DP Pumps Hydro-Unit Premium Line F Installation & Operating Manual Download Page 1

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Pressure Booster System

Installation/Operating Manual

Hydro‑Unit Premium Line

Hydro-Unit Premium Line F

Hydro-Unit Premium Line VC

Hydro-Unit Premium Line SVP

Summary of Contents for Hydro-Unit Premium Line F

Page 1: ...Pressure Booster System Installation Operating Manual Hydro Unit Premium Line Hydro Unit Premium Line F Hydro Unit Premium Line VC Hydro Unit Premium Line SVP ...

Page 2: ...ein must neither be distributed copied reproduced edited or processed for any other purpose nor otherwise transmitted published or made available to a third party without the manufacturer s express written consent Subject to technical modification without prior notice Duijvelaar Pompen Alphen aan den Rijn Netherlands 22 10 2019 ...

Page 3: ...isposal 12 3 1 Checking the condition upon delivery 12 3 2 Transport 12 3 3 Storage preservation 12 3 4 Return to supplier 13 3 5 Disposal 13 4 Description 15 4 1 General description 15 4 2 Product information as per Regulation No 1907 2006 REACH 15 4 3 Designation 15 4 4 Name plate 15 4 5 Design details 16 4 6 Configuration and function 17 4 7 Noise characteristics 18 4 8 Scope of supply 18 4 9 D...

Page 4: ...Control panel 31 7 1 2 Menu structure 33 7 1 3 Access levels 34 7 1 4 Displaying and changing parameters 34 7 1 5 Displaying messages 35 7 1 6 Description of parameters 35 7 1 7 Quick menu 40 7 1 8 Saving and restoring settings 40 7 1 9 Alerts and warnings 41 7 1 10 Connecting the remote ON OFF input 42 7 1 11 Connecting the fire alert 42 7 1 12 Filling the accumulator 42 7 1 13 Energy saving mode...

Page 5: ...5 64 10 1 3 Hydro Unit Premium Line SVP 58 11 EU Declaration of Conformity 59 12 Certificate of Decontamination 60 13 Commissioning Report 61 Index 62 ...

Page 6: ...handled Dry running protection Dry running protection devices prevent the pump from being operated without the fluid to be handled which would result in pump damage Energy saving mode Setting designed to avoid the energetically inefficient operation of a pump at minimum water consumption Filling the accumulator Function to fill a discharge side accumulator it prevents pump sets from starting if on...

Page 7: ...ed This does not however apply to software updates supplied by DP 1 3 Installation of partly completed machinery To install partly completed machinery supplied by DP refer to the sub sections under Servicing Maintenance 1 4 Target group This operating manual is aimed at the target group of trained and qualified specialist technical personnel ð Section 2 3 Page 10 1 5 Other applicable documents Tab...

Page 8: ...s signal word indicates a hazard which if not avoided could result in damage to the machine and its functions General hazard In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or serious injury Electrical hazard In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and identifies informati...

Page 9: ...nsible for ensuring compliance with all local regulations not taken into account 2 2 Intended use The pressure booster system must only be operated within the operating limits described in the other applicable documents Only operate pressure booster systems which are in perfect technical condition Do not operate partially assembled pressure booster systems The pressure booster system must only han...

Page 10: ...rical thermal mechanical and chemical effects and explosions Failure of important product functions Failure of prescribed maintenance and servicing practices Hazard to the environment due to leakage of hazardous substances 2 5 Safety awareness In addition to the safety information contained in this operating manual and the intended use the following safety regulations shall be complied with Accide...

Page 11: ... and the pump must have been drained When taking the pressure booster system out of service always adhere to the procedure described in the manual Decontaminate pressure booster systems which handle fluids posing a health hazard As soon as the work has been completed re install and or re activate any safety relevant and protective devices Before returning the product to service observe all instruc...

Page 12: ...eight has been selected and is on hand 1 Remove the packaging Remove the caps from the connection openings 2 Check for any in transit damage 3 Transport the pressure booster system to the place of installation 4 Detach the pressure booster system from the pallet using a suitable tool 5 Attach the pressure booster system to the lifting equipment as illustrated 6 Lift it off the wooden skids Dispose...

