KSB Hya-Rain Installation instructions

Rainwater Harvesting System
Hya-Rain/Hya-Rain N
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual Hya-Rain/Hya-Rain N
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 21/01/2019

Contents
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Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Target group.....................................................................................................................................................6
1.3 Other applicable documents............................................................................................................................6
1.4 Symbols .............................................................................................................................................................6
1.5 Key to safety symbols/markings.......................................................................................................................7
2 Safety...................................................................................................................................................... 8
2.1 General..............................................................................................................................................................8
2.2 Intended use .....................................................................................................................................................8
2.3 Personnel qualification and training...............................................................................................................9
2.4 Consequences and risks caused by non-compliance with these operating instructions ..............................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..................................................................................................................9
3 Transport/Temporary 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 Designation.....................................................................................................................................................14
4.3 Name plate......................................................................................................................................................14
4.4 Design details..................................................................................................................................................15
4.5 Configuration and function...........................................................................................................................16
4.6 Noise characteristics .......................................................................................................................................17
4.7 Scope of supply...............................................................................................................................................17
4.8 Dimensions and weights ................................................................................................................................17
5 Installation at Site................................................................................................................................ 18
5.1 Safety regulations...........................................................................................................................................18
5.2 Checks to be carried out prior to installation...............................................................................................18
5.3 Setting up and installing the system.............................................................................................................18
5.4 Connecting the piping ...................................................................................................................................19
5.4.1 Connecting the mains water inlet ....................................................................................................19
5.4.2 Connecting the inlet line...................................................................................................................20
5.4.3 Connecting the discharge line ..........................................................................................................20
5.4.4 Connecting the overflow...................................................................................................................21
5.5 Electrical connection ......................................................................................................................................22
5.5.1 Connecting the float switch ..............................................................................................................22
5.5.2 Connecting the level control system.................................................................................................24
5.5.3 Connecting a booster pump (optional) ............................................................................................25
5.5.4 Connecting the system ......................................................................................................................27
6 Commissioning/Start-up/Shutdown................................................................................................... 28
6.1 Commissioning/Start-up.................................................................................................................................28
6.1.1 Prerequisites for commissioning/start-up .........................................................................................28
6.1.2 Priming and venting the system .......................................................................................................28
6.1.3 Start-up...............................................................................................................................................29
6.1.4 Functional test....................................................................................................................................29
6.2 Operating limits..............................................................................................................................................30

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6.2.1 Ambient conditions ...........................................................................................................................30
6.2.2 Maximum operating pressure ...........................................................................................................30
6.2.3 Fluid handled .....................................................................................................................................30
6.3 Shutdown/storage/preservation ....................................................................................................................31
6.3.1 Measures to be taken for shutdown ................................................................................................31
6.3.2 Stopping the system ..........................................................................................................................31
7 Operation.............................................................................................................................................. 32
7.1 Control panel..................................................................................................................................................32
7.2 Mode of operation.........................................................................................................................................33
7.2.1 Automatic mode ................................................................................................................................33
7.2.2 Mains water mode (manual mode) ..................................................................................................33
7.2.3 Rainwater mode (manual mode) ......................................................................................................33
7.2.4 Priming ...............................................................................................................................................34
7.3 Level control system (Hya-Rain N only).........................................................................................................35
7.3.1 Calibrating the level control system/ setting the rainwater storage tank design ........................36
7.3.2 Setting the switching level for the rainwater storage tank............................................................37
7.3.3 Setting and displaying the rainwater storage tank water replacement ........................................38
7.3.4 Setting the valve switchover .............................................................................................................39
8 Servicing/Maintenance........................................................................................................................ 40
8.1 General information/safety regulations........................................................................................................40
8.2 Maintenance/inspection.................................................................................................................................41
8.2.1 Replacing the stored mains water ...................................................................................................41
8.2.2 Checking the mains water mode ......................................................................................................41
8.2.3 Checking the pump control unit.......................................................................................................42
8.2.4 Checking the discharge lines.............................................................................................................42
8.3 Drainage/cleaning ..........................................................................................................................................42
8.4 Dismantling the system..................................................................................................................................42
8.4.1 Removing the pump set from the piping.........................................................................................42
8.4.2 Removing the pump control unit .....................................................................................................44
8.4.3 Removing the mechanical seal..........................................................................................................46
8.5 Reassembling the system ...............................................................................................................................47
8.5.1 Installing the mechanical seal ...........................................................................................................47
8.5.2 Installing the pump control unit.......................................................................................................48
8.5.3 Installing the pump set......................................................................................................................49
9 Trouble-shooting.................................................................................................................................. 51
10 Related Documents.............................................................................................................................. 53
10.1 General assembly drawing with list of components ....................................................................................53
10.2 Exploded view with list of components (pump)...........................................................................................54
10.3 Dimensions and connections .........................................................................................................................56
10.3.1 Hya-Rain / Hya-Rain N........................................................................................................................56
10.3.2 Connections........................................................................................................................................57
10.4 Drilling pattern for wall mounting ...............................................................................................................57
10.5 Wiring diagrams .............................................................................................................................................58
10.5.1 Hya-Rain .............................................................................................................................................58
10.5.2 Hya-Rain N..........................................................................................................................................59
11 EU Declaration of Conformity............................................................................................................. 61
12 Certificate of Decontamination........................................................................................................... 62
Index ..................................................................................................................................................... 63

Glossary
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Glossary
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.
Rainwater storage tank
Tank for collecting rainwater, for buried
installation or above-floor installation

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 centre to
maintain the right to claim under warranty.
1.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (ðSection2.3,Page9)
1.3 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
1.4 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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1.5 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:
– Arrow indicating the direction of rotation
– Markings for connections
– Type designation
▪The operator is responsible for ensuring compliance with all local regulations not
taken into account.
2.2 Intended use
▪The system must only be operated within the operating limits described in the
other applicable documents.
▪Only operate systems which are in perfect technical condition.
▪Do not operate partially assembled systems.
▪The system may only handle the fluids described in the product literature of the
relevant design variant.
▪Never operate the 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 system.
▪Consult the manufacturer about any other modes of operation not described in
the product literature.
Prevention of foreseeable misuse
▪Never exceed the permissible application and operating limits specified in the
product literature regarding pressure, temperature, etc.
▪Observe all safety information and instructions in this manual.

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2.3 Personnel qualification and training
All personnel involved must be fully qualified to install, operate, maintain and
inspect the equipment 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 at the system must always be supervised by the technical specialist
personnel.
2.4 Consequences and risks caused by non-compliance with these operating
instructions
▪Non-compliance with this operating manual 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:
– Hazard to persons by electrical, thermal and mechanical effects
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
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
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws
2.6 Safety information for the operator/user
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
2.7 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the pump (set) are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts/components authorised by the
manufacturer. The use of other parts/components 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.
▪Only carry out work on the system during standstill, with the system de-energised
and secured against unintentional start-up.
▪When taking the system out of service always adhere to the procedure described
in the manual.
▪As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ðSection6.1,Page28)
▪Make sure the system cannot be accessed by unauthorised persons (e.g. children).
2.8 Unauthorised modes of operation
Always observe the limits stated in the product literature.

2 Safety
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The warranty relating to the operating reliability and safety of the system supplied is
only valid if the system is used in accordance with its intended use.