Related Manuals for DP Pumps Hydro?Unit Premium Line Series
Summary of Contents for DP Pumps Hydro?Unit Premium Line Series
- Page 1 Pressure Booster System Installation/Operating Manual Hydro‑Unit Premium Line Hydro-Unit Premium Line F Hydro-Unit Premium Line VC Hydro-Unit Premium Line SVP...
- Page 2 2 / 64 Legal information/Copyright Original operating manual Hydro‑Unit Premium Line All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose, nor otherwise transmitted, published or made available to a third party without the manufacturer's express written consent.
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Page 3: Table Of Contents
Contents Glossary...................... 6 General....................... 7 Principles ............................. 7 Software changes .......................... 7 Installation of partly completed machinery................... 7 Target group ............................ 7 Other applicable documents ........................ 7 Symbols ............................... 7 Key to safety symbols/markings ...................... 8 Safety ......................... 9 General .............................. 9 Intended use ............................ 9 2.2.1 Prevention of foreseeable misuse ................... - Page 4 5.5.4 Connecting the dry running protection device ............... 24 5.5.5 Connecting the fire alert ...................... 24 5.5.6 Connecting the ambient temperature monitoring device (optional)........ 24 5.5.7 Connecting the digital inputs (optional) ................. 24 Commissioning/Start-up/Shutdown.............. 25 Commissioning/Start-up ........................ 25 6.1.1 Prerequisites for commissioning/start-up ................ 25 6.1.2 Priming and venting the pressure booster system ..............
- Page 5 10.1.3 Hydro-Unit Premium Line SVP.................... 58 EU Declaration of Conformity................ 59 Certificate of Decontamination.............. 60 Commissioning Report .................. 61 Index......................... 62 5 / 64...
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Page 6: Glossary
Glossary Accumulator Pressure losses may occur in the piping downstream of the pressure booster system as a result of losses due to leakage. The accumulator serves to compensate for pressure losses and minimises the frequency of starts of the pressure booster system. -
Page 7: General
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. -
Page 8: Key To Safety Symbols/Markings
1.7 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. -
Page 9: Safety
2 Safety All the information contained in this section refers to hazardous situations. DANGER 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. -
Page 10: Personnel Qualification And Personnel Training
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. -
Page 11: Safety Information For Maintenance, Inspection And Installation
2.7 Safety information for maintenance, inspection and installation – Modifications or alterations of the pressure booster system are only permitted with the manufacturer's prior consent. – Use only original spare parts or parts authorised by the manufacturer. The use of other parts can invalidate any liability of the manufacturer for resulting damage. -
Page 12: Transport/Temporary Storage/Disposal
3 Transport/Temporary Storage/ Disposal 3.1 Checking the condition upon delivery 1. On transfer of goods, check each packaging unit for damage. 2. In the event of in-transit damage, assess the exact damage, document it and notify DP or the supplying dealer and the insurer about the damage in writing immediately. 3.2 Transport DANGER Pressure booster system tipping over... -
Page 13: Return To Supplier
Store the pressure booster system in a dry, protected room where the atmospheric humidity is as constant as possible. Table 4: Ambient conditions for storage Ambient condition Value Relative humidity 50 % maximum Ambient temperature 0 °C to +40 °C – Frost-free – Well-ventilated 3.4 Return to supplier 1. - Page 14 Electrical or electronic equipment marked with the adjacent symbol must not be disposed of in household waste at the end of its service life. Contact your local waste disposal partner for returns. If the used electrical or electronic equipment contains personal data, the operator is responsible for deleting it before the equipment is returned.
