hyamat® v - ksb...2010/03/29 · sound pressure level lpa in db(a). glossary 6 of 58 hyamat® v 1...

Pressure Booster System

Hyamat® V

from series S-V/1

Installation/OperatingManual

Copyright/Legal information Installation/Operating Manual Hyamat® VOriginal operating manual KSB Aktiengesellschaft Frankenthal All rights reserved. Contents provided herein must neither be distributed, copied, reproduced,processed for any other purpose, nor otherwise transmitted to a third party without KSB´s expresswritten consent. Subject to technical modification without prior notice. © KSB Aktiengesellschaft Frankenthal 29.3.2010

Contents

Glossary ................................................................................................ 6

1 General ................................................................................................ 7

1.1 Principles .......................................................................................................... 7

1.2 Installation of partly completed machinery .................................................. 7

1.3 Target group ................................................................................................... 7

1.4 Other applicable documents .......................................................................... 7

1.5 Symbols ............................................................................................................ 7

2 Safety ................................................................................................... 8

2.1 Key to safety symbols/markings ..................................................................... 8

2.2 General ............................................................................................................ 8

2.3 Intended use .................................................................................................... 8

2.4 Personnel qualification and training ............................................................. 9

2.5 Consequences and risks caused by non-compliance with these operatinginstructions ...................................................................................................... 9

2.6 Safety awareness ............................................................................................. 9

2.7 Safety information for the operator/user ...................................................... 9

2.8 Safety information for maintenance, inspection and installation work ... 10

2.9 Unauthorised modes of operation ............................................................... 10

3 Software Changes ............................................................................. 11

4 Transport/Temporary Storage/Disposal ........................................... 12

4.1 As-delivered condition .................................................................................. 12

4.2 Transport ....................................................................................................... 12

4.3 Storage/Preservation ..................................................................................... 13

4.4 Return to supplier ........................................................................................ 13

4.5 Disposal of pressure booster system ............................................................ 13

5 Description ........................................................................................ 14

5.1 General description ....................................................................................... 14

5.2 Designation ................................................................................................... 14

5.3 Name plate .................................................................................................... 14

5.4 Design details ................................................................................................ 14

5.5 Configuration and function ......................................................................... 15

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

5.7 Scope of supply ............................................................................................. 17

5.8 Dimensions and weights ............................................................................... 17

5.9 Terminal wiring diagram ............................................................................. 18

5.10 Potential equalisation terminal .................................................................... 19

Contents

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6 Installation at Site ............................................................................. 20

6.1 Installation ..................................................................................................... 20

6.2 Checking the site before installation .......................................................... 20

6.3 Installing the pressure booster system ......................................................... 21

6.4 Installing the piping ...................................................................................... 21

6.5 Installing unpressurised inlet tanks .............................................................. 22

6.6 Fitting the dry running protection device ................................................... 23

6.7 Connection to power supply ........................................................................ 23

6.8 Acoustic cladding .......................................................................................... 24

7 Commissioning/Start-up/Shutdown ................................................. 25

7.1 Commissioning/start-up ................................................................................ 25

7.2 Switching on the pressure booster system .................................................. 27

7.3 Check list for commissioning/start-up .......................................................... 28

7.4 Shutdown ...................................................................................................... 28

8 Operating the Control Panel of the Pressure Booster System ........ 29

8.1 Control panel functions ................................................................................ 29

8.2 Menu structure .............................................................................................. 32

8.3 Access levels ................................................................................................... 32

8.4 Displaying and changing parameters .......................................................... 33

8.5 Displaying messages ...................................................................................... 34

8.6 Description of parameters ............................................................................ 34

8.7 Quick menu ................................................................................................... 38

8.8 Saving and restoring settings ....................................................................... 39

8.9 Alerts and warnings ..................................................................................... 39

8.10 Connecting the External OFF contact .......................................................... 40

8.11 Connecting the fire alert .............................................................................. 40

8.12 Charging the accumulator ............................................................................ 40

8.13 Energy-saving mode ...................................................................................... 41

8.14 Flow detection ............................................................................................... 41

8.15 Connecting the ambient temperature monitoring device (option) .......... 41

8.16 Digital inputs for remote reset, setpoint changeover and check run(option) .......................................................................................................... 41

9 Servicing/Maintenance ...................................................................... 43

9.1 General notes/Safety regulations ................................................................. 43

9.2 Servicing/inspection ...................................................................................... 44

10 Trouble-shooting ............................................................................... 46

11 Related Documents ........................................................................... 48

11.1 List of components ........................................................................................ 48

11.2 Flow diagram ................................................................................................. 52

Contents

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12 EC Declaration of Conformity .......................................................... 53

13 Certificate of Decontamination ....................................................... 55

14 Commissioning Report ...................................................................... 56

Index .................................................................................................. 57

Contents

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Glossary

AccumulatorThe 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 decontaminationA certificate of decontamination certifies thatthe pressure booster system has been properlycleaned and decontaminated to eliminate anyenvironmental and health hazards arising fromcomponents in contact with the fluid handled.

Charging the accumulatorOption offered by speed-controlled pressurebooster systems of filling a discharge-sideaccumulator before the last pump stops.

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

Energy-saving modeSetting designed to avoid the energeticallyinefficient operation of a pump at minimumwater consumption.

Manual modeIn manual mode, the pressure booster system isoperated directly on mains power,independently of the control unit.

Noise characteristicsThe noise emission to be expected, indicated assound pressure level LpA in dB(A).

Glossary

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1 General

1.1 Principles

This manual is supplied as an integral part of the type series and variants indicatedon the front cover. It describes the proper and safe use of this equipment in allphases of operation.

The name plate indicates the type series/size, the main operating data and the ordernumber. The series/serial number clearly 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 (⇨ Section 5.6 Page 16)

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB, please refer to the sub-sections under Servicing/Maintenance.

