1 General 7.5.4.

9 Program Pressure
4
2 Safety 7.5.4.10 Specific Function
4
2.1 Symbols used in these operating instructions 7.5.4.11 Set Alarm
2.2 Personnel qualification and training 7.5.4.12 System
2.3 Non–compliance with safety instructions 7.5.4.13 Sensor
2.4 Safety awareness 7.5.4.14 Communication
2.5 Safety instructions for the operator/user 7.5.4.15 Check
2.6 Safety instructions for maintenance, inspection and 7.5.5 Default Values
installation work 7.6 Terminal Connection Diagram
2.7 Unauthorized modification and manufacture of 7.7 Circuit Diagram
spare parts 8 Dismantling / reassembling the pumps
2.8 Unauthorized modes of operation 9 Returning to Service
3 Transport and interim storage 10 Maintenance
4 Description 10.1 Operation Monitoring
4.1 General description 11 Work on the Control Cabinet
4.2 Configuration and function 12 Inspection
4.2.1 Configuration 13 Inspection Checklist
4.2.2 Function 14 Pre-Charge Pressure
4.3 Dry running protection (Accessory equipment)
4.4 Manual mode (Accessory equipment)
4.5 Control cabinet ANNEX
4.6 Flow diagram 1. Installation & Commissioning Check List moviBOOST:
5 Installation at site 1.1 Site conditions:
5.1 Readiness for operation 1.2 Commissioning / Start up:
5.2 Installation and location as per DIN 1988 2. Test Run Procedure and Check List
5.3 Piping 3 Electrical performance data
5.4 Foundation 4 Shutoff head
5.5 Installation 5 Trouble–shooting
5.6 installing an expansion joint
5.7 Installing a pressure reducer
5.8 Location and installation of unpressurized inlet tanks
5.8.1 Location
5.8.2 Installation
5.9 Valves and fittings
5.10 Noise characteristics
6 Connection to power supply
6.1 Electric wiring
6.2 Power supply cable
6.2.1 Sizing the power supply cable
6.3 Protective measures
6.4 Temperature requirements
6.5 Humidity requirements
6.6 Installation altitude
6.7 Pollution exposure
6.8 Checking the voltage
6.9 Logic / Circuit wiring diagrams
6.10 Motor protection switch
6.11 Potential equalization1
7 Commissioning / start–up
7.1 Preparations for commissioning / start–up
7.2 Test run
7.3 Checking the direction of rotation
7.4 Functional description / Automatic operation
7.5 Starting the unit
7.5.1 Function of the control panel
7.5.1.1 Key Function
7.5.1.2 LCD Display
7.5.2 Functions
7.5.3 Security
7.5.4 Menu Items Settings
7.5.4.1 Setting the Set Pressure
7.5.4.2 Alarm Data View
7.5.4.3 Operating Data View
7.5.4.4 Date Setup
7.5.4.5 Inverter Setup
7.5.4.6 P.I.D Setup
7.5.4.7 Sub Pump
7.5.4.8 Program Operating
1 General
Configuration and function of the moviBoost pressure 2.2 Personnel qualification and training
boosting units are in accordance with DIN 1988 stipulations. All personnel involved in operating, maintaining,
These operating instructions are intended to facilitate servicing, inspecting and installing the unit must be fully
familiarization with the unit and its designated use. qualified to carry out the work involved. Areas of
The manual contains important information for reliable, responsibility and personnel monitoring must be clearly
proper and efficient operation. Compliance with the operating specified by the operator. If the personnel in question does
instructions is of vital importance to ensure reliability and a not already possess the requisite know–how, appropriate
long service life of the unit and to avoid any risks. training and instruction must be provided. If required, the
These operating instructions do not take into account local operator may commission the manufacturer / supplier to take
regulations; the operator must ensure that such regulations care of such training. In addition, the operator is responsible
are strictly observed by all, including the personnel called in for ensuring that the contents of the operating instructions
for installation. are fully understood by the responsible personnel.
This pump / unit must not be operated beyond the limit 2.3 Non–compliance with safety instructions
values for the fluid, capacity, speed, density, pressure, Non–compliance with safety instructions can jeopardize
temperature and motor rating specified in the technical the safety of personnel, the environment and the machine /
documentation. Make sure that operation is in accordance unit itself. Non–compliance with these safety instructions will
with the instructions laid down in this manual or in the also lead to forfeiture of any and all rights to claims for
contract documentation. damages.
The name plate indicates the type series / size, main In particular, non–compliance can, for example, result in:
operating data and works / serial number; please quote this - failure of important machine/system functions,
information in all queries, repeat orders and particularly when - failure of prescribed maintenance and servicing practices,
ordering spare parts. - hazard to persons by electrical, mechanical and chemical
If you need additional information or instructions or if the effects,
device is damaged, contact your nearest KSB customer - hazard to the environment due to leakage of hazardous
service centre. substances.

2 Safety 2.4 Safety awareness

These operating instructions contain important information It is imperative to comply with the safety instructions
which must be observed when installing, operating and contained in this manual, the relevant national health and
maintaining the unit. For this reason, they must be read and safety regulations and the operator’s own internal work,
understood by the installing personnel and the responsible operation and safety regulations.
technical staff / operators before the unit is installed and
commissioned. They must always be kept available at the
place of installation of the unit for future reference. 2.5 Safety instructions for the operator / user
In addition to the general safety instructions laid down in this - Any hot or cold components that could pose a hazard
chapter on “Safety”, the special safety instructions provided must be equipped with a guard by the operator.
in other sections must also be observed. - Guards which are fitted to prevent accidental contact with
moving parts (e.g. coupling) must not be removed whilst
2.1 Symbols used in these operating the unit is operating.
instructions - Leakages (e.g. at the shaft seal) of hazardous fluids
Safety information in these operating instructions whose handled (e.g. explosive, toxic, hot) must be contained so
non–observance might cause hazards to persons is specially as to avoid any danger to persons and the environment.
marked with the general hazard sign All relevant laws must be heeded.
- Electrical hazards must be eliminated. (In this respect
refer to the relevant safety regulations applicable to
different countries and / or the local energy supply
companies.)

