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KSB Hya-Rain, Installation & Operating Manual

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8 Servicing/Maintenance

40 of 64

Hya-Rain/Hya-Rain N

8 Servicing/Maintenance

8.1 General information/safety regulations

 DANGER

Unintentional start-up of the rainwater harvesting system

Danger to life from live parts!

▷

Always disconnect the rainwater harvesting system from the power supply
before repair or maintenance work is carried out.

▷

Disconnect the plug from the electric mains.

▷

Secure the system against unintentional starting.

 WARNING

Unintentional start-up of the rainwater harvesting system

Risk of injury by moving parts!

▷

Only carry out work on the rainwater harvesting system after checking that the
system has been disconnected from the power supply.

▷

Secure the rainwater harvesting system against unintentional starting.

 WARNING

Work on the rainwater harvesting system by unqualified personnel

Risk of personal injury!

▷

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

 WARNING

Insufficient stability

Risk of crushing hands and feet!

▷

During assembly/dismantling, secure the pump (set)/pump parts to prevent
tilting or tipping over.

The operator ensures that maintenance, inspection and installation are performed by
authorised, qualified specialist personnel who are thoroughly familiar with the
manual.

Always observe the safety instructions and information.

A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the rainwater harvesting system with a minimum
of maintenance expenditure and work.

Never use force when dismantling and reassembling the rainwater harvesting system.

NOTE

All maintenance work, service work and installation work can be carried out by KSB
Service or authorised workshops. For contact details please refer to the enclosed
"Addresses" booklet or visit "

www.ksb.com/contact

" on the Internet.

Summary of Contents for Hya-Rain

Page 1: ...Rainwater Harvesting System Hya Rain Hya Rain N Installation Operating Manual ...

Page 2: ... contents provided herein must neither be distributed copied reproduced edited or processed for any other purpose nor otherwise transmitted published or made available to a third party without the manufacturer s express written consent Subject to technical modification without prior notice KSB SE Co KGaA Frankenthal 21 01 2019 ...

Page 3: ... General description 14 4 2 Designation 14 4 3 Name plate 14 4 4 Design details 15 4 5 Configuration and function 16 4 6 Noise characteristics 17 4 7 Scope of supply 17 4 8 Dimensions and weights 17 5 Installation at Site 18 5 1 Safety regulations 18 5 2 Checks to be carried out prior to installation 18 5 3 Setting up and installing the system 18 5 4 Connecting the piping 19 5 4 1 Connecting the m...

Page 4: ...ation safety regulations 40 8 2 Maintenance inspection 41 8 2 1 Replacing the stored mains water 41 8 2 2 Checking the mains water mode 41 8 2 3 Checking the pump control unit 42 8 2 4 Checking the discharge lines 42 8 3 Drainage cleaning 42 8 4 Dismantling the system 42 8 4 1 Removing the pump set from the piping 42 8 4 2 Removing the pump control unit 44 8 4 3 Removing the mechanical seal 46 8 5...

Page 5: ...the customer when returning the product to the manufacturer to certify that the product has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled Rainwater storage tank Tank for collecting rainwater for buried installation or above floor installation ...

Page 6: ...in the right to claim under warranty 1 2 Target group This operating manual is aimed at the target group of trained and qualified specialist technical personnel ð Section 2 3 Page 9 1 3 Other applicable documents Table 1 Overview of other applicable documents Document Contents Sub supplier product literature Operating manuals logic diagram and other product literature of accessories and integrated...

Page 7: ...in damage to the machine and its functions Explosion protection This symbol identifies information about avoiding explosions in potentially explosive atmospheres in accordance with EU Directive 2014 34 EU ATEX General hazard In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or serious injury Electrical hazard In conjunction with one of t...

Page 8: ...the direction of rotation Markings for connections Type designation The operator is responsible for ensuring compliance with all local regulations not taken into account 2 2 Intended use The system must only be operated within the operating limits described in the other applicable documents Only operate systems which are in perfect technical condition Do not operate partially assembled systems The...

