INSTRUCTION MANUAL 19-001-200R2 INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE. SILENT STORM VFD Pumping System NOTE: This product is not intended for use in potable water applications.
Acknowledgements All materials ©2013 by Xylem Flowtronex, an Xylem company. Flowtronex© is a registered trademark of Xylem Flowtronex. All rights reserved. No parts of this work may be reproduced in any form or by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of the publisher.
TABLE OF CONTENTS Manual VFD Operation ..............................................16 VFD Bypass Operation, Manual mode ......................16 VFD Bypass Operation, Auto mode...........................17 PLC Bypass Operation ..............................................18 SYSTEM SAFETIES ........................................................19 Automatic Mode of Operation ....................................19 Manual Mode of Operation ........................................19 Low Discharge Pressure..
WARRANTY INFORMATION Company warrants title to the product(s) and, except as noted below with respect to items not of Company’s Manufacturer, also warrants the product(s) on date on shipment to Purchaser, to be of the kind and quality described herein, and free of defects in workmanship and material. conditions shall extend to replacement parts furnished by Company hereunder. Company shall have the right of disposal of parts replaced by it.
SAFETY Read all safety information prior to installation of the Silent Storm Pumping System. All operating instructions must be read, understood, and followed by the operating personnel. Flowtronex accepts no liability for damages or operating disorder which are the result of non compliance with the operating instructions. SAFETY INSTRUCTIONS SAFETY INSTRUCTION This is a SAFETY ALERT SYMBOL. It is used to alert you to potential personal injury hazards.
Maintenance Safety: ADDITIONAL SAFETY INFORMATION This pump has been designed for safe and reliable operation. A pump is a pressure-containing device with rotating parts that could be hazardous. Operators and maintenance personnel must realize this and follow necessary safety measures. Proper safety procedures must be followed. Xylem Flowtronex shall not be liable for damage or delays caused by a failure to observe the instructions in this manual.
GENERAL DESCRIPTION PRODUCT DESCRIPTION NAMEPLATE INFORMATION A Flowtronex Silent Storm Variable Speed Pumping System is custom built to the requirements provided by the purchaser. The Silent Storm pumping system is a modular variable speed system designed to maintain a constant discharge pressure while providing a variable flow rate to match the water demand of the system. The system minimizes power consumption by combining a variable speed lead pump with constant speed lag pumps.
S = Submerged Sled pump assembly The unit is top heavy due to the position of the equipment. Do not use component eyebolts to lift the pump station. M = Floating pump assembly 3. Pump Type: WARNING: Falling Objects Hazard C = Horizontal Eyebolts, if provided, are designed to lift only the components to which they are attached. S = Submersible T = Vertical Turbine Failure to follow these instructions could result in serious personal injury, death, and/or property damage.
GROUND CONNECTIONS A grounding terminal is provided for a dedicated ground wire connection. All provisions of the National Electrical Code and local codes must be followed. WARNING: Electrical Shock Hazard Conduit grounds are not adequate. A separate ground wire must be attached to the ground lug provided in the enclosure to avoid potential safety hazards. Failure to follow these instructions could result in serious personal injury, death, or property damage.
INSTALLATION After the pumping system has been leveled, install the correct number of anchor bolts and tighten to secure the system. LOCATION Locate the pumping system in a clean, well ventilated, and properly drained location. It is recommended that the location selected facilitates ease of inspection, maintenance, and service. Outside installation requires protection from freezing.
Figure 3: Lifting Pump 2. After the cable-sling is attached to the lifting lugs (lifting eyes) on the pump head, raise the pump to a vertical position. While in this position, install the strainer basket with bolts and clips. Position the pump over its access hole on the skid. Figure 4: WARNING: Falling Objects Hazard DO NOT work under heavy suspended object unless there is positive support and safeguards should a hoist or sling fail.
6. Line up the spool with the pump isolation valve on the manifold-discharge pipe and set the pump on the skid. Start threading the base bolts on the pump head. Slide the Victaulic clamp gasket so that the clamp rides in the gloves on both the isolation valve and the spool. Tighten the Victaulic clamp. Tighten the base bolts. 7. If the pumps are shipped unassembled, refer to the Gould Pumps, Model VIT Installation, Operation, & Maintenance Instructions. 8.
STATION OPERATION This section covers the sequence of operation for your station including: Door Switch Operation, Automatic Operation, and System Safeties. VFD This switch position enables VFD operation in either automatic or manual mode depending on the position of the system switch. VFD is the normal position of the switch.
ACTIVE PRESSURE OVERRIDE AUTO Causes the Lake Screen solenoid to open after the main VSP has been operating at least one minute, the minimum flow requirement is met, and the speed test is not trying to stop the VSP. This is the normal position of this switch. This activates both the "low discharge pressure" and "filter differential pressure" protection systems.
AUTOMATIC OPERATION Combo 1. The values of 30 PSI and 90 seconds were intentionally selected since they are out of range and will never be used. Overview The primary benefit of Variable Speed Pumping (VSP) Systems is to ensure surgefree starts and stops while maintaining a constant down-stream line pressure with no mechanical pressure-regulating valve. This minimizes pipeline failures due to surges and, not incidentally, reduces the utility bill for the station.
leakage, or other small demands. A PM pump is provided to address this issue. Most stations, but not all, include a PM pump.