safety sign to ISO 7000 - 0434. 2.6 Safety instructions for maintenance,
The electrical danger warning sign is inspection and installation work
The operator is responsible for ensuring that all
maintenance, inspection and installation work be performed
by authorized, qualified specialist personnel who are
thoroughly familiar with the manual. Work on the machine /
safety sign to IEC 417 - 5036.
unit must be carried out only during standstill. The shutdown
The word procedure described in the manual for taking the unit out of
Caution service must be adhered to without fail. Pumps or pump units
handling fluids injurious to health must be decontaminated
is used to introduce safety instructions whose non– Immediately following completion of the work, all
observance may lead to damage to the machine and its safety–relevant and protective devices must be re–installed
functions. and / or re–activated.
Instructions attached directly to the machine, e.g. Please observe all instructions set out in the chapter on”
-arrow indicating the direction of rotation Commissioning/start–up” before returning the unit to service.
-markings for fluid connections must always be complied with
and be kept in a perfectly legible condition at all times.
2.7 Unauthorized modification and 4.2 Configuration and function
manufacture of spare parts
Modifications or alterations of the equipment supplied are 4.2.1 Configuration
only permitted after consultation with the manufacturer. Between 2 and 6 vertical high–pressure pumps (for
Original spare parts and accessories authorized by the description and function, please refer to the pump’s
manufacturer ensure safety. The use of other parts can operating instructions) are arranged on a baseplate. Each
invalidate any liability of the manufacturer for resulting pump may be seated on its own anti–vibration mounts. The
damage. pumps are arranged in a line and connected to header pipes.
On the system side, a combined non–return / shut–off valve
2.8 Unauthorized modes of operation or a spring loaded check valve and a shut–off butterfly valve
The warranty relating to the operating reliability and safety of are fitted downstream of each pump.
the unit supplied is only valid if the equipment is used in On the suction side, a ball valve or a shut–off butterfly
accordance with its designated use. The limits stated in the valve are fitted upstream of each pump as a service valve.
data sheet must not be exceeded under any circumstances. The shut–off elements permit dismantling of individual
pumps without having to drain the pipe-work. The discharge
side non–return valve ensures that the unit remains filled
3 Transport and interim storage with water and prevents backflow through the pumps.
The package unit is packed on pallets or in wooden crates Both headers feature additional connections for draining,
and wrapped in plastic foil for shipping and interim storage. venting and installation of various dry running protection
All connecting points are capped. It is imperative that the devices.
shipping / handling instructions shown on the package be The accumulator is fitted with an isolating valve. It
followed. compensates discharge–side peak pressures and, together
with the minimum operating period, limits the pumps’
Caution
switching frequency.
The unit must be protected against frost. moviBoost units are started up as a function of
pressure. To this effect, a pressure transmitter is fitted in the
If upon unpackaging the unit you should discover that the control panel along side pressure switch as an alternative
package has been damaged by dropping or some other form with a connection to discharge–side piping.
of mechanical impact, please carefully inspect the unit itself Depending on the number and power of the pumps, the
for possible damage and inform the freight forwarder / KSB’s completely wired control cabinet is either supplied mounted
customer service, even if you have not been able to detect on the baseplate or as a free–standing cabinet.
any such damage. Only supplementary and special equipment is supplied
Once the unit has been removed from the package, it must fitted on the unit. Accessories such as expansion joints,
be stored in accordance with the location and installation tanks, accumulators, pressure reducers, etc. are supplied
instructions (see Installation and location). with the unit but are not mounted.
The unit is driven by surface–cooled three–phase
squirrel–cage motors, 50 Hz, air–cooled, 2–pole, KSB
4 Description standard motor with main dimensions to IEC.
4.1 General description up to 2.2 kW 220-240 V/380-420 V,
The fully electronic pressure boosting package units from 3 kW 380-420 V/660-725 V
are supplied ready for connection. The equipment circuitry enclosure IP 55, thermal class F, up to 4 kW design V18,
allows both direct and indirect connection to the water supply from 5.5 kW design V1, all motors >3 kW with PTC
system. thermistor.
For combined use as drinking water supply and fire 4.2.2 Function
protection system, moviBoost can be installed as an moviBoost is started as a function of pressure and
interconnected system in accordance with DIN 1988, Part 5. stopped as a function of demand.
The equipment must be operated and maintained in
accordance with DIN 1988 (DVGW) so as to ensure Automatic mode
uninterrupted reliability of water supply, without causing The pressure boosting unit consisting of 2 to 6 pumps
disturbances in the public water supply or other starts up the first pump as soon as the actual system
consumer supply systems. pressure is approx. 0.3 bar lower than the pre–set system
The instructions put forth in DIN 1988 must be pressure.
adhered to for connection to the public water supply system; This pump is speed–controlled via frequency inverter
any applicable water utility or fire protection regulations as a function of service demand. If the first pump cannot
must also be complied with. meet the demand, this is recognized by the control system,
Furthermore, local conditions must be taken into and the next pump available is started. This routine is
account (for example excessive or very unsteady supply repeated until all pumps are running. The system pressure is
pressure requiring the installation of a pressure reducer). maintained at a constant level by means of the frequency
inverter controlled pump.
 If the unit has been correctly selected in accordance with Furthermore, in manual mode a minimum flow rate is
DIN 1988, it must be capable of covering the demand without required for each pump in order to ensure sufficient cooling
using the stand–by pump. of the pumps.
As demand decreases, the pumps are automatically Example:
sequenced out by the control unit. Pressure differences are An open tap means a water consumption of approx. 800 to
equalized by the speed–controlled pump. The control unit will 1200 l/h.
recognize when demand has dropped to zero and stop the Minimum flow rate per pump:
speed–controlled pump last. Movitec V 2 300 l/h
For an equal distribution of operating hours, the pumps Movitec V 4 600 l/h
which have been started up first will be stopped first. After Movitec V 10 1200 l/h
the base load pump completes its operating hours, the Movitec VF 18 2400 l/h
frequency inverter changes to the next pump available. Movitec VF 32 4000 l/h
Movitec VF 45 4600 l/h
4.3 Dry-running protection Movitec VF 65 6100 l/h

Set of electrodes are supplied with the unit for water 4.5 Control cabinet
level sensing & dry run protection The control cabinet is completely wired and connected to the
The dry running protection terminal is deactivated by package unit. It is equipped with:
means of a bridge. At time of installation, the terminals - Advanced control unit with multi–line touch display, function
should be properly connected to electrode wires, otherwise and navigation keys and 4 LEDs signalling operating status
the operator shall assume responsibility for any dry running - 1 VFD
that might occur. - 1 MCCB
- 1 manual contactor switch (motor protection switch) per
pump and for VFD
4.4 Manual mode
- 2 D-line Relays (magnetic contactors) per pump
The control panel is fitted with manual–0–automatic
- 1 master switch and three individual switches for each
switches. The pumps can also be started up in manual mode
pump (accessible from the outside)
by means of the manual–0–automatic switches. The pumps
- 1 Alarm buzzer
are then connected directly to the mains, independently of
- 1 mains and control transformer
the control unit.
- 1 pressure switch
For this mode of operation no pressure control and no lack–
- 1 Auto and Manual Relay
of–water monitoring will be affected.
- 1 Timer
- 1 Noise Filter

4.6 Flow diagram

Movitec 18 / 32 / 45 / 65
Fig 1 Flow Diagram for Direct Connection

1
Service pipe 15 Discharge pipe
2 Shut–off element 16 Accumulator, discharge pressure side
3 Ball valve 17 Pressure reducer, discharge pressure side
4 Water meter 18 Distribution line, downstream of Hyamat
5 Check valve 19 Consumer lines, downstream of Hyamat
6 Distribution line, inlet pressure side 20 By–pass line (for direct connection only)
7 Pressure reducer, inlet pressure side 21 Consumer lines, upstream of Hyamat
8 Inlet line 22 Distribution line, upstream of Hyamat
9 Shut–off elements 23 Inlet tank with float valve and level monitor
10 Pressure transmitter 24 Expansion joint
11 Pressure reading indicator 25 Drain valve
12 Control system 26 Swing check valve
13 Pump with drain and vent valve
14 Combined non return / shut–off valve

The formation of air pockets must be avoided. For

moviBoost suction lift operation, the suction side piping must be laid
with a continuously rising slope.