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Page 15: Description
4 Description 4.1 General description – Pressure booster system 4.2 Product information as per Regulation No. 1907/2006 (REACH) For information as per chemicals Regulation (EC) No. 1907/2006 (REACH), see http:// www.dp.nl/reach. 4.3 Designation Example: Premium Line HU3 DPV 15/8 B SVP Table 5: Designation key Code Description... -
Page 16: Design Details
4.5 Design details Design – Compact system mounted on a common base frame – 2 or 3 (VC) / 4 (F / SVP) vertical high-pressure pumps – Hydraulic components made of stainless steel / brass – Integrated dry running protection Hydro-Unit Premium Line F: –... -
Page 17: Configuration And Function
4.6 Configuration and function Fig. 2: Hydro-Unit Premium Line Control cabinet Control unit Pump Membrane-type accumulator Manifold Baseplate Design Fully automatic pressure booster system with two, three or four vertical high-pressure pumps (3) for ensuring the required supply pressure. Function Hydro-Unit Premium Line F: Either two, three or four pumps are controlled and monitored by a microprocessor control unit (Megacontrol). -
Page 18: Noise Characteristics
individual pumps operate only in line with actual demand. If the demand drops towards 0, the pressure booster system slowly runs down to the stop point. Hydro-Unit Premium Line SVP 1 volt-free general contact is provided in the control cabinet for reporting warnings and alerts. -
Page 19: Dimensions And Weights
– One frequency inverter per pump – Service interface for Servicetool 4.9 Dimensions and weights For dimensions and weights refer to the outline drawing. 4.10 Potential equalisation A terminal marked with the earth symbol is provided at the power connection for connecting a PE conductor. -
Page 20: Installation At Site
5 Installation at Site 5.1 Installation WARNING Installation on mounting surfaces which are unsecured and cannot support the load Personal injury and damage to property! Ø Use a concrete of compressive strength class C12/15 which meets the requirements of exposure class X0 to EN 206-1. Ø... -
Page 21: Mounting The Accumulator
NOTE To prevent the transmission of piping forces and solid-borne noise, installing expansion joints with length-limiters is recommended. ü The pressure booster system’s packaging has been removed. ü A suitable installation site has been selected that meets the requirements. ü Sufficient clearance in all directions is provided for servicing work. 1. -
Page 22: Fitting An Expansion Joint (Optional)
5.4.1 Fitting an expansion joint (optional) DANGER Sparks and radiant heat Fire hazard! Ø Take suitable precautions to protect the expansion joint if any welding work is carried out. CAUTION Leaking expansion joint Flooding of installation room! Ø Do not apply any paint to the expansion joint. Ø... -
Page 23: Electrical Connection
5.5 Electrical connection DANGER Electrical connection work by unqualified personnel Danger of death from electric shock! Ø Always have the electrical connections installed by a trained and qualified electrician. Ø Observe regulations IEC 60364. WARNING Incorrect connection to the mains Damage to the mains network, short circuit! Ø... -
Page 24: Connecting The Pressure Booster System
5.5.2 Connecting the pressure booster system ü The pressure booster system can be operated on the power supply network in accordance with the data on the name plate. ü The wiring diagram is available. 1. Connect terminals L1, L2, L3, PE and N in accordance with the wiring plan. 2. -
Page 25: Commissioning/Start-Up/Shutdown
6 Commissioning/Start-up/Shutdown 6.1 Commissioning/Start-up 6.1.1 Prerequisites for commissioning/start-up CAUTION Pump set running dry Damage to the pump set/pressure booster system! Ø Use dry running protection. If the dry running protection terminal is disabled by means of a bridge, the operator shall assume responsibility for any dry running that might occur. -
Page 26: Dry Running Protection
ü The original operating manual of the pump set is on hand. ü The pipe unions between the pump set and the piping have been re-tightened. ü Flange connections have been firmly tightened. ü The cooling air inlet openings and cooling air outlet openings at the motor are unobstructed. -