1.3 Target group

This manual is aimed at the target group of trained and qualified specialist technicalpersonnel. (⇨ Section 2.4 Page 9)

1.4 Other applicable documents

Table 1: Overview of other applicable documents

Document ContentsSub-supplier documentation Operating manuals, logic diagram and other

product literature of accessories and integratedmachinery components

1.5 Symbols

Table 2: Symbols used in this manual

Symbol Description✓ Conditions which need to be fulfilled before proceeding with the

step-by-step instructions⊳ Safety instructions⇨ Result of an action⇨ Cross-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 DANGERindicates a high-risk hazard which, if not avoided, will result indeath or serious injury.

! WARNING WARNINGindicates a medium-risk hazard which, if not avoided, could resultin death or serious injury.

CAUTION CAUTIONindicates a hazard which, if not avoided, could result in damage tothe machine and its functions.General hazardin conjunction with one of the signal words indicates a hazardwhich will or could result in death or serious injury.

Electrical hazardidentifies information about protection against electrical voltage.

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 limits whichare 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 handle the fluids described in the product

literature 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 minimum flow rates indicated in the product literature (to preventoverheating, bearing damage, etc.).

▪ Observe the maximum flow rates indicated in the product literature (to preventoverheating, 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 use or mode of operation not described inthe product literature.

Prevention of foreseeable misuse

▪ Never exceed the permissible operating limits specified in the product literatureregarding pressure, temperature, etc..

▪ 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 sufficiently trained specialist personneltraining and instructing the personnel who will carry out the respective tasks. Ifrequired, the operator can commission the manufacturer/supplier to train thepersonnel.

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

2.5 Consequences and risks caused by non-compliance with these operatinginstructions

▪ Non-compliance with these operating instructions will lead to forfeiture of anyand all rights to claims for damages.

▪ Non-compliance can, for example, have the following consequences:– Hazards to persons due to electrical, 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

2.6 Safety awareness

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

▪ Accident prevention, health and safety regulations▪ Explosion protection regulations▪ Safety regulations for handling hazardous substances▪ Applicable standards 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.

▪ Never remove a contact guard while the pump is running.▪ Eliminate all electrical hazards.

2 Safety

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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 the

procedure described in the manual.

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

▪ As soon as the work is completed, re-install and/or re-activate any safety-relevantand protective devices. Before returning the product to service, observe allinstructions on commissioning. (⇨ Section 7.1 Page 25)

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

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 8)

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 As-delivered condition

NOTEPrior to dispatch, the pressure booster system was tested and inspected to ensure fullcompliance with the specifications and should therefore be in perfect electrical andmechanical condition upon arrival at its destination.It is recommended that the pressure booster system be inspected for in-transit damageimmediately upon receipt. If there are any complaints or objections, the recipient andcarrier must jointly draw up a damage report.

4.2 Transport

NOTEThe pressure booster system is mounted on wooden skids and wrapped in plastic foil forshipping and temporary storage. All connecting points are capped.

DANGERPressure booster system tipping overRisk of injury by falling pressure booster system!

▷ Never suspend the pressure booster system by its power cable.▷ Observe the local accident prevention regulations.▷ Use suitable, approved transport equipment, e.g. crane, forklift or pallet truck.▷ To transport the pressure booster system, suspend it from the lifting tackle as

illustrated.

Movitec 2, 4, 6, 10, 18 Movitec 32, 45, 65, 90Fig. 1: Transport

✓ The pressure booster system has been checked for in-transit damage.1. Make sure the transport equipment is suitable for safely carrying the indicated

load.

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

3. Attach the pressure booster system to the lifting tackle as shown, lift it off thewooden skids and dispose of the wooden skids.

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


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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 boosting system!

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

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 fluids handled by the system leave residues which might lead to corrosionwhen coming into contact with atmospheric humidity, or which might ignitewhen coming into contact with oxygen, the pressure booster system must also beneutralised and blown through with anhydrous inert gas for drying purposes.

4. Always complete and enclose a certificate of decontamination when returningthe pressure booster system. It is imperative to indicate any safety and decontamination measures taken.

NOTEIf required, a blank certificate of decontamination can be downloaded from the KSB website at: www.ksb.com/certificate_of_decontamination

4.5 Disposal of pressure booster system

WARNINGFluids posing a health hazardHazardous to persons and the environment!

▷ Collect and properly dispose of flushing liquid and any fluid residues.▷ Wear safety clothing and a protective mask, if required.▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Dismantle the pressure booster system.Collect greases and other lubricants during dismantling.

2. Separate and sort the pump materials, e.g. by:- Metals- Plastics- Electronic waste- Greases and other lubricants

3. Dispose of materials in accordance with local regulations or in another controlledmanner.


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

5 Description

5.1 General description

Fully automatic pressure booster package system with two to six vertical high-pressure pumps and continuously variable speed adjustment of one pump; for fullyelectronic control of the required supply pressure at the consumer installations.

5.2 Designation

Example: Hyamat V 4 / 1807 / 1 ,2 - 3 ,2

Table 4: Key to the designation

Code DescriptionHyamat Pressure booster systemV One variable-speed pump4 Number of pumps18 Pump size07 Number of pump stages1,2 Minimum inlet pressure in bar3,2 Maximum usable inlet pressure in bar

5.3 Name plate

Flow rate max

Head at flow rate Q=0Pressure Vessel:Initial vessel pressureWhole area content

Head

Com. No.Hyamat V 5/1806/0.0-0.3 Pos.

Serial No.

Flow rate (max)*Switching-on pressure (pE)Inlet pressure

bar

barbar

mm

kWkWHzHzA

Liter

m3/hm3/h

* with stand-by pump

Please read the Operating Instructions before running

Motor rating per unit P2Motor rating complete P2Operating Voltage / Freq.Actuating Voltage / Freq.Rated current per pumpWiring diagramm No.