Fig 2 Indirect Connection

5.5 Foundation
The package unit is designed for installation on a level
5 Installation at Site concrete floor. Its anti–vibration pads provide adequate
5.1 Readiness for operation insulation against solid–borne noise. Units with Movitec
32, 45 or 65 pumps can be supplied with level–adjustable
The owner or the owner’s representative must report the feet to be fitted by the user. 2 of these feet can be fixed to
system’s readiness for operation to the responsible the floor.
authorities. Prior to commissioning, the installation
contractor must demonstrate conclusively that the
5.5 Installation
installation requirements have been complied with.
Prior to installing the unit, remove the packaging. Connect
The power supply line must be installed / connected by a
the unit’s inlet and discharge lines with the corresponding
duly authorized professional.
distribution lines (DIN 1988).
In order to avoid transmission of piping forces onto the
5.2 Installation and location as per DIN 1988 system and transmission of solid–borne noise, we
The moviBoost must be located either in the technical recommend installing length–limited expansion joints.
equipment room or in a well–ventilated, frost–free, The unit must be accessible to allow maintenance and
lockable room used for no other purpose. No harmful repair work.
gases are allowed to enter the place of installation. An
adequately sized drain connection (leading to a sewer or
5.6 Installing an expansion joint
equivalent) must be provided.
The expansion joint must have a length limiter with
The unit is designed for a maximum ambient temperature
solid–borne sound insulation so as to be able to absorb
of 0 °C to +40 °C at a relative humidity of 50 %.
reaction forces. The expansion joint must be installed in
moviBoost units should not be installed next to sleeping or
the piping free of twist. It must not be used to compensate
living quarters.
for misalignment or mismatch of the piping. During
If expansion joints are used for damping vibrations, their
assembly, the bolts must be evenly tightened crosswise.
fatigue strength (endurance limit) must be given due
The ends of the bolts must not protrude from the flange. If
consideration. They must be installed for quick and easy
any welding work is carried out nearby, the expansion
replacement.
joint must be covered for protection (sparks, radiant heat).
The expansion joint must remain unpainted and shall not
5.3 Piping be allowed to come into contact with oil. Its position within
All piping must be installed without transmitting any the system must allow easy access and inspection and,
stresses or strains. The use of length–limited expansion therefore, it must not be insulated along with the
joints is advisable. piping.
Expansion joints are subject to wear.
Consequently, the expansion joint must be
checked at regular intervals for early detection of cracks Single pump = . . . . ., dB(A)
or blisters, exposed fabric or other defects (see 2 pumps, total +3 dB(A)
recommendations laid down in DIN 1988). 3 pumps, total +4.5 dB(A)
4 pumps, total +6 dB(A)
5.7 Installing a pressure reducer
A length of approximately 600 mm must be provided on
the inlet pressure side to accommodate a pressure 5 pumps, total +7 dB(A)
reducer, if necessary. 6 pumps, total +7.5 dB(A)
A pressure reducer must be installed if the inlet
pressure fluctuation is so high that the unit must Example Single pump 48 dB(A)
be stopped or if the total system pressure (inlet 4 pumps, total +6 dB(A)
pressure plus shutoff head) exceeds the design = 54 dB(A)
pressure.
The maximum pump discharge pressure at zero flow point The maximum sound pressure level of 54 dB(A) for this
is reached in manual mode. For the pressure reducer to configuration may develop when all four pumps are
function properly there must be a minimum pressure running under full–load conditions. For noise
gradient of 5m. The pressure downstream of the pressure characteristics of the pumps refer to the pumps’ operating
reducer (downstream pressure) is the basic parameter for instructions. On units with acoustic cladding the noise
defining the pump head. emission of the unit is reduced by 7 dB (A).

Example: 6 Connection to power supply

The inlet pressure fluctuates between 4 and 8 bar. A
pressure reducer is needed upstream of the unit on the 6.1 Electric wiring
inlet pressure side.
All work marked with the symbol
Min. inlet pressure (Hvor) = 4 bar
Minimum pressure gradient = 0.5 bar must be performed by a qualified electrician or a
Downstream pressure = 3.5 bar duly trained, experienced person as described in
DIN EN 50110–1:2004.
5.8 Location and installation of unpressurized 6.2 Power supply cable
inlet tanks A 3+PE wire power supply cable is required for
5.8.1 Location the control cabinet.
As per DIN 1988 inlet tanks may be installed in the same All connections shall be effected in accordance
location as the pressure boosting unit. Installation and with the technical specifications issued by the
location are governed by the rules applicable to the local energy supply company.
pressure boosting unit (see 5.2).
6.2.1 Sizing the power supply cable
The cross–section of the power supply cable must be
5.8.2 Installation
sized for the total rated power requirement.
The closed PE inlet tank (under atmospheric pressure)
External fusing as per DIN VDE 0100 Part 430/11.91 and
must be installed as described in the installation
DIN VDE 0100 Part 520/2003–06 (see circuit diagram).
instructions supplied with the tank.
Mechanical and electrical installation of the tank must be 6.3 Protective measures
completed prior to commissioning of the unit. - Neutralization (4–wire system) PE and N connected
- Earthing (5–wire system) PE and N separate
Caution Clean the tank before filling it. - Earth leakage circuit breaker

5.9 Valves and fittings 6.4 Temperature requirements

All other valves and fittings in the service pipes, e.g. gate - Operation 0oC to 40oC
valves, water meters and non–return valve must be sized For temperatures exceeding 40 oC the power must be
in accordance with the data provided by the responsible reduced by 1.5 % per additional degree. A maximum
water company. cooling air temperature of 45 oC must not be exceeded.
- Storage up to 55 oC
5.10 Noise characteristics 6.5 Humidity requirements
moviBoost systems are available with different pump - Maximum relative humidity 50 % at 40 oC
models in variable numbers. Therefore, the total sound - Condensation must be effectively precluded.
pressure level in dB(A) needs to be calculated.
For the noise level of the individual pumps refer to the 6.6 Installation altitude
pumps’ operating instructions or to the type series booklet Maximum 1000 m above sea level. For any higher
moviBoost. altitude, the power must be reduced accordingly. Please
Calculation: contact your nearest KSB customer service centre.
6.7 Pollution exposure via the corresponding motor protection switch, making
The room air may contain dry dust comparable to sure that the motor runs in the correct direction of rotation
that normally encountered in work environments with no as indicated by the arrow on the motor. Prior to starting up
extraordinary machinery–induced dust accumulation. individual pumps, open the discharge–side shut–off
Exposure to unusually high dust levels, acids, corrosive element.
gases, salts, etc. must be avoided. When the pumps are running, loosen the vent plugs again
to let any remaining air escape. Then retighten the vent
6.8 Checking the voltage plugs carefully.
Compare the mains voltage with the name plate data and Check the pump for smooth running and close the
the control unit’s circuit diagram. discharge–side shut–off element for a short period in
order to verify whether the pump reaches the shutoff
6.9 Logic / circuit diagrams
head. Having checked each pump as described above, all
For each unit are included in the control cabinet, where
motor protection switches may be actuated and the unit
they must remain when not in use. This documentation
set to automatic mode.
includes a parts list for electric components.
Minor leakage of the mechanical seals during start–up is
When ordering spare parts for electric components,
normal and will cease after a short period of operation.
please always indicate the circuit diagram No.
6.10 Motor protection switch Caution
For d.o.l. starting the adjusting screw on the motor
If the master switch was turned off at any time during the
protection switch must be set to the rated motor current.
above procedure, the system will not begin operation until
For the setting range, refer to electrical performance data.
after the pre–set delay period.
Compare these data with the motor rating plate. If there
are any discrepancies, the data stated on the rating plate 7.3 Checking the direction of rotation
must be observed. For test operation each pump must be started up
individually to check the direction of rotation. If a pump is
6.11 Potential equalization found to be running in the wrong direction, switch two
A terminal is provided on the bottom right corner of panel phases on the motor terminal board.
for connecting a PE wire.
7.4 Functional description / Automatic mode
After start–up, pressure boosting units in standard design
7 Commissioning / start–up
will run in automatic mode. For units with manual–0–
automatic switch, set all pumps to automatic mode.
7.1 Preparations for commissioning/start–up Each pressure boosting unit has been factory–checked
Safety instructions and set to the required operating data.
All health and safety regulations relevant to
commissioning shall be observed. Please carefully read Caution
the Installing and commissioning checklist for moviBoost
in Annex. The factory settings may only be altered by
authorized, duly qualified staff.
The PBU comprises 2 to 6 pump units (including stand–by
7.2 Test run pump). The variable–speed pump ensures a constant
Commissioning should be carried out by specialist KSB supply pressure. The other pumps are started up in
staff. Please read the Test Run Procedure and checklist in parallel or stopped by the controller depending on the
the Annex. requirements, i.e. the individual pumps run only in line
Caution with the actual demand.
The stand–by pump ensures uninterrupted operation of
The unit must not be put in operation without having the system if one pump does not function properly or
been filled with water first; this also applies to test breaks down. In the case of a pump failure, the next free
runs, even for checking the direction of rotation. pump is started up at once and the fault is reported.
Connections between the pump and the pipeline must
always be retightened. Flanged connections must 7.5 Starting the unit
also be checked for tight fit. Switch on the master switch to supply the unit with power.
Set the master switch to”0”; unlock all motor protection The LED on the control panel indicates the unit’s
switches (if applicable). Provide connection to power readiness for operation.
supply. Ensure that the motor’s cooling–air inlet and outlet
openings remain unobstructed. 7.5.1 Function of the control panel
Open / loosen the vent plugs on the pumps (for vent The control panel comprises a back–lit display, function
plugs refer to the pump operating instructions). and navigation keys, LEDs. The display shows important
Slowly open the inlet–side shut–off element and prime the information for operating moviBoost. Data can be
system until the fluid escapes through all vent holes. displayed in plain text and parameters can be set.
Close and slightly tighten the pump vent plugs. Switch on
the master switch and start up one pump after the other
7.5.1.1. Function Keys
1. Display Current Pressure
2. Display Alarm, Date and Time (Display Alarm when it
It consists of Touch Panel / LCD Display / LED Display /
happened).
Key Pad.
3. Display Pump: “L” indicates Lead Pump and “P” indicate
1) Touch: All values set up by touch screen
Sub Pump. The “P” sign blinks while the pump is running
2) LCD: Display operates status and set up menu
4. “%” and “Hz” indicate Output rate transmitted to Inverter.
3) LED Display: Operate status / Alarm / operating pump
It can be displayed “100% ", “60Hz ", “50Hz " three types
Turn off: Stop (System Stop)
according to set up value “Inverter” / “Output”
Turn on: Operate stand-by
5. Individual Pump status Icon: displays running status and
Blink: Operating
error.
The "ERROR" LED will be turned on when alarm
* You can check the pump running data when you touch
happened.
the pump Icon.
And that LED will be turned off when alarm dismissed
6. Menu button: When you push the MENT Button, you can
4) Keys
find main menu after you input the password
MODE: Press to go to <Menu Items> Screen (Go to
password screen)
ENTER: Saving set up values
Direction Icon: Move to menu line or change the values

