Hya-Compact Pressure Booster System€¦ · Training on the pressure booster system must always be...

Pressure Booster System

Hya-Compact

Installation/Operating Manual

Legal information/Copyright

Installation/Operating Manual Hya-Compact

Original operating manual

All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited orprocessed for any other purpose, nor otherwise transmitted, published or made available to a third party withoutthe manufacturer's express written consent.

Subject to technical modification without prior notice.

© KSB Aktiengesellschaft, Frankenthal 02.04.2015

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

2.2 General .............................................................................................................. 7

2.3 Intended use ..................................................................................................... 7

2.4 Personnel qualification and training ............................................................... 8

2.5 Consequences and risks caused by non-compliance with this manual ......... 8

2.6 Safety awareness .............................................................................................. 8

2.7 Safety information for the operator/user ....................................................... 8

2.8 Safety information for maintenance, inspection and installation work ....... 9

2.9 Unauthorised modes of operation .................................................................. 9

3 Software Changes ...............................................................................10

4 Transport/Temporary Storage/Disposal .............................................11

4.1 Checking the condition upon delivery .......................................................... 11

4.2 Transport ......................................................................................................... 11

4.3 Storage/preservation ...................................................................................... 11

4.4 Return to supplier .......................................................................................... 11

4.5 Disposal ........................................................................................................... 12

5 Description ..........................................................................................13

5.1 General description ........................................................................................ 13

5.2 Designation ..................................................................................................... 13

5.3 Name plate ...................................................................................................... 13

5.4 Design details .................................................................................................. 13

5.5 Configuration and function ........................................................................... 14

5.6 Noise characteristics ....................................................................................... 16

5.7 Scope of supply ............................................................................................... 16

5.8 Dimensions and weights ................................................................................ 16

5.9 Terminal wiring diagram ............................................................................... 16

6 Installation at Site ...............................................................................17

6.1 General instructions for installation .............................................................. 17

6.2 Checks to be carried out prior to installation ............................................... 17

6.3 Installing the pressure booster system .......................................................... 17

Contents

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6.4 Installing the piping ....................................................................................... 18

6.5 Connection to power supply .......................................................................... 19

7 Commissioning/Start-up/Shutdown ...................................................21

7.1 Commissioning/start-up ................................................................................. 21

7.2 Shutdown ........................................................................................................ 23

8 Control panel ......................................................................................24

8.1 Control panel .................................................................................................. 24

8.2 Menu structure ............................................................................................... 26

8.3 Access levels .................................................................................................... 27

8.4 Displaying and changing parameters ............................................................ 28

8.5 Displaying messages ....................................................................................... 29

8.6 Parameter list .................................................................................................. 30

8.7 Quick menu ..................................................................................................... 51

8.8 Saving and restoring settings ........................................................................ 51

8.9 Fault messages ................................................................................................ 51

8.10 Energy-saving mode ....................................................................................... 54

8.11 Flow detection ................................................................................................ 54

8.12 Connecting the ambient temperature monitoring device (option) ............ 55

8.13 Digital inputs for remote reset, setpoint changeover and check run (option).......................................................................................................................... 55

9 Servicing/Maintenance .......................................................................56

9.1 General information/Safety regulations ....................................................... 56

9.2 Servicing/inspection ........................................................................................ 57

10 Trouble-shooting ................................................................................59

11 Related Documents ............................................................................61

11.1 Dimensions ...................................................................................................... 61

11.2 General arrangement drawings .................................................................... 62

12 EC Declaration of Conformity ............................................................64

13 Certificate of Decontamination .........................................................65

14 Commissioning Report .......................................................................66

Index ....................................................................................................67

Contents

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Glossary

Accumulator

The accumulator serves to compensate forpressure losses in the piping systemdownstream of the pressure booster systemwhich may be caused by the consumption ofsmall quantities of water. As a result, thefrequency of starts of the pressure boostersystem is minimised.

Certificate of decontamination

A certificate of decontamination is enclosed bythe customer when returning the product tothe manufacturer to certify that the producthas been properly drained to eliminate anyenvironmental and health hazards arising fromcomponents in contact with the fluid handled.

Dry running protection

Dry running protection devices prevent thepump from being operated without the fluid tobe handled, which would result in pumpdamage.

Energy-saving mode

Setting designed to avoid the energeticallyinefficient operation of a pump at minimumwater consumption.

Manual mode

In manual mode, the pressure booster system isoperated directly on mains power,independently 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 variantsindicated on the front cover. The manual describes the proper and safe use of thisequipment in all phases of operation.

The name plate indicates the type series/size, the main operating data and the ordernumber. The series/serial number uniquely identifies the pressure booster system andserves as identification for all further business processes.

In the event of damage, immediately contact your nearest KSB service centre tomaintain the right to claim under warranty. Noise characteristics see (⇨ Section 5.6 Page 16)

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB refer to the sub-sections underServicing/Maintenance.

1.3 Target group

This operating manual is aimed at the target group of trained and qualified specialisttechnical personnel. (⇨ Section 2.4 Page 8)

1.4 Other applicable documents

Table 1: Overview of other applicable documents

Document ContentsSub-supplier product literature Operating manuals and other product literature

describing accessories and integrated machinerycomponents

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-references1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General

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2 SafetyAll 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 DANGERThis signal word indicates a high-risk hazard which, if not avoided,will result in death or serious injury.

! WARNING WARNINGThis signal word indicates a medium-risk hazard which, if notavoided, could result in death or serious injury.

CAUTION CAUTIONThis signal word indicates a hazard which, if not avoided, couldresult in damage to the machine and its functions.General hazardIn conjunction with one of the signal words this symbol indicates ahazard which will or could result in death or serious injury.

Electrical hazardIn conjunction with one of the signal words this symbol indicates ahazard involving electrical voltage and identifies information aboutprotection against electrical voltage.Machine damage In conjunction with the signal word CAUTION this symbol indicatesa hazard for the machine and its functions.

2.2 General

This manual contains general installation, operating and maintenance instructionsthat must be observed to ensure safe operation of the pressure booster system andprevent personal injury and damage to property.

The safety information in all sections of this manual must be complied with.

This manual must be read and completely understood by the responsible specialistpersonnel/operators prior to installation and commissioning.

The contents of this manual must be available to the specialist personnel at the siteat all times.

Information attached directly to the pressure booster system must always becomplied with and be kept in a perfectly legible condition at all times. This appliesto, for example:

▪ Arrow indicating the direction of rotation

▪ Markings for connections

▪ Name plate

The operator is responsible for ensuring compliance with all local regulations whichare not taken into account in this manual.

2.3 Intended use

▪ The pressure booster system must only be operated within the operating limitsdescribed 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 productliterature of the respective design variant.

▪ Never operate the pressure booster system without the fluid to be handled.

! DANGER

2 Safety

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▪ Observe the information on minimum flow rates specified in the productliterature (to prevent overheating, bearing damage, etc).

▪ Observe the information on maximum flow rates specified in the productliterature (to prevent overheating, mechanical seal damage, 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 inthe product literature.

Prevention of foreseeable misuse

▪ Never exceed the permissible operating limits (pressure, temperature, etc.)specified in the product literature.

▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to install, operate, maintain andinspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved ininstallation, operation, maintenance and inspection must be clearly defined by theoperator.

Deficits in knowledge must be rectified by means of training and instructionprovided by sufficiently trained specialist personnel. If required, the operator cancommission the manufacturer/supplier to train the personnel.

Training on the pressure booster system must always be supervised by technicalspecialist personnel.

2.5 Consequences and risks caused by non-compliance with this manual

▪ Non-compliance with this operating manual will lead to forfeiture of warrantycover 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 chemicaleffects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

In addition to the safety information contained in this manual and the intended use,the following safety regulations shall be complied with:

▪ Accident prevention, health and safety regulations

▪ Explosion protection regulations

▪ Safety regulations for handling hazardous substances

▪ Applicable standards, directives and laws

2.7 Safety information for the operator/user

▪ The operator shall fit contact guards for hot, cold and moving parts and checkthat the guards function properly.

▪ Do not remove any contact guards during operation.

▪ Eliminate all electrical hazards. (In this respect refer to the applicable nationalsafety regulations and/or regulations issued by the local energy supplycompanies.)

2 Safety

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▪ If shutting down the pump does not increase potential risk, fit an emergency-stop control device in the immediate vicinity of the pump (set) during pump setinstallation.

2.8 Safety information for maintenance, inspection and installation work

▪ Modifications or alterations of the pressure booster system are only permittedwith the manufacturer's prior consent.

▪ Use only original spare parts or parts authorised by the manufacturer. The use ofother parts can invalidate any liability of the manufacturer for resulting damage.

▪ The operator ensures that all maintenance, inspection and installation work isperformed by authorised, qualified specialist personnel who are thoroughlyfamiliar 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 theprocedure described in the manual.

▪ Decontaminate pressure booster systems which handle fluids posing a healthhazard.

▪ 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, observeall instructions on commissioning.

▪ Make sure the pressure booster system cannot be accessed by unauthorisedpersons (e.g. children).

▪ Prior to opening the device, pull the mains plug and wait for at least 10 minutes.

2.9 Unauthorised modes of operation

Always observe the limits stated in the product literature.

The warranty relating to the operating reliability and safety of the pressure boostersystem supplied is only valid if the equipment is used in accordance with its intendeduse. (⇨ Section 2.3 Page 7)

2 Safety

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3 Software ChangesThe 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 thesoftware. 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 andnotify KSB or the supplying dealer (as applicable) and the insurer about thedamage in writing immediately.

4.2 Transport

DANGER

Improper transportRisk of injury by falling pressure booster system!

▷ Never suspend the pressure booster system by its power cable.

▷ Observe the applicable local health and safety regulations.

▷ Use suitable, approved transport equipment, e.g. crane, forklift or pallet track.

✓ The pressure booster system has been checked for in-transit damage.

1. Make sure the transport equipment is suitable for safely carrying the indicatedload.

2. Transport the pressure booster system to the place of installation.

3. Use suitable lifting equipment to lift the pressure booster system and carefullyput it down at the place of installation.

4.3 Storage/preservation

If commissioning is to take place some time after delivery, we recommend that thefollowing measures be taken when storing the pressure booster system:

CAUTIONDamage during storage by frost, moisture, dirt, UV radiation or verminCorrosion/contamination of pressure booster system!

▷ Store the pressure booster system in a frost-proof room. Do not store outdoors.

CAUTIONWet, contaminated or damaged openings and connectionsLeakage or damage of the pressure booster system!

▷ Only open the openings of the pressure booster system at the time ofinstallation.

Store the pressure booster system in a dry, protected room where the atmospherichumidity 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 beenused for handling noxious, explosive, hot or other hazardous fluids.

3. If the pressure booster system has handled fluids whose residues could lead tocorrosion in the presence of atmospheric humidity or could ignite upon contactwith oxygen, the pressure booster system must also be neutralised and treatedwith anhydrous inert gas to ensure drying.

4. Always complete and enclose a certificate of decontamination when returningthe pressure booster system. (⇨ Section 13 Page 65) Always indicate any safety and decontamination measures taken.


