KSB BoosterControl Advanced Instructions d'installation
BoosterControl Advanced
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual BoosterControl Advanced
Original operating manual
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.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 12/03/2018
Contents
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BoosterControl Advanced
Contents
1 General.................................................................................................................................................... 5
1.1 Principles ...........................................................................................................................................................5
1.2 Target group.....................................................................................................................................................5
1.3 Other applicable documents............................................................................................................................5
1.4 Symbols .............................................................................................................................................................5
2 Safety...................................................................................................................................................... 6
2.1 Key to safety symbols/markings.......................................................................................................................6
2.2 General..............................................................................................................................................................6
2.3 Intended use .....................................................................................................................................................6
2.4 Personnel qualification and training...............................................................................................................7
2.5 Consequences and risks caused by non-compliance with this operating manual........................................7
2.6 Safety awareness ..............................................................................................................................................7
2.7 Safety information for the user/operator.......................................................................................................7
2.8 Safety information for maintenance, inspection and installation work.......................................................7
2.9 Unauthorised modes of operation..................................................................................................................8
2.10 Software Changes.............................................................................................................................................8
2.11 Electromagnetic compatibility.........................................................................................................................8
3 Transport/Temporary Storage/Disposal............................................................................................... 9
3.1 Checking the condition upon delivery............................................................................................................9
3.2 Transport...........................................................................................................................................................9
3.3 Storage..............................................................................................................................................................9
3.4 Disposal .............................................................................................................................................................9
4 Description............................................................................................................................................ 10
4.1 General description ........................................................................................................................................10
4.2 Designation.....................................................................................................................................................10
4.3 Name plate......................................................................................................................................................10
4.4 Functions.........................................................................................................................................................10
4.5 Technical data.................................................................................................................................................11
4.5.1 Parameterisable inputs/outputs ........................................................................................................12
4.6 Combination options......................................................................................................................................12
4.7 Options............................................................................................................................................................13
4.8 Software scope of supply...............................................................................................................................13
4.9 Dimensions and weight..................................................................................................................................13
5 Installation at Site................................................................................................................................ 14
5.1 Safety regulations...........................................................................................................................................14
5.2 Checking ambient conditions ........................................................................................................................14
5.3 Installing BoosterControl Advanced..............................................................................................................14
5.4 Electrical connection ......................................................................................................................................14
5.4.1 Electrical connections ........................................................................................................................14
5.4.2 Connection to power supply .............................................................................................................17
5.4.3 Connecting/bridging the motor protection device..........................................................................17
5.4.4 Connecting the pump contactors .....................................................................................................18
5.4.5 Connecting the pressure sensor ........................................................................................................18
5.4.6 Connecting the dry running protection device................................................................................18
5.4.7 Other connections required depending on the operating mode...................................................18
5.4.8 Making optional connections ...........................................................................................................19
6 Operation.............................................................................................................................................. 21
6.1 Control panel..................................................................................................................................................21
6.1.1 "Traffic light" LEDs ............................................................................................................................21
6.1.2 Graphical display................................................................................................................................21
6.1.3 Menu keys ..........................................................................................................................................22
6.1.4 Navigation keys..................................................................................................................................26
6.2 Operating the device via the service interface.............................................................................................27
Contents
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6.3 Operating the device via the control panel..................................................................................................27
6.3.1 Displaying and changing parameters ...............................................................................................27
6.4 General functions ...........................................................................................................................................28
6.4.1 Setting the physical units ..................................................................................................................28