7.5.1.2 LCD Display

7.5.2 Functions
Here’s the summarized description of the overall function of the controller
7.5.3 Security (2) Push the “Menu” button to return to main screen.
The benefits of this controller is the convenient control
of the system program realized by the Touch Screen
buttons and the security system programmed to prevent

the system from handling by unauthorized person without

a User Password to access to the control setup or setup
change.
Password screen
When you press a [Menu] button to set up the control of
the system, the Password pop-up window will appear as
shown in the following figure. You must enter your User
Password to go to the Menu items screen. The default
User Password is “1111” Input the password using
direction buttons and press [Enter] button.
You will game desired Menu items screen.
- The Password must consist of 4 numbers.

Note:
1) Once you enter the Password, you can go to the Menu
items screen without repeating the Password entering (1) Set Pressure:
process for next five minutes. If you don’t touch any button The (Set Pre.) refers to the System Piping Pressure
on the screen for 5 minute, the User Password will be maintained while the pumps run.
required again. * Do not set the setting pressure higher than the
2) LCD back-light automatically fades out if you don’t give setting value of the pressure transmitter.
any touch on the LCD for 2 minutes. This is designed to (2) High Pre. Limit: refers to the maximum allowable
maximize the LCD lifespan. The back-light will light on system operating pressure.
when you touch the LCD screen. (3) Low Pre. Limit: refers to the lower limit of system
3) If you don’t give a touch on current screen for 2 minutes operating pressure.
except the main screen, the display automatically goes * This option is to prevent possibly severe damage on
back to the Main screen. the system due to imminent system pressure drop
4) It is strongly recommended to change the PASSWORD cause by pipe crack, etc.
after the system test run. (4) Run pressure:
5) If you initialize the system control setting, the The pressure difference between the main pump stop
PASSWORD is also initialized to the default at the setting pressure and restart.
password“1111”. Ex). “Set Pressure = 4.0 Bar”, “Run pressure = -0.3 Bar”
The main pump will start at 3.7 Bar.
(5) Stop Ratio:
7.5.4 Menu Items Settings If the main pump operates below stop ratio, the pump
7.5.4.1 Setting the Set Pressure will stop after fixed time.
You can see the below screen without input * Please set up the Stop ratio higher when the pumps
password when you push the ↑ button for two seconds. don’t stop even if you do not use the water.
(6) Shift Time:
This function is designed to reduce the system life
cycle cost. The system makes all pumps operate for equal
period of time so that prevent the over-use of a particular
pump resulting in relatively high parts wear of the pump.
(7) Main Pump:
Shift the main pump manually.
• You must stop the system to shift the main
Use the direction button to move the curser and pump manually.
locate the curser to “set up pressure” and push the “Mody”
Icon. 7.5.4.2 Alarm Data View
(1) Locate the curser to where you want to change the You can see the screen, when you push the ↓
value and use the ↑↓buttons to change the values and button for two seconds.
push the “Save” button. (1) It can save total 32 alarm data.
 (3) Push the “Etr.” button to save the changes.
(4) Push the “Menu” button to back to main menu.

7.5.4.5 Inverter Setup

You can find Number, kind of alarm, date, the number of

alarm.
(2) No. 1 is resent alarm data.
Push ↓ button when you want to go to next alarm data.

7.5.4.3 Operating Data View

You can see the below screen when you push the
pump No. or you push L1 pump on main screen. Push the
“Etr.” button to return to main screen.

Push “Inverter” button on “control” menu.

7.5.4.4 Date Setup - Move the curser using ↑↓ direction buttons to value.
You can see the below password input screen when - Push the “Mody” button to change values.
you push the “Menu” button - Change the values using ↑↓ buttons.
- Push the “Etr.” button to save the changes.
You can see the below menu screen when you input the - Push the “Menu” button to back to main menu.

password using direction buttons and push the “Etr.”

button.

(1) Stop Time: Use this option to setup the operating time
at the minimum output rate before stopping the pump(s)
Push the “Date Time” button to enter next menu. when no water is being used.
(1) Move the curser using ←→ direction buttons to year / (2) Min. output: Setting inverter minimum output
month / day / date value. You can change the values Ex) “Min output = 50%”
when you push the “Mody” button. Inverter Min output is 30Hz (for 60Hz)
(2) Change the values using ↑↓ buttons. (3) Stop Ratio: The pumps occasionally may still run
although no water is being used.
 This doesn’t mean the system is under an abnormal change the values when you push the “Mody” button.-
condition. In this case, when you increase the Inverter Change the values using ↑↓ buttons.
Stop Ratio, the pumps will stop - Push the “Etr.” button to save the changes.
(4) Max. Output: setting inverter maximum output. - Push the “Menu” button to back to main menu.
(5) Display: You can setup as %, Hz (1) Run Diff.: Setting run diff. on sub pumps
(6) Auto Return: Setting No. of restart if the alarm Ex) “Setting pressure = 4.0 Bar”, “Run Diff. = -0.3 Bar”
happened in inverter

7.5.4.6 PID Setup

Sub pumps will start at 3.7bar.

(2) Stop Diff.: Setting stop diff. on sub pumps
Ex) “Setting pressure = 4.0 Bar”, “Stop Diff. = 0.2 Bar”
Sub pumps will stop at 4.2 bar.
(3) Run Delay: If setting pressure is below run diff., the
pumps will not start.
(4) Stop Delay: If setting pressure is above stop diff., the
pumps will delay stop during setting time.

7.5.4.8 Set Pressure Reservations

Push “Prog Ope” button on “control” menu.
- Move the curser using ↑↓ direction buttons to value.
- You can change the values when you push the “Mody”
button.

Push “Set PID” button on “control” menu.

- Move the curser using ↑↓ direction buttons to value.
- You can change the values when you push the “Mody”
button.
- Change the values using ↑↓ buttons.
- Push the “Etr.” button to save the changes.
- Push the “Menu” button to back to main menu.