Page 27: Commissioning/Start-Up Of Pressure Booster System
6.1.5 Commissioning/start-up of pressure booster system NOTE Prior to its delivery, the pressure booster system will be tested hydraulically with water and then drained again. For technical reasons the presence of some residual water is unavoidable. Prior to commissioning/start-up observe EN 806. After prolonged standstill periods, flushing or professional disinfection is recommended. -
Page 28: Checklist For Commissioning/Start-Up
NOTE Minor leakage of the mechanical seals during commissioning is normal and will cease after a short period of operation. 6.1.6 Checklist for commissioning/start-up Table 7: Checklist Actions Done Read the operating manual. Verify the power supply against the name plate data. Check the earthing system (taking measurements). -
Page 29: Ambient Conditions
6.2.2 Ambient conditions Observe the following parameters and values during operation: Table 8: Permissible ambient conditions Ambient condition Value Ambient temperature 0 °C to +40 °C Relative humidity 50 % maximum 6.2.3 Maximum operating pressure CAUTION Permissible operating pressure exceeded Damage to connections and seals! Ø... -
Page 30: Shutdown
Size Minimum flow rate per pump [l/h] DPV 60 6100 DPV 85 8500 DPV 125 12500 6.3 Shutdown 6.3.1 Shutdown Standard design 1. Set the master switch to 0. Additional instruments 1. Set manual-0-automatic selector switch to 0. 6.3.2 Measures to be taken for shutdown Fig. 6: Venting and draining the accumulator Vent plug ü... -
Page 31: Operating The Pressure Booster System
7 Operating the Pressure Booster System 7.1 Hydro-Unit Premium line F, VC, SVP CAUTION Incorrect operation Water supply is not assured! Ø Make sure to comply with all local regulations, particularly the EC Machinery Directive and the EC Directive on Low-Voltage Equipment. The pressure booster system is factory-set to the start-up pressure and stop pressure indicated on the name plate. - Page 32 7.1.1.1 Display The display contains the following information: Fig. 8: Display elements Table 11: Display elements and description Display element Description Parameter No./pump Shows the number of the parameter or pump selected The parameter No. indicates the path through the menu levels. Current selection Shows the current parameter in plain text Parameter information...
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Page 33: Menu Structure
Table 14: Control unit: navigation keys Description Arrow keys: – Move up/down in the menu options. – Increase/decrease a numerical value. – Scroll up/down. Escape key: – Cancel an entry without saving it. – Move up one menu level. OK key: –... -
Page 34: Access Levels
Main menu Sub-menu Menu display ➡ Settings ➡ Time/date ➡ Program outputs ➡ Messages ➡ Main menu ➡ Information ➡ Control module Serial number Material number Firmware Parameter set Hardware version 7.1.3 Access levels Various access levels have been defined to prevent unintentional or unauthorised access to the pressure booster system parameters. -
Page 35: Displaying Messages
First digit of the 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 the parameter number: 3-5-1 Change the display 3-1 (top left) to 3-5 by pressing the navigation keys. Confirm the selection by pressing OK. - Page 36 Parameter Description 1-1-7 Ambient temperature, if "Temperature" function has been selected under 3-3-4, WSD. For Service only. Status of digital inputs. 1-1-8 1-1-10 Power down speed. If the rotational speed of the variable-speed pump drops below this speed (set under 3-11-3), the pump will stop.
- Page 37 Parameter Description 3-2-2-2 "Service" level. Resetting the service interval. "Customer" level. Resetting to the settings made at the site and saved under 3-2-2-4. 3-2-2-3 3-2-2-4 "Customer" level. Saving the settings made at the site. "Factory" level. Saving the factory settings the pressure booster system is delivered with. 3-2-2-5 3-2-2-6 "Factory"...
- Page 38 Parameter Description 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.
- Page 39 Parameter Description 3-7-1 Date 3-7-2 Time 3-7-3 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 a given time on a given day of week (Time of week based).