Page 13: ...e drying 4 Always complete and enclose a certificate of decontamination when returning the pressure booster system ð Section 12 Page 60 Always indicate any safety and decontamination measures taken NOTE If required a blank certificate of decontamination can be downloaded from the KSB web site at www dp pumps com certificates of decontamination 3 5 Disposal WARNING Fluids handled consumables and su...

Page 14: ...must not be disposed of in household waste at the end of its service life Contact your local waste disposal partner for returns If the used electrical or electronic equipment contains personal data the operator is responsible for deleting it before the equipment is returned ...

Page 15: ...stem frequency inverter in the control cabinet SVP Variable speed pressure booster system with Megacontrol pump control system frequency inverter mounted on the IE5 motor 4 4 Name plate ID PN Prod IP RDP PO U Kalkovenweg 13 F Alphen a d Rijn NL Imax www dp pumps com Made in NL Premium Line HU3 DPV15 8 B SVP SDAPL30150805SMD 56 1A 50 Hz 3x400V PT 10 2019 1234567 01 123456789 54 16 1 14 13 12 6 11 1...

Page 16: ...or per pump Installation Stationary dry installation Drive Hydro Unit Premium Line F VC Electric motor Efficiency class IE3 to IEC 60034 30 Hydro Unit Premium Line SVP Magnetless synchronous reluctance motor Efficiency class IE5 to IEC 60034 30 SuPremE Automation Control unit IP54 enclosure Sheet steel housing colour RAL 7035 Megacontrol Control panel display keys LEDs service interface Lockable m...

Page 17: ...e zero This ensures equal distribution of pump operating hours If a duty pump fails the next pump is started up immediately Via a volt free contact a general fault message can be transmitted e g to the control station Hydro Unit Premium Line VC SVP Either two or three VC or four SVP pumps are controlled and monitored by a microprocessor control unit Megacontrol Each pump is operated on a frequency...

Page 18: ... system with 4 pump sets value 6 dB A Single pump 48 dB A 48 dB A 6 dB A 54 dB A The expected total sound pressure level of 54 dB A may develop when all 4 pump sets are running under full load conditions 4 8 Scope of supply Depending on the model the following items are included in the scope of supply 2 or 3 vertical high pressure centrifugal pumps with oval flange Powder coated epoxy resin coated...

Page 19: ...sions and weights For dimensions and weights refer to the outline drawing 4 10 Potential equalisation A terminal marked with the earth symbol is provided at the power connection for connecting a PE conductor 1 2 Fig 3 PE connection 1 Earthing terminal 2 Location of power connection ...

Page 20: ...h the dimensions in the outline drawing The pressure booster system can be operated on the power supply network in accordance with the data on the name plate The place of installation is frost free The place of installation can be locked The place of installation is well ventilated A suitably dimensioned drain connection e g leading to a sewer is available If expansion joints are used take note of...

Page 21: ...he pressure booster system 5 3 Mounting the accumulator CAUTION Dirt in the pressure booster system Damage to the pump sets Ø Clean the accumulator before filling it ü The original operating manual of the pressure booster system is on hand 1 Mechanically and electrically connect the accumulator in accordance with the original operating manual supplied 5 4 Connecting the piping CAUTION Air pockets ...

Page 22: ...ds of the bolts must not protrude from the flange 5 4 2 Fitting the pressure reducer optional NOTE A pipe length of approximately 600 mm must be provided on the inlet side to accommodate a pressure reducer if necessary NOTE A pressure reducer must be installed if the inlet pressure fluctuation is too high for the pressure booster system to operate as intended or if the total pressure inlet pressur...

Page 23: ... maximum cable length of 10 metres should not be exceeded between the surge protective device usually type 1 internal lightning protection installed at the service entrance and the equipment to be protected For longer cables additional surge protective devices type 2 must be provided in the sub distribution board upstream of the equipment to be protected or directly in the equipment itself The ass...

Page 24: ...ablish the connection in accordance with the wiring diagram 5 5 4 Connecting the dry running protection device ü The original operating manual of the dry running protection device is on hand 1 Fit the dry running protection device in accordance with the supplied original operating manual Connect it in the control unit in accordance with the supplied original operating manual 5 5 5 Connecting the f...

Page 25: ...AUTION Foreign matter in the piping Damage to the pump pressure booster system Ø Before commissioning starting up or functional check running the pressure booster system make sure that there is no foreign matter in the pressure booster system or piping CAUTION Operation without the fluid to be handled Damage to the pump sets Ø Prime the pressure booster system with the fluid to be handled NOTE Pri...