PID Control is the most ideal control type for the Booster
Pump System

7.5.4.7 Sub Pump

Push “Sub Pump” button on “control” menu.- Move the

curser using ↑↓ direction buttons to value. - You can

- Change the values using ↑↓ buttons.

- Push the “Etr.” button to save the changes.
- Push the “Menu” button to back to main menu. You can change the values when you push the “Mody”
*You can setup five program operations on one day button.

7.5.4.9 Set Pressure Scheduling Change the values using ↑↓ buttons.

- Push the “Etr.” button to save the changes.
- Push the “Menu” button to back to main menu.

Push “Prog. Pre” button on “control” menu.

- Move the curser using ↑↓ direction buttons to value.
(1) Freeze Prevention: Prevent the pump freeze with
- You can change the values when you push the “Mody”
operating minimum output when the temperature down to
button.
0°C. (Optional)
- Change the values using ↑↓ buttons.
(2) Fix Prevention: This function is to prevent the problem
- Push the “Etr.” button to save the changes.
said above by running the lead pump for 60 seconds in
- Push the “Menu” button to back to main menu.
case the pumps didn’t run for the fix prevention setting
time.
(3) Friction Compensation: This factor is to compensate
system friction loss due to piping Friction resistance or
pump paralleled operation in accordance with System
environment.
Ex) “Setting pressure = 4.0 Bar”, Friction Compensation =
0.1 Bar”
Sub pump 1 run = Setting pressure will be 4.1Bar
Sub pump 2 run = Setting pressure will be 4.2 Bar
(1) Timely: Setting the pressure timely (4) Lead Pump Shift Time: This function is designed to
(2) Weekly: Setting the pressure weekly reduce the system life cycle cost.
The system makes all pumps operate for equal
(3) Monthly: Setting the pressure
period of time so that prevents the over-use of a particular
pump resulting in relatively high parts wear of the pump.
7.5.4.10 Specific Functions

Push “Specfunc” button on “Advance” menu.

7.5.4.11 Set Alarm
- Move the curser using ↑↓ direction buttons to value.
 - You can change the values when you push the “Mody”
button.

Push “SetAlarm” button on “Advance” menu.

- Move the curser using ↑↓ direction buttons to value.
- You can change the values when you push the “Mody”
button.
- Change the values using ↑↓ buttons.
- Push the “Etr.” button to save the changes. - Change the values using ↑↓ buttons.
- Push the “Menu” button to back to main menu. - Push the “Etr.” button to save the changes.

- Push the “Menu” button to back to main menu.

(1) Main return: Setup main screen return time

(2) Back Light: Setup LCD Back Light off time
(3) Password: Change Password
(4) Test Code: Test system.
(1) Max. Pressure: All pumps stop when the pressure
7.5.4.13 Sensor
above max. Pressure
(2) Min. Pressure: All pumps stop when the pressure
below min. pressure
(3) Low water level: Setup low water level or not
(4) Low pressure alarm: Setup low pressure alarm or not
(5) High pressure alarm: Setup high pressure alarm or not
(6) Low water level stop: Setup low water level stop time
(7) Low water level return: Setup low water level return
time
(8) Low pressure stop: Setup low pressure stop time
(9) Relay1, 2: You can setup pump run, operate, stop,
alarm
(10) Buzzer No.: The pumps stop after buzzer no.

7.5.4.12 System
Push “System” button on “Advance” menu.
- Move the curser using ↑↓ direction buttons to value.
 Push “Sensor” button on “Advance” menu. - Push the “Mody” button to change values
- Move the curser using ↑↓ direction buttons to value. - Change the values using ↑↓ buttons.
- Push the “Mody” button to change values. - Push the “Etr.” button to save the changes.
- Change the values using ↑↓ buttons. - Push the “Menu” button to back to main menu.
- Push the “Etr.” button to save the changes.
- Push the “Menu” button to back to main menu 7.5.4.15 Check: You can check the panel
(1) Sensor type: Setup sensor type of pressure transmitter. information and operating data.
* If you setup different sensor type, the system cannot (1) Information: Display the model and version
operate normally.
(2) Sensor Adjust: Setup sensor adjustment between screen
and pressure gage.

7.5.4.14 Communication

(2) Daily data: Save data for daily operation

(3) Check Alarm: It save recent alarm and descriptions
with date, time.
Push ↑↓ buttons to check alarm list
- No. 1 is recent alarm
(4) A/S: A/S information
(5) Operating Data: Save each pump’s daily operating
data.

- Push “Communic” button on “Advance” menu.

- Move the curser using ↑↓ direction buttons to value.
7.5.5 Default Values
7.6 Circuit Diagram
7.7 Terminal Connection Diagram
 cabinet and motor terminal box, de–energize the
8 Dismantling / reassembling the pumps system Even when the mains lamp goes out, check
The pumps can be individually dismantled to facilitate
.