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NOTEIf required, a blank certificate of decontamination can be downloaded from theKSB web site at: www.ksb.com/certificate_of_decontamination

4.5 Disposal

WARNINGFluids, consumables and supplies which are hot and/or pose a health hazardHazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any residues of the fluidhandled.

▷ 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 anothercontrolled manner.



http://www.ksb.com/GRAS-Cert

5 Description

5.1 General description

▪ Pressure booster system

System for ensuring the required supply pressure at the consumer installations.

5.2 DesignationExample: Hya-Compact K 2/0406 B

Table 4: Designation key

Code DescriptionHya-Compact Type seriesK Control method

K Cascade control of pump; started and stopped asa function of pressure

VP Individual pump speed control; started andstopped as a function of pressure

2 Number of pumps (including stand-by pump)04 Pump size06 Number of stagesB Design status

5.3 Name plate

Hya-Compact K 2 / 0406 / _ _B

IDApp.Con.RDPPO

K

KSB Aktiengesellschaft

Mad

e in N

L

HU1234567890AISI304 5/4“AISI304 6/4“PT600094559

UFImaxPNProd.

3x400VAC+N+PE50Hz12APN10N03/2010/873549/01

1

357

2

468

Fig. 1: Name plate

1 Type series 2 Rated voltage3 Series number 4 Mains frequency5 Mating dimensions 6 Max. pump power input7 Dry running protection with

pressure transmitter8 Nominal pressure

5.4 Design detailsDesign

▪ Fully automatic pressure booster package system

▪ Integrated stand-by pump

▪ Two standard volt-free changeover contacts for fault indication

▪ Design and function as per DIN 1988, Part 500

Hya-Compact K

▪ Two vertical high-pressure pumps for cascade operation, with BoosterControlAdvanced

▪ Two integrated pressure transmitters for suction and discharge side

Hya-Compact VP

▪ Two vertical high-pressure pumps with continuously variable speed control andBoosterControl Advanced

5 Description


Type of installation

▪ Stationary installation

▪ Floor- or wall-mounted

Drive

▪ Three-phase motor, speed-controlled

▪ Electric motor IE3

5.5 Configuration and function

1

2

3

4

5

Fig. 2: Sectional drawing

1 Pump 2 Internal leakage monitoring3 Integrated swing check valve 4 Integrated shut-off elements5 BoosterControl Advanced

The system consists of two non-self-priming multistage high-pressure centrifugalpumps (1) with suction-side and discharge-side shut-off valves and a discharge-sideaccumulator. The fully automatic pressure booster system is equipped with oneintegrated frequency inverter per pump. The second pump is the stand-by pump. Thedischarge-side shut-off valves enable dismantling of the pumps or check valveswithout taking the entire system out of service or draining the piping system. Theswing check valves are integrated in the pumps' discharge nozzles and preventbackflow through the pumps when the pumps are not running. This reduces the loadon the mechanical seals. Pressure monitoring and the individual start-up of thepumps are taken care of by the micro-processor-controlled BoosterControl Advanced.An internal leakage monitoring system will trigger a warning if any leakage isdetected in the piping. The leakage monitoring system is suitable for both floor- andwall-mounted installation.

▪ Design and function as per DIN 1988, Part 500

Automatic operation Hya-Compact K

The system is started and stopped as a function of pressure. One pump is started upas a function of pressure when consumer installations are opened. Systems consistingof 2 pumps start the first pump when the pressure falls below the start-up pressurepE. When the start-up pressure is reached, a minimum runtime is activated. If thispump meets the current demand and if a pressure greater than pE and smaller thanpA is maintained, the pump operates until the demand drops and the stop pressurepA is reached.

When the consumer installations are closed again, the pump is stopped as a functionof pressure after an adjustable after-run time. Lack of water will cause the controlunit to stop the pump automatically (integrated dry running protection).

As soon as the demand increases after one pump has been stopped, another pumpwhich has not been in operation before is started up. The stand-by pump is alsoincluded in the alternating cycle. The standard setting is for the pressure boostersystem to start automatically as a function of pressure; the actual pressure is

Design

Function

5 Description


measured by an analog pressure measuring device (pressure transmitter). Thefunction of this pressure transmitter is monitored (live-zero). As long as the pressurebooster system is in operation, both pumps are started and stopped as a function ofdemand (standard setting). In this way it is ensured that the individual pumpsoperate only in line with the actual demand.If a duty pump fails, the next pump is started up immediately and a fault is output,which can be reported via volt-free contacts (e.g. to the control station). If thedemand drops towards 0, the pressure booster system runs down to the stop point.The operating status can be called up on the display.

Automatic operation Hya-Compact VP

Two pumps are controlled and monitored by a micro-processor control unit (5). Eachpump is connected to a frequency inverter and controlled by the control unit so as toensure a practically constant discharge pressure of the pressure booster system. Thesystem is started and stopped as a function of pressure. One pump is started up as afunction of pressure when consumer installations are opened.

When the consumer installations are closed again, the pump is stopped as a functionof pressure after an adjustable after-run time. Lack of water will cause the controlunit to stop the pump automatically (integrated dry running protection).

As soon as the demand increases after one pump has been stopped, another pumpwhich has not been in operation before is started up. The stand-by pump is alsoincluded in the alternating cycle. The standard setting is for the pressure boostersystem to start automatically as a function of pressure; the actual pressure ismeasured by an analog pressure measuring device (pressure transmitter). Thefunction of this pressure transmitter is monitored (live-zero). As long as the pressurebooster system is in operation, both pumps are started and stopped as a function ofdemand (standard setting). In this way it is ensured that the individual pumpsoperate only in line with the actual demand. The use of variable-speed pumpsreduces wear as well as the pumps' frequency of starts in parallel operation.If a duty pump fails, the next pump is started up immediately and a fault is output,which can be reported via volt-free contacts (e.g. to the control station). If thedemand drops towards 0, the pressure booster system slowly runs down to the stoppoint. The operating status can be called up on the display.

Manual mode

By making the appropriate settings at the control panel display, one of the pumpscan be operated directly on mains power for 10 seconds, independently of thecontrol unit. The pump will then automatically switch to OFF mode.

NOTEContinuous manual mode is reserved exclusively for emergencies!Continuous operation of the pressure booster system in manual mode may result inwaste of energy and water.Continuous operation of the pressure booster system in manual mode may causethe fluid handled and the pump to overheat.

In manual mode, a minimum flow (see table below) is essential to prevent the fluidhandled and the pump from overheating when no water is consumed at theconsumer installations.

Table 5: Minimum consumption per pump in manual mode

Pump Minimum consumption per pump in manual mode[l/h]

Movitec 2 200Movitec 4 400Movitec 6 600

An open 1/2-inch tap equals a water consumption of approx. 800 to 1,200 l/h.

Example

5 Description


5.6 Noise characteristics

For the noise characteristics of the individual pump refer to the pump's installation/operating manual.

Table 6: Noise characteristics without acoustic cladding in db(A)

Hya-Compact

Number of pumps

2 3 4 5 62/ 02../.B 63,0 63,0 63,0 63,0 63,02/ 04../.B 63,0 63,0 63,0 63,0 67,02/ 06../.B 63,0 63,0 67,0 67,0 -

Table 7: Noise characteristics with acoustic cladding in db(A)

Hya-Compact

Number of pumps

2 3 4 5 62/ 02../.B 58,0 58,0 58,0 58,0 58,02/ 04../.B 58,0 58,0 58,0 58,0 62,02/ 06../.B 58,0 58,0 62,0 62,0 -

5.7 Scope of supply

Depending on the model, the following items are included in the scope of supply:

▪ Two vertical high-pressure centrifugal pumps

▪ Pump control and monitoring unit

▪ Transformer for control voltage

▪ Lockable master switch (repair switch)

▪ Terminal strip/terminals with identification for all connections

▪ Circuit diagram, settings for frequency inverters and list of electrical components

▪ Accumulator (8 litres)

▪ Adapter for wall mounting

Per pump:

▪ Check valve

▪ Shut-off valves

▪ Motor protection switch

5.8 Dimensions and weights

For dimensions and weights refer to the outline drawings of the pressure boostersystem.

5.9 Terminal wiring diagram

For the terminal assignment refer to the circuit diagram.

5 Description


6 Installation at Site

6.1 General instructions for installation

Install pressure booster systems either in the technical equipment room or in a well-ventilated, frost-free, lockable room used for no other purpose. The place ofinstallation must be protected against any ingress of harmful gases. An adequatelysized drain (leading to a sewer or equivalent) must be provided.

The pressure booster system is designed for a maximum ambient temperature of 0 °Cto +40 °C at a relative humidity of 50 %.

NOTEDo not install pressure booster systems next to sleeping or living quarters.

If expansion joints (KSB accessory) are used for damping vibrations, their fatiguestrength (endurance limit) must be given due consideration. Expansion joints must beinstalled to allow quick and easy replacement.

6.2 Checks to be carried out prior to installationPlace of installation

WARNINGInstallation on mounting surfaces which are unsecured and cannot support the loadPersonal injury and damage to property!

▷ Use a concrete of compressive strength class C12/15 which meets therequirements of exposure class X0 to EN 206-1.

▷ The mounting surface must have set and must be completely horizontal andeven.

▷ Observe the weights indicated.

NOTEThe anti-vibration mounts of the pressure booster system provide adequateinsulation against solid-borne noise.Thanks to level-adjustable feet (KSB accessory) the pressure booster system can alsobe installed in horizontal position on uneven floors.

Check the structural requirements.All structural work required must have been prepared in accordance with thedimensions stated in the outline drawings.

6.3 Installing the pressure booster system

WARNINGTop-heavy pressure booster systemRisk of personal injury by pressure booster system tipping over!

▷ Pressure booster systems awaiting final installation must be secured againsttipping over.

▷ Firmly anchor the pressure booster system.

Level-adjustable feet are available as accessories for all pressure booster systems.

For wall-mounted installation use the corresponding mounting tool (KSB accessory).

Remove all packaging before installing the pressure booster system. Connect thepressure booster system's inlet line and discharge line to the corresponding sitedistribution lines.



NOTEIn order to avoid transmission of piping forces onto the pressure booster system andtransmission of solid-borne noise, we recommend installing length-limitedexpansion joints.

Allow sufficient space for maintenance and repair work.

✓ All structural work required has been checked.

✓ The dimensions of the concrete foundation are correct, and the concrete has setfirmly.

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. Set the pressure booster system down in its correct installation position.

5. Use suitable bolts to firmly anchor the pressure booster system.

6.4 Installing the piping

Make sure that piping is installed without transmitting any stresses or strains. The useof length-limited expansion joints (see accessories) is recommended.

CAUTIONAir pockets in suction linePressure booster system cannot prime!

▷ Lay piping with a continuously rising slope (as shown).

Suction lift operation

Incorrect Correct

NOTEFor suction lift operation install suitable swing check valves at the suction line endswhich are submerged in the fluid handled. Take into account the head losses causedby these swing check valves.Do not exceed the maximum suction lift of the pumps.

6.4.1 Fitting an expansion joint

DANGER

Sparks and radiant heatFire hazard!

▷ Take suitable precautions to protect the expansion joint if any welding work iscarried out nearby.

CAUTIONLeaking expansion jointFlooding of installation room!

▷ Regularly check for cracks or blisters, exposed fabric or other defects.