Page 9: ... Accident prevention health regulations and safety regulations Safety regulations for handling hazardous substances Applicable standards directives and laws 2 6 Safety information for the operator user Eliminate all electrical hazards In this respect refer to the applicable national safety regulations and or regulations issued by the local energy supply companies 2 7 Safety information for mainten...

Page 10: ...2 Safety 10 of 64 Hya Rain Hya Rain N The warranty relating to the operating reliability and safety of the system supplied is only valid if the system is used in accordance with its intended use ...

Page 11: ...tion Never suspend the system by its power cable Use suitable approved transport equipment e g crane forklift or pallet trucks NOTE The system and accessories are shipped secured to a wooden pallet and covered with a cardboard box For transport two handles are provided on the side of the cardboard box 1 Cut the packing straps 2 Carefully open the upper part of the cardboard box 3 Take the accessor...

Page 12: ...ng measures be taken for storage Store the rainwater harvesting system in a dry protected room with a constant atmospheric humidity For storing a rainwater harvesting system which has already been operated observe the measures to be taken for shutdown ð Section 6 3 1 Page 31 3 4 Return to supplier 1 Drain the system as per operating instructions 2 Always flush and clean the system 3 In addition an...

Page 13: ...le the product Collect greases and other lubricants during dismantling 2 Separate and sort the materials e g by Metals Plastics Electronic waste Greases and other lubricants 3 Dispose of materials in accordance with local regulations or in another controlled manner Electrical or electronic equipment marked with the adjacent symbol must not be disposed of in household waste at the end of its servic...

Page 14: ...ain N With fill level display and sensor 4 3 Name plate 1 2 4 3 8 7 9 10 Hya Rain N 11037303 ZNI1448 P 230 V 3 7 A 50 Hz 800 W IP 44 Hmax 43 0 m Qmax 4 0 m h 2018w09 Made in Germany Johann Klein Straße 9 Deutschland 67227 Frankenthal KSB SE Co KGaA 6 5 26 5 kg Hya Rain N Fig 1 Name plate example 1 Type series 6 Maximum head 2 Rated current 7 Serial number 3 Rated voltage 8 Total weight 4 Rated pow...

Page 15: ...approx 13 l Float valve for mains water supply approx 2 7 m h IP42 enclosure Pump set 230 V 10 DOL starting Thermal class F Enclosure IP44 Thermal motor protection with automatic reset and start up Bearings Grease packed deep groove ball bearings sealed for life Electrical connection 230 V 50 Hz 800 W Power input in stand by mode 2 5 3 Watt 1 5 m power cable with shockproof plug ...

Page 16: ...lve If the sensor fitted in the rainwater storage tank indicates that the rainwater storage tank is empty the system will automatically switch to the mains water storage tank via a three way valve 4 It will withdraw water from the mains water storage tank until the rainwater storage tank contains a sufficient amount of water again Once the rainwater storage tank contains enough water again this co...

Page 17: ...e tank and mains water storage tank Set of mounting elements for wall mounting bolts plug fixings and mounting brackets Flexible expansion joints for the discharge side as well as for connection to the mains water supply length approx 30 50 cm Bolt hole pattern Installation operating manual Hya Rain Float switch cable length 20 m Hya Rain N Sensor cable length 3 m including connection box 4 8 Dime...

Page 18: ...ription of suitable fluids ð Section 6 2 3 1 Page 30 The installation room is dry frost free and well ventilated The ambient conditions have been met ð Section 6 2 1 Page 30 The wall e g outside wall is suitable for accommodating 4 plug fixings of 10 mm diameter and for carrying the weight of the system ð Section 4 8 Page 17 5 3 Setting up and installing the system ü A suitable installation site h...

Page 19: ...e reducers upstream of the system to make sure that the inlet pressure of the mains water supply does not exceed 4 bar CAUTION Solid substances in the drinking water stones sediments limescale deposits System defect due to impermissible loads Reduced service life If used in areas where the drinking water quality is affected by the above provide a drinking water filter NOTE Fitting a shut off valve...