whether all phases are actually dead prior to

maintenance. performing any work on the control cabinet.
Dismantling sequence: It is recommended to have the control cabinet
1. Disconnect the pump from the power supply. serviced once a year. For this purpose you can take out
De–energize the pump via the motor a maintenance contract with one of KSB’s Service
protection switch. Partners.
2. Close the suction and discharge side valves.
12. Inspection
Reassembly:
KSB offers inspection services to relieve you as far as
1. Insert pump (original spare part only), always use
possible of the routine necessity of inspecting your
new gaskets for unions and tighten. Check tightness
moviBoost package system(s). Take advantage of this
of screwed connection!
additional after–sales service by taking out a
2. Fasten the pump foot to the baseplate using hexagon
maintenance contract with KSB. Get in touch with your
head bolts.
Service Partner for details.
3. Connect to power supply, set motor protection switch.
9 Returning to service 12.1 Inspection Checklist
Return the unit to service as described under In the event that you decide to conduct your own
Commissioning/ start–up. inspections, proceed according to the following checklist
at least once a year:
10 Maintenance 1. Check the pumps and drives for quiet running and the
10.1 Operation monitoring mechanical seal for integrity.
All technical systems require a certain degree of 2. Check the flexible transmission elements for wear.
monitoring. The same applies to our package units for 3. Check the function and seal condition of the shut–off,
which the following checks and inspections are drain and non–return valves.
prescribed: 4. Clean the strainer in the pressure reducer (if
- Check the unit’s readiness for operation. applicable).
- Check the operation check run, if activated. 5. Check the expansion joints for wear (if applicable).
- With the aid of the pressure gauge, compare the start 6. Verify the pre–charge pressure level and check the
and stop pressures of the pumps against the data on accumulator for integrity, if required (see section 14 pre–
the name plate. charge pressure table).
- The pump’s mechanical seal allows little or no visible 7. Check automatic switching.
leakage. It is maintenance–free. 8. Check the ON and OFF points of the system.
- The motor requires practically no maintenance. 9. Check if the functional check run is working.
- Verify whether the accumulator pre–charge pressure 10. Check the function of the overall system and
corresponds to the data in the pre–charge pressure compare the actual data with the name plate data.
table (see section 14). Close the shut–off elements 11. Check the water inlet, inlet pressure, lack–of–water
under the accumulator for this purpose and drain the monitoring, flow monitoring and pressure reducer.
accumulator via the drain valve. Remove the 12. Check the inlet tank and float valve, if applicable.
protective cap of the accumulator valve and check Check the overflow for integrity and cleanliness.
the pressure with the aid of a tyre pressure gauge.
Add nitrogen as necessary. 13 Pre–charge pressure
The pre–charge pressure in the accumulator should
Do not add any other gases. be set to a value which is 10 % lower than the set start–
11 Work on the control cabinet up pressure. The setting can be affected via a valve
Each pump can be switched off via the motor protection located under the cover at the top of the accumulator.
switch. The motor protection switches can be locked Pre–charge pressure table
with a padlock as a standard. The pumps can be Pre–charge pressure of accumulator
stopped by using the manual–0–automatic switch p = 0.9 x pE; pE = system start–up pressure
(supplementary equipment). However, this will not Recommendation
disconnect the system from the power Fill the accumulator with nitrogen only (risk of
supply, i.e. all electric devices are still live, Corrosion).
even if the pumps are not in automatic The stated values are average values. Tests on
operation mode. accumulators have shown that
Prior to working on the control cabinet or opening the pressures >3 bar for factor 0.9 and
motor terminal box, set the master switch to ”0” and pressures <3 bar for factor 0.8
unscrew the back–up fuse. result in the best storage volumes.
Example:
Do not tamper with the control unit, which should
pE = 5 bar pre–charge pressure 5 x 0.9 = 4.5 bar
only be serviced by KSB’s customer service. Prior to
pE = 2 bar pre–charge pressure 2 x 0.8 = 1.6 bar
opening any electric equipment such as control
 10. Turn the Auto/Stop/Manual switch on the front or
1. Installation & Commissioning Check List rear face of the panel to Manual position.
moviBOOST: 11. Check the rotating direction as repeating to turn
on and off the pump manual switches one by
one. The rotating direction is marked on Pump
1.1 Site conditions: foot.
1. Is the water reservoir filled with water? 12. If the rotating direction is not correct, switch the
2. Is the piping layout according to our wiring to the 2 phases of the motor terminals
recommendations (see fig 2)? each other.
3. Is the Power supply correctly connected? 13. Turn the Auto/Stop/Manual switch on the front or
4. Is the Piping connection correctly completed? rear face of the panel to Auto position.
5. Check if the three phases of power supply giving 14. The pump starts first is the inverter driven lead
correct Voltages? pump. Check its rotating direction.
6. Check if the power supply is correctly connected 15. If the rotating direction isn’t correct, switch the
to the motor and the panel? wiring of the 2 phases of the U, V and W inside
7. Check if the capacity of the cable is correct. the panel each other.
8. Check if the ambient temperature range is 0°C to 16. Please note that the rotating direction is Auto
+40°C at a relative humidity of 50 %? mode may be different from Manual mode,
9. Check if all piping be installed without because the inverter has the single power
transmitting any stresses or strains. The use of source.
length-limited expansion joints is advisable 17. Check the rotating direction every time you
10. The formation of air pockets must be avoided. change the run mode between Auto and Manual.
For suction lift operation, the suction side piping 18. When the pumps are running, loosen the vent
must be laid with a continuously rising slope. plugs again to let any remaining air escape. Then
(See fig1). retighten the vent plugs carefully.
11. In case if suction lift operation, check if the 19. Check the pump for smooth running and close
suction pipe is not undersized. It must be the discharge-side shut-off element for a short
properly equipped with foot valve & strainer. period in order to verify whether the pump
reaches the shutoff head
1.2 Commissioning / Start up: 20. Having checked each pump as described above,
1. Commissioning should be carried out by all motor protection switches may be actuated
specialist KSB staff. and the unit set to automatic mode.
2. It is highly recommended to use the three phase 21. Minor leakage of the mechanical seals during
sequence meter for mains connection. start-up is normal and will cease after a short
3. Check the electrical connections of panel period of operation.
terminals as per circuit diagram. 22. Close the piping discharge valve slowly and
4. Verify whether the accumulator pre-charge check if the pump(s) stops as the operating
pressure is set to a value which is 10% lower pressure reaches to the setting pressure
than the start up pressure. If not close the shut- Note: If the pump(s) does not stop, check if
off elements under the accumulator for this there’s any back flow from the check valve to the
purpose and drain the accumulator via the drain pump.
valve. Remove the protective cap of the 23. If the master switch was turned off at any time
accumulator valve and check the pressure with during the above procedure, the system will not
the aid of a tyre pressure gauge. Add air begin operation until after the pre-set delay
pressure as necessary. period.
Example: Pre-charge pressure of accumulator 24. Each pressure boosting unit has been factory-
p = 0.9 x pE; pE = system start-up pressure. checked and set to the required operating data.
pE = 5 bar Pre-charge pressure 5 x 0.9 = 4.5 bar 25. The factory setting should always be altered by a
5. Ensure that the motor’s cooling-air inlet and skilled & qualified KSB Staff.
outlet openings remain unobstructed. 26. For Detailed functional parameters refer to
6. Open the vent plugs on the pumps (for vent control unit operation manual.
plugs refer to the pump operating instructions).
7. Slowly open the inlet-side shut-off element and
prime the system until the fluid escapes through
all vent holes. Close and slightly tighten the
pump vent plugs one by one.
8. Open the suction and discharge valves
completely.
9. Switch on the master switch and start up one
pump after the other via the corresponding motor
protection switch.
2. Test Run Procedure and Check List
3 Electrical performance data
moviBoost Rated power Rated current Total rated power requirement in kVA
per motor (P2) per motor at moviBoost
with pumps 3~400 V Number of pumps (motors)
Movitec kW A 2 3 4 5 6
3202 4.0 9.0 12.78 19.02 25.25 31.49 37.72
3203 5.5 11.8 16.76 24.93 33.11 41.29 49.46
3204 7.5 14.3 20.31 30.22 40.12 50.03 59.94
3205 11.0 26.6 37.78 56.21 74.64 93.07 111.50
3206 11.0 26.6 37.78 56.21 74.64 93.07 111.50
3207 15.0 31.7 45.02 66.99 88.95 110.91 132.87
3208 15.0 31.7 45.02 66.99 88.95 110.91 132.87
4502–1 5.5 11.8 16.76 24.93 33.11 41.29 49.46
4502 7.5 14.3 20.31 30.22 40.12 50.03 59.94
4503–1 11.0 26.6 37.78 56.21 74.64 93.07 111.50
4503 11.0 26.6 37.78 56.21 74.64 93.07 111.50
4504–1 11.0 26.6 37.78 56.21 74.64 93.07 111.50
4504 15.0 31.7 45.02 66.99 88.95 110.91 132.87
4505–1 15.0 31.7 45.02 66.99 88.95 110.91 132.87
4505 18.5 40.5 57.52 85.58 113.64 141.70 169.76
4506–1 18.5 40.5 57.52 85.58 113.64 141.70 169.76
4506 22.0 44.5 63.20 94.03 124.86 155.69 186.52
6502 5.5 11.8 16.76 24.93 33.11 41.29 49.46
6503 7.5 14.3 20.31 30.22 40.12 50.03 59.94
6504 11.0 26.6 37.78 56.21 74.64 93.07 111.50
6505 15.0 31.7 45.02 66.99 88.95 110.91 132.87
6506 15.0 31.7 45.02 66.99 88.95 110.91 132.87
6507 18.5 40.5 57.52 85.58 113.64 141.70 169.76
6508 22.0 44.5 63.20 94.03 124.86 155.69 186.52
6509 22.0 44.5 63.20 94.03 124.86 155.69 186.52

4 Shutoff head
4506–1 143
moviBoost Head in m
4506 147
at flow rate Q = 0
6502 34
3202 39
6503 52
3203 59
6504 69
3204 79
6505 87
3205 99
6506 104
3206 118
6507 121
3207 138
6508 139
3208 158
6509 156
4502–1 45
4502 50
4503–1 70
4503 74
4504–1 94
4504 98
4505–1 118
4505 123
5 Trouble–shooting
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Description
The M5100 series from SENSYS sets the price / performance standard for transducers used in
demanding environments. The M5100 exceeds the latest heavy industrial CE requirements including
surge protection, and is over voltage protected to 16VDC in both positive and reverse polarity. The
pressure port is machined from a solid piece of 17-4PH stainless steel(316L optional). There are
no O-rings, organics or welds exposed to the pressure media. This allows for a leak proof,
all-metal sealed pressure system which withstands more than 10 million pressure cycles without
failure.