✓ The expansion joint has a length limiter with solid-borne sound insulation so asto be able to absorb reaction forces.

1. Install the expansion joint in the piping free of twist or distortion. Never use theexpansion joint to compensate for misalignment or mismatch of the piping.

2. Tighten the bolts evenly and crosswise during assembly. The ends of the boltsmust not protrude from the flange.

3. Do not apply paint to the expansion joint. Protect it from any contact with oil.

4. The position of the expansion joint within the pressure booster system mustallow easy access and inspection and it must, therefore, not be insulated alongwith the piping.

5. Expansion joints are subject to wear.

6.4.2 Installing a pressure reducer

NOTEA pipe length of approximately 600 mm must be provided on the inlet side toaccommodate a pressure reducer, if necessary.

NOTEA pressure reducer must be installed- if the inlet pressure fluctuation is too high for the pressure booster system tooperate as intended or- if the total pressure (inlet pressure plus shut-off head) of the pressure boostersystem exceeds the design pressure. The maximum pump discharge pressure at zero flow point is reached in manualmode.

A minimum pressure gradient of 5 metres is required for the pressure reducer tofulfill its function. The pressure downstream of the pressure reducer (downstreampressure) is the basic parameter for determining the pump head.

For example:

The inlet pressure fluctuates between 4 and 8 bar. A pressure reducer is neededupstream of the pressure booster system on the inlet side. Min. inlet pressure (pinl) = 4 bar Min. pressure gradient = 0.5 bar Downstream pressure = 3.5 bar.

6.5 Connection to power supply

DANGER

Electrical connection work by unqualified personnelDanger of death from electric shock!

▷ Always have the electrical connections installed by a trained and qualifiedelectrician.

▷ Observe regulations IEC 60364.

WARNINGIncorrect connection to the mainsDamage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.



NOTEA motor protection device is recommended.

NOTEIf a residual current device is installed, observe the operating manual for thefrequency inverter.

The circuit diagrams for the pressure booster system are included in the controlcabinet, where they must remain when not in use. The product literature of the switchgear and controlgear assembly supplied with thepressure booster system includes a list of the electrical components installed. Whenordering spare parts for electrical components, please always indicate the circuitdiagram number.

6.5.1 Sizing the power cable

The cross-section of the power cable must be sized for the total rated powerrequirement.

6.5.2 Connecting the pressure booster system

The pressure booster system is connected to the power supply via the factory-fittedmaster switch and the power cable.

1. Permanently install the pressure booster system as described in the manual.



7 Commissioning/Start-up/Shutdown

7.1 Commissioning/start-up

7.1.1 Prerequisites for commissioning/start-up

Before commissioning/start-up of the pressure booster system make sure that thefollowing requirements are met:

▪ The pressure booster system has been properly connected to the electric powersupply and is equipped with all protection devices.

▪ All relevant regulations applicable in the country of use are complied with.

▪ The dry running protection device has been installed.

CAUTIONDry running of pumpDamage to the pump/pressure booster system!

▷ If no dry running protection device is connected when commissioning takesplace, pressure booster systems in manual or test run mode will be stoppedautomatically after approx. 10 seconds. If the dry running protection terminal isdisabled by means of a bridge, the operator shall assume responsibility for anydry running that might occur.

NOTEThe competent authorities must be informed in due time prior to commissioning/test running the system.

7.1.2 Dry running protection

Pressure booster systems can be factory-equipped with pressure switches, pressuretransmitters or flow monitors as dry running protection devices. Such dry runningprotection devices will be factory-set to the inlet pressure values specified in thepurchase order.

If the factory settings should not match the site data, the dry running protectiondevice must be adjusted accordingly.

▪ Set the start and stop pressure in parameters 3-5-15 and 3-5-16.

Table 8: Recommended pressure switch/pressure transmitter settings

Stop pressure Start-up pressurePressure switch 0.5 bar below pinl 0.2 bar below pinl

Pressure transmitter 0.5 bar below pinl 0.2 bar below pinl

▪ Flow monitor: Set the stop pressure in parameter 3-5-17. (⇨ Section 8.4 Page 28) The flow monitor will stop the pressure booster system due to lack of waterwhen no flow can be detected on the suction side and the discharge-sidepressure drops below the set value.

Table 9: Recommended flow monitor settings

Stop pressure Start-up pressureFlow monitor 0.5 bar below pset Cannot be adjusted

NOTESystems protected against dry running by flow monitoring cannot be resetautomatically! One pump at least must be started in manual mode to build uppressure on the discharge side.This will reset the dry running protection device.



7.1.3 Commissioning/start-up of pressure booster system

NOTEThe hydraulic connections are closed in as-supplied condition. They must only beopened immediately before installation. In accordance with DIN EN 806, prior tocommissioning, the pressure booster system must be flushed by the operator anddisinfected, if necessary.

CAUTIONForeign matter in the pipingDamage to the pumps/pressure booster system!

▷ Before commissioning/starting (or even test running) the pressure boostersystem, make sure that there is no foreign matter in the pressure boostersystem or piping.

NOTECommissioning of the pressure booster system - even test running - shall only becarried out in full compliance with all pertinent VDE (German Association ofElectrical Engineers) regulations.

CAUTIONOperation without the fluid to be handledDamage to the pump!

▷ Prime the pressure booster system with the fluid to be handled.

✓ The pipe unions between the pump and the piping have been re-tightened.

✓ The flange bolting has been checked for firm seating.

✓ The cooling air inlet and outlet openings on the motor are unobstructed.

✓ All shut-off valves of the pressure booster system are open.

✓ The pre-charge pressure of the membrane-type accumulator has been checked.(⇨ Section 9.2.3 Page 58)

1. Set the master switch to "0"; unlock all motor protection switches (ifapplicable).

2. Provide connection to power supply.

3. Open/loosen the vent plugs on the pumps (refer to the pump's installation/operating manual).

4. Slowly open the inlet-side shut-off element and prime the pressure boostersystem until the fluid to be handled escapes through all vent holes.

5. Close and slightly tighten the pump vent plugs.

6. Switch on all motor protection switches.

7. Set manual-0-automatic selector switches (if any) to Automatic.

8. Switch on the master switch.

9. Open the discharge-side shut-off element.

10. Check the direction of rotation of the pump.

⇨ The direction of rotation must match the rotation arrow on the motor.If the pump runs in the wrong direction of rotation, interchange two phasesat the motor terminal strip.

11. When all pumps are running, loosen the vent plugs again to let any remainingair escape.

12. Then re-tighten the vent plug firmly.

13. Check that the pumps are running smoothly.

14. Close the discharge-side shut-off element for a short period and verify that thepump(s) reach(es) the shut-off head.



15. Close the discharge-side shut-off element, causing all pumps to stop.

NOTEMinor leakage of the mechanical seals during commissioning is normal and willcease after a short period of operation.

7.1.4 Switching on the pressure booster system

Switch on the master switch to energise the pressure booster system. The green LEDon the control panel lights up, indicating the system's readiness for operation.

NOTEThe pressure booster system is factory-set to the operating data indicated on thename plate.

7.1.5 Checklist for commissioning/start-up

Table 10: Checklist

Operations Done1 Read the operating instructions. 2 Check power supply and compare against the name plate data. 3 Check the earthing system (by measuring). 4 Check the mechanical connection to the water mains.

Re-tighten the flange bolting and pipe unions.

5 Prime and vent the pressure booster system from the inlet side. 6 Check inlet pressure. 7 Check whether all cables are still firmly connected to the terminals inside the control unit. 8 Compare the settings of the motor protection switches with the name plate data; re-adjust, if

necessary.

9 Check the start and stop pressure; re-adjust, if necessary. 10 Test the proper function of the lack-of-water and dry running protection equipment. If not

fitted, make a relevant note in the commissioning report.

11 Vent the pumps for a second time after they have been running for 5 to 10 minutes. 12 Set all switches to "automatic". 13 Check the pre-charge pressure. 14 Record all system conditions that do not correspond to our specifications or to the purchase

order in the commissioning report (i.e. no dry running protection or inlet pressure + max.pressure of pressure booster system higher than 16 bar).

15 Complete the commissioning report together with the operator/user and instruct the operator/user as to the function of the system.

7.2 Shutdown

NOTEAs long as the pressure booster system is out of operation, water is supplied directlyat pinl through the pressure booster system.

Set the master switch to "0".

NOTEDrain the pressure booster system for prolonged shutdown.



8 Control panel

CAUTIONIncorrect operationWater supply is not assured!

▷ Make sure to comply with all local regulations, particularly the EC MachineryDirective and the EC Directive on Low-Voltage Equipment.

The pressure booster system is factory-set to the operating data indicated on thename plate. The settings can be modified via the control panel, if necessary.

NOTEThe factory settings are permanently stored in the control unit. Should an incorrectsetting result in pressure booster system failure, the factory settings can berestored. (⇨ Section 8.8.2 Page 51)

NOTEThe settings made at the site can be saved and loaded when required. (⇨ Section8.8.1 Page 51) (⇨ Section 8.8.2 Page 51)

8.1 Control panel

The control panel comprises a back-lit display, LEDs, function and navigation keys,and an access point for the service interface.

The display shows important information for operating the pressure booster system.Plain-text data can be accessed and parameters can be set.

12

3

4

5

Fig. 3: BoosterControl Advanced control panel

8 Control panel


1 Display 2 "Traffic light" LEDs3 Function keys 4 Navigation keys5 Service interface

8.1.1 Display

The six-row display contains the following information:

Fig. 4: Control unit: Display elements

Display element DescriptionParameter No./Pump Shows the number of the parameter or pump

selectedCurrent selection Shows the current parameter in plain textParameter information List of selectable parameters/parameter

informationAccess level Shows the current access level:

Blank = Standard(limited access to parameters)C = Customer, access to main parametersS = ServiceF = Factory

Date, time Shows the set date and time

Example: Setpoint adaptation at "Customer" access level:

3-5 C

Pressure

SetpointBandwidthAccumulator pressureMax. setpoint

22-05 13:40

Fig. 5: Display: Setpoint adaptation

The number of the current menu or parameter is always displayed at the top left ofthe screen. This number indicates the path through the menu levels and thus enablesthe user to quickly locate parameters. See "Displaying and changing parameters".(⇨ Section 8.4 Page 28)

8.1.2 LEDs

The "traffic light" LEDs provide information about the pump system's operatingstatus.

8 Control panel


Table 11: LED description

LED DescriptionRed: One or more than one alert is activeAmber: One or more than one warning is activeGreen: Trouble-free operation

8.1.3 Function keys

You can use the menu keys to access the elements at the first menu level directly.

Table 12: Assignment of menu keys

Key MenuOperation

Diagnosis

Settings

Information

8.1.4 Navigation keys

For navigating through the menus and confirming settings:

Table 13: Control unit: Navigation keys

Key DescriptionDirection keys:

▪ Move up/down in the menu options

▪ Increase/decrease a numerical value

▪ Scroll up or down

EscEscape key:

▪ Cancel an entry without saving it.

▪ Move up one menu level.

OKOK key:

▪ On the start display: Open the quick menu.

▪ Confirm settings.

▪ Confirm a menu selection.

▪ When entering numbers: Go to the next digit.

