Mechanical Installation, Operation, and Maintenance Manual TechnoForce and TechnoForce XLS Package System
Table of Contents Table of Contents Introduction and Safety..................................................................................................................3 Introduction..................................................................................................................................3 Safety.............................................................................................................................................3 Safety terminology and symbols.............
Table of Contents Troubleshooting........................................................................................................................... 22 Pump station troubleshooting.................................................................................................22 The pump station does not power up................................................................................ 22 The station powers up, but the pumps do not run..........................................................
Introduction and Safety Introduction and Safety Introduction Purpose of this manual The purpose of this manual is to provide necessary information for: • Installation • Operation • Maintenance CAUTION: Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty. NOTICE: Save this manual for future reference, and keep it readily available at the location of the unit.
Introduction and Safety Hazard levels Hazard level Indication DANGER: A hazardous situation which, if not avoided, will result in death or serious injury WARNING: A hazardous situation which, if not avoided, could result in death or serious injury CAUTION: A hazardous situation which, if not avoided, could result in minor or moderate injury NOTICE: • A potential situation which, if not avoided, could result in undesirable conditions • A practice not related to personal injury Hazard categories Haz
Introduction and Safety Recycling guidelines Always follow local laws and regulations regarding recycling. User safety General safety rules These safety rules apply: • Always keep the work area clean. • Pay attention to the risks presented by gas and vapors in the work area. • Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards. • Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Introduction and Safety 6 Condition Action Chemicals or hazardous fluids in eyes 1. 2. 3. Hold your eyelids apart forcibly with your fingers. Rinse the eyes with eyewash or running water for at least 15 minutes. Seek medical attention. Chemicals or hazardous fluids on skin 1. 2. 3. Remove contaminated clothing. Wash the skin with soap and water for at least 1 minute. Seek medical attention, if necessary.
Transportation and Storage Transportation and Storage Inspect the delivery Inspect the package 1. Inspect the package for damaged or missing items upon delivery. 2. Note any damaged or missing items on the receipt and freight bill. 3. File a claim with the shipping company if anything is out of order. If the product has been picked up at a distributor, make a claim directly to the distributor. Inspect the unit 1. Remove packing materials from the product.
Transportation and Storage Long term storage The following procedure applies to Boosters and HVAC Packages. 1. Customer furnished equipment and accessories that are not offered as standard or optional by the factory must be handled in accordance with the respective manufacturer's recommendations. 2. Storage longer than one month Is considered long term storage. 3. Pumps should be prepared for storage using the following procedure.
Transportation and Storage • Pumps • Every 30 days, the pump and motor shaft should be rotated by hand (10-15 turns) to prevent bearing damage and potential for binding. Be sure shaft comes to rest in different positions. • Close-coupled pumps may have minimal access to exposed shaft areas. In those cases, care must be taken to avoid damage to the shaft though use of channellock pliers or similar tools.
Product Description Product Description General description Description A pump station is a pre-engineered and fabricated line of packaged booster systems that provides: • Energy efficiency • System protection • Hydraulic capability up to 1600 GPM • Boost pressures up to 300 PSI Intended applications The pump station is intended for these applications: • High rise buildings • Industrial plants • Municipal and rural water districts • Agriculture / irrigation • General water pressure boosting Operational li
Product Description Model Number Serial Number Station Voltage System FLA SCCR Largest Motor HP Station Flow Suction Pressure Discharge Pressure Pump Boost Date Code Applied Water Solutions Dallas, Texas, U.S.A . Customer Service 1.800.786.7480 Nameplate field Explanation Model number The manufacturer's number to indicate the particular type of product which has been acquired.
Installation Installation Reference manuals Additional installation information For information on installing controllers, use the following IOM: • Technologic = S14367 — constant speed systems • TechnoForce Pump Controller = 10–001–265 — variable speed systems Field connections Diagrams Actual equipment manufacturers/models installed are system specific. Refer to specific manufacturer Installation, Operation, and Maintenance manuals for details unique to each component.
Installation Guideline Explanation/comment If you require lifting equipment such as a hoist or tackle, This makes it easier to properly use the lifting equipment make sure that there is enough space above the pump and safely remove and relocate the components to a safe package. location. Protect the unit from weather and water damage due to rain, flooding, and freezing temperatures. This is applicable if nothing else is specified.
Installation Piping checklist WARNING: • The heating of water and other fluids causes volumetric expansion. The associated forces can cause the failure of system components and the release of hightemperature fluids. In order to prevent this, install properly sized and located pressure-relief valves. Failure to follow these instructions can result in serious personal injury or death, or property damage. • Avoid serious personal injury and property damage.
Commissioning, Startup, Operation, and Shutdown Commissioning, Startup, Operation, and Shutdown Preparation for startup DANGER: Electrical hazard sufficient to kill. Always disconnect and lock out the power before you service the unit. WARNING: • Failure to follow these precautions before you start the unit will lead to serious personal injury and equipment failure. • Do not operate the pump below the minimum rated flows or with the suction or discharge valves closed.
Commissioning, Startup, Operation, and Shutdown Checks Checked Check that all high points in the piping system are vented in order to remove trapped air. Check that all pumps and drivers are properly lubricated. Check that the piping is clean and has been flushed. Final installation checks Installation checklist CAUTION: Serious damage to the pump may result if it is started dry. Make sure that the pump is completely filled with liquid before it is started.
Commissioning, Startup, Operation, and Shutdown a) Check all of the power wiring connections and secure them as required. b) Confirm with the owner/installing contractor if there are plans for any required building automation or remote connections. c) Inspect and/or install any customer remote terminations. 2. Make note of the design data supplied on the data label. The label is located on the inside of the control panel door. 3.