Page 26: ... Open the discharge side valve 10 When all pump sets have been run once loosen the vent plugs again to let any remaining air escape while the pump is switched off 11 Close the vent plug 12 Check that the pump sets are running smoothly 13 Close the discharge side valve in order to verify whether the pump sets reach the maximum shut off head 14 Open the discharge side valve 15 Set the dry running pr...

Page 27: ...he pipe unions between the pump and the piping have been re tightened ü The flange bolting has been checked for firm seating ü The cooling air inlet and outlet openings on the motor are unobstructed ü All shut off valves of the pressure booster system are open ü The pre charge pressure of the membrane type accumulator has been checked ð Section 8 2 4 Page 47 1 Set the master switch to 0 unlock all...

Page 28: ...er they have been running for 5 to 10 minutes 13 Check the pre charge pressure of the membrane type accumulator 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 ...

Page 29: ...sign variant See name plate 6 2 4 Fluid handled 6 2 4 1 Permissible fluids to be handled Clean fluids not chemically or mechanically aggressive to the pump materials Drinking water Service water Cooling water 6 2 4 2 Fluid temperature Table 9 Temperature limits of the fluid handled Permissible fluid temperature Value Maximum 60 C 25 C to DIN 1988 DVGW 4 Minimum 0 C 6 2 5 Minimum flow rate Table 10...

Page 30: ...truments 1 Set manual 0 automatic selector switch to 0 6 3 2 Measures to be taken for shutdown 1 Fig 6 Venting and draining the accumulator 1 Vent plug ü The pressure booster system has been switched off ð Section 6 3 1 Page 30 1 Loosen vent plug 1 at the accumulator ð The pressure booster system is being vented and drained 2 Re tighten vent plug 1 on the accumulator ...

Page 31: ...icated on the name plate The settings can be modified via the control panel if necessary NOTE The factory settings are permanently stored in the control unit Should an incorrect setting result in pressure booster system failure the factory settings can be restored ð Section 7 1 8 2 Page 41 NOTE The settings made at the site can be saved and loaded when required ð Section 7 1 8 1 Page 40 ð Section ...

Page 32: ...rameters parameter information Level Shows the current access level ð Section 7 1 3 Page 34 Date time Shows the set date and time 7 1 1 2 LEDs The LED provides information on the operating status Table 12 LED description LED Description Green Trouble free operation Yellow One or more warnings are active Red One or more alerts are active 7 1 1 3 Function keys Use the function keys for direct access...

Page 33: ... actual value display Main menu Key Sub menu Menu display 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 histo...

Page 34: ...is access level becomes the Standard access level The password is 7353 Service level Access level for service personnel You must enter the password under 3 2 1 1 Login to gain access S is displayed Factory level Access level for the manufacturer only F is displayed NOTE If no keys are pressed for ten minutes the system will automatically return to the Standard access level 7 1 4 Displaying and cha...

Page 35: ...y 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 and acknowledged individually if the cause of the fault has gone The history of messages can be accessed in the Diagnosis menu under 2 1 2 It indicates the start and end of a fault The list of fault messages can be acknowledged in the Diagnosis menu under 2 1 3 The his...

Page 36: ...e last six faults are displayed A ring next to the fault means that the fault has gone but has not been acknowledged yet A ring filled with a dot means that the fault is still active but cannot be acknowledged 2 1 3 Acknowledging faults 2 1 4 For Service only Deleting the fault history 7 1 6 3 Parameter group 3 Settings Access via the Settings function key Fig 11 Settings key This key is used to c...

Page 37: ...l Input of inlet tank level in cm or m depending on setting made under 3 1 1 3 2 at 100 of sensor signal 3 4 1 4 3 Sensor level Sensor distance from tank floor 3 4 1 4 4 Low level shut down At this level the pressure booster system stops owing to lack of water 3 4 1 4 5 Low level reset At this level the pressure booster system starts again 3 4 1 4 6 Critical water level Level at which a warning is...

Page 38: ...increased or decreased per running pump For difficult site conditions only 3 5 11 Customer level High pressure alarm This parameter defines the maximum pressure at which a warning is to be output 3 5 12 Customer level High pressure action This parameter defines the control unit s response when the pressure set under 3 5 11 is reached Selection options Stop pumps or Message only 3 5 13 Customer lev...