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Page 40: Quick Menu
7.1.7 Quick menu The Quick Menu allows access to the main parameters which may be required for adapting the pressure booster system to site conditions. Press OK to call up the Quick Menu from the start screen. – PIN – Proportional constant –... -
Page 41: Alerts And Warnings
7.1.8.2 Restoring settings Three types of settings can be restored if the system does not operate any more as a result of incorrect settings made at the site. – Parameter 3-2-2-1 Resetting to factory settings. The control unit is reset to the values and settings the pressure booster system was delivered with. -
Page 42: Connecting The Remote On/Off Input
Warning Description 3 V out of range Internal 3 V outside valid range. External OFF Warning when opening the "external OFF" contactor. Curr. temp. too high Ambient temperature (parameter 3-4-4-3) exceeded. Failure VFD 7.1.10 Connecting the remote ON/OFF input 1. Establish the connection in accordance with the wiring diagram. 7.1.11 Connecting the fire alert 1. -
Page 43: Setting Flow Detection
3. Activate parameter 3-5-4 (charging accumulator). 4. Set parameter 3-11-1 (energy-saving mode) to ON. 5. Set parameter 3-11-2 (direct OFF) to ON. The setting OFF (flow detection) should only be selected for difficult site conditions and by an expert. [ð Section 7.1.14, Page 43] 6. - Page 44 ü The accumulator’s water flow detection (WSD) function is deactivated. ü Logged in at Service level. 1. Call up parameter 3-3-4 (WSD). 2. Set water flow detection on accumulator to OFF. ð WSD inputs 1 to 3 are available. The following functions can be assigned via the digital inputs: –...
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Page 45: Servicing/Maintenance
8 Servicing/Maintenance 8.1 General information/safety regulations DANGER Unintentional start-up of pressure booster system Danger to life! Ø De-energise the pressure booster system for any repair work or servicing work. Ø Ensure that the pressure booster system cannot be re-energised unintentionally. WARNING Improper lifting/moving of heavy assemblies or components Personal injury and damage to property! -
Page 46: Servicing/Inspection
8.2 Servicing/Inspection 8.2.1 Supervision of operation CAUTION Increased wear due to dry running Damage to the pump set! Ø Never operate the pump set without liquid fill. Ø Never close the shut-off element in the suction line and/or supply line during pump operation. -
Page 47: Maintenance Schedule
Check the automatic switching functionality. Check the start and stop points of the pressure booster system. Check the water inflow, lack-of-water monitoring and pressure reducer. 8.2.3 Maintenance schedule Table 16: Overview of maintenance work Maintenance interval Servicing/maintenance work At least once a year Check the pump sets for smooth running and the mechanical seal for integrity. -
Page 48: Replacing The Non-Return Valve
4. Check the pre-charge pressure using suitable equipment (e.g. tyre pressure gauge). 5. Fit the protective cap of the membrane-type accumulator valve. Filling the membrane-type accumulator 1. Remove and store the protective cap of the membrane-type accumulator valve. 2. Add nitrogen through the valve. 3. - Page 49 Fig. 15: Removing the body 7. Remove the body of the non-return valve. 8. Remove the insert check valve including O-rings. 9. Remove excessive contamination or deposits with a clean cloth. 10.Re-insert the insert check valve into the body. Apply lubricant to new O-rings. See table below.
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Page 50: Mounting The Manifold In A Mirrored Position
Fig. 18: Verifying the alignment 13.Verify the correct alignment. Fig. 19: Fitting the screw 14.Fit and tighten the screw. 15.Close the drain plugs of the pump. Properly dispose of the fluid collected. 16.Slowly open the shut-off valve and check for any leakage. Table 17: Spare parts for servicing non-return valves, per pump Material number Description... - Page 51 Fig. 20: Removing the bolts 5. Remove the tie bolts between the two oval flanges and the pumps. Fig. 21: Removing the manifold 6. Remove the entire manifold (with shut-off valves). 51 / 64...
- Page 52 Fig. 22: Loosening the EF locknut EF locknut 7. Undo the EF locknut at both shut-off valves by half a turn. The O-ring is now exposed. Fig. 23: Turning the pressure measuring set Pressure measuring set Lever of the shut-off valve 8. Close the lever of the shut-off valve about half way to enable the 180° turn required in the next step.