?Help key:

▪ Displays a help text for each selected menu option.

8.1.5 Service interface

The service interface allows a PC/Notebook to be connected via a special cable (USB -RS232).

The pressure booster system can be parameterised by using the Service-Toolsoftware.

The control unit can also be updated via this interface.

8.2 Menu structure

Main menu: KSB logo/actual value display

8 Control panel


Main menu Key Sub-menu Information displayed➡ Operation ➡ General System pressure

System load % RDP switch present/not present Inlet pressure Level content % Level height m Ambient temp. Digital inputs

➡ Pumps Operating mode of pumps Display pump load Display thermal protection

➡ Time and statistics Operating hours Service interval Current min. runtime

➡ Diagnosis ➡ General Display messages Show history Acknowledge faults Clear history

➡ Settings ➡ Control panel Basic settings CAN configuration Service interface Logo

➡ Control unit Login Service

➡ System configuration Number of pumps Configuration suction side Configuration operating mode

➡ System settings Suction side Discharge sideConfiguration of frequency inverter

➡ Pressure configuration Configuration setpoint and dry running protection➡ Timer settings Operation check run/alternative setpoint➡ Time/date ➡ Program outputs ➡ Messages ➡ Main menu

➡ Information ➡ Control module Serial number Material number Firmware Parameter set Hardware version

8.3 Access levels

Various access levels have been defined to prevent unintentional or unauthorisedaccess to the pressure booster system parameters.

Unless users log on to one of the other access levels, they will only have limited accessto parameters.

Access level for expert users. This level enables access to all the parameters required for commissioning. You mustenter the password under (3-2-1-1) Login to gain access. "C" is displayed. If password protection is deactivated via parameter 3-2-1-2, this access level becomesthe "Standard" access level.The password is "7353".

Access level for service personnel. You must enter the password under (3-2-1-1) Login to gain access. "S" is displayed.

Access level for the manufacturer only."F" is displayed.

"Standard" level

"Customer" level

"Service" level

"Factory" level

8 Control panel


NOTEIf no keys are pressed for ten minutes, the system will automatically return to the"Standard" access level.

8.4 Displaying and changing parameters

The parameter numbers contain the navigation path, which helps you find aparticular parameter quickly and easily.

The first digit of the parameter number indicates the first menu level, which is calledup directly via the four function keys.

Table 14: Function keys

Operation

Diagnosis

Settings

Information

Subsequent steps are carried out via the navigation keys.

Example: Parameter 3-5-1 Setpoint

First, enter the customer password. (⇨ Section 8.3 Page 27) Then change the setpoint as follows:

First digit of parameter number: 3-5-1

Press the third function key for Settings. 3-1 appears on the top left of the screen.

Second digit of parameter number: 3-5-1

Change the display 3-1 (top left) to 3-5 by pressing the navigationkeys.To confirm the selection, press OK. 3-5-1 appears on the top left ofthe screen. You have reached the required parameter.

To change this parameter, press OK again.

Numbers can then be entered digit by digit from left to right.

Increase value.

Reduce value.

The bar above the entry displays the value currently being entered in relation to thevalue range.

Confirm the selected value by pressing OK. The cursor moves to thenext position (second position from the left).

Make the settings for the subsequent positions as described above and then

press OK to save the new parameter value.

Press ESC several times to return to the main display. The new setpoint is now active.

8 Control panel


8.5 Displaying messages

All monitoring and protective functions trigger warnings or alerts. These aresignalled by the yellow or red LED and connected to the relay outputs.

▪ All current messages can be displayed in the Diagnosis menu under 2-1-1 andacknowledged individually if the cause of the fault has gone.

▪ The history of messages can be accessed in the Diagnosis menu under 2-1-2. Itindicates the start and end of a fault.

▪ The list of fault messages can be acknowledged in the Diagnosis menu under2-1-3.

▪ The history of messages can be deleted in the Diagnosis menu under 2-1-4. Forthis step, you have to login at the "Service" level.

When the pressure booster system is reset (by switching the pressure booster systemoff and on with the master switch), all alerts are acknowledged automatically.Acknowledging alerts may cause the system to re-start.

8 Control panel


8.6 Parameter list

Table 15: Overview of parameters

Parameters Description Factory setting Possible settings Min. value Max. value Read access right Write accessright

1 OperationDisplay of operating mode

- - - - Everybody Nobody

1-1 SystemGeneral operating status indicators


1-1-1 System pressureDisplaying the measured system pressure


1-1-2 System load %Displaying the total pump load inpercent


1-1-3 RDP switchDetection of dry running protection viapressure switch is activated/deactivated

- Not available,available

- - Everybody Nobody

1-1-4 Inlet pressureDisplaying the suction-side pressure


1-1-5 Level content in %Displaying the water level in inlet tankin percent


1-1-6 Level heightDisplaying the water level in the inlettank


1-1-7 Ambient temp. (WSD)Displaying the measured ambienttemperature if water flow detection isavailable


1-1-8 Digital inputsDisplaying the status of the digitalinputs

- - - - Service Service

1-1-9.2 Position suppl.valvePosition of supply valve

Open Open,closed

- - Everybody Nobody

1-1-9.1 Position suppl.valvePosition of proportional supply valve0 % ... 100 %

0 0...100 0 100 Everybody Nobody

1-1-10 Power down speedCalculated stop speed if zero-flowdetection is activated in energy-savingmode.

- - - - Service Nobody

1-1-14 WSD pulses tank 1Water flow detection, number of fills intank 1

0 - - - Everybody Nobody



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1-2 PumpsPump-relevant status information


1-2-1 Operating modeSetting the operating mode for eachindividual pump

- - - - Everybody Everybody

1-2-1.1.1 Pump numberEntering the pump number for whichthe operating mode is configured

1 1.. 3 1 3 Everybody Everybody

1-2-1.2.1 Operating modeDisplaying the operating status of thepump

1 Automatic,manual On (10 s),manual Off

- - Everybody Everybody

1-2-2 Pump loadDisplaying the pump load


1-2-3 Thermal fail. flagsBit-based display of status of all thermalfault inputs

- Not trippedTripped

- - Service Nobody

1-2-4 Running hours pumpDisplaying the operating hours perpump


1-2-5 Number of pumpstartsDisplaying the number of starts perpump

- - - - Customer Nobody

1-3 Time and statisticsOperating times and statistics


1-3-1 Act runtime Op hoursOperating hours of the system


1-3-2 Time to serviceTime to next service interval


1-3-3 Act Minimum RuntimeCurrent minimum pump runtime inseconds


2 DiagnosisMonitoring and diagnosis


2-1 GeneralGeneral monitoring functions


2-1-1 Active MessagesCurrent messages for all availablewarnings/alerts

- - - - Everybody Customer

2-1-2 HistoryHistory of all warnings/alerts


2-1-3 Acknowledge AllAll messages are acknowledged


2-1-4 Clear HistoryDeleting the message history


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3 SettingsSettings


3-1 HMIControl panel


3-1-1 Basic settingsBasic settings for control panel


3-1-1-1 LanguageLanguage settings

English English,German,Dutch,French,Turkish


3-1-1-4 contrastContrast

13 5.. 20 5 20 Everybody Everybody

3-1-1-2 BacklightConfiguring the illumination time of thedisplay


3-1-1-2-1 ModeIllumination type of system display

Timed Always on,timer-based


3-1-1-2-2 Backlight TimeSystem display: setting the illuminationtime in seconds

600 10.. 999 10 999 Everybody Service

3-1-1-3 Displayed unitsSelecting the units shown on the displayThe measured values are converted inthe device.


3-1-1-3-1 PressureUnits of measured pressurevalues

kPa kPa,bar,PSI,feet,mwc

- - Everybody Service

3-1-1-3-2 HeightUnits of tank fill level

cm cm,m


3-1-1-3-3 TemperatureUnits of water flow detectiontemperature

°C °C,°F


3-1-2 FieldbusField bus settings

- - - - Nobody Nobody

3-1-2-1 Fieldbus TypeType of connected field bus module

No module No module,Profibus,Modbus

- - Nobody Nobody

3-1-4 LogoSetting the logo displayed


3-1-4-1 LogoSelecting of logo displayed

No logo KSB logo,dp logo,no logo

- - Service Service

3-2 DeviceDevice-specific settings


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3-2-1 LoginLogin


3-2-1-1.1 PINEntering the user level and password


3-2-1-1.1.1 Access LevelSelecting the login level

User level User level,service level,factory level


3-2-1-1.1.2 PIN acceptancePrompt to enter PIN

- 0.. 9999 0 9999 Everybody Everybody

3-2-1-1.2 PINEntering the user level and password

- - - - Factory Nobody

3-2-1-1.2.1 Access LevelSelecting the login level

User level User level,service level,factory level,development level

- - Factory Factory

3-2-1-1.2.2 PIN acceptancePrompt to enter PIN

- 0.. 9999 0 9999 Factory Factory

3-2-1-2 Login requiredPassword entry required

Yes No,yes

- - Customer Customer

3-2-2 ServiceService settings


3-2-2-1 Factory settingFactory-set defaults

- Reset ok,no set available


3-2-2-2 Reset Srv IntervalResetting the service interval

- OK,failed

- - Service Service

3-2-2-3 Customer settingLoading locally saved settings.

- Reset ok,no set available


3-2-2-4 Save custom. settingSaving the customer settings

- - - - Customer Customer

3-2-2-5 Save factory settingSaving the factory settings

- - - - Factory Factory

3-2-2-6 Default settingResetting to default settings


3-2-2-6.1.1 Reset default param.Resetting to default settings

default default,Hyamat K,Hyamat V,Hyamat VP,HyaEco VP

- - Service Service

3-2-2-7 Edit Pump Opera. hrsEditing pump operating hours


3-2-2-7.1.1 Pump numberNumber of pump

1 1.. 6 1 6 Service Service

3-2-2-7.2.1 HoursHours

0 0.. 500000 0 500000 Service Service

3-2-2-7.2.2 MinutesMinutes


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3-2-2-7.2.3 SecondsSecond


3-2-2-8 Reset Sys. Oper. hrsResetting the operating hours

- OK, failed

- - Service Service

3-2-3 Factory TestFactory test

- - - - Factory Nobody

3-2-3-1 Factory TestFactory test

- - - - Factory Factory

3-2-3-1.1.1 Test resultTest result

Failed Failed, passed

- - Factory Factory

3-3 ConfigurationSystem configuration


3-3-1 Number of pumpsMaximum number of pumps used insystem


3-3-2 InletGeneral configuration, suction side

Pressure switch Pressure switch,pressure sensor,water flow detection,inlet tank/gate valve,inlet tank/proportional valve


3-3-3 DischargeGeneral configuration, discharge side

Cascade Cascade (withoutfrequency inverter),1 jockey,2 jockeys,floating frequencyinverter,frequency inverterper pump


3-3-4 WSDConfiguring the water flow detectionfor the tank

Off Off,1 tank,2 tanks,3 tanks,1 tank + temp.,2 tanks + temp.,3 tanks + temp.,temperature


3-3-5 Leakage detectionActivating leakage monitoring

Off On,off


3-3-6 MPO FunctionalitySynchronous operation

Off Off,on

- - Service Service

3-3-7 PumpMode int/extSetting for pump mode via HMI(internal) or switch (external)