Page 39: ...selected under 3 7 8 1 Enter the weekday 3 7 8 4 Change ON OFF times Can only be selected if Adapt ON OFF per day has been selected under 3 7 8 1 Enter hour and minute for activating and deactivating the alternative setpoint 3 7 9 Date adapt level ON Month from which the alternative level specified under 3 4 1 4 Level configuration is to be activated 3 7 10 Date adapt level OFF Month from which th...

Page 40: ... 2 4 saving customer settings 2 Select OK Restoring settings Restoring factory settings ü Logged in at Customer level 1 Call up parameter 3 2 2 1 factory settings 2 Select RESET OK ð Resets the pressure booster system s values and settings to factory set defaults Resetting to saved settings ü Logged in at Customer level 1 Call up parameter 3 2 2 3 customer settings 2 Select RESET OK ð Resets to se...

Page 41: ...and reset system Br wire sens inl Fault at inlet side sensor defective sensor or broken wire Replace sensor and reset system Fire alarm Alert when the external ON contact opens Warning Description Fail several FCs Faults on several frequency inverters Maintenance required Customer service required Failure Pump 1 Thermal fault of pump 1 temperature too high Failure Pump 2 Thermal fault of pump 2 te...

Page 42: ...ng filled 5 Set the setpoint to 0 ð The function is disabled 7 1 13 Energy saving mode CAUTION Hunting excessive starting stopping of pressure booster system Damage to the pumps Ø Only activate the energy saving mode if a sufficiently sized accumulator is fitted on the discharge side NOTE No recommendation can be given for the parameters of the energy saving mode The values depend on the system in...

Page 43: ...ccumulator and stops the pump set Setting the time interval ü Logged in at Service level 1 Call up parameter 3 4 3 5 2 time flow rate 2 Set time seconds Setting the bandwidth ü Logged in at Service level 1 Call up parameter 3 4 3 5 1 bandwidth flow rate 2 Set the setpoint 7 1 15 Setting the ambient temperature monitoring device optional If the configurable ambient temperature value is exceeded a w...

Page 44: ...2 Set water flow detection on accumulator to OFF ð WSD inputs 1 to 3 are available The following functions can be assigned via the digital inputs Remote reset Activated by pulse to terminals Setpoint changeover see parameter 3 5 9 Activated by closing the contact de activated by opening the contact Functional check run Pulse activated ...

Page 45: ...ure booster system Ø Prepare a maintenance schedule for the pressure booster system with special emphasis on lubricants shaft seals and pump couplings The operator ensures that maintenance inspection and installation are performed by authorised qualified specialist personnel who are thoroughly familiar with the manual Observe the safety instructions and information For any work on the pump set obs...

Page 46: ...es with the specifications on the name plate Compare the pre charge pressure of the accumulator with the recommended data ð Section 8 2 4 Page 47 Check the rolling element bearings for running noises Vibrations noise and an increase in current input occurring during unchanged operating conditions indicate wear Monitor the functions of auxiliary connections if any Also see 2 Setting the pre charge ...

Page 47: ...er 8 2 4 Setting the pre charge pressure WARNING Wrong gas Danger of poisoning Ø Use only nitrogen to charge the accumulator CAUTION Pre charge pressure too high Damage to the accumulator Ø Observe the manufacturer s product literature see name plate or operating manual of the accumulator The accumulator s pre charge pressure p must be lower than the set start up pressure pE of the pressure booste...

Page 48: ...ressure booster system Danger to life Ø Prior to opening the device wait at least 10 minutes for any residual voltage to dissipate 1 De energise the pump set and secure it against unintentional start up Comply with the local regulations 2 Close the shut off valve of the pump 3 Place a suitable container under the drain connection 4 Open the drain connections To do so observe the pump s operating m...

Page 49: ...ts with a clean cloth 10 Re insert the insert check valve into the body Apply lubricant to new O rings See table below Fig 16 Mounting the body 11 Mount the body of the non return valve Fig 17 Loosening the screwed connection of the body parts 12 Use a suitable tool to loosen the screwed connection of the body parts of the non return valve to extend the body length ...