9971341255000100

S - T

Max operating pressure bar55,016,0 5,50

5 x 5,5400 V 50230 V 50

12,0BD 705 133

86,0

4,98,0

105,084,0

5,50,0-0,3

Fig. 2: Hyamat V name plate

Key to the ser ies number

Calendar year 2009 2010 2011 2012 20131st half of the year S-U S-W S-Y S-A S-C2nd half of the year S-V S-X S-Z S-B S-D

5.4 Design details

Design

The pressure booster system consists of two to six non-self-priming multistage high-pressure centrifugal pumps with suction and discharge side shut-off valves. The shut-off valves enable dismantling of the pumps or check valves without taking the entirepressure booster system out of service or draining the piping system. The check valves on the discharge side prevent backflow through the pumps duringstandstill and reduce the load on the mechanical seals. A direct-flow accumulator to DIN 4807-5, a pressure transmitter and a pressure gaugeare fitted on the discharge side of the pressure booster system. Depending on the motor rating and control cabinet equipment, the control cabinet iseither mounted on the system baseplate and ready-wired to the pressure boostersystem, or supplied as a separate, floor-mounted cabinet. The pump feet or the baseplate are mounted on anti-vibration mounts.

5 Description

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5.5 Configuration and function

1

2

3

4

5

Fig. 3: Hyamat V

1 Control unit 2 Control cabinet3 Pump 4 Manifold5 Baseplate

The fully automatic pressure booster system is equipped with two to six vertical high-pressure pumps (3) (one of which is speed-controlled) for pumping the fluid handledto the consumer installations in the set pressure range.

Two to six pumps (3) are controlled and monitored by a micro-processor control unit(1). One of the pumps is connected to a frequency inverter and controlled by thecontrol unit so as to ensure a constant discharge pressure of the pressure boostersystem of ±0.4 bar. As the demand increases or decreases, peak load pumps are started and stoppedautomatically. As soon as the demand increases again after one pump has been stopped, anotherpump which has not been in operation before is started up. When the last (FI-controlled) pump has been stopped and the demand increasesagain, the next pump in line is started up and operated on the frequency inverter. The stand-by pump is also included in the alternating cycle. The standard setting is for the pressure booster system to start automatically as afunction of pressure; the actual pressure is measured by an analog pressuremeasuring device (pressure transmitter). The function of this pressure transmitter ismonitored (live-zero). As long as the pressure booster system is in operation, the pumps are started andstopped as a function of demand (standard setting). In this way it is ensured that theindividual pumps operate only in line with the actual demand. The variable-speed pump reduces wear as well as the pumps' frequency of starts inparallel operation. If a duty pump fails, the next pump is started up immediately anda fault is output, which can be reported via volt-free contacts (e.g. to the controlstation). If the demand drops towards 0, the pressure booster system slowly runs down to thestop point. The operating status is displayed via LEDs.

The pressure booster system's response to a potential frequency inverter failure canbe set at the control unit.As a standard, the control unit will switch to cascade operation if the frequencyinverter fails. All the parameters required for this mode of operation can be set atthe control unit. If automatic switchover to cascade operation is not wanted, parameters can be setfor the pressure booster system to stop.

In conjunction with a very large discharge-side accumulator, the energy-saving modeprevents the pressure booster system from running at the least efficient operating

Design

FunctionAutomatic mode

FunctionResponse to FI fault

FunctionEnergy-saving mode

5 Description

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point, supplying very small amounts of water. If very small amounts of water are consumed the pressure booster system only fillsthe downstream accumulator and stops. Any small water volumes required can then be supplied from the accumulator.

Depending on the equipment the pressure booster system is supplied with, thepumps can be operated in manual mode in two different ways. Standard: By making the appropriate settings at the display, one of the pumps can beoperated directly on mains power for 10 seconds, independently of the control unit.Afterwards, the pump automatically returns to the previous mode of operation, seeparameter 1-2-1. (⇨ Section 8.6.1 Page 34)Supplementary equipment: Manual-0-automatic selector switches can be supplied assupplementary equipment. They can be used to operate each pump directly on mainspower, independently of the control unit.

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 cause thefluid 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.

Minimum f low for pump in manual mode

Table 5: Minimum flow per pump in manual mode

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

Movitec 2 300Movitec 4 600Movitec 10 1200Movitec 18 2400Movitec 32 4000Movitec 45 4600Movitec 65 6100Movitec 90 8000

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

5.6 Noise characteristics

Hyamat pressure booster systems are available with different numbers and sizes ofpumps.Therefore, the expected total sound pressure level in dB(A) needs to be calculated. For the expected sound pressure level (noise characteristics) of the individual pumpsplease refer to the pump's operating instructions.

Calculat ion example:

Number of pumps Expected total sound pressure level in dB(A)

Single pump . . . . . dB(A)2 pumps, total +3 dB(A)3 pumps, total +4,5 dB(A)4 pumps, total +6 dB(A)5 pumps, total +7 dB(A)6 pumps, total +7.5 dB(A) Example Single pump 48 dB(A)

FunctionManual mode

Example

5 Description

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Number of pumps Expected total sound pressure level in dB(A)

4 pumps, total +6 dB(A) 54 dB(A)

The total expected sound pressure level of 54 dB(A) for this configuration maydevelop when all four pumps are running under full-load conditions.For noise characteristics of the pumps refer to the pumps' operating instructions.On pressure booster systems with acoustic cladding the expected total sound pressurelevel is reduced by approx. 7 dB(A).

5.7 Scope of supply

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

▪ Two to six vertical high-pressure centrifugal pumps (standard pumps)Movitec 2, 4, 6, 10 and 18 with oval flange/round flange Movitec 32, 45, 65 and 90 with round flange

▪ Hydraulic components made of stainless steel▪ One check valve and shut-off valves for each pump▪ Membrane-type accumulator on the discharge side, approved for drinking water▪ Pressure transmitter on the discharge side▪ Pressure indication via pressure gauge▪ Powder-coated/epoxy resin-coated steel baseplate▪ Pumps fixed to the baseplate on anti-vibration mounts (pump sizes 2, 4, 6, 10 and

18).