Internal Internal,external


3-4 System settingsParameterisation of system


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3-4-1 InletSuction-side parameterisation


3-4-1-1 Sensor press. 4 mAAnalog measured value at 4 mA, suctionside

0 -100.. 1000 -100 1000 Everybody Service

3-4-1-2 Sensor press. 20 mAAnalog measured value at 20 mA,suction side


3-4-1-3 Damp. Time InletDamping time for smoothing measuredvalue to compensate for measurementpeaks

200 100.. 2000 100 2000 Factory Factory

3-4-1-4 Level configConfiguring inlet tank control

- - - - Everybody Service

3-4-1-4-1 0% levelMinimum water level at which no airenters into tank, in percent, from upperedge of inlet nozzle


3-4-1-4-2 100% levelMaximum water level of inlet tank, inpercent, from upper edge of inlet nozzle


3-4-1-4-3 Sensor levelDistance of sensor positioned abovetank floor to tank floor, in centimetres


3-4-1-4-4 Low level shut downSystem stop when dry running levelreached


3-4-1-4-5 Low level resetResetting the system when defined dryrunning level is reached


3-4-1-4-6 Critical water levelThreshold of critical water level in inlettank


3-4-1-4-7 High water levelThreshold of high water level in inlettank


3-4-1-4-8 Threshold1 or 2 extra signalling relay contacts forswitching thresholds


3-4-1-4-8-1 Threshold 1 ONInlet tank level for relay 1 energised inpercent

50 0...199 0 199 Everybody Service

3-4-1-4-8-2 Threshold 1 OFFInlet tank level for relay 1 de-energisedin percent


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3-4-1-4-8-3 Threshold 2 ONInlet tank level for relay 2 energised inpercent


3-4-1-4-8-4 Threshold 2 OFFInlet tank level for relay 2 de-energisedin percent


3-4-1-4-9 Supply valve ON/OFFPosition of inflow gate valve for fillinginlet tank


3-4-1-4-9-1 Level 1 openLevel for opening gate valve to startfilling inlet tank


3-4-1-4-9-2 Level 1 closedLevel for closing gate valve to stopfilling inlet tank


3-4-1-4-9-3 Level 1A openSecond level (timer-based) for openinggate valve to start filling


3-4-1-4-9-4 Level 1A closedSecond level (timer-based) for closinggate valve to stop filling


3-4-1-4-10 Supply valve prop.Use of a proportional valve to fill inlettank


3-4-1-4-10-1 Level setpoint 1Level in inlet tank at which valve iscompletely closed


3-4-1-4-10-2 Level setpoint 1ASecond level (timer-based) in inlet tankat which valve is completely closed


3-4-1-4-10-3 HysteresisSetting the hysteresis for fully openvalve


3-4-1-4-10-4 Sample timeMeasurement cycle for measuring tocontrol proportional valve


3-4-1-4-10-5 Analog outputConfiguring the analog output

4-20mA 4-20mA,0-20mA


3-4-1-5 Auto. Setpoint Redu.Automatic setpoint reduction in case ofinlet pressure drop


3-4-1-5-1 ASR functionAutomatic setpoint reduction in case ofinlet pressure drop

Off Off,on


3-4-1-5-2 Switch on pointRe-start point


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3-4-1-5-3 Inlet Set pointEntering the minimum inlet pressuresetpoint


3-4-1-5-4 Switch off pointStop point


3-4-1-5-5 Proportional const.Proportional constant of PID controller


3-4-1-5-6 Integral timeIntegral constant of PID controller


3-4-1-5-7 Differential timeDifferential constant of PID controller


3-4-1-5-9 Switch On timeTime to pump start


3-4-1-5-10 Switch Off timeTime to pump stop


3-4-2 DischargeDischarge-side parameterisation


3-4-2-1 Sensor press. 4 mAAnalog measured value at 4 mA,discharge side


3-4-2-2 Sensor press. 20 mAAnalog measured value at 20 mA,discharge side


3-4-2-3 Pumps ON sensor failNumber of pumps started up in theevent of a sensor failure on thedischarge side


3-4-2-4 Max powerLimitation of maximum system power (nx 100 %, n = number of pumps)


3-4-2-5 Max power ext. oper.Limitation of maximum system powerfor operation on emergency power


3-4-3 Variable freq. driveConfiguring the frequency inverters


3-4-3-1 CommunicationConfiguring the communicationprotocol for the frequency inverter

None None,analog 4-20 mA,analog 0-20 mA,PumpDrive,Danfoss VLT 2800,Danfoss MicroDrive,Danfoss AquaDrive


3-4-3-2 Proportional const.Proportional constant of PID controller


3-4-3-3 Integral timeIntegral constant of PID controller


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3-4-3-4 Differential timeDifferential constant of PID controller

0 0.. 99,99 0 99,99 Everybody Service

3-4-3-9 VFD Ramp-UpConfiguring the start ramp forfrequency inverters in seconds

3 0,1.. 999 0,1 999 Everybody Service

3-4-3-10 VFD Ramp-DownConfiguring the stop ramp for frequencyinverters in seconds


3-4-3-11 VFD min. frequencyConfiguring the minimum frequency forfrequency inverters in Hz


3-4-3-12 VFD max. frequencyConfiguring the maximum frequency forfrequency inverters in Hz


3-4-3-13 P nominal of VFDNominal power of frequency inverters


3-4-3-14 U nominal of VFDNominal voltage of frequency inverters


3-4-3-15 F nominal of VFDNominal frequency of frequencyinverters


3-4-3-16 I nominal of VFDNominal amperage of frequencyinverters


3-4-3-17 RPM nominal of VFDNominal speed of frequency inverters


3-4-3-20 Motor Speed UnitMotor speed unit

rpm rpm,Hz


3-4-3-21 Digital I/P 33 func.Selecting the digital input

No Function No function,coasting stop inv.


3-4-3-22 Digital I/P 29 func.Selecting the digital input

No Function No function,jog function,jog function


3-4-3-23 Jog frequencySpeed in manual mode


3-4-3-24 Jog ramp timeRamp time


3-4-3-25 Costing selectSelecting the manual mode

Digital and bus Digital input,bus,digital and bus,digital or bus


3-4-3-26 Start selectSelecting the start signal

Digital and bus Digital input,bus,digital and bus,digital or bus


3-4-3-27 Slip CompensationSlip compensation


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3-4-3-5 No flow detectionAccuracy with which a minimum flow isdetected (procedure for stopping thepumps)


3-4-3-5-1 No flow bandwithBandwidth of flow detection


3-4-3-5-2 No flow timeFlow detection time in seconds


3-4-3-5-3 No flow stepStep height of flow detection in percent


3-4-3-5-4 No flow max. powerFlow detection is active below this pumpload in percent


3-4-4 WSD settingsConfiguring water flow detection


3-4-4-1 Nbr of refreshmentsNumber of water replacement cycles


3-4-4-2 Refresh time span Duration of water replacementprocedure in hours


3-4-4-3 Average room temp.Measured average ambient temperature


3-4-4-4 Room temp. time spanDuration of ambient temperaturemeasurement in hours


3-4-5 MPO settingsConfiguring the multiple pumpoperation functions


3-4-5-1 High Load ProfileCharacteristic of pump

Cubic Linear,cubic

- - Customer Develop

3-4-5-2 Rated FreqRated frequency of pump


3-4-5-3 Switch On Freq.Start frequency of pump


3-4-5-4 Switch Off Freq.Stop frequency of pump


3-4-5-5 Cubic settingCubic setting


3-4-5-5-1 Power 1Power 1 of pump




3-4-5-6 Linear settingLinear setting of pump




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3-4-5-7 Motor settingsMotor settings


3-4-5-7-1 Rated Motor PowerRated power of motor as per name plate


3-4-5-7-2 Rated Motor SpeedRated speed of motor as per name plate


3-4-5-7-3 Rated FreqRated frequency of motor as per nameplate


3-4-5-7-4 Rated CurrentRated current of motor as per nameplate


3-4-5-7-5 Rated CosphiRated cos phi of motor as per nameplate

1 0,1.. 0,99 0,1 0,99 Everybody Service

3-4-5-8 Pump parametersPump settings


3-4-5-8-1 Rated Pump SpeedRated speed of pump for rated H/Qcharacteristic curve


3-5 Pressure Configuring the system pressure


3-5-1 Set pointEntering the pressure setpoint (systempressure)

400 0.. 1000 0 1000 Everybody Customer

3-5-3 BandwidthBandwidth within which the frequencyinverters remain at the same, constantspeed independent of pressure.


3-5-4 Accumulation press.Procedure for increasing pressure in theaccumulator before the system stops


3-5-5 Max.set pointLimit value for maximum setpoint


3-5-9 Adapt. setpointDate/time-based alternative setpoint


3-5-10 Delta p Dynamic pressure compensationQuadratic function for correcting thesetpoint

0 -999.. 999 -999 999 Everybody Customer

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3-5-11 High pressure alarmUpper limit value for maximum systempressure


3-5-12 High pressure actionParameter for selecting action in case ofexcessively high system pressure (stoppumps or output message only)

Stop pumps Stop pumps,message only

- - Everybody Customer

3-5-13 Low pressure alarmLower limit value for minimum systempressure


3-5-14 Low pressure actionParameter for selecting action in case ofexcessively low system pressure (stoppumps or output message only)

Stop pumps Stop pumps,message only


3-5-15 Shut down RDP Minimum suction-side pressure limit fordry running protection


3-5-16 Reset RDPSuction-side pressure for re-startfollowing dry running occurrence


3-5-17 Press. Flow ControlLack-of-water fault is set if setpointminus pressure defined is undershot.


3-6 Timer settingsConfiguring the time parameters


3-6-1 Opt. pump starts /hEntering the optimal pump starts perhour. The pump runtime is adjustedautomatically


3-6-2 Min. run timeLimit for minimum runtime of pump


3-6-3 Min. run time corr.Correction value for minimum runtimeof pump


3-6-4 Max. run timeMaximum pump runtime. After the time has lapsed, the systemswitches over to the next pump.


3-6-5 Start delayStart delay of pumps if pressure remainsbelow setpoint


3-6-6 Stop delayStop delay of pumps if pressure remainsat setpoint


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3-6-8 RDP delayStop delay following detection of dryrunning occurrence


3-6-9 High/low alarm delayTime window for suppressing alertswhen system pressure is exceeded/undershot


3-6-10 WSD 1 pulse lengthWater flow detection 1, length of pulsein seconds






3-6-13 Sys. start up delayStart delay following re-start


3-6-14 Jockey min. run timeLimit for minimum runtime of jockeypump


3-7 Time/DateDate and time


3-7-1 DateSetting the date


3-7-1.1.1 YearSetting the year

... 1970.. 2099 1970 2099 Everybody Customer

3-7-1.1.2 MonthSetting the month


3-7-1.1.3 DaySetting the day of the week


3-7-2 TimeSetting the time


3-7-2.1.1 TimeSetting the time in the formatHH:MM:SS


3-7-3 Check run modeBasic setting for forced start (check run)

Interval Off,digital input,interval,day-based,week-based


3-7-4 Check run intervalInterval-controlled forced start (checkrun);the pumps are started at fixed, definedintervals.