Page 20: ...let line to the suction nozzle at the bottom of the rainwater harvesting system 3 Fit a lift check valve at the rainwater storage tank end of the suction line 5 4 3 Connecting the discharge line CAUTION Excessive bend of connection line System defect due to impermissible loads on the system Reduced service life Connect the connection line without transmitting any stresses or strains No forces must...

Page 21: ...the overflow as soon as it rises above the maximum fluid level Operation without backflow protection from the sewage system is impermissible such operation voids the DVGW approval and the warranty If no overflow is fitted in the system the siphon trap available as accessory must be connected to the sewage system The siphon trap is not permanently fastened to the system Install it as per DIN 1986 1...

Page 22: ...RNING Incorrect connection to the mains Damage to the mains network short circuit Observe the technical specifications of the local energy supply companies NOTE A motor protection device is recommended 5 5 1 Connecting the float switch 10 cm 20 cm 10 cm Fig 7 Switching points to be observed when fitting the float switch 1 Fasten the float switch to the conduit e g with cable ties or hose clamps ob...

Page 23: ... the terminal box from the system and opening it 5 Feed the power cable of the float switch through the cable gland provided Make sure the cable gland is pointing down Fasten it in this position Fig 10 Connecting the power cable in the terminal box 6 Tighten the cable gland 7 Connect the power cable 8 Close the terminal box 9 Mount the terminal box on the system ...

Page 24: ...nsor at terminal S The cables must not be twisted To tighten the cable the suspended sensor can end just above the tank floor 10 cm PG2 PG3 PG1 Connect the cable at terminal K 100 reference value Mark the sensors at this point Fig 11 Connecting the sensor 1 Mount the terminal box supplied at least 10 cm above the overflow Fasten it to the rainwater storage tank wall or to a pipe ð The sensors hang...

Page 25: ...oing the nuts at the terminal box 2 Remove the terminal box from the system and open it Fig 13 Removing the terminal box from the system and opening it 3 Feed the stripped end of the power cable through the cable gland provided Make sure the cable gland is pointing down Fasten it in this position Fig 14 Connecting the cable in the terminal box 4 Tighten the cable gland 5 Close the terminal box 6 M...

Page 26: ... box Fig 15 Undoing the nuts at the terminal box 2 Remove the terminal box from the system and open it Fig 16 Removing the terminal box from the system and opening it 3 Feed the booster pump connection cable through the provided cable gland Make sure the cable gland is pointing down Fasten it in this position Fig 17 Connecting the power cable in the terminal box 4 Tighten the cable gland 5 Close t...

Page 27: ...27 of 64 Hya Rain Hya Rain N 40 cm 10 cm 10 cm Fig 18 Installation example for a booster pump 5 5 4 Connecting the system 1 Check the available mains voltage against the data on the name plate 2 Plug the system into the mains ...

Page 28: ...ling ü Connect the mains water back up system to the mains water supply ð Section 5 4 1 Page 19 ü The system has been properly connected to the power supply ð Section 5 5 Page 22 1 Set the operating mode selector switch to mains water mode for approximately 15 seconds ð Section 7 Page 32 ð The mains water storage tank will fill automatically Venting ü The mains water storage tank has been filled ü...

Page 29: ...evel display ð Section 7 3 1 Page 36 6 1 4 Functional test Dry running protection ü The system has been properly set up installed connected and commissioned 1 Close the suction side inlet of the rainwater storage tank ð No flow The pump control unit stops the pump set after an after run time of approx 10 seconds 2 If necessary repeat the after run time by pressing the reset key Operating modes ü T...

Page 30: ...ure 40 C maximum Atmospheric humidity 50 maximum at 40 C 6 2 2 Maximum operating pressure CAUTION Permissible operating pressure exceeded Damage to connections and seals Never exceed the operating pressure specified in the data sheet The maximum operating pressure is 6 bar 6 2 3 Fluid handled 6 2 3 1 Permissible fluids to be handled Service water Rainwater not containing abrasive substances 6 2 3 ...