▪ Pressure booster system supplied with level-adjustable feet with integrated anti-vibration pads (supplied, but not fitted; pump sizes 32, 45, 65 and 90).

▪ Control cabinet IP 54, EMC interference suppression class B▪ Pump control and monitoring unit▪ Graphical display with operating panel▪ LEDs indicating operational availability and fault of the pressure booster system▪ Service interface for connection to a PC▪ Frequency inverter▪ Transformer for control voltage▪ Motor protection switch per pump▪ Lockable master switch (repair switch)▪ Terminals with identification for all connections▪ Circuit diagram and list of electric components▪ Terminal for connecting analog or digital dry running protection equipment▪ Terminal for external ON▪ Terminal for external OFF

5.8 Dimensions and weights

For dimensions and weights please refer to the outline drawings of the pressurebooster system.

Pressure booster system

Control cabinet

5 Description

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5.9 Terminal wiring diagram

5 Description

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5.10 Potential equalisation terminal

A terminal marked with the earth symbol is provided on the baseplate for connectinga PE conductor.

1

2Fig. 5: PE terminal

1 Earthing terminal 2 Baseplate

Fig. 4: Earth symbol

5 Description

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6 Installation at Site

6.1 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. No harmful gases areallowed to enter the place of installation. An adequately sized floor drain (leading toa 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.

The anti-vibration mounting of the pressure booster system provides adequateinsulation against solid-borne noise. The systems are also available with acousticcladding (accessory) to reduce motor noise. If expansion joints (KSB accessory) areused for damping vibrations, their fatigue strength (endurance limit) must be givendue consideration. Expansion joints must be installed to allow quick and easyreplacement.

6.2 Checking the site before installation

Place of instal lat ion

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

▷ Make sure the concrete of the installation surface is of sufficient strength (min.X0 to EN 206-1).

▷ Place the pressure booster system on firmly set concrete only.▷ Place the pressure booster system on level surfaces only.▷ Refer to any weights given.

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

For pressure booster systems with Movitec 2, 4, 6, 10 and 18, level-adjustable feet areavailable as accessories.

Pressure booster systems with Movitec 32, 45, 65 and 90 are supplied with separatelevel-adjustable feet, two of which can be fixed to the floor.

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


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6.3 Installing the pressure booster system

WARNINGTop-heavy pressure booster systemsRisk of personal injury in case of pressure booster systems equipped with small pumps!

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

▷ Firmly anchor the pressure booster system to its foundation.

Remove 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 to install length-limited expansionjoints.

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 set

firmly.

1. Mark out the anchoring holes on the floor as shown in the outline drawing(attached to the order confirmation).

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 anchor the pressure booster system firmly to its foundation.

6.4 Installing the piping

Make sure that piping is installed without transmitting any stresses or strains. The useof length-limited expansion joints (KSB accessory) is advisable.

CAUTIONAir pockets in suction linePressure booster system cannot prime!

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

Suction lift operation

Incorrect Correct

6.4.1 Fitting an expansion joint

DANGERSparks and radiant heatFire hazard!

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


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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 the expansion joint to compensate for misalignment or mismatch ofthe 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.The position of the expansion joint within the piping system must allow easyaccess and inspection and it must, therefore, not be insulated along with thepiping.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 pressure 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 to operate asintended or- if the total pressure (inlet pressure plus shut-off head) of the pressure booster systemexceeds the design pressure. The maximum pump discharge pressure at zero flow point is reached in manual mode.

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 pressure side. Min. inlet pressure (pinl) = 4 bar Min. pressure gradient = 0.5 bar Downstream pressure = 3.5 bar.

6.5 Installing unpressurised inlet tanks

Installation and location of an unpressurised inlet tank together with the pressurebooster system are governed by the same rules applicable to the pressure boostersystem.

Install the closed PE inlet tank (under atmospheric pressure) available as a KSBaccessory as described in the installation instructions supplied with the tank. (⇨Section 6.1 Page 20)

CAUTIONContamination in the pressure booster systemDamage to the pumps!

▷ Clean the tank before filling it.


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The tank must be connected mechanically and electrically to the pressure boostersystem prior to commissioning of the system.

6.6 Fitting the dry running protection device

Install the dry running protection device supplied together with the pressure boostersystem as a separate, non-fitted accessory, or supplied at a later date for retrofitting,in accordance with its operating instructions and connect it to the switchgear andcontrolgear assembly. The switchgear and controlgear assembly is provided with the requisite inputs.

6.7 Connection to power supply

DANGERWork on the pressure booster system by unqualified personnelDanger of death from electric shock!

▷ Always have the electrical connections installed by a trained electrician.▷ Comply with regulation IEC 30364.

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

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

NOTEIt is recommended to fit a motor protection device.

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.

6.7.1 Sizing the power cable

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

6.7.2 Connecting the pressure booster system

Connect the pressure booster system to the power supply via terminals L1, L2, L3, PEand N as shown in the enclosed circuit diagram.Observe the data given on the name plate.

6.7.3 Connecting electrical accessories

The standard version of the switchgear and controlgear assembly is provided withthe following terminals for connecting electrical accessories:

▪ Dry running protection device, analog▪ Dry running protection device, digital▪ External-ON (fire alert)▪ Remote OFF▪ Clip-on temperature sensor per pump


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The terminals are marked in the circuit diagram and in the switchgear andcontrolgear assembly.

6.7.4 Volt-free contacts

Volt-free contacts are provided for the following messages:

▪ Warning▪ Alert

The terminals are marked in the circuit diagram and in the switchgear andcontrolgear assembly.

6.8 Acoustic cladding

Acoustic cladding reduces the air-borne sound caused by the motors.

CAUTIONInsufficient air circulation after installation of acoustic claddingRisk of motors overheating!