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3-7-5 Check run atDay-controlled forced start (check run); the pumps are started at a defined time


3-7-5.1.1 HoursHours for daily forced start (check run)


3-7-5.1.2 MinutesMinutes for daily forced start (check run)


3-7-6 Check run atWeekly forced start (check run): at adefined time on specific days


3-7-6.1.1 HoursWeekly forced start (check run): at adefined time (hours) on specific days

_ 0.. 23 0 23 Everybody Customer

3-7-6.1.2 MinutesWeekly forced start (check run): at adefined time (minutes) on specific days

_ 0.. 59 0 59 Everybody Customer

3-7-6.1.3 DayWeekly forced start (check run): at adefined time on a specific day

Sunday Sunday,Monday,Tuesday,Wednesday,Thursday,Friday,Saturday


3-7-7 Check run durationSpecifying the duration of the forcedstart (check run)


3-7-9 Date adapt level OnThe alternative fill level is activated inaccordance with day(s)/month(s).


3-7-9.1.1 Month adapt level OnEntering the month in which thealternative fill level is activated

Off Off,January,February,March,April,May,June,July,August,September,October,November,December


3-7-9.1.2 Day adapt level OnEntering the weekday on which thealternative fill level is activated.


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3-7-10 Date adapt level OffEntering the date on which thealternative fill level is deactivated.


3-7-10.1.1 Month adapt lev OffEntering the month in which thealternative fill level is deactivated

Off Off,January,February,March,April,May,June,July,August,September,October,November,December


3-7-10.1.2 Day adapt level OffEntering the weekday on which thealternative fill level is deactivated.


3-7-11 Maintenance intervalConfiguring the maintenance intervalfor the system in days.


3-7-8 Clock adapt setp.Alternative setpoint to take effect basedon time


3-7-8-1 Adaptation modeConfiguring the alternative setpoint totake effect on a daily or weekly basis

Off Off,weekly,daily


3-7-8-2 Change on/off timesThe alternative pressure setpoint isactivated/deactivated


3-7-8-2.1.1 Hours adapt setp.ONEntering the hours when the alternativepressure setpoint is activated


3-7-8-2.1.2 Min adapt setp.ONEntering the minutes when thealternative pressure setpoint is activated


3-7-8-2.1.3 Hours adapt setp.OFFEntering the hours when the alternativepressure setpoint is deactivated


3-7-8-2.1.4 Min adapt setp.OFFEntering the minutes when thealternative pressure setpoint isdeactivated


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3-7-8-3 Select day of weekEntering the weekday on which thealternative pressure setpoint isactivated.

Sunday Sunday,Monday,Tuesday,Wednesday,Thursday,Friday,Saturday


3-7-8-4 Change on/off timesEntering the weekday on which thealternative pressure setpoint isdeactivated.


3-7-8-4.1.1 Hours adapt setp.ONEntering the hours when the alternativepressure setpoint is activated


3-7-8-4.1.2 Min adapt setp.ONEntering the minutes when thealternative pressure setpoint is activated


3-7-8-4.1.3 Hours adapt setp.OFFEntering the hours when the alternativepressure setpoint is deactivated


3-7-8-4.1.4 Min adapt setp.OFFEntering the minutes when thealternative pressure setpoint isdeactivated


3-8 Definable I/OProgramming inputs/outputs


3-8-1 InputsInputs


3-8-1-1 Input 1Configuration of input 1

None None,forced start (checkrun),alt. setpoint,leakage,remoteacknowledgement,bypass valve,emergency power

- - Service Service



- - Service Service

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- - Service Service

3-8-2 OutputsOutputs


3-8-2-1 Output 1 (P4)Configuration of output 1

None None,threshold 1,threshold 2,supply valve,bypass valve,lack of water

- - Service Service



- - Service Service



- - Service Service

3-8-2-4 Output 4 (FR4)Configuration of output 4


- - Service Service



- - Service Service



- - Service Service

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3-9 MessagesMessages


3-9-1 Message SettingsList of all alerts


3-9-1.1.1 failure idFault ID

- - - Service Service

3-9-1.2.1 Traffic Light Assignment of fault as warning or alert

Red Green,amber,red

- - Service Service

3-9-1.2.2 Fault on HoldWithout/with automatic reset (re-start)

Off Off,on

- - Service Service

3-10 Root menuConfiguring the main menu


3-10-1.1 Root Menu SettingsList of all main menu elements

- - Customer Everybody

3-10-1.2 Root Menu SettingsList of all main menu elements

- - - - Develop Develop

3-10-1.2.1 rootmenu selectionRoot menu selection

1 1.. 65 1 65 Develop Develop

3-10-1.2.1 Traffic Light Assignment of fault as warning or alert

Off Off,on

- - Develop Develop

3-11 Energy Saving ModeEnergy-saving mode


3-11-1 Energy Saving ModeEnergy-saving mode

Off Off,on

- - Service Service

3-11-2 direct offEnergy-saving mode is carried outwithout zero-flow detection function

Off Off,on

- - Service Service

3-11-3 Power down speed %Calculated stop speed if zero-flowdetection is activated in energy-savingmode (in %).


3-11-4 time direct offTime after which the energy-savingmode is carried out without the zero-flow detection function


3-13 Pump ChangeoverPump changeover


3-13-1 Supply reactionSelection of oversupply/undersupply

Undersupply Undersupply,oversupply


3-13-2 Changeover delayTime delay between pump changeover


3-14 By Pass ValveBypass valve


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3-14-1 Valve FunctionActivating/deactivating the valvefunction

Off Off,forced start (checkrun),PT1000,digital input


3-14-2 Open delayDelay time that lapses before valve isopened.


3-14-3 Close delayDelay time that lapses before valve isclosed.


3-14-4 TemperatureTemperature above which the valve isopened


3-14-5 Flush TimeTime window in which the valve isopened


3-14-6 Attemps in 24HrsValve opening frequency before an alertis displayed


3-14-7 Min. open timeMinimum opening time of valve


3-15 FieldbusField bus settings


3-15-1 ProfibusProfibus settings


3-15-1-1 PB Slave AddressProfibus slave address

126 1.. 255 1 255 Customer Customer

3-15-2 ModbusModbus settings


3-15-2-1 MB Slave AddressModbus slave address

247 1.. 247 1 247 Customer Customer

3-15-2-2 BaudrateBaud rate

192 9600,192 - - Customer Customer

4 InfoInformation


4-1 DeviceControl module (CM)


4-1-1 Serial NumberSerial number of control module


4-1-2 Parameter SetVersion of the control panel parameterset

0 - - - Everybody Everybody

4-2 IO Info

IO information for internalcommunications unit


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4-2-1 IO Serial Number

IO information for serial number ofinternal communications unit


4-2-2 IO FW-Version

IO information for firmware of internalcommunications unit


4-2-3 IO FW-Revision

IO information for revision of internalcommunications unit


4-2-4 IO HW-Revision

IO information for hardware of internalcommunications unit


4-3 HMI Info

IO information for HMI


4-3-1 HMI Serial Number

IO information for serial number of HMI


4-3-2 HMI FW-Version

IO information for firmware of HMI


4-3-3 HMI FW-Revision

IO information for revision of HMI


4-3-4 HMI HW-Revision

IO information for hardware of HMI


4-4 Profibus Info

Information for Profibus used


4-4-1 PB FW-Version

Information for firmware of Profibus


4-4-2 PB FW-Revision

Information for firmware of Profibus


4-4-3 PB HW-Revision

Information for hardware of Profibus


4-5 Modbus Info

Information for Modbus used


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4-5-1 MB FW-Version

Information for firmware of Modbus


4-5-2 MB FW-Revision

Information for revision of Modbus


4-5-3 MB HW-Revision

Information for hardware of Modbus


5 Quickmenu

Information for quick menu


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8.7 Quick menu

The following main parameters, which may be required for adapting the pressurebooster system to site conditions, can be called directly via the Quick Menu, whichcan be accessed directly from the start screen by pressing the OK key:

▪ PIN

▪ Proportional constant

▪ Integral constant

▪ Differential constant

▪ Setpoint

▪ Bandwidth

▪ Accumulator pressure

▪ Delta P

▪ High pressure alarm

▪ Low pressure alarm

▪ Min. run time

▪ Start delay

▪ Stop delay

▪ RDP delay

▪ High/low alarm delay

8.8 Saving and restoring settings

Users have to be logged in at "Customer" level to save and restore settings.

8.8.1 Saving settings

The changes made to the control unit parameters at the site can be saved under3-2-2-4.

8.8.2 Restoring settings

Three types of settings can be restored if the system does not operate any more as aresult of incorrect settings made at the site.

▪ Parameter 3-2-2-1 Resetting to factory settings. The control unit is reset to thevalues and settings the pressure booster system was delivered with.

▪ Parameter 3-2-2-3: Resetting to the site-specific settings.

▪ Parameter 3-2-2-6: Resetting to default settings ("Factory" level only). Thecontrol unit is reset to the pressure booster system type (no settings for pressure,dry running protection, etc.)

8.9 Fault messages

Table 16: Overview of fault messages

Fault message Description Type of message

Warning AlertFailure PT. Dis. Fault, discharge-side pressure sensor - ✘Sys. press.to low System pressure below minimum pressure - ✘Sys press.to high System pressure above maximum pressure - ✘No water Insufficient water or insufficient inlet pressure on

suction side- ✘

Maintenance req. Service interval exceeded ✘ -More pumps fail Multiple pump faults - ✘No refresh tank 1 Insufficient water replacement, tank 1 - ✘No refresh tank 2 Insufficient water replacement, tank 2 - ✘No refresh tank 3 Insufficient water replacement, tank 3 - ✘

8 Control panel



Warning AlertAver temp to high Average temperature of water flow detection too high - ✘Curr temp to high Current temperature of water flow detection too high ✘ -Temp. Fail. Pump 1 Fault (temperature, motor protection switch, etc.),

pump 1✘ -

Temp. Fail. Pump 2 Fault (temperature, motor protection switch, etc.),pump 2

✘ -


✘ -


✘ -


✘ -


✘ -

Failure valve Fault, suction-side valve ✘ -Inlet sensor fail Fault, suction-side pressure or level sensor ✘ -High water level Water level in inlet tank too high - ✘Crit. water level Water level in inlet tank too low ✘ -Low water level Water level in inlet tank low (lack of water) - ✘Comm. Error FC 1 Communication not possible, frequency inverter 1 ✘ -Comm. Error FC 2 Communication not possible, frequency inverter 2 ✘ -Comm. Error FC 3 Communication not possible, frequency inverter 3 ✘ -Comm. Error FC 4 Communication not possible, frequency inverter 4 ✘ -Comm. Error FC 5 Communication not possible, frequency inverter 5 ✘ -Comm. Error FC 6 Communication not possible, frequency inverter 6 ✘ -incor. check sum F1 Communication fault, frequency inverter 1 ✘ -incor. check sum F2 Communication fault, frequency inverter 2 ✘ -incor. check sum F3 Communication fault, frequency inverter 3 ✘ -incor. check sum F4 Communication fault, frequency inverter 4 ✘ -incor. check sum F5 Communication fault, frequency inverter 5 ✘ -incor. check sum F6 Communication fault, frequency inverter 6 ✘ -Temp. sensor fail Fault, temperature sensor of water flow detection ✘ -24V out of range Internal 24 V voltage outside permissible range ✘ -5V out of range Internal 5 V voltage outside permissible range ✘ -3V out of range Internal 3 V voltage outside permissible range ✘ -External off External command for system stop active ✘ -Fire alarm External fire alert command for starting all pumps active - ✘Br. Wire Sens.dis Fault, discharge-side pressure sensor - ✘Br. Wire Sens.Inl Fault, suction-side pressure sensor - ✘Fail. several FCs Fault, several frequency inverters - ✘Leakage Leak detected - ✘Eeprom HW Error EEPROM data not saved due to hardware problems - ✘Manual off Pump 1 Pump 1 switched off