Page 31: ... the rainwater harvesting system against unintentional starting NOTE To drain the mains water storage tank disconnect the suction line from the system and set the three way valve to the middle position 1 Disconnect the system from the power supply and protect it against inadvertent start up 2 Remove the system as per operating instructions 3 Shut off the mains water supply and the discharge line 4...

Page 32: ...c cables prior to commissioning start up 7 1 Control panel 3 1 3 2 3 3 1 1 1 1 2 1 3 2 2 2 2 3 3 4 5 2 1 Fig 20 Control panel 1 Operating mode selector switch with operating mode indicator 1 1 Automatic mode 1 2 Mains water mode manual mode 1 3 Rainwater mode manual mode 2 Level control system Hya Rain N only 2 1 Display 2 2 Percentage setting key 2 3 Timer key 3 Pump control unit 3 1 Lamp green 3...

Page 33: ...s water supplied will not exceed current actual requirements The mains water flow rate depends on the inlet pressure of the public water supply system The mains water mode lamp is lit in the operating mode indicator The system will return to rainwater mode as soon as the water level in the rainwater storage tank has risen back up to the minimum level 7 2 2 Mains water mode manual mode Symbol The s...

Page 34: ...e priming process the process can take up to 4 minutes ü The mains water storage tank has been filled with water 1 Open a consumer installation e g water connection in the garden 2 Set the master switch to 1 3 Set the operating mode selector switch to rainwater mode 4 Press and hold down the reset key until the pump set is operating normally ð The pressure gauge indicates 2 5 to 4 bar Should the p...

Page 35: ...play the remaining pump runtime during the flushing process Table 11 Level control system display Display Description 8 8 8 Fill level of the rainwater storage tank and days remaining until the next rainwater storage tank water replacement tF Selection of the rainwater storage tank design 75 Fill level in the rainwater storage tank in here 75 L Switching level of the rainwater storage tank level x...

Page 36: ...splay Rainwater storage tank design Fill level tF1 Cylinder vertical The fill level corresponds to the fill quantity tF2 Cylinder horizontal The fill level is computed tF3 Round tank The fill level is computed Factory setting Rainwater storage tank design tF1 Table 13 Calibrating the level display and setting the rainwater storage tank design Step 1 Calibrate the level display ü The level control ...

Page 37: ...Switching level 5 Table 14 Setting the switching level for the rainwater storage tank Step 1 Opening the menu 1 Press down and hold the timer key for 3 seconds ð The menu opens Step 2 Choosing the function 1 Press down and hold the timer key until L switching level of the rainwater storage tank is displayed Step 3 Setting the switching level 1 Press down and hold the percentage setting key to set ...

Page 38: ... rainwater storage tank water replacement is displayed Step 2 Choosing the function 1 Press the timer key repeatedly until t days remaining until the next rainwater storage tank water replacement is displayed Step 3 Setting the interval for rainwater storage tank water replacement 1 Press the percentage setting key and set the number of days 10 to 60 days for the flushing interval 2 Press down and...

Page 39: ... to its previous position Valve switchover can be set to between 01 and 10 days Factory setting Valve switchover 2 days Table 17 Setting the valve switchover Step 1 Opening the menu 1 Press down and hold the timer key for 3 seconds ð The menu opens Alternative 1 After setting some other functions press the timer key repeatedly until U days until next automatic valve switchover is displayed Step 2 ...

Page 40: ... of personal injury Always have repair and maintenance work performed by specially trained qualified personnel WARNING Insufficient stability Risk of crushing hands and feet During assembly dismantling secure the pump set pump parts to prevent tilting or tipping over The operator ensures that maintenance inspection and installation are performed by authorised qualified specialist personnel who are...

Page 41: ...de ð Section 7 2 2 Page 33 2 Flush the toilet or activate another consumer installation 2 or 3 times ð The noise of the mains water flowing into the tank can be heard 3 Set the operating mode selector switch back to automatic mode ð Section 7 2 1 Page 33 Hya Rain N The stored mains water is replaced automatically 8 2 2 Checking the mains water mode 1 Check the overflow for any escaping water ð If ...