▷ Do not obstruct the cooling openings.


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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 VDE standards and/or regulations applicable in the country of use arecomplied with.

▪ The dry running protection device has been installed.

CAUTIONInlet pressure does not match the name plate dataIncorrect starting/stopping of pressure booster system!

▷ If dry running protection is provided by a pressure switch, the correct inletpressure must be entered at parameter 3-5-8, otherwise the pressure boostersystem or individual pumps will start or stop incorrectly. (⇨ Section 8.4 Page33)This parameter is not relevant for other dry running protection equipment.

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/testrunning the system.

7.1.2 Setting the dry running protection device

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.

▪ Pressure switch: Set the start and stop pressure as described in the operatingmanual of the pressure switch

▪ Pressure transmitter: Set the start and stop pressure in parameters 3-5-15 and3-5-16 (⇨ Section 8.4 Page 33)

Table 6: Recommended pressure switch/pressure transmitter settings

Stop pressure Start pressurePressure switch 0.5 bar below pinl 0.2 bar below pinlPressure 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 Page33) The flow monitor will stop the pressure booster system due to lack of water


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when no flow can be detected on the suction side and the discharge-sidepressure drops below the set value.

Table 7: Recommended flow monitor settings

Stop pressure Start pressureFlow monitor 0.5 bar below pset cannot be set

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

7.1.3 Commissioning/start-up of pressure booster system

Commissioning should be carried out by specialist KSB staff.

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 booster systemor piping.

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

CAUTIONOperation without water fillDamage to the pumps!

▷ 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 45)1. Set the master switch to "0"; unlock all motor protection switches (if applicable).

2. Provide connection to power supply.

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

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 vent plugs.

6. Switch on all motor protection switches.

7. Switch on the master switch.

8. Start one pump after the other in manual mode, checking the direction ofrotation. The direction of rotation must match the rotation arrow on the motor. If a pump runs in the wrong direction of rotation, interchange two phases at themotor terminal strip.

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


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10. When all pumps are running, loosen the vent plugs again to let any remaining airescape.

11. Then re-tighten the vent plugs firmly.

12. Check that the pumps are running smoothly.

13. Close the discharge-side shut-off element for a short period in order to verifythat the pump reaches the shut-off head.

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

15. On pressure booster systems with manual-0-automatic switch (supplementaryequipment) set all pumps to automatic mode.

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

7.2 Switching on the pressure booster system

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

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


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7.3 Check list for commissioning/start-up

Table 8: Check list

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 Set pump to "0", if manual-0-automatic switch is provided. Briefly start up one pump after the other in manual mode and compare the direction ofrotation at the fanwheel with the arrow indicating the direction of rotation.

10 Check the direction of rotation in automatic mode. 11 Check the start and stop pressure; re-adjust, if necessary. 12 Test the proper function of the dry running protection equipment. If not fitted, make a

relevant note in the commissioning report.

13 Vent the pumps for a second time after they have been running for 5 to 10 minutes. 14 Set all switches to "automatic". 15 Check the pre-charge pressure. 16 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).

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

7.4 Shutdown

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

Set master switch to "0".

NOTEDrain the pressure booster system for prolonged shutdown.


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8 Operating the Control Panel of the Pressure Booster System

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 be restored. (⇨Section 8.8.2 Page 39)

NOTEThe settings made at the site can be saved and loaded when required. (⇨ Section 8.8.1Page 39) (⇨ Section 8.8.2 Page 39)

8.1 Control panel functions

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. 6: BoosterControl Advanced control panel

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


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8.1.1 Display

The six-row display contains the following information:

Fig. 7: 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

SetpointDelta offMax. setpointAdapt. setpoint

22-05 13:40

Fig. 8: Example: 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 33)

8.1.2 LED display

The LED "traffic light" signals provide information about the pump system'soperating status:

Table 9: Control unit: LEDs

LED DescriptionRed: One or several alerts are activeYellow: One or several warnings are activeGreen: Trouble-free operation


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8.1.3 Function keys

For direct access to the elements of the first menu level:

Table 10: Control unit: Function keys

Key DescriptionMenu 1: Operation

Menu 2: Diagnosis

Menu 3: Settings

Menu 4: Information

8.1.4 Navigation keys

For navigating through the menus and confirming settings:

Table 11: 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.


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8.2 Menu structure

Main menu: KSB logo/actual value display

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 accidental or unauthorised accessto 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. Apassword has to be entered under 3-2-1-1, Login. "C" is displayed. If password protection is deactivated via parameter 3-2-1-2, this access level becomesthe "Standard" access level.

"Standard" level

"Customer" level


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Access level for service personnel. A password has to be entered under 3-2-1-1, Login. "S" is displayed.

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

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 12: 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 32)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

"Service" level

"Factory" level


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press OK to save the new parameter value.

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

8.5 Displaying messages

All monitoring and protective functions trigger alerts or warnings. 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 alerts and warnings can be acknowledged in the Diagnosis menuunder 2-1-3.

▪ 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.

8.6 Description of parameters

8.6.1 Parameter group 1 "Operation"

Access v ia "Operat ion" key

Parameters starting with the digit "1" indicate current operating conditions.Exception: Parameter 1-2-1, which can be used to start and stop individual pumps inmanual mode.