(independent of automatic mode)✘ -

Manual off Pump 2 Pump 2 switched off (independent of automatic mode)

✘ -


✘ -


✘ -


✘ -


✘ -

Manual On Pump 1 Pump 1 in manual mode (independent of automatic mode)

✘ -


✘ -


✘ -

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Warning AlertManual On Pump 4 Pump 4 in manual mode

(independent of automatic mode)✘ -


✘ -


✘ -

More Pumps off Several pumps switched off (independent of automaticmode)

✘ -

Internal Failure P1 Internal fault, frequency inverter 1 ✘ -Internal Failure P2 Internal fault, frequency inverter 2 ✘ -Internal Failure P3 Internal fault, frequency inverter 3 ✘ -Internal Failure P4 Internal fault, frequency inverter 4 ✘ -Internal Failure P5 Internal fault, frequency inverter 5 ✘ -Internal Failure P6 Internal fault, frequency inverter 6 ✘ -Mains Failure P1 Power supply fault, frequency inverter 1 ✘ -Mains Failure P2 Power supply fault, frequency inverter 2 ✘ -Mains Failure P3 Power supply fault, frequency inverter 3 ✘ -Mains Failure P4 Power supply fault, frequency inverter 4 ✘ -Mains Failure P5 Power supply fault, frequency inverter 5 ✘ -Mains Failure P6 Power supply fault, frequency inverter 6 ✘ -Over voltage P1 DC link voltage too high, frequency inverter 1 ✘ -Over voltage P2 DC link voltage too high, frequency inverter 2 ✘ -Over voltage P3 DC link voltage too high, frequency inverter 3 ✘ -Over voltage P4 DC link voltage too high, frequency inverter 4 ✘ -Over voltage P5 DC link voltage too high, frequency inverter 5 ✘ -Over voltage P6 DC link voltage too high, frequency inverter 6 ✘ -Under voltage P1 DC link voltage too low, frequency inverter 1 ✘ -Under voltage P2 DC link voltage too low, frequency inverter 2 ✘ -Under voltage P3 DC link voltage too low, frequency inverter 3 ✘ -Under voltage P4 DC link voltage too low, frequency inverter 4 ✘ -Over voltage P5 DC link voltage too low, frequency inverter 5 ✘ -Over voltage P6 DC link voltage too low, frequency inverter 6 ✘ -Overload Failure P1 Overload, frequency inverter 1 ✘ -Overload Failure P2 Overload, frequency inverter 2 ✘ -Overload Failure P3 Overload, frequency inverter 3 ✘ -Overload Failure P4 Overload, frequency inverter 4 ✘ -Overload Failure P5 Overload, frequency inverter 5 ✘ -Overload Failure P6 Overload, frequency inverter 6 ✘ -Brake resistor P1 Braking resistor fault, frequency inverter 1 ✘ -Brake resistor P4 Braking resistor fault, frequency inverter 2 ✘ -Brake resistor P3 Braking resistor fault, frequency inverter 3 ✘ -Brake resistor P4 Braking resistor fault, frequency inverter 4 ✘ -Brake resistor P5 Braking resistor fault, frequency inverter 5 ✘ -Brake resistor P6 Braking resistor fault, frequency inverter 6 ✘ -Temp. Failure P1 Temperature too high, frequency inverter 1 ✘ -Temp. Failure P2 Temperature too high, frequency inverter 2 ✘ -Temp. Failure P3 Temperature too high, frequency inverter 3 ✘ -Temp. Failure P4 Temperature too high, frequency inverter 4 ✘ -Temp. Failure P5 Temperature too high, frequency inverter 5 ✘ -Temp. Failure P6 Temperature too high, frequency inverter 6 ✘ -ATM Failure P1 Automatic motor adaptation fault, frequency inverter 1 ✘ -ATM Failure P2 Automatic motor adaptation fault, frequency inverter 2 ✘ -ATM Failure P3 Automatic motor adaptation fault, frequency inverter 3 ✘ -ATM Failure P4 Automatic motor adaptation fault, frequency inverter 4 ✘ -ATM Failure P5 Automatic motor adaptation fault, frequency inverter 5 ✘ -ATM Failure P6 Automatic motor adaptation fault, frequency inverter 6 ✘ -Flushing Flushing procedure in progress ✘ -Valve opened oftenly Several flushing procedures carried out ✘ -Circuit Fail. FC1 Short circuit/earth fault, frequency inverter 1 ✘ -Circuit Fail. FC2 Short circuit/earth fault, frequency inverter 2 ✘ -

8 Control panel



Warning AlertCircuit Fail. FC3 Short circuit/earth fault, frequency inverter 3 ✘ -Circuit Fail. FC4 Short circuit/earth fault, frequency inverter 4 ✘ -Circuit Fail. FC5 Short circuit/earth fault, frequency inverter 5 ✘ -Circuit Fail. FC6 Short circuit/earth fault, frequency inverter 6 ✘ -Ext. Power Operation Emergency power mode active; maximum system load

limited✘ -

Setpoint Reduction Setpoint reduced due to drop in inlet pressure ✘ -Factory Test No test carried out in factory - ✘MPO Failure Fault in VP mode, synchronous operation ✘ -ASR Shutdown Cancellation of automatic setpoint reduction - ✘

8.10 Energy-saving mode

In energy-saving mode (-> Parameter 3-11 ff.) the energetically inefficient operationof a single pump at minimum water consumption can be reduced.

CAUTIONHunting (excessive starting/stopping) of pressure booster systemDamage to the pumps!

▷ Only activate the energy-saving mode if a sufficiently sized accumulator is fittedon the discharge side.

NOTENo recommendation can be given for the parameters of the energy-saving mode. The values depend on the system installed and can only be defined at theoperational pressure boosting system installed on site.

Making settings:

1. Close the discharge-side shut-off valve slowly until only a single pump is leftrunning and delivering a small amount of water.

2. Read the pump load in parameter 1-1-2.

3. Activate "Charge accumulator" in parameter 3-5-4.

4. Set parameter 3-11-1 to "ON".

5. Set parameter 3-11-2, "Direct OFF", to "ON". The setting "OFF" (flow detection) should only be selected for difficult siteconditions and by an expert.

6. Enter the value read under item 2 in parameter 3-11-3.

7. Set parameter 3-11-4 to define the period the pump is to keep on running inorder to charge the accumulator before stopping.

8. Keep changing parameters 3-11-3 and 3-11-4 to obtain the required pumpstopping behaviour.

8.11 Flow detection

When only one pump is operated, the control unit checks whether a liquid volume isbeing pumped. To this end, the rotational speed is reduced slightly every 10 seconds. If the control unit detects that the actual value is within a settable bandwidth (->parameter 3-4-3-5-1) during a settable period (-> parameter 3-4-3-5-2), the "Chargeaccumulator" function is carried out and the pump stops.

8 Control panel


8.12 Connecting the ambient temperature monitoring device (option)

If ambient temperature monitoring has been selected under parameter 3-3-4, WSD, aPt1000 sensor must be connected. The ambient temperature can be read on thedisplay.A warning can be output if a set temperature has been exceeded, see parameter3-4-4-3.

NOTEThis function cannot be used in conjunction with digital inputs for remote reset,setpoint changeover and check run!

8.13 Digital inputs for remote reset, setpoint changeover and check run(option)

If "OFF" (standard setting) has been selected at parameter 3-3-4, WSD, the WSDinputs 1 to 3 can be used for the following functions:

▪ Remote reset, activated by pulse to terminals.

▪ Setpoint changeover (see parameter 3-5-9), activated by closing of contact,deactivated by opening of contact.

▪ Check run, pulse-activated.

NOTEThis function cannot be used in conjunction with ambient temperature monitoring.

8 Control panel


9 Servicing/Maintenance

9.1 General information/Safety regulations

The operator ensures that all maintenance, inspection and installation work isperformed by authorised, qualified specialist personnel who are thoroughly familiarwith the manual.

DANGER

Unintentional start-up of pressure booster systemDanger to life!

▷ The pressure booster system must be de-energised before repair ormaintenance work is carried out.Switching the system off via the motor protection switch will not de-energisethe motor power cables reliably.

WARNINGUnintentional start-up of pressure booster systemRisk of injury by moving parts!

▷ Make sure the pressure booster system has been de-energised beforecommencing work on the pressure booster system.

▷ Make sure that the pressure booster system cannot be started upunintentionally.

WARNINGUnqualified personnel performing work on the pressure booster systemRisk of personal injury!

▷ Always have repair and maintenance work performed by specially trained,qualified personnel.

CAUTIONIncorrectly serviced pressure booster systemFunction of pressure booster system not guaranteed!

▷ Regularly service the pressure booster system.

▷ Prepare a maintenance schedule for the pressure booster system with specialemphasis on the lubricants and shaft seals of the pumps.

Observe the general safety instructions and information.

Observe the operating manual of the pump when performing work on the pumps.

In the event of damage you can always contact our service staff.

A regular maintenance schedule will help avoid expensive repairs and contribute totrouble-free, reliable operation of the pressure booster system with a minimum ofmaintenance expenditure and work.

Never use force when dismantling and re-assembling the pressure booster system.

9.1.1 Inspection contract

For all inspection and servicing work to be carried out at regular intervals werecommend taking out the inspection contract offered by KSB. Contact your ServicePartner for details.

Checklist for commissioning/inspection and maintenance



9.2 Servicing/inspection

9.2.1 Supervision of operation

CAUTIONIncreased wear due to dry runningDamage to the pump set!

▷ Never operate the pump set without liquid fill.

▷ Never close the shut-off element in the suction line and/or supply line duringpump operation.

CAUTIONImpermissibly high temperature of fluid handledDamage to the pump!

▷ Prolonged operation against a closed shut-off element is not permitted(heating up of the fluid).

▷ Observe the temperature limits in the data sheet and in the section onoperating limits.

While the system is in operation, observe and check the following:

▪ Check the test run (if activated).

▪ Compare the start and stop pressures of the pumps with the data on the nameplate (using the pressure gauge).

▪ Compare the pre-charge pressure of the accumulator with the recommendeddata. (⇨ Section 9.2.3 Page 58) Close the shut-off elements under the accumulator and drain the accumulator viathe drain valve. Remove the protective cap of the accumulator valve and check the pre-chargepressure with the aid of a tyre pressure gauge. Add nitrogen as necessary.

WARNINGWrong gasDanger of poisoning!

▷ Use only nitrogen to charge the accumulator.