Commissioning, Startup, Operation, and Shutdown 5. Open a faucet in order to create a demand for water on the system pressure piping. 6. Observe the suction pressure and confirm that it is equal to or greater than the suction pressure listed on the nameplate. System is designed for a specific suction pressure. Deviation results in degraded system performance. Contact factory if suction pressure varies from design specifications. Start the package 1.
Commissioning, Startup, Operation, and Shutdown 5. Press the Alternation key and observe the operation of each pump. 6. Close the running water faucet. It is assumed that no demand for water is required. For example, no flow. 7. Observe the No Flow Shutdown sequence. All minimum run timers must elapse for this sequence to occur. 8. Demand water from the system and observe the restart of the package. If you encountered no problems, then you are done.
Maintenance Maintenance Precautions DANGER: Electrical hazard sufficient to kill. Always disconnect and lock out the power before you service the unit. WARNING: • This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal.
Maintenance Motor lubrication checks • For grease-filled bearings, make sure that grease is not all over the inside of the motor and in the bottom of the motor. This could be a sign of overfilling. Refer to the lubrication instructions from the motor manufacturer. Close-coupled pumps • For a horizontal pump, verify that the mechanical seal is not leaking between the pump and the motor.
Troubleshooting Troubleshooting Pump station troubleshooting DANGER: • Personal injury hazard. Troubleshooting a live control panel exposes personnel to hazardous voltages. Electrical troubleshooting must be done by a qualified electrician. Failure to follow these instructions will result in serious personal injury, death, and/or property damage. • Electrical hazard sufficient to kill. Always disconnect and lock out the power before you service the unit.
Troubleshooting Cause Remedy The fuses are blown or breakers are tripped. Check circuit breaker and fuses. Transducer isolation valves are closed. Make sure that the transducer isolation valves are in the open position. Automatic mode is faulty. Check to see if the pump can be run in Manual mode on the PLC. The impeller is bound. Check to see if you can turn the pump by hand. Check for a bound impeller. A pressure transducer is faulty. Replace faulty pressure transducers. Motor wiring is loose.
Troubleshooting The pump station experiences excessive vibration Cause Remedy The motor, pump, or piping is loose. Make sure that all fasteners and components are properly tightened. Pump station vibration dampers are missing or improperly installed. Check for properly installed pump station vibration dampers. Pumps are running off their design curve. Check the application.
Troubleshooting Cause Remedy The pressure transducers are faulty. Check the pressure transducers. Does the actual mechanical gauge pressure match the pressure displayed on the VFDs and the PLC? A check valve is malfunctioning. Check for malfunctioning check valves. Replace faulty valves. There is an error in the PLC programming. Check the customer programming on the PLC. Correct any errors.
Technical Reference Technical Reference Pump station numbering system The pump station label located on the inside of the control enclosure door identifies the product code number for the various versions of the pump systems. This number is also the catalog number for the pump station. The pump station numbering systems describe the meaning of each digit. Not all combinations are possible.
Technical Reference Seventh character: Stages / impeller size 1 = 1, 2 = 2, 3 = 3, and so forth Eighth character: reduced number of stages 0 = 0 reduced, 1 = 1 reduced, 2 = 2 reduced, and so forth Ninth character: Branch A = 1.5 in. Chk D = 3 in. Chk G = 1.5 in. PRV K = 3 in. PRV B = 2 in. Chk E = 4 in. Chk H = 2 in. PRV L = 4 in. PRV C = 2.5 in. Chk F = 6 in. Chk J = 2.5 in. PRV M = 6 in.
Technical Reference Fifth character: Supply voltage 4 = 208 V / 3 PH / 60 Hz 8 = 380 V / 3 PH / 60 Hz 5 = 230 V / 3 PH / 60 Hz 9 = 380 V / 3 PH / 50 Hz Sixth character: HP rating A = 1/2 E=2 B = 3/4 F=3 C=1 G=5 D = 1-1/2 H = 7-1/2 Seventh character: Trim 1ST 2ST 3ST A 6-1/8 5-1/4 4-3/4 B 5-3/4 5-1/16 4-5/8 C 5-3/16 4-7/8 4-3/8 D 4-3/4 4-5/8 4-1/16 E 4-7/16 4-1/4 3-5/8 F 4-1/16 3-7/8 — G — 5-15/16 5-3/8 H — 5-1/2 5 K — 6-1/8 5-3/8 Eighth character: Branch s
Technical Reference Numbering system definitions First character: Variable or constant speed V = variable speed X = XLS variable speed C = constant speed Second character: Number of pumps 2, 3, or 4 Third character: Pump type and size H9 = 9SH HA = 10SH HB = 11SH H4 = 4SH H7 = 7SH H5 = 5SH H8 = 8SH H6 = 6SH HC = 24SH HD = 25SH HE = 22SH HF = 27SH HG = 23SH HH = 28SH — — Fourth character: Header size C = 3 in. E = 6 in. G = 10 in. D = 4 in. F = 8 in. H = 12 in.
Technical Reference Ninth character For factory use Tenth character: Options B = Suction pressure switch G = Suction pressure sensor J = LOP C = High temperature relief valve D = System flex connectors F = Lightning arrestor Special options for B, G, J Constant Lift/flooded Boost (greater than 10 PSI) 30 Variable LOP (option J) Switch (option B) Switch (option B or G) TechnoForce and TechnoForce XLS Package System Mechanical Installation, Operation, and Maintenance Manual
Product warranty Product warranty Commercial warranty Warranty.
Product warranty Consumer warranty Warranty.
Product warranty To make a warranty claim, check first with the dealer from whom you purchased the product or call the following number for the name and location of the nearest dealer providing warranty service. For Goulds Water Technology contact 315-568-7123. For all other products, contact 847-966-3700.
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