Parameter Description1-1-1 Operating pressure1-1-2 Pump load 0 to 600 %, depending on the number of pumps in operation.1-1-3 Indicates whether a dry running protection device is connected or not.1-1-4 Suction-side pressure, if lack-of-water monitoring by pressure sensor has been set (parameter 3-3-2).1-1-5 Water level in the inlet tank in %, if "Level/valve on-off" or "Level/valve prop." has been selected under

3-3-2.1-1-6 Water level in the inlet tank in cm or m, if "Level/valve on-off" or "Level/valve prop." has been selected

under 3-3-2.1-1-7 Ambient temperature, if "Temperature" function has been selected under 3-3-4, WSD.1-1-8 For Service only: Status of digital inputs.1-1-10 Stop speed. If the rotational speed of the variable-speed pump drops below this speed (set under 3-11-3),

the pump will stop. Only active if energy-saving mode has been activated under 3-11-1.1-2-1 Pump operation. After the pump has been selected (by entering the pump number), it can be run either in

automatic mode, in manual mode (for 10 seconds), or switched off. If the pump was switched off via thisparameter, the same parameter will have to be used to return the pump to automatic mode again. This pump cannot be switched on again by means of a voltage reset! If a pump has been operated in manual mode via this parameter, it will automatically return to its previousoperating mode after 10 seconds.

1-2-2 Indicates individual pump loads.1-2-3 For Service only: Indicates status of motor protection.1-2-4 Indicates the operating hours of the individual pumps.1-2-5 For Service only: Indicates the number of pump starts and the faults which occurred.

Fig. 9: Operation key


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8.6.2 Parameter group 2 "Diagnosis"

Access v ia "Diagnosis" key

Parameters starting with the digit "2" are used for fault diagnosis.

Parameter Description2-1-1 Displaying messages. Current 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.

2-1-2 Displaying history. The 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.

8.6.3 Parameter group 3 "Settings"

Access v ia "Sett ings" key

This key is used to change parameters which are required to adjust the pressurebooster system to site conditions if the data specified in the purchase order no longerapplies or if accessories or supplementary equipment have been retrofitted.

Parameter Description3-1 HMI3-1-1 Basic settings of the control panel. Parameters (except 3-1-1-3) can be changed at the "Standard" access

level.3-1-1-1 Selecting language options3-1-1-2 Display settings: 3-1-1-2-1 serves to select backlighting as "Always ON“ or "Timed OFF". If "Timed OFF" is

selected, the backlight time can be set from 0 to 999 seconds under 3-1-1-2-2.3-1-1-3 For Service only: Indicates the physical units for pressure (3-1-1-3-1), fill level (3-1-1-3-2) and temperature

(3-1-1-3-3).3-1-2 For Service only: Fieldbus type and address.3-1-3 Factory only: Settings for service interface.3-1-4 Factory only: Logo in start screen.3-2 Device3-2-1 Login. The various login levels can be selected under 3-2-1-1. The password for the "Customer" level is

7353. After the login, the password prompt for this access level can be deactivated under 3-2-1-2.3-2-2 Service. 3-2-2 provides access to the parameters required for saving and restoring settings.3-2-2-1 "Customer" level. Resetting the pressure booster system to the factory settings it was delivered with.3-2-2-2 "Service" level. Resetting the service interval.3-2-2-3 "Customer" level. Resetting to the settings made at the site and saved under 3-2-2-4.3-2-2-4 "Customer" level. Saving the settings made at the site.3-2-2-5 "Factory" level. Saving the factory settings the pressure booster system is delivered with.3-2-2-6 "Factory" level. Resetting to default settings.3-3 System configuration

All parameters can be changed at "Service" level.3-3-1 Number of pumps installed in the system.3-3-2 The "inlet" configuration defines the type of dry running protection used (by pressure switch, pressure

sensor or flow monitoring), or whether the individual inlet tank levels are processed and whether inflowinto the tank is controlled by means of a proportional valve or gate valve (on/off valve).

3-3-3 "Discharge" configuration. Defines the control method (cascade operation, frequency inverter (VFD),jockey pumps).

3-3-4 WSD. Only processing of the ambient temperature is supported at present. If "Temperature" has beenselected, a PT1000 sensor can be connected and the temperature measured can be displayed. If thetemperature exceeds the value entered under 3-4-4-3, a warning is output.

3-4 System settings All parameters can be changed at "Service" level.

Fig. 10: Diagnosis key

Fig. 11: Settings key


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Parameter Description3-4-1 Inlet3-4-1-1 Sensor press. 4 mA. Lower sensor limit, factory setting: 0 bar.3-4-1-2 Sensor press. 20 mA. Upper sensor limit. Factory setting: 10 bar3-4-1-3 Automatic RDP reset. Control unit response when lack of water signal has gone. Factory setting: automatic

reset.3-4-1-4 Inlet tank configuration if inlet tank has been selected under 3-3-2.3-4-1-4-1 0 % level. Input of inlet tank level in cm or m (depending on setting made under 3-1-1-3-2) at 0 % of

sensor signal.3-4-1-4-2 100 % level. 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 output: tank is almost empty.3-4-1-4-7 High water level. Level at which a warning is output: high-water level is reached.3-4-1-4-8 Threshold3-4-1-4-8-1 Threshold 1: ON3-4-1-4-8-2 Threshold 1: OFF3-4-1-4-8-3 Threshold 2: ON3-4-1-4-8-4 Threshold 2: OFF3-4-1-4-9 Supply valve ON/OFF. These parameters define the levels at which the supply valve is opened and closed,

respectively. Level 1A is an alternative level which is activated under 3-7-9 and 3-7-10.3-4-1-4-9-1 Level 1 open. Level in the inlet tank at which the gate valve is to open.3-4-1-4-9-2 Level 1 closed. Level in the inlet tank at which the gate valve is to close.3-4-1-4-9-3 Level 1A open. Level in the inlet tank at which the gate valve is to open.3-4-1-4-9-4 Level 1A closed. Level in the inlet tank at which the gate valve is to close.3-4-1-4-10 Supply valve prop.3-4-1-4-10-1 Level setpoint 1. This parameter defines the level at which the proportional valve is fully open.3-4-1-4-10-2 Level setpoint 1A. This parameter defines the alternative level at which the proportional valve is fully

open. The alternative level is activated under 3-7-9 and 3-7-10.3-4-1-4-10-3 Hysteresis3-4-1-4-10-4 Sample time3-4-2 Discharge side3-4-2-1 Sensor press. 4 mA. Lower sensor limit, factory setting: 0 bar.3-4-2-2 Sensor press. 20 mA. Upper sensor limit. Factory setting: 16 bar3-4-2-3 Pumps ON sensor fail. This parameter defines the control unit response if the sensor current drops below

4 mA. A number between 0 and 6 is input. 0 means that all pumps are stopped, 1 means that one pump isrunning, 6 means that six pumps are running.