▪ Check the rolling element bearings for running noises.Vibrations, noise and an increase in current input occurring during unchangedoperating conditions indicate wear.

▪ Monitor the correct functioning of any auxiliary connections.

9.2.2 Checklist for inspection

In the event that you decide to conduct your own inspections, proceed according tothe following checklist at least once a year:

1. Check the pump and drive for smooth running and the mechanical seal forintegrity.

2. Check the shut-off, drain and check valves for proper functioning and tightness.

3. Clean the strainer in the pressure reducer (if applicable).

4. Check expansion joints for wear (if applicable).

5. Verify the pre-charge pressure level and check the accumulator for integrity, ifrequired. (⇨ Section 9.2.3 Page 58)

6. Check the automatic switching functionality.

7. Check the start and stop points of the pressure booster system.



8. Check the water inflow, inlet pressure, lack-of-water monitoring, flowmonitoring and pressure reducer.

9. Check the inlet tank and the float valve (if applicable). Check the overflow forintegrity and cleanliness.

9.2.3 Setting the pre-charge pressure

WARNINGWrong gasDanger of poisoning!

▷ Use only nitrogen to charge the accumulator.

The pre-charge pressure in the accumulator should be set to a value below the setstart-up pressure. The setting can be effected via a valve located under the cover at the top of theaccumulator.

Example: Pre-charge pressure 10 % lower than start-up pressure

Pre-charge pressure of accumulator p = 0.9 x pstart

pstart = start-up pressure of pressure booster system

Recommendation

The stated values are average values. Tests on accumulators have shown that the beststorage volumes are achieved with the following factors: pressures >3 bar: factor 0.9 and pressures <3 bar: factor 0.8

Example:

pstart= 5 bar: pre-charge pressure 5 x 0.9 = 4.5 barpstart = 2 bar: pre-charge pressure 2 x 0.8 = 1.6 bar

CAUTIONPre-charge pressure too highDamage to accumulator!

▷ Observe data provided by accumulator manufacturer (see name plate oroperating manual of accumulator).



10 Trouble-shooting

WARNINGImproper work to remedy faultsRisk of injury!

▷ For any work to remedy faults observe the relevant information in this manualor in the relevant accessory manufacturer's product literature.

NOTEBefore performing any work on the pump's internal parts during the warrantyperiod please always consult the manufacturer. Our after-sales service will be atyour disposal. Non-compliance will lead to forfeiture of any and all rights to claimsfor damages.

If problems occur that are not described in the following table, consultation withKSB’s customer service is required.

Pumps fail to start in automatic mode or cut out shortly after start-up. Lack of wateris indicated.

Pressure booster system does not start up.

Pumps running but not delivering water.

Insufficient delivery of pressure booster system.

Discharge-side pressure too low.

Discharge-side pressure too high.

Leakage at mechanical seal

One/several pumps/motors overheated.

Motor protection switch(es) triggered. Warning LED lit.

Pump(s) do(es) not stop.

Pumps start too often (more than 30 start-ups per pump and hour).

One/several pumps/motors overheated.

Table 17: Trouble-shooting

A B C D E F G H I J K L Possible cause Remedy1)

- - ✘ ✘ - - - ✘ - ✘ - - Pumps and/or piping are notcompletely vented or primed.

Vent and/or prime.

✘ ✘ ✘ ✘ ✘ - - ✘ - - ✘ - Shut-off valves (partially) closed Check, open as necessary.✘ - - ✘ ✘ - - - - ✘ ✘ - Strainer clogged (inlet-side pressure

reducer)Clean.

✘ - - ✘ ✘ ✘ - - - ✘ ✘ - Inlet-side pressure reducer setincorrectly

Check, adjust as necessary.

- - ✘ ✘ ✘ - - ✘ ✘ ✘ ✘ - Check valve in bypass line defective Replace.✘ ✘ - - - - - - - - - - Inlet-side shut-off valve closed Check, open as necessary.- ✘ - - - - - ✘ - ✘ - - Discharge-side shut-off valve closed

or defectiveCheck, open as necessary.

✘ - - ✘ ✘ - - ✘ - ✘ ✘ - Inlet pressure lower than stated inthe purchase order

Contact KSB.

- ✘ - - - ✘ - - - - - - Inlet pressure higher than stated inthe purchase order

Contact KSB.

- - - - ✘ - - - - ✘ - - Start-up pressure set too high Check setting.- ✘ - - ✘ ✘ - ✘ - ✘ - ✘ Pressure transmitter set incorrectly

or defectiveCheck setting.

- - - - - - - ✘ - - ✘ ✘ Pre-charge pressure of theaccumulator too low

Restore nitrogen cushion.

- - - - - - - ✘ - - ✘ ✘ Defective accumulator Check integrity/replace, if necessary.

A

B

C

D

E

F

G

H

I

J

K

L

1) The pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.Disconnect the pump from the power supply!

10 Trouble-shooting


A B C D E F G H I J K L Possible cause Remedy1)

- - - - - - ✘ - - - - - Defective mechanical seal Replace.✘ - - - - - - ✘ - ✘ - - Suction-side pressure transmitter/

pressure switch set incorrectly ordefective.

Check setting.

- - ✘ ✘ ✘ - - ✘ ✘ ✘ ✘ - Defective check valve in the pressurebooster system

Check, replace sealing element asnecessary.

- - - - ✘ - - - ✘ ✘ - ✘ Water extraction higher than statedin the purchase order

Contact KSB.

- ✘ - - - - - - ✘ - - ✘ Motor protection switch triggeredor set incorrectly, or pump seized

Compare setting with the motor'srating plate data.

- - - - - - - - - - ✘ - Delay setting too short Check setting.- ✘ - - - - - - - - - - Mains supply interrupted Check and remedy defect/check fuse.- ✘ - - - - - - - - - - Control current fuse tripped (control

cabinet)Determine cause and reset.

- ✘ - - - - - - ✘ - - - Main fuse on (owner-supplied)distribution board loose or blown;fuses possibly too small or too fast

Check fuses and replace asnecessary. Measure the motorcurrent.

- - - - - - - - ✘ - - - Intermittent voltage fluctuations Press reset and faultacknowledgement key.

- ✘ - - - - - - - - - - Phase failure Check individual phases; replacefuse, if necessary.

✘ - - - - - - - - - - - Inlet tank empty or float switchdefective / disconnected

Check and remedy defect.

1) The pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.Disconnect the pump from the power supply!

10 Trouble-shooting


11 Related Documents

11.1 Dimensions

503530 220

300

608

644

L1

685

525

648

689

60

636

811

783

75

75

*)

Fig. 6: Dimensions



11.2 General arrangement drawings

11.2.1 General arrangement drawing — floor-mounted version

Fig. 7: General arrangement drawing — floor-mounted version



11.2.2 General arrangement drawing — wall-mounted version

Fig. 8: General arrangement drawing — wall-mounted version



12 EC Declaration of Conformity

Manufacturer: KSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

Hya-Compact K, Hya-Compact VP

KSB order number: ...................................................................................................

▪ is in conformity with the provisions of the following Directives as amended from time to time:

– Pump set: Machinery Directive 2006/42/EC

– Pump set: Electromagnetic Compatibility Directive 2004/108/EC

The manufacturer also declares that

▪ the following harmonised international standards have been applied:

– ISO 12100,

– EN 809/A1,

– EN 60204-1

▪ Applied national technical standards and specifications, in particular:

– DIN 1988-500

Person authorised to compile the technical file: Name

Function Address (company)Address (Street, No.)Address (post or ZIP code, city) (country)

The EC Declaration of Conformity was issued in/on:

Place, date

..............................2).............................

Name

FunctionCompanyAddress

2) A signed, legally binding declaration of conformity is supplied with the product.

12 EC Declaration of Conformity


13 Certificate of Decontamination

Type: ................................................................................................................................Order number/Order item number3): ................................................................................................................................

Delivery date: ................................................................................................................................ Field of application: ................................................................................................................................ Fluid handled3): ................................................................................................................................

Please tick where applicable3):

⃞ ⃞ ⃞ ⃞Radioactive Explosive Corrosive Toxic

⃞ ⃞ ⃞ ⃞Harmful Bio-hazardous Highly flammable Safe

Reason for return3): ................................................................................................................................

Comments: ................................................................................................................................ ................................................................................................................................

The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placing at your disposal.

We herewith declare that this product is free from hazardous chemicals, biological and radioactive substances.

For mag-drive pumps, the inner rotor unit (impeller, casing cover, bearing ring carrier, plain bearing, inner rotor) has beenremoved from the pump and cleaned. In cases of containment shroud leakage, the outer rotor, bearing bracket lantern,leakage barrier and bearing bracket or intermediate piece have also been cleaned.

For canned motor pumps, the rotor and plain bearing have been removed from the pump for cleaning. In cases of leakage atthe stator can, the stator space has been examined for fluid leakage; if fluid handled has penetrated the stator space, it hasbeen removed.

⃞ No special safety precautions are required for further handling.⃞ The following safety precautions are required for flushing fluids, fluid residues and disposal:

...............................................................................................................................................................

...............................................................................................................................................................

We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with therelevant legal provisions.

.................................................................... ....................................................... .......................................................Place, date and signature Address Company stamp

3) Required fields

13 Certificate of Decontamination


14 Commissioning ReportThe KSB pressure booster system specified below was today commissioned by the undersigned authorised KSBcustomer service engineer who created this report.

Pressure booster system detailsType series ........................................................................................................................................Size ........................................................................................................................................Serial number ........................................................................................................................................Order No. ........................................................................................................................................

2 Purchaser/place of installationPurchaser Place of installation Name .................................................... .......................................................................... Address .................................................... .......................................................................... .................................................... ..........................................................................

3 Operating data For further details refer to the circuit diagram.Start-up pressure pstart bar .................................................... Inlet pressure monitoring pinl - x (setting of inlet pressure switch)

....................................................

Stop pressure pstop bar .................................................... Inlet pressure pinl bar .................................................... Pre-charge pressure of accumulator ppre-charge

bar....................................................

The system operator/operator's representative herewith confirms to have received instructions on how to operateand service the pressure booster system. The relevant circuit diagrams and operating instructions have beenhanded over.

Non-conformities found during commissioning Deadline for remedial action Non-conformities 1 ........................................................................... .......................................................................... ............................................................................................................. .......................................................................... ............................................................................................................. .......................................................................... ............................................................................................................. .......................................................................... Name of KSB representative Name of purchaser or representative ............................................................................................................. .......................................................................... Place Date ............................................................................................................. ..........................................................................

14 Commissioning Report


Index

CCertificate of decontamination 65Commissioning/Start-up 21

DDisposal 12

EEnergy-saving mode 54

FFaults

Causes and remedies 59Flow detection 54

IIntended use 7

LLEDs 25

MManual mode 15

Misuse 8

NNavigation keys 26

OOperating limits 7Other applicable documents 6

PPartly completed machinery 6Product description 13

QQuick menu 51

RReturn to supplier 11

SSafety 7Safety awareness 8Scope of supply 16Setting the setpoint 28

Index


1972

.8/0

2-EN

KSB Aktiengesellschaft67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)Tel. +49 6233 86-0 • Fax +49 6233 86-3401www.ksb.com

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