KSB Hya-Duo D FL Compact Montageanleitung

Break Tank Package Booster Set for Fire

Fighting

Hya-Duo D FL Compact

From Series 2014w33

Installation/Operating Manual

Legal information/Copyright

Installation/Operating Manual Hya-Duo D FL Compact

Original operating manual

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.

Contents

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Contents

Glossary .................................................................................................................................................. 5

1 General.................................................................................................................................................... 6

1.1 Principles ...........................................................................................................................................................6

1.2 Installation of partly completed machinery....................................................................................................6

1.3 Target group.....................................................................................................................................................6

1.4 Other applicable documents............................................................................................................................6

1.5 Symbols .............................................................................................................................................................6

1.6 Key to safety symbols/markings.......................................................................................................................6

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

2.1 General..............................................................................................................................................................8

2.2 Intended use .....................................................................................................................................................8

2.3 Personnel qualification and personnel training.............................................................................................9

2.4 Consequences and risks caused by non-compliance with this manual .........................................................9

2.5 Safety awareness ..............................................................................................................................................9

2.6 Safety instructions for the operator/user........................................................................................................9

2.7 Safety information for maintenance, inspection and installation ..............................................................10

2.8 Unauthorised modes of operation................................................................................................................10

3 Transport/Temporary Storage/Disposal............................................................................................. 11

3.1 Checking the condition upon delivery..........................................................................................................11

3.2 Transport.........................................................................................................................................................11

3.3 Storage/preservation......................................................................................................................................12

3.4 Return to supplier...........................................................................................................................................13

3.5 Disposal ...........................................................................................................................................................13

4 Description............................................................................................................................................ 15

4.1 General description ........................................................................................................................................15

4.2 Product information as per Regulation No. 1907/2006(REACH).................................................................15

4.3 Designation.....................................................................................................................................................15

4.4 Name plate......................................................................................................................................................15

4.5 Design details..................................................................................................................................................15

4.6 Configuration and function...........................................................................................................................17

4.7 Noise characteristics .......................................................................................................................................18

4.8 Scope of supply...............................................................................................................................................18

4.9 Dimensions and weights ................................................................................................................................18

5 Installation at Site................................................................................................................................ 19

5.1 Checks to be carried out prior to installation...............................................................................................19

5.2 Installing the break tank package booster set for fire fighting..................................................................20

5.3 Mounting the accumulator............................................................................................................................20

5.4 Connecting the piping ...................................................................................................................................21

5.4.1 Connecting the overflow line ...........................................................................................................21

5.4.2 Fitting an expansion joint (optional)................................................................................................22

5.5 Installing operator-supplied valves ...............................................................................................................22

5.6 Setting up the float valve ..............................................................................................................................23

5.7 Electrical connection ......................................................................................................................................23

5.7.1 Sizing the power cable ......................................................................................................................24

5.7.2 On-site protective measures..............................................................................................................24

5.7.3 Connecting the break tank package booster set for fire fighting .................................................24

5.7.4 Connecting the limit switches (remote ON/OFF)..............................................................................25

5.7.5 Connecting the dry running protection device................................................................................25

5.7.6 Connecting the volt-free contacts ....................................................................................................25

5.7.7 Connecting electrical accessories ......................................................................................................25

Contents

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6 Commissioning/Start-up/Shutdown................................................................................................... 26

6.1 Commissioning/Start-up.................................................................................................................................26

6.1.1 Prerequisites for commissioning/start-up .........................................................................................26

6.1.2 Priming and venting the break tank package booster set for fire fighting ..................................27

6.1.3 Setting the dry running protection device.......................................................................................28

6.1.4 Start-up...............................................................................................................................................29

6.1.5 Checklist for commissioning/start-up................................................................................................29

6.2 Operating limits..............................................................................................................................................30

6.2.1 Application limits ...............................................................................................................................30

6.2.2 Frequency of starts.............................................................................................................................31

6.2.3 Ambient conditions ...........................................................................................................................31

6.2.4 Maximum operating pressure ...........................................................................................................31

6.2.5 Fluid handled .....................................................................................................................................31

6.2.6 Drainage capacity ..............................................................................................................................31

6.2.7 Minimum flow rate............................................................................................................................32

6.3 Shutdown........................................................................................................................................................32

6.3.1 Shutdown ...........................................................................................................................................32

6.3.2 Measures to be taken for shutdown ................................................................................................32

7 Operation.............................................................................................................................................. 33

7.1 LED display......................................................................................................................................................33

7.2 Operating modes............................................................................................................................................33

7.2.1 Manual mode .....................................................................................................................................33

7.2.2 Functional check run..........................................................................................................................33

7.3 Functions.........................................................................................................................................................34

7.3.1 Automatic switchover (duty system and back-up system)...............................................................34

7.3.2 Dry running protection......................................................................................................................35