6.4.2 Saving/loading customer settings .....................................................................................................28
6.4.3 Saving/loading factory settings.........................................................................................................29
6.4.4 Resetting to default settings.............................................................................................................29
6.4.5 Enabling/disabling the password ......................................................................................................29
6.4.6 Displaying general information ........................................................................................................29
6.4.7 Displaying status information ...........................................................................................................30
6.5 General information on parameterisation ...................................................................................................31
6.6 User login........................................................................................................................................................31
7 Quick Start Instructions ....................................................................................................................... 32
8 Commissioning/Start-up/Shutdown................................................................................................... 34
8.1 Ambient conditions for commissioning and operation ...............................................................................34
8.2 Commissioning................................................................................................................................................34
8.2.1 Starting up the system.......................................................................................................................34
8.3 Setting BoosterControl Advanced.................................................................................................................34
8.3.1 Setting the display language ............................................................................................................34
8.3.2 Setting the time/date.........................................................................................................................34
8.4 Basic configurations of the pressure booster system ...................................................................................34
8.4.1 Cascade control ..................................................................................................................................36
8.4.2 Cascade control - with jockey pump.................................................................................................37
8.4.3 Control with one frequency inverter (per system)...........................................................................38
8.4.4 Control with one frequency inverter per pump (sequential starting/stopping of pumps) ...........41
8.4.5 Control with one frequency inverter per pump (synchronous operation of pumps), multiple
pump operation .................................................................................................................................42
8.4.6 Setting the frequency inverter parameters......................................................................................44
8.5 Application functions.....................................................................................................................................45
8.5.1 Setting the parameters for dry running protection ........................................................................45
8.5.2 Setting an alternative setpoint .........................................................................................................45
8.5.3 Parameterisation of inlet tank function...........................................................................................46
8.5.4 Parameterising the accumulator function (frequency-controlled systems only) ...........................49
8.5.5 Water flow detection (WSD) .............................................................................................................49
8.5.6 Fire-fighting function ........................................................................................................................51
8.5.7 Emergency power function (limitation of number of pumps)........................................................51
8.5.8 Automatic setpoint reduction in case of inlet pressure drop (ASR) ..............................................52
8.5.9 Configuring the functional check run ..............................................................................................52
8.5.10 Dynamic pressure compensation (DFS).............................................................................................52
8.5.11 Setting freely parameterisable inputs ..............................................................................................53
8.5.12 Setting freely configurable outputs ................................................................................................53
8.5.13 Configuration example......................................................................................................................54
8.5.14 Setting alternative setpoint using a timer .......................................................................................54
9 Servicing/Inspection............................................................................................................................. 55
9.1 Safety regulations...........................................................................................................................................55
9.2 Servicing/Inspection........................................................................................................................................55
9.2.1 Supervision of operation ...................................................................................................................55
10 Parameter list ....................................................................................................................................... 56
11 Trouble-shooting.................................................................................................................................. 78
11.1 Fault messages................................................................................................................................................78
12 Related documents .............................................................................................................................. 81
12.1 Checklist for commissioning and inspection.................................................................................................81
13 EU Declaration of Conformity............................................................................................................. 82
Index ..................................................................................................................................................... 83
1 General
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1 General
1.1 Principles
This manual is supplied as an integral part of the type series indicated on the front
cover. The 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 centre to
maintain the right to claim under warranty.
1.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.
1.3 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Logic diagram Description of electrical connections and
performance data
For accessories and/or integrated machinery components, observe the relevant
manufacturer's product literature.
1.4 Symbols
Table2: 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
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
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 Key to safety symbols/markings
Table3: 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.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies 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.
2.2 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.
The safety information in all sections of this manual must be complied with.
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 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:
▪Markings for connections
▪Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this operating manual.
2.3 Intended use
This product must not be operated beyond the values specified in the technical
product literature for the mains voltage, mains frequency, and ambient temperature,
or be used in any manner that is not compliant with the instructions provided in the
operating manual and in other, applicable documents.
The product must not be used in potentially explosive atmospheres.
2 Safety
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2.4 Personnel qualification and training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the product this manual refers to. The responsibilities, competence and
supervision of all personnel involved in 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 product must always be supervised by specialist technical personnel.