3-4-2-4 Max power. This parameter defines the maximum number of pumps allowed to run at the same time.Input is in number of pumps x 100 %.

3-4-3 Variable freq. drive.3-4-3-1 Communication. Configuration of communication protocol used by control unit and frequency inverter.3-4-3-2 Proportional const. Proportional amplification factor of controller. The higher the value, the higher the

amplification.3-4-3-3 Integral const. Integration time of controller. The higher the value the faster the controller.3-4-3-4 Differential const. Not used in pressure boosting applications.3-4-3-5 No-flow detection. Parameters determining the pressure booster system's stopping behaviour at zero flow.3-4-3-5-1 No-flow bandwidth. Permissible deviation of actual value from setpoint (settable from 2 to 18 %)

interpreted as constant pressure at zero flow by the control unit.3-4-3-5-2 No-flow time. Period (settable from 4 to 20 s) during which the deviation set under 3-4-3-5-1 must be valid

for the control unit to identify zero flow.3-4-3-5-3 No-flow step. Value must not be changed for pressure booster systems!3-4-4 WSD settings. Only the temperature monitoring function is supported at the moment.3-4-4-3 Average room temp. A warning is output if this temperature is exceeded.3-5 Pressure3-5-1 "Customer" level. Setpoint. Pressure at which the pumps start.


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Parameter Description3-5-3 "Customer" level. Bandwidth. Value in bar (standard: 0.05 bar) of permissible deviation of actual value

from setpoint.3-5-4 "Customer" level. Accumulator press. Value added to the actual value before the last pump is stopped.3-5-5 "Service" level. Max. setpoint3-5-6 "Service" level. Max. pump pressure. Max. pump head at zero flow.3-5-8 "Service" level. Average inlet press. This parameter indicates the inlet pressure of the system if a pressure

switch is used as dry running protection device.3-5-9 "Customer" level. Adapt. setpoint. Activated under 3-7-8, Adapt. setpoint.3-5-10 Delta p. This parameter defines by how many bar the setpoint is 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: "Shutdown pumps" or "Only message".3-5-13 "Customer" level. Low pressure alarm. This parameter defines the minimum pressure at which a warning is

to be output.3-5-14 "Service" level. Low pressure action. This parameter defines the control unit's response when the pressure

set under 3-5-13 is reached. Selection options: "Shutdown pumps" or "Only message".3-5-15 "Service" level. Shut down RDP. Can only be selected if a pressure sensor has been selected for dry running

protection. This parameter defines the pressure at which lack of water is to be signalled.3-5-16 "Service" level. Reset RDP. Can only be selected if a pressure sensor has been selected for dry running

protection. This parameter defines the pressure at which the lack of water has gone.3-5-17 "Service" level. Press. Flow Control. Can only be selected if flow monitoring has been selected for dry

running protection. Lack of water is signalled when the flow sensor detects zero throughflow and thedischarge-side pressure drops below the setpoint minus the value entered here.

3-6 Timer settingsAll parameters can be changed at "Service" level.

3-6-1 Opt. pump starts/h. Permissible pump starts per hour.3-6-2 Min. run time. Minimum run time of the pump, even if the period between the start and stop command is

shorter.3-6-3 Min. run time corr.. Value added to the minimum run time if the number of pump starts is exceeded.3-6-4 Max. run time. Period after which the pumps will be changed over in any case.3-6-5 Start delay. Time between the start command and the actual pump start.3-6-6 Stop delay. Time between the stop command and the actual pump stop.3-6-8 RDP delay. Time between lack-of-water signal and pump stop.3-6-9 High/low alarm delay. Time between the occurrence of a fault and the associated warning/alert.3-7 Time/Date

All parameters except 3-7-7 and 3-7-11 can be changed at "Customer" level.3-7-1 Date3-7-2 Time3-7-3 Check run mode. Set according to requirements: System does not perform check run (set to OFF), performs

check run at given interval (set to "Interval-based"), every day at the same time (Time of day based) or at agiven time on a given weekday (Time of week based).

3-7-4 Check run interval. Can only be selected if "Interval-based" has been selected under 3-7-3. Enter theinterval in seconds.

3-7-5 (Daily) Check run at. Can only be selected if "Time of day based" has been selected under 3-7-3. Enter hourand minute.

3-7-6 (Weekly) Check run at. Can only be selected if "Time of week based" has been selected under 3-7-3. Enterhour, minute and weekday.

3-7-7 Check run duration. Duration of check run of each pump.3-7-8 Clock adapt. setp.3-7-8-1 Adaptation mode. Set according to requirements: no alternative setpoint (set to OFF), every day at the

same time ("Adapt ON/OFF ev. day") or at a given time on a given weekday ("Adapt. ON/OFF per day").3-7-8-2 Change ON/OFF times. Can only be selected if "Adapt ON/OFF ev. day" has been selected under 3-8-1.

Enter hour and minute for activating and deactivating the alternative setpoint.3-7-8-3 Select day of week. Can only be selected if "Adapt ON/OFF per day" has been selected under 3-8-1. Enter

the weekday.


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Parameter Description3-7-8-4 Change ON/OFF times. Can only be selected if "Adapt ON/OFF per day" has been selected under 3-8-1.