7.3.3 Temperature monitoring...................................................................................................................35

7.3.4 Mains water supply............................................................................................................................35

7.3.5 Drinking water stop...........................................................................................................................35

7.3.6 Flushing ..............................................................................................................................................36

8 Servicing/Maintenance........................................................................................................................ 37

8.1 General information/safety regulations........................................................................................................37

8.2 Inspection contract.........................................................................................................................................38

8.3 Servicing/Inspection........................................................................................................................................38

8.3.1 Supervision of operation ...................................................................................................................38

8.3.2 Maintenance schedule.......................................................................................................................38

8.4 Setting the pre-charge pressure ....................................................................................................................39

9 Trouble-shooting.................................................................................................................................. 40

10 Related Documents.............................................................................................................................. 42

10.1 General assembly drawing with list of components ....................................................................................42

10.2 Wiring diagram (limit switches).....................................................................................................................43

11 EU Declaration of Conformity............................................................................................................. 44

12 Certificate of Decontamination........................................................................................................... 45

13 Commissioning Report......................................................................................................................... 46

Index ..................................................................................................................................................... 47

Glossary

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Glossary

Accumulator

Pressure losses may occur in the piping system

downstream of the break tank package booster

set for fire fighting which may be caused by

leakage of small quantities of water. The

accumulator serves to compensate pressure losses

and minimises the frequency of starts of the break

tank package booster set for fire fighting.

Back-up system

The part of the fire-fighting system / break tank

package booster set for fire-fighting which

ensures the supply of fire-fighting water in the

event of a fire if the duty system fails (see also

duty system).

Certificate of decontamination

A certificate of decontamination is enclosed by the

customer when returning the product to the

manufacturer to certify that the product has been

properly drained to eliminate any environmental

and health hazards arising from components in

contact with the fluid handled.

DIN 1988

German Standard which stipulates technical rules

for drinking water installations.

DIN14462

The fire-fighting systems/ break tank package

booster sets for fire fighting must comply with the

German standard for water conduits for fire

extinguishing.

Duty system

The active part of the fire-fighting system / break

tank package booster set for fire-fighting which

ensures the supply of fire-fighting water in the

event of a fire (see also back-up system).

Flushing

If the volume of the inlet line exceeds 1.5l and/or

the length of the inlet line ≥10×DN, a flushing

system must be provided. This will prevent

stagnating fluid handled and microbial

contamination of drinking water.

IE3

Efficiency class to IEC60034-30: 3=Premium

Efficiency (IE = International Efficiency)

Manual mode

Direct operation on the power supply network,

independently of the control unit.

Pump activation

Pump activation means that a pump is started up

by a starting signal from the pressure switch, from

a wall hydrant (limit switch) via remote ON/OFF, or

from the broken wire and short-circuit monitoring

relay.

Rainwater storage tank

Tank for collecting rainwater, for buried

installation or above-floor installation

Switchgear and controlgear assembly

Control cabinet with one or several control units/

switchgears and electrical equipment.

1 General

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1 General

1.1 Principles

This operating manual is valid for the type series and variants indicated on the front

cover.

The operating manual describes the proper and safe use of this equipment in all

phases of operation.

The name plate indicates the type series, the main operating data and the serial

number. The serial number uniquely describes the product and is used as

identification in all further business processes.

In the event of damage, immediately contact your nearest KSB service facility to

maintain the right to claim under warranty.

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB refer to the sub-sections under

Servicing/Maintenance.

1.3 Target group

This operating manual is aimed at the target group of trained and qualified specialist

technical personnel. (ðSection2.3,Page9)

1.4 Other applicable documents

Table1: Overview of other applicable documents

Document Contents

Sub-supplier product literature Operating manuals, logic diagram and other

product literature of accessories and integrated

machinery components

1.5 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-references

Step-by-step instructions

Note

Recommendations and important information on how to handle

the product

1.6 Key to safety symbols/markings

Table3: Definition of safety symbols/markings

Symbol Description

!DANGER

DANGER

This signal word indicates a high-risk hazard which, if not avoided,

will result in death or serious injury.

!WARNING

WARNING

This signal word indicates a medium-risk hazard which, if not

avoided, could result in death or serious injury.

1 General

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Symbol Description

CAUTION

This signal word indicates a hazard which, if not avoided, could

result in damage to the machine and its functions.

Explosion protection

This symbol identifies information about avoiding explosions in

potentially explosive atmospheres in accordance with EU Directive

2014/34/EU (ATEX).

General hazard

In conjunction with one of the signal words this symbol indicates a

hazard which will or could result in death or serious injury.

Electrical hazard

In conjunction with one of the signal words this symbol indicates a

hazard involving electrical voltage and identifies information about

protection against electrical voltage.

Machine damage

In conjunction with the signal word CAUTION this symbol indicates

a hazard for the machine and its functions.