Page 50: ...Molykote G 5511 5 2x Eriks 12711457 71630410 ER non return valve DN 50 Watts Industries IN 050 DN 50 1x Eriks 12192264 2x Eriks 12711459 8 2 6 Mounting the manifold in a mirrored position DANGER Voltage at the pressure booster system Danger to life Ø Prior to opening the device wait at least 10 minutes for any residual voltage to dissipate 1 De energise the pump set and secure it against unintenti...

Page 51: ...51 64 Fig 20 Removing the bolts 5 Remove the tie bolts between the two oval flanges and the pumps Fig 21 Removing the manifold 6 Remove the entire manifold with shut off valves ...

Page 52: ...rning the pressure measuring set A Pressure measuring set B Lever of the shut off valve 8 Close the lever of the shut off valve about half way to enable the 180 turn required in the next step 9 Turn the pressure measuring set by 90 NOTE For some variants the pressure gauge or a pressure sensor need to be removed to be able to turn the pressure measuring set ...

Page 53: ...t off valves by 180 A Fig 25 Turning the pressure measuring set A Pressure measuring set 11 Turn the pressure measuring set by a last 90 12 If the pressure gauge and or pressure sensors have been removed connect them again ð The manifold is now fitted in a mirrored position 13 Tighten the EF locknuts of the shut off valves again ...

Page 54: ...essure too low F Discharge side pressure too high G Leakage at mechanical seal H One several pumps motors overheated I Motor protection switch es triggered Warning LED lit J Pump s do es not stop K Pumps start too often more than 30 starts per pump and hour L One several pumps motors overheated Table 18 Trouble shooting A B C D E F G H I J K L Possible cause Remedy 6 Pumps and or piping are not co...

Page 55: ...er than stated in the purchase order Contact KSB Motor protection switch triggered or set incorrectly or pump seized Compare setting with the motor s rating 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 f...

Page 56: ...1 743 412 79 1 Fig 26 Hydro Unit Premium Line F Table 19 List of components Part No Description Part No Description 79 1 Automatic switchgear 655 Pump 79 2 Measuring transducer 691 Pressure gauge 412 O ring 742 01 02 Lift check valve 591 Accumulator 743 90 Ball valve 595 Anti vibration pad The individual parts of the pump set are shown in the product literature of the pump set ...

Page 57: ... List of components Part No Description Part No Description 79 1 Automatic control unit 595 Anti vibration pad 79 2 Measuring transducer 655 Pump 79 10 Frequency inverter 691 Pressure gauge 412 O ring 742 01 02 Lift check valve 591 Accumulator 743 90 Ball valve The individual parts of the pump set are shown in the product literature of the pump set ...

Page 58: ...SVP Table 21 List of components Part No Description Part No Description 79 1 Automatic switchgear 655 Pump 79 2 Measuring transducer 691 Pressure gauge 412 O ring 742 01 02 Lift check valve 591 Accumulator 743 90 Ball valve 595 Anti vibration pad The individual parts of the pump set are shown in the product literature of the pump set ...

Page 59: ...ction of the use of certain hazardous substances in electrical and electronic equipment RoHS 2014 30 EU Electromagnetic Compatibility EMC The manufacturer also declares that the following harmonised international standards have been applied ISO 12100 EN 809 EN 60204 1 EN 806 2 Person authorised to compile the technical file Menno Schaap Manager Competence Centre Products D P Industries B V Kalkove...

Page 60: ...aring inner rotor has been removed 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 at the stator can the stator space has been examined for fluid ...

Page 61: ...ure pstart bar Setpoint Delta p Minimum runtime 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 operator or operator s representative herewith confirms to have received instructions on how to operate and service the pressure booster system The relevant circuit diagrams and opera...

Page 62: ...nd remedies 54 Filling the accumulator 42 I Installation 16 Installation at site 20 Intended use 9 K Key to safety symbols markings 8 L LED display 32 M Maintenance work 47 N Navigation keys 32 No flow detection 43 O Operating limits 9 Other applicable documents 7 P Partly completed machinery 7 Personnel 10 Preservation 12 Q Qualification 10 Quick menu 40 R Return to supplier 13 S Safety 9 Safety ...

Page 63: ......

Page 64: ...P O Box 28 2400 AA Alphen aan den Rijn The Netherlands t 0172 48 83 88 f 0172 46 89 30 dp dp pumps com www dp pumps com DP Pumps 22 10 2019 BE00001122 1983 812 02 EN ...

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