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 the alternative level specified under 3-4-1-4, Level configuration,

is to be deactivated.3-7-11 Maintenance interval. Enter the number of operating hours after which maintenance is to be performed.3-10 Main menu

"Customer" level. Set the information to be displayed in the main menu.3-11 Energy-saving mode3-11-1 Energy-saving mode ON/OFF. This parameter serves to activate/deactivate the energy-saving mode.3-11-2 Direct OFF. This parameter defines whether, upon reaching the stop speed, the pressure booster system

stops after the delay set under 3-11-4 or flow detection is started.3-11-3 Stop speed. Enter the pump load at which the last pump is to stop.3-11-4 Time direct OFF3-12 FI failure behaviour

All parameters can be changed at "Service" level. This parameter defines whether the pressure booster system stops or switches to cascade operation in theevent of a frequency inverter fault. In cascade operation the following parameters will be processed by thecontrol unit.

3-12-2-1 Max power. This parameter defines the maximum number of pumps allowed to run at the same time.3-12-2-2 Setpoint. Pressure at which the pumps start.3-12-2-3 Delta off. Pressure difference from setpoint at which the pumps stop.3-12-2-4 Min. run time. Minimum run time of the pump, even if the period between the start and stop command is

shorter.3-12-2-5 Max. run time. Period after which the pumps will be changed over in any case.3-12-2-6 Start delay. Time between the start command and the actual pump start.

8.6.4 Parameter group 4 "Information"

Access v ia " Information" key

Parameters starting with the digit "4" provide information on:

Parameter Description4-1-1 Serial number4-1-2 Product ID ("Factory" access level only)4-1-3 FW version4-1-4 Parameter set4-1-5 HW version

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

Fig. 12: Information key


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▪ 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 made under 7.8.1.▪ Parameter 3-2-2-6: Resetting to default settings ("Factory" level only). The

control unit is reset to the pressure booster system type (no settings for pressure,dry running protection, etc.)

8.9 Alerts and warnings

Alert DescriptionFailure PT. Dis. Fault at discharge-side sensor (current < 4 mA).

Replace sensor and reset system.Br. wire sens.dis Fault at discharge-side sensor (defective sensor or broken

wire). Replace sensor and reset system.Sys. press. too low System pressure below minimum value (3-5-13) for too

long.Sys. press. too high System pressure above maximum value (3-5-11) for too

long.No water Insufficient water or water pressure on suction side.More pumps fail High-priority thermal alert.Failure valve Thermal fault of valve for inlet tank supply (current too

high).Inlet sensor fail Fault at inlet sensor (pressure or level value < 4 mA -

Replace sensor 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 DescriptionFailure FC Maintenance required Customer service required.Failure Pump 1 Thermal fault of pump 1 (temperature too high).Failure Pump 2 Thermal fault of pump 2 (temperature too high).Failure Pump 3 Thermal fault of pump 3 (temperature too high).Failure Pump 4 Thermal fault of pump 4 (temperature too high).Failure Pump 5 Thermal fault of pump 5 (temperature too high).


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Warning DescriptionFailure Pump 6 Thermal fault of pump 6 (temperature too high).P1 out of order 1st pump set to manual OFF (parameter 1-2-1). Deactivate

by selecting automatic mode.P2 out of order 2nd pump set to manual OFF (parameter 1-2-1). Deactivate

by selecting automatic mode.P3 out of order 3rd pump set to manual OFF (parameter 1-2-1). Deactivate

by selecting automatic mode.P4 out of order 4th pump set to manual OFF (parameter 1-2-1). Deactivate



by selecting automatic mode.High water level Water level in inlet tank too high.Crit. water level Water level in inlet tank critical (almost empty).Low water level Water level in inlet tank too low (system stopped by dry

running protection).Spurious data Unknown data received from frequency inverter.Serial framing Frame error.Serial parity Serial parity errorSerial time out Communication time outUnrequest message Unrequested message received from frequency inverterBuffer overrun Buffer overrun message of frequency inverter log.24 V out of range Internal 24 V outside valid range5V out of range Internal 5 V outside valid range3 V out of range Internal 3 V outside valid rangeExternal OFF Warning when opening the "external OFF" contactorCurr. temp. too high Ambient temperature (parameter 3-4-4-3) exceeded

8.10 Connecting the External OFF contact

The External OFF connection is a NC contact. When this contact opens, all pumpswhich are in operation are sequenced out after the set stop delay, and a warning isoutput (yellow LED).When this contact closes, the pumps are started up again in line with demand, andthe warning is cleared. Connect to terminals X3, 17 and 18.

8.11 Connecting the fire alert

The fire alert connection is a NC contact. When this contact opens, all pumps aresequenced in after the set start delay and an alert (red LED) is output. The dryrunning protection and External OFF functions are ignored.

When this contact closes, the pumps are sequenced out again in line with demand.The alert is cleared. Connect to terminals X3, 19 and 20.

8.12 Charging the accumulator

The "Charge accumulator" function can be activated at parameter 3-5-4. Before thelast pump stops the actual value is increased by the value entered here, in order tofill the accumulator located on the discharge side of the pressure booster system. If "0" is entered the function is deactivated.


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8.13 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 the operationalpressure boosting system installed on site.

Making sett ings:

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. (⇨ Section 8.12 Page 40)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.

8.14 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.

8.15 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.Connect to terminals X6, 7 and 8.

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

8.16 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:


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▪ 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.Connect to terminals X6, 1 and 2, 3 and 4, 5 and 6.

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


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9 Servicing/Maintenance

9.1 General notes/Safety regulations

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

DANGERInadvertent start-up of pressure booster systemDanger to life!

▷ The pressure booster system must be de-energised before repair or maintenancework is carried out.Switching off the motor protection switch will not de-energise the motor powercables reliably.

WARNINGInadvertent 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 up accidentally.

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 special

emphasis on lubricants, shaft seals and pump couplings.

Observe the general safety instructions and information. (⇨ Section 9 Page 43)

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.

Check list for commissioning, inspection and maintenance (⇨ Section 7.3 Page 28)

9 Servicing/Maintenance

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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 during

pump operation.

CAUTIONImpermissibly high temperature of fluid handledDamage to the pump!

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