2 Safety

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2 Safety

!DANGER

All the information contained in this section refers to hazardous situations.

In addition to the present general safety information the action-related safety

information given in the other sections must be observed.

2.1 General

▪This operating manual contains general installation, operating and maintenance

instructions that must be observed to ensure safe operation of the system and

prevent personal injury and damage to property.

▪Comply with all the safety instructions given in the individual sections of this

operating manual.

▪The operating manual must be read and understood by the responsible specialist

personnel/operators prior to installation and commissioning.

▪The contents of this operating manual must be available to the specialist

personnel at the site at all times.

▪Information and markings attached directly to the product must always be

complied with and kept in a perfectly legible condition at all times. This applies

to, for example:

– Flow direction arrow

– Markings for connections

– Name plate

▪The operator is responsible for ensuring compliance with all local regulations not

taken into account.

2.2 Intended use

▪The break tank package booster set for fire fighting must only be operated

within the operating limits described in the other applicable documents.

▪Only operate break tank package booster sets for fire fighting which are in

perfect technical condition.

▪Do not operate partially assembled break tank package booster sets for fire

fighting.

▪Only use the break tank package booster set for fire fighting to handle the fluids

described in the product literature of the respective design variant.

▪Never operate the break tank package booster set for fire fighting without the

fluid to be handled.

▪Observe the information on minimum flow rates specified in the product

literature (to prevent overheating, bearing damage, etc).

▪Observe the maximum flow rates indicated in the data sheet or product

literature (to prevent overheating, cavitation damage, bearing damage, etc).

▪Do not throttle the flow rate on the suction side of the break tank package

booster set for fire fighting (to prevent cavitation damage).

▪Consult the manufacturer about any other modes of operation not described in

the product literature.

2 Safety

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2.3 Personnel qualification and personnel training

▪ All personnel involved must be fully qualified to install, operate, maintain and

inspect the product this manual refers to.

▪The responsibilities, competence and supervision of all personnel involved in

transport, installation, operation, maintenance and inspection must be clearly

defined by the operator.

▪Deficits in knowledge must be rectified by means of training and instruction

provided by sufficiently trained specialist personnel. If required, the operator can

commission the manufacturer/supplier to train the personnel.

▪Training on the break tank package booster set for fire fighting must always be

supervised by specialist technical personnel.

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

▪Non-compliance with these operating instructions will lead to forfeiture of

warranty cover and of any and all rights to claims for damages.

▪Non-compliance can, for example, have the following consequences:

– 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

2.5 Safety awareness

In addition to the safety information contained in this operating manual and the

intended use, the following safety regulations shall be complied with:

▪Accident prevention, health regulations and safety regulations

▪Explosion protection regulations

▪Safety regulations for handling hazardous substances

▪Applicable standards, directives and laws

2.6 Safety instructions for the operator/user

▪Fit protective equipment (e.g. contact guards) supplied by the operator for hot,

cold or moving parts, and check that the equipment functions properly.

▪Do not remove any protective equipment (e.g. contact guards) during operation.

▪Provide the personnel with protective equipment and make sure it is used.

▪Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.

explosive, toxic, hot) so as to avoid any danger to persons and the environment.

Adhere to all relevant laws.

▪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 Safety

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2.7 Safety information for maintenance, inspection and installation

▪Modifications or alterations of the break tank package booster set for fire

fighting require the manufacturer's prior consent.

▪Use only original spare parts or parts/components authorised by the

manufacturer. The use of other parts/components can invalidate any liability of

the manufacturer for resulting damage.

▪The operator ensures that maintenance, inspection and installation are

performed by authorised, qualified specialist personnel who are thoroughly

familiar with the manual.

▪Carry out work on the break tank package booster set for fire fighting during

standstill only.

▪The pump (set) must have cooled down to ambient temperature.

▪Pump pressure must have been released and the pump must have been drained.

▪When taking the break tank package booster set for fire fighting out of service

always adhere to the procedure described in the manual.

▪Decontaminate break tank package booster sets for fire fighting which handle

fluids posing a health hazard. (ðSection8.1,Page37)

▪As soon as the work has been completed, re-install and re-activate any safety-

relevant devices and protective devices. Before returning the product to service,

observe all instructions on commissioning. (ðSection6.1,Page26)

▪Make sure the break tank package booster set for fire fighting cannot be

accessed by unauthorised persons (e.g. children).

▪Prior to opening the break tank package booster set for fire fighting, pull the

mains plug and wait for at least 10minutes.

2.8 Unauthorised modes of operation

▪Always observe the limits stated in the product literature.

▪The warranty relating to the operating reliability and safety of the break tank

package booster set for fire fighting supplied is only valid if the break tank

package booster set for fire fighting is used in accordance with its intended use.

(ðSection2.2,Page8)

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