Page 42: ...luid residues Wear safety clothing and a protective mask if required Observe all legal regulations on the disposal of fluids posing a health hazard 1 Flush the system 8 4 Dismantling the system DANGER Work on the rainwater harvesting system by unqualified personnel Hazard from live parts The system must only be dismantled and reassembled by a trained and qualified electrician The system must be de...

Page 43: ...emoving the mounting plate 7 Pull the plate with pressure gauge and hose out sideways Fig 25 Removing the plate 8 For Hya Rain N disconnect the power supply of the display panel Fig 26 Disconnecting the power supply of the display panel Hya Rain N 9 Undo the nuts Remove the system cover 10 Disconnect the discharge line with a suitable tool ...

Page 44: ...ecting the discharge line 11 Undo the screws securing the pump Fig 28 Undoing the screws securing the pump 12 Pull out the pump set Fig 29 Pulling out the pump set 8 4 2 Removing the pump control unit 1 Remove the cable ties 2 Undo the union nut at the discharge nozzle ...

Page 45: ...8 Servicing Maintenance 45 of 64 Hya Rain Hya Rain N Fig 30 Undoing the union nut at the discharge nozzle ...

Page 46: ...he pump set with the motor below in a clean assembly area 2 Undo the hexagon socket head cap screws at the motor Remove the suction casing Fig 31 Removing the suction casing from the motor 3 Undo the impeller nut Fig 32 Undoing the impeller nut 4 Remove the impeller ð The mechanical seal is freely accessible Fig 33 Removing the impeller 5 Remove the circlip with a suitable tool ...

Page 47: ...only be dismantled and reassembled by a trained and qualified electrician The system must be de energised before any work is carried out Secure the system against unintentional starting 8 5 1 Installing the mechanical seal ü The components have been cleaned and checked for any wear They have been replaced if necessary 1 Slide the mechanical seal onto the shaft with a suitable tool Make sure that t...

Page 48: ...t hand tight Fig 37 Tightening the impeller nut 5 Fit an O ring flush on the motor 6 Position the suction casing on the motor Fasten it with hexagon socket head cap screws 8 5 2 Installing the pump control unit 1 Fasten the union nut at the discharge nozzle Fig 38 Fastening the union nut at the discharge nozzle 2 Connect the cables ...

Page 49: ... in position and inserting the inlet section into the fitting 3 Tighten the screws securing the pump Fig 40 Fitting the screws securing the pump 4 Connect hose 719 02 leading it out at the right or left of the rainwater piping system Prevent excessive bending of the flexible connection lines Fig 41 Connecting the discharge line 5 Fit the system cover Fasten it with nuts 6 For Hya Rain N connect th...

Page 50: ...hand tight Fig 44 Fitting the mounting plate 9 Insert the control unit Fasten it with the locking pin Fig 45 Inserting the control unit 10 Connect the suction line Set the three way valve to the corresponding position 11 Connect and open the mains water supply and the discharge line ð Section 5 4 Page 19 12 Check the available mains voltage against the data on the name plate Plug the power plug in...

Page 51: ...ved Increase toilet flush volume clean strainer in toilet cistern if necessary Pump is running but delivering insufficient flow rate or pressure Pump takes in air Check suction line Suction strainer clogged Clean the suction strainer Pump stops during operation Power failure Undervoltage Check power supply Thermal switch tripped because of overheating Check pump for smooth operation Earth leakage ...

Page 52: ...lve or a pressure reducer is fitted in the mains water supply line upstream of the system the valve reducer must be throttled until the pressure surge is eliminated The drawback of this method is the low mains water back up flow rate It must be checked if the mains water back up flow rate is sufficient to meet standard consumption requirements The lack of water monitoring equipment must not trip i...