Features
▶ Heavy Industrial CE Approval
▶ 100V/m EMI Protection
▶ Reverse Polarity Protection
▶ Extended temperature range
▶ 1% Total Error Band
▶ Compact Outline
▶ -40 to 125℃

Applications
▶ Advanced HVAC Controllers
▶ Refrigeration Systems
▶ Automotive Test Stands
▶ Gas compressors
▶ Industrial process control
▶ Pumps and Compressors
▶ Hydraulic/Pneumatic
▶ Agriculture Equipment
▶ Energy and Water Management

Specifications

Range
3.5, 7, 10, 20, 35, 70, 200, 350, 700 bar
Performance
Total Error Band ±1%FS over compensated range
(±1.5% typical over extended range contact factory)
Compensated Temperature Range -20 ~ 85℃
Operating Temperature Range -40 ~ 125℃
-40 ~ 85℃(4~20mA)
Physical
Proof Pressure 200%FS Max.
Burst Pressure 500%FS Min.
Vibration 20G at 20 to 200Hz
Shock 200G / 11ms
Media-Wetted Materials Stainless Steel 630 (316L optional)
CE compliant per the following specification

EN55022 Emission Class A & B

IEC61000-4-2 Electrostatic Discharge Immunity(6kV contact/8kV air)
IEC61000-4-3 EM Field Immunity(30V/m)
IEC61000-4-4 Electrical Fast Transient Immunity(1kV)
IEC61000-4-5 Surge(1kV)
IEC61000-4-6 Conducted Immunity(10V)
IEC61000-4-9 Pulsed Magnetic Field Immunity(100A/m)
Automotive EM field immunity 100V/m 80MHz to 1GHz

Dimension

▶ Cable Type

Wire Connections
Color V Output mA Output
Red Input ○
+ Input ○
+
Black Common○
- Output ○
+
Green Output ○
+ ×

▶ Packard Connector Type

Pin Connections
No. V Output mA Output
A Input ○
+ Input ○
+
B Common○
- Output ○
+
C Output ○
+ ×

▶ Mini DIN Connector Type

Pin Connections
No. V Output mA Output
1 Input ○
+ Input ○
+
2 Output ○
+ Output ○
+
3 Common○
- ×
ｌ Earth ×
==
Technical data sheet

Type 402RR
Non-return valve
System 02

Applications • Operates in any position

and special features • Minimum head loss
• Silent, reliable sealing, compact
• Exceptional robustness
• Does not generate hammering
• Closing system in stainless steel :
long back axial guiding for reduced
displacement
• Sealing guaranteed by a flat seal
• Return spring
• Internal/external polyamid coated

Technical description DN
PN
PFA PS in bar
Cat. References Vvs-nr
• Connection : flanges drilled PN : see table
“ mm in bar L1 L2 G1 G2
• Permissible operating pressure PFA - water- (for supply,
1 40 10/16 16 16 16 16 16 I 149B 2281 RR
1/2

2 50 10/16 16 16 16 16 16 I 149B 2282 RR

distribution and disposal of water) : see table
21/2 65 10/16 16 16 16 15 16 I 149B 2283 RR • Maximum permissible pressure PS - other mediums:
3 80 10/16 16 16 16 12 16 I 149B 2284 RR See table
4 100 10/16 16 16 16 10 16 I 149B 2285 RR • T° : Mini. -10 °C
Important notice : 5 125 10/16 16 16 16 0,5 16 I 149B 2226 RR Maxi. 100 °C
The indicated pressure for the different 6 150 10/16 16 13 16 0,5 16 I 149B 2227 RR • Mediums : clear liquids, gas
categories of fluids (L1/L2/G1/G2) is 8 200 10 10 10 10 0,5 10 I 149B 2229 RR • Approvals : VERITAS (France) - ACS (France)
under no condition a guarantee of use.
Therefore, it is essential to validate the 10 250 10 10 10 10 0,5 10 I 149B 2230 RR KIWA (Holland)
use of products under given operating 12 300 10 10 10 10 0,5 10 I 149B 2231 RR Conformity (Europe)
conditions.
The operating instructions are available 14 350 10 10 10 10 0,5 8 I 149B 2232 RR • International construction Standards :
on our web site www.danfoss-socla.com
or by requesting from our sales department. 16 400 10 10 10 10 0,5 7 I 149B 2233 RR CE Conformity Directive 97/23/CE
20 500 10 10 10 10 0,5 7 I 149B 2235 RR Flange drilling according to EN1092-2

Overall dimensions DN B C D Weight

” mm mm mm mm kg
1 1/2 40 85 80 150 4,2
2 50 100 97 165 5,8
2 1/2 65 120 125 185 8,1
3 80 140 150 200 10,2
4 100 170 187 220 14,5
5 125 200 220 250 24
6 150 230 260 285 32
8 200 288 340 340 53
10 250 354 420 405 94
12 300 395 490 460 140
14 350 472 586 533 225
16 400 560 680 597 312
20 500 750 880 670 540

uk402rr - Updated : 21/06/04 1

Technical data sheet Type 402RR - Non-return valve

Spare parts list and Nb Description Materials EURO ANSI

materials
1 CASING Cast iron + rilsan EN-GJL-250 ASTM A 48 35 B
2 RING Stainless steel X5CrNi18-10 AISI 304
GUIDE DN50 Bronze CuSn5Zn5Pb5-C ASTM B 505
3
Other DN Cast iron + rilsan EN-GJL-250 ASTM A 48 35 B
4 SPRING Stainless steel X10CrNi18-8 AISI 302
5 SEAL EPDM
6 CLOSING SYSTEM Stainless steel GX5CrNi19.10 AISI 304

Working principle DN Opening pressure in mm/WC Kv

Without ζ
“ mm m3/H
spring
1 1/2 40 440 210 320 120 47,00 1,80
2 50 440 220 330 110 99,00 1,00
2 1/2 65 450 190 320 130 159,00 1,10
3 80 450 190 320 130 222,00 1,30
4 100 500 240 370 130 396,00 1,00
5 125 510 210 360 150 619,00 1,00
6 150 550 210 380 170 890,00 1,00
8 200 590 210 400 190 1120,00 2,00
10 250 710 210 460 250 2010,00 1,50
12 300 820 90 460 365 2459,00 2,10
14 350 860 100 480 380 2843,00 2,90
16 400 800 50 410 390 4370,00 2,10
20 500 1030 0 430 580 6914,00 2,05
Direction for use :
• Solid line : Valve completely open
• Dotted line : opening stage of valve

Danfoss can accept no responsibility for possible errors in catalogue, brochures and other printed material. Danfoss reserve the right to alter its products without notice.
This also applies to products already agreed. All trademarks in this material are the property of the respective companies. Danfoss and the logo type are trademarks of
Danfoss A/S. All right reserved.

Danfoss Socla
365 rue du lieutenant Putier Tel : 33 3 85 97 42 52
71530 VIREY LE GRAND Fax : 33 3 85 97 97 42
Postal address : BP273 http://www.danfoss-socla.com
71107 CHALON SUR SAONE Cedex e-mail:commer@danfoss.com

2 uk402rr - Updated : 21/06/04

Technical leaflet
8413.1/11--10 BOAX
Centred disc butterfly valve
with AMRING
elastomer liner
for H.V.A.C. applications

Sizes 20 to 400 mm
(3/4 to 14”)

PS 16 and 10 bar
Manual and electric
actuation

Applications  Marking in accordance with EN 19.

