, Frankenthal 26.03.2015

Contents
Glossary .................................................................................................5
1 General ..................................................................................................6
1.1 Principles ........................................................................................................... 6
1.2 Installation of partly completed machinery .................................................... 6
1.3 Target group ..................................................................................................... 6
1.4 Other applicable documents ............................................................................ 6
1.5 Symbols ............................................................................................................. 6
2 Safety .....................................................................................................7
2.1 Key to safety symbols/markings ....................................................................... 7
3 Software Changes .................................................................................8
4 Transport/Temporary Storage/Disposal ...............................................9
4.1 Checking the condition upon delivery ............................................................ 9
4.2 Transport ........................................................................................................... 9
4.3 Storage/preservation ........................................................................................ 9
4.4 Return to supplier .......................................................................................... 10
4.5 Disposal ........................................................................................................... 10
5 Description ..........................................................................................11
5.1 General description ........................................................................................ 11
5.2 Designation ..................................................................................................... 11
5.3 Name plate ...................................................................................................... 11
5.4 Design details .................................................................................................. 11
5.5 Configuration and function ........................................................................... 12
5.6 Noise characteristics ....................................................................................... 13
5.7 Scope of supply ............................................................................................... 13
5.8 Dimensions and weights ................................................................................ 13
5.9 Terminal wiring diagram ............................................................................... 13
6 Installation at Site ...............................................................................19
6.1 Installation to DIN 1988 ................................................................................. 19
6.2 Checks to be carried out prior to installation ............................................... 19
6.3 Installing the pressure booster system .......................................................... 19
6.4 Installing the piping ....................................................................................... 20
6.5 Installing unpressurised inlet tanks ............................................................... 21
6.6 Fitting the dry running protection device .................................................... 22
6.7 Connection to power supply .......................................................................... 22
7 Commissioning/Start-up/Shutdown ...................................................24
7.1 Commissioning/start-up ................................................................................. 24
7.2 Switching on the pressure booster system .................................................... 25
7.3 Check list for commissioning/start-up ........................................................... 25
Contents
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7.4 Shutdown ........................................................................................................ 26
8 Operating the Pressure Booster System ............................................27
8.1 Control panel functions ................................................................................. 27
8.2 Menu structure ............................................................................................... 30
8.3 Access levels .................................................................................................... 31
8.4 Displaying and changing parameters ............................................................ 31
8.5 Monitoring ...................................................................................................... 32
8.6 Description of parameters ............................................................................. 33
8.7 Adjusting the settings .................................................................................... 34
9 Servicing/Maintenance .......................................................................41
9.1 General information/Safety regulations ....................................................... 41
9.2 Servicing/inspection ........................................................................................ 42
10 Trouble-shooting ................................................................................44
10.1 Hya-Solo DV .................................................................................................... 44
10.2 PumpDrive ....................................................................................................... 45
11 Related Documents ............................................................................47
11.1 List of components ......................................................................................... 47
12 EC Declaration of Conformity ............................................................49
13 Certificate of Decontamination .........................................................50
14 Commissioning Report .......................................................................51
Index ....................................................................................................52
Contents
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Glossary
Accumulator
The accumulator serves to compensate for pres-
sure losses in the piping system downstream of
the pressure booster system which may be
caused by the consumption of small quantities
of water. As a result, the frequency of starts of
the pressure booster system is minimised.
Automatic mode
The pump is started as a function of pressure
and stopped as a function of flow.
Certificate of decontamination
A certificate of decontamination is enclosed by
the customer when returning the product to
the manufacturer to certify that the product
has been properly drained to eliminate any en-
vironmental 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 dam-
age.
Manual mode
In manual mode, the pressure booster system is
operated directly on mains power, independ-
ently of the control unit.
Glossary
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1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover. The manual describes the proper and safe use of this
equipment in all phases of operation.
The name plate indicates the type series/size, the main operating data and the order
number. The series/serial number uniquely identifies the pressure booster system and
serves as identification for all further business processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
Noise characteristics see (⇨ Section 5.6 Page 13)
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.
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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2 Safety
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 3: Definition of safety symbols/markings
Symbol Description
!DANGER
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 avoi-
ded, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could re-
sult 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.
!DANGER
2 Safety
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3 Software Changes
The software has been specially created for this product and thoroughly tested.
It is impermissible to make any changes or additions to the software or parts of the
software. Software updates supplied by KSB are excluded from this rule.
3 Software Changes
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4 Transport/Temporary Storage/Disposal
4.1 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 no-
tify KSB or the supplying dealer (as applicable) and the insurer about the dam-
age in writing immediately.
4.2 Transport
NOTE
The pressure booster system is bolted to a pallet and wrapped in plastic foil for
shipping and temporary storage. All connecting points are capped.
DANGER
Pressure booster system tipping over
Risk of injury by falling pressure booster system!
▷Never suspend the pressure booster system by its power cable.
▷Observe the applicable local accident prevention regulations.
▷Pay attention to the weight data and the centre of gravity.
▷Use suitable and permitted transporting equipment, e.g. crane, forklift or ele-
vating platform truck.
▷Attach the pressure booster system to crane lifting tackle as shown, or use a
forklift or pallet truck to move the pallet.
Fig. 1: Transporting the pressure booster system
✓The pressure booster system has been checked for in-transit damage.
1. Make sure the transport equipment is suitable for safely carrying the indicated
load.
2. Transport the pressure booster system to the place of installation.
3. Attach the pressure booster system to the lifting tackle as shown, lift it off the
pallet and dispose of the pallet.
4. Use suitable lifting equipment to lift the pressure booster system and carefully
put it down at the place of installation.
4.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken when storing the pressure booster system:
4 Transport/Temporary Storage/Disposal
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CAUTION
Damage during storage by 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 installa-
tion.
Store the pressure booster system in a dry, protected room where the atmospheric
humidity is as constant as possible.
4.4 Return to supplier
1. Drain the pressure booster system as per operating instructions.
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 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. (⇨ Section 13 Page 50)
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.ksb.com/certificate_of_decontamination
4.5 Disposal
WARNING
Fluids, 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 residues of the fluid han-
dled.
▷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 control-
led manner.
4 Transport/Temporary Storage/Disposal
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