Page 53: ... for the rainwater storage tank 655 Pump complete with set of sealing elements3 672 Globe valve vent valve 691 Pressure gauge 71 14 Pipe with sealing element 719 01 Hose inlet side 719 02 Hose discharge side 719 03 Hose with clamp 741 01 Three way valve with tank 741 02 Float valve complete 741 03 Thee way valve 81 9 Relay 81 99 Electrical part complete 81 99 01 Electrical part printed circuit boa...

Page 54: ... 47 Exploded view of the pump Table 21 List of components Part No Comprising Description 10 5 01 02 Pump section 106 Suction casing 109 Stage casing without return vanes 171 Diffuser 230 Impeller 746 Valve disc 270 Deflector 321 01 02 Radial ball bearing 45 4 Spacer 400 01 02 Gasket 412 01 02 03 O ring ...

Page 55: ...1 42 Terminal box 81 22 01 03 Terminal box cover 824 Cable 838 Switch 900 01 02 03 Bolt screw 831 831 Fan impeller 832 Fan hood 837 Capacitor 99 20 Repair kit 270 Deflector 321 01 02 Radial ball bearing 45 4 Spacer 400 01 02 Gasket 412 01 02 03 O ring 554 02 Mechanical seal 921 01 02 Shaft nut 931 Lock washer 932 01 02 03 Circlip 921 Shaft nut 931 Lock washer 932 01 02 03 Circlip ...

Page 56: ...Rain Hya Rain N 10 3 Dimensions and connections 10 3 1 Hya Rain Hya Rain N 56 28 154 168 360 R1 132 90 410 R1 583 439 630 A B C D Fig 48 Dimensions mm A Suction side C Discharge side B Overflow drain line DN 70 D Mains water connection ...

Page 57: ... with air gap inside the tank 2 Mechanical float valve 3 Overflow4 for direct connection of DN 70 drain lines to EN 12056 10 4 Drilling pattern for wall mounting 476 185 Fig 50 Drilling pattern for wall mounting dimensions mm 4 The overflow must be connected via an air gap to EN 1717 otherwise the DVGW approval is void ...

Page 58: ...21 PE A2 BN 122 1 133 M M2 S2 L N PE 1 2 L N PE 132 sw rt PE bl PZ 039 A5 niv N L1 BN 125 BU PE 132 1 K1 2 2 TW PE BU 126 Fig 51 Hya Rain wiring diagram 118 Master switch 130 Plug 119 Operating mode selector switch with operating mode indicator A automatic 0 mains water mode manual mode H rainwater mode manual mode 131 Pump set 122 Automatic mode 132 Display of the pump control unit 122 1 Float sw...

Page 59: ...M2 S2 L N PE 1 2 L N PE 132 sw rt PE bl K1 2 2 rt bl PZ 039 04 A5 niv N L1 A4 138 139 N L1 132 1 Fig 52 Hya Rain N wiring diagram 118 Master switch 132 Display of the pump control unit 119 Operating mode selector switch with operating mode indicator A automatic 0 mains water mode manual mode H rainwater mode manual mode 132 1 Pump control unit 122 Automatic mode 133 Booster pump optional 123 Mains...

Page 60: ...10 Related Documents 60 of 64 Hya Rain Hya Rain N ...

Page 61: ...bility Directive 2014 30 EU The manufacturer also declares that the following harmonised international standards have been applied ISO 12100 EN 809 Applied national technical standards and specifications in particular DIN 1988 100 EN 1717 Person authorised to compile the technical file Armin Reisinger Technical Project Manager Product Development Business Unit Automation and Drives KSB SE Co KGaA ...

Page 62: ...rrier plain bearing 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 adapter 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 flu...

Page 63: ...n 14 Disposal 13 E Event of damage 6 F Faults Causes and remedies 51 Fields of application 8 I Intended use 8 K Key to safety symbols markings 7 M Misuse 8 O Other applicable documents 6 P Personnel 9 Q Qualification 9 R Rainwater storage tank 36 Return to supplier 12 S Safety 8 Safety awareness 9 Shutdown 31 W Warnings 7 Warranty claims 6 ...

Page 64: ...KSB SE Co KGaA Johann Klein Straße 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 5602 81 14 EN 01442695 ...

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