 Design in accordance with EN 593.
 Heating, ventilation, air conditioning.
 This valve cannot be dismantled.
 Fuel, gas, compressed air.
 The valves meet the safety requirements of the pressure
Working conditions Equipments Directive 97/23/EC (PED) appendix 1 for fluids
 Temperature range: the working temperature depends on of the groups 1 and 2.
the media and the nature of the elastomer used:
-- from --10° C up to + 130° C: E.P.D.M.--XV, External coating
-- from --10° C up to + 90° C: High content nitrile -- K.  Polyurethane paint, 80 ← thickness, colour orange ref.
 Allowable pressure (PS): RAL 2002.
-- 16 bar: sizes 20 to 200 mm at ambient temperature, Materials
-- 10 bar: sizes 250 to 400 mm at ambient temperature.
 Body: JS 1030 ductile iron.
 Differential pressure: identical to ps.
 Shaft: 13 % chromium stainless steel.
 Vacuum service down to 0,2 absolute bar.
 Disc: JS 1030 ductile iron nickel coated.
 Maximum fluid velocity under PS: 4 m/s.
 AMRING liner: -- E.P.D.M--XV,
Design -- High content nitrile -- K.
 Median rib body (Type 2) with aligment holes allowing
downstream pipe dismantling under PS or dead--end service. For the other parts, please refer to the parts list.
 Extended neck allowing insulation. Actuator selection
 Thermal isolating device facilitating the clamping of the
 Operation by ¼ padlockable handle (LP), in aluminium alloy,
insulating jacket around the plate skirt.
locking in 13 intermediate positions; sizes 20 to 250 mm.
 E.P.D.M. liner: an extra volume of rubber, located at the shaft
 Operation by manual gear reducer; sizes 20 to 400 mm.
passage areas, provides by compression between the valve
 Operation by ¼ turn electric actuator fitted directly onto the
body and the disc edge a perfect leak--tightness at the shaft
ISO mounting plate; sizes 20 to 400 mm.
passages.
 Spherical machined disc ensures perfect upstream/ Data to be supplied when ordering
downstream sealing: zero leakage visible to the naked eye.  BOAX series valve in accordance with leaflet 8413.1/11--10
 Face--to--face dimensions in accordance with:  Size.
-- ISO 5752 series 20, EN 558--1series 20.  Working conditions:
 Mounting plate meeting the following standards: -- nature of fluid,
-- ISO 5211. -- pressure,
 Flange connection standard: PN 6, 10 and 16. -- temperature.
For sizes 20 to 300 mm, one body allows 3 connections.  Actuation.
For sizes 350 and 400 mm, connection drillings are made to
customer’s requirement.

97/23/EC (PED)
 BOAX

Valve without actuator

Overall dimensions (mm) and weights (kg)
Flat end s machined
in Øz or s
Sizes 20 to 65 Size 80 Size 100 Sizes 125 and 150
h3
h4
ø d4

h1

e1

h2

e2
d1 d1 d1 d1
l1

Size 200 Size 250 Size 300 Sizes 350 and 400

d1 d1 d1 d1

Face Mounting Square

q
to plate Disc
Size Flat shaft end Weight
face ISO 5211 shaft end clearance

mm l1 d1 d4 h1 h2 N° h4 s øz h3 s h3 e1 e2 kg
20 27 76 101 38 9 12 14 -- -- 0,5
25 27 84 104 42 9 12 14 15 2 0,6
32 27 101 108 51 9 12 14 31 5 0,9
40 33 108 60 126 54 F04 29 9 12 18 32 4 1,2
50 43 118 131 60 9 12 18 33 4 1,5
65 46 132 157 67 9 12 24 55 11 2,2
80 46 138 163 89 9 12 24 71 17 2,8
100 52 150 191 99 11 14 24 90 23 4,4
70 F05 38
125 56 234 205 112 11 14 24 119 35 5,6
150 56 260 224 130 17 22 25 144 46 7,8
95 F07 42
200 60 322 252 161 17 22 25 196 69 11,9
250 68 394 133 275 197 F10 38 19 25 249 92 17,8
300 78 462 158 289,5 231 F12 28,5 22 29 297 111 32
350 78 538 183 338 269 F12 29 25 40 326 127 60
400 102 604 183 383 302 F14 29 36 50 370 140 80

4
 BOAX

Valve with manual actuation

Overall dimensions (mm) and weight (kg)

LP ¼ turn handle operation -- sizes 20 to 250 mm

Size LP ¼ turn handle operation
l2
mm l2 h5 d4 Weight*
20 153 1,0
25 156 1,1
32 160 1,4
ø d4 40 165 178 60 1,7
h5
50 183 2,0
65 209 2,7
80 215 3,3
100 253 5,1
230 70
125 266 6,1
150 298 8,8
330 95
200 326 12,9
250 460 374 133 20,0
* The indicated weights are those of the valve + the handle.
Manual gear reducer operation -- sizes 20 to 250 mm
ø d2 Size Manual gear reducer operation

mm Type d2 h5 d4 Weight*
20 195 60 2,0
25 198 60 2,1
32 202 60 2,4
40 220 60 2,7
h5
ø d4 50 MA 12 140 225 60 3,0
65 251 60 3,7
80 257 60 4,3
100 285 70 5,9
125 299 70 7,1
150 355 95 10,8
200 MA 25 225 383 95 14,9
250 406 133 20,8
* The indicated weights are those of the valve + the actuator.

Manual gear reducer operation -- sizes 300 to 400 mm

A B D C

Size Manual gear reducer operation

ØE
mm Type A B C D ØE h5 Weight*
h5 300 MN 40 70 225 60 60 225 350 35,4
350 416 64,6
MN 80 90 245 70 75 225
400 461 84,6
* The indicated weights are those of the valve + the actuator.

5
 BOAX

Valve with electric actuation

Actuator selection

Single phase A. C. 230 V, 50 Hz

Size Standard
ACTELEC
mm operating time
20
25
32
Z3 11 s
40
50
65
80
OA6 6s
100
125 OA8 6s*
150 OA15 15 s *
200
AS25 10 s *
250
300
AS50 30 s *
350
400 BS100 60 s *
* For other operating time, please consult us.

3--phase A. C. 400 V, 50 Hz
Size Standard
ACTELEC
mm operating time
20
25
32
40
OA6 6s
50
65
80
100
125 OA8 6s*
150 OA15 15 s *
200
AS25 10 s *
250
300
AS50 30 s *
350
400 BS100 60 s *
* For other operating time, please consult us.

6
 BOAX

Valve with electric actuation

Main electrical equipments

ACTELEC Z3 OA6 OA8 OA15 AS25 AS50 BS100

Opening and closing
Standard
limit switches
Adjustable extreme
Standard
position mechanical stops
Opening and closing
Standard
torque limit switches
Heating resistance 6 W Standard

Electrical characteristics

Single phase A. C. 230 V, 50 Hz

ACTELEC
Z3 OA6 OA8 OA15 AS25 AS50 BS100
Nominal intensity (A) 0,7 0,6 1,2 0,6 1,8 1,2 1,2
Starting intensity (A) 0,9 0,9 1,7 0,9 2,5 1,7 1,7
Power (W) 27 30 60 30 100 60 60

3--phase A. C. 400 V, 50 Hz
ACTELEC
OA6 OA8 OA15 AS25 AS50 BS100
Nominal intensity (A) 0,3 0,6 0,3 0,8 0,3 0,6
Starting intensity (A) 0,5 1,1 0,5 1,6 0,8 1,1
Power (W) 30 100 30 150 60 100

 Rated current:  Motor protection by thermoswitch.

-- single phase A. C. 230 V, 50 Hz: all types,
-- 3--phase A. C. 400 V, 50 Hz: all types except Z3.  Working temperature: from --20° C to + 70° C.

 Intermittent duty:  On request:

-- S4--20 % for Z3, -- OA8, AS25, AS50 and BS100 for regulating service,
-- S4--30 % for OA6, OA8, OA15, AS25, AS50 and -- potentiometer,
BS100. -- extra adjustable limit switches,
-- position transmitter.
 Protection: IP 67.
Please consult us.
 Manual emergency control by handwheel.