- Page 53 Fig. 24: Turning the shut-off valves Shut-off valve 10.Turn the shut-off valves by 180°. Then turn the manifold with shut-off valves by 180°. 53 / 64 Fig. 25: Turning the pressure measuring set Pressure measuring set 11.Turn the pressure measuring set by a last 90°. 12.If the pressure gauge and/or pressure sensors have been removed, connect them again.
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Page 54: Trouble-Shooting
9 Trouble-shooting WARNING Improper work to remedy faults Risk of injury! Ø For any work performed to remedy faults, observe the relevant information given in this instruction manual and/or in the product literature provided by the accessories manufacturer. NOTE Before performing any work on the pump's internal parts during the warranty period please always consult the manufacturer. - Page 55 A B C D E F G H J K L Possible cause Remedy ✘ ✘ ✘ ✘ - Start-up pressure set too high Check setting. ✘ ✘ ✘ ✘ ✘ ✘ Pressure transmitter set incorrectly or Check setting. defective ✘...
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Page 56: Related Documents
10 Related Documents 10.1 General assembly drawings/exploded views with list of components 10.1.1 Hydro-Unit Premium Line F 79-1 79-2 743.90 742.02 742.01 743.90 Fig. 26: Hydro-Unit Premium Line F Table 19: List of components Part No. Description Part No. Description 79-1 Automatic switchgear Pump 79-2 Measuring transducer... -
Page 57: Hydro-Unit Premium Line Vc
10.1.2 Hydro-Unit Premium Line VC 79-1 79-2 79-7 743.90 742.02 742.01 743.90 Fig. 27: Hydro-Unit Premium Line VC Table 20: List of components Part No. Description Part No. Description 79-1 Automatic control unit Anti-vibration pad 79-2 Measuring transducer Pump 79-10 Frequency inverter Pressure gauge O-ring 742.01/.02... -
Page 58: Hydro-Unit Premium Line Svp
10.1.3 Hydro-Unit Premium Line SVP 79-1 79-2 743.90 742.02 742.01 743.90 Fig. 28: Hydro-Unit Premium Line SVP Table 21: List of components Part No. Description Part No. Description 79-1 Automatic switchgear Pump 79-2 Measuring transducer Pressure gauge O-ring 742.01/.02 Lift check valve Accumulator 743.90 Ball valve... -
Page 59: Eu Declaration Of Conformity
11 EU Declaration of Conformity Manufacturer: D.P. Industries B.V. Kalkovenweg 13 2401 LJ Alphen aan den Rijn (The Netherlands) The manufacturer herewith declares that the product: Hydro-Unit Premium Line (F, VC, SVP) Serial number: 10/2019 0000000-0001 - 52/2020 9999999-9999 – is in conformity with the provisions of the following Directives as amended from time to time: –... -
Page 60: Certificate Of Decontamination
12 Certificate of Decontamination Type: ..........................Order number/ Order item number ..........................Delivery date: ..........................Applications: ..........................Fluid handled ..........................Please tick where applicable ⃞ ⃞ ⃞ ⃞ ⃞ Corrosive Oxidising Flammable Explosive Hazardous to health ⃞ ⃞ ⃞ ⃞ ⃞... -
Page 61: Commissioning Report
13 Commissioning Report The pressure booster system specified below has been commissioned today by the undersigned, authorised DP Service who created this report. Pressure booster system details Type series ............................Size ............................Serial number ............................Order No............................Purchaser/place of installation Purchaser Place of installation Name... -
Page 62: Index
Index Alerts 41 Partly completed machinery 7 Automation 16 Personnel 10 Preservation 12 Certificate of Decontamination 60 Commissioning/start-up 25 Qualification 10 Control panel 31 Quick menu 40 Design 16 Return to supplier 13 Designation 15 Disposal 13 Drive 16 Safety 9 Dry running protection 25... - Page 64 DP Pumps P.O. Box 28 2400 AA Alphen aan den Rijn The Netherlands t (0172) 48 83 88 f (0172) 46 89 30 dp@dp-pumps.com www.dp-pumps.com 22/10/2019 BE00001122 (1983.812/02-EN)
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