2.5 Consequences and risks caused by non-compliance with this operating
manual
▪Non-compliance with this operating manual 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
2.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪Accident prevention, health and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards and legislation (e.g. EN50110-1)
2.7 Safety information for the user/operator
▪Fit contact guards supplied by the operator for hot, cold or moving parts, and
check that the guards function properly.
▪Do not remove any contact guards during operation.
▪Provide the personnel with protective equipment and make sure it is used.
▪Eliminate all electrical hazards. (In this respect, refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
2.8 Safety information for maintenance, inspection and installation work
▪Modifications or alterations 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.
▪The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Any work on the product shall only be performed when it has been disconnected
from the power supply (de-energised).
▪Carry out work on the product during standstill only.
▪As soon as the work has been completed, re-install and/or re-activate any safety-
relevant and protective devices. Before returning the product to service, observe
all instructions on commissioning.
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2.9 Unauthorised modes of operation
Never operate the product outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the product supplied
is only valid if the product is used in accordance with its intended use.
2.10 Software Changes
The 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 the
software. Software updates supplied by KSB are excluded from this rule.
2.11 Electromagnetic compatibility
EMC Directive 2004/108/EC ("Electromagnetic Compatibility") sets out the
requirements concerning the interference immunity and interference emissions of
electric and electronic equipment.
3 Transport/Temporary Storage/Disposal
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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 KSB or the supplying dealer (as applicable) and the insurer about the
damage in writing immediately.
3.2 Transport
▪Transport the device in its original packaging.
▪Observe the transport instructions on the original packaging.
▪Keep the original packaging for future transport and storage.
3.3 Storage
If the ambient conditions for storage are met, the function of the control unit is
safeguarded even after a prolonged period of storage.
CAUTION
Damage during storage by humidity, dirt or vermin
Corrosion/contamination of the control unit!
▷For outdoor storage cover the (packed or unpacked) control unit and
accessories with water-proof material.
Table4: Ambient conditions for storage
Ambient condition Value
Relative humidity 85% max. (non-condensing)
Ambient temperature -10°C to + 70°C
▪Store the control unit in dry, vibration-free conditions and, if possible, in its
original packaging.
▪Store the control unit in a dry room where the level of atmospheric humidity is as
constant as possible.
▪Prevent excessive fluctuations in atmospheric humidity (see table on ambient
conditions for storage).
3.4 Disposal
The product is classified as special waste due to several installed components:
1. Dismantle the product.
2. Separate and sort the materials
e.g. by:
- Aluminium
- Plastic cover (recyclable plastic)
3. Dispose of materials in accordance with local regulations or in another
controlled manner.
PCBs, power electronics, capacitors and electronic components are all special
waste.
The requirements pertaining to RoHs 2002/95/EC are fulfilled.
4 Description
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4 Description
4.1 General description
▪Control unit for pressure booster systems
With BoosterControl Advanced, up to 3 or 6 pump sets can be started, stopped and
controlled as a function of pressure.
4.2 Designation
Example: BCA 6
Table5: Key to the designation
Code Description
BCA BoosterControl Advanced
6 Number of pumps that can be connected
4.3 Name plate
BoosterControl 1.5 - 3P
P/N 01464675
S/N 010201211290018
Date 29-11-2012
Made in EU
230VAC
50/60Hz
IP20
15W
Warning!!!
High voltage
1
2
3
4
5
6
7 8
Fig.1: Name plate (example)
1 Type series, size 2 Ident. number
3 Series number 4 Year of construction
5 Input voltage 6 Mains frequency
7 Enclosure 8 Power input
4.4 Functions
Control system Control of up to 3 or 6 pump sets as a function of pressure
The following functions, among others, are possible:
▪Even distribution of operating hours among the pumps connected
▪Automatic pump changeover
–as a function of operating hours
–in the case of a pump fault
▪Pump starting and stopping in line with demand
▪Functional check run
▪Control of an inlet tank valve (for corresponding system configuration)
Table des matières
Autres manuels KSB Contrôleurs