PSI. If the VFD speed falls below a predetermined value and the pressure remains above the reduced setpoint for 15 seconds, the VSP turns OFF, and the setpoint returns to normal. Speed Test returns the station to "System Charging" mode until a new demand for water is created. If the demand for water is still greater than the capacity of these two pumps, then Combo 4 starts. As occurred in the previous Combo, the inverter (VFD) speed immediately ramps down to the “speed when lag pump starts” setting.
mode, return the system switch to AUTO and turn ON all pump switches. Manual VFD Operation Overview VFD Bypass Operation, Manual mode Manual operation is selected by the system control switch. In manual operation, all pump activity is controlled by the individual pump switches. In the case of multiple pumps available for VFD operation, the VFD select switch determines which pump(s) run in VFD mode. However, some stations do not come equipped with a VFD select switch.
NOTE: When done, turn OFF all pump switches and place system control switch in OFF. Return Override/Active switch to ACTIVE.
Override/Active switch: LDP Override (Low Discharge Pressure fault disabled). If initial system pressure is high enough, place in Active. PLC Bypass Operation Overview This is an abnormal operating mode and would be used if the PLC was not operable and there is need to irrigate.
SYSTEM SAFETIES Manual Mode of Operation All faults are cleared by pressing the Reset button, or by re-arming individual pump faults. Overview The program in the PLC protects the system by shutting down in either of the “Auto” or “Manual” Modes of operation if it detects any of the following problems: Alarm or Fault Low Discharge Pressure The pressure transducer located in your station discharge line communicates the downstream pressure to the PLC.
down. Once the high pressure condition clears, the station automatically resets, and automatic operation resumes. The PLC allows three (3) automatic restarts in a one-hour period. At the fourth occurrence in a one-hour period, the station shuts down (hard fault). The red station fault light on the control panel door comes on, and the display indicates an "Alarm Shutdown Alert." Go to "Alarms," and the display should show that a "High Discharge Pressure fault" has occurred.
fault). The red station fault light on the control panel door comes on, and the display indicates an "Alarm Shutdown Alert." Go to "Alarms," and the display should show that a "Phase Failure fault" has occurred. WARNING: Equipment Damage Hazard Do not attempt to bypass this safety, as pump damage will occur. NOTE: At this point, shut the station down, and determine what the problem is. Consult the Troubleshooting section of this manual for assistance.
VFD Fault Resetting the overload is accomplished by pushing in the blue Differential Overloads button on the right front face of the device, and rotating it approximately an eighth of a turn clockwise. The VFD sends a fault signal (120 VAC) directly to the PLC. The display shows, "Inverter Fault." This is normally a VFD fault. To determine the nature of the problem, you must use the VFD keypad display and review the fault/alarm history. This procedure is outlined in the VFD section of this manual.
MAINTENANCE REGULAR MAINTENANCE = INVESTMENT 3. Motor lubrication: Maintenance is an investment that will pay dividends in the form of improved reliability and durability. Site maintenance checks are a matter of day to day, week to week care that is important to the proper operation of the pumping equipment. Periodic equipment checks will ensure that the recommended lubricants, fluids and service parts are available and planned for. Flowtronex recommends Preventative Maintenance be performed quarterly. a.
even electrical arcing or that something is in a bind? This can indicate a serious problem. DANGER: Personal Injury Hazard Pump station maintenance must be performed by properly trained and qualified personnel. Hazards exist for electrocution, shock, rotating components, and pressurized components. b. There is going to be some harmonic vibration with the pumps and motor. We are looking for excessive vibration or noise.
4. Drain all valve pilots, including the sensing chamber and all pressure switches. WARNING: Pump Pressure Hazard 5. Loosen valve bonnet bolts, loosen the bonnet, and drain the valve bonnet of water. Pumping system must be isolated from the system and pressure released before disassembly of any piping, valves, or pumps. 6. Re-tighten the relief or the control valve bonnets. Failure to follow these instructions could result in serious personal injury, death, or property damage. 7.
TROUBLESHOOTING 1. If a troubleshooting step needs to be performed by a qualified person, it is labeled “To be performed by a qualified person only.” 2. Steps that can be performed by unqualified persons are not labeled. 3. Qualified persons are those who have been trained in avoiding the electrical hazards of working on or near exposed energized parts. Only qualified persons may open the electrical enclosure. 4. Unqualified persons are those with little or no such training.
HIGH DISCHARGE PRESSURE FAULT Cause Cure High system pressure setting too low. Press F1, F8, F11 and verify n70:0 is set to 60 seconds. System pressure transducer reading high. Compare display readout to the pressure gauge. Calibrate if possible, and replace transducer if necessary (FlowNet). Isolation valve for DSR or main discharge is closed. Open the valve. DSR will not open fully. The pilot valve is set too low. Adjust as necessary, 15 PSI over set pressure.
and verify that the supply valve is open. If equipped with a suction manifold strainer, clean as required. Ensure the supply piping not clogged or restricted. Pressure is actually low – dynamic. Ensure that the flow rate is less than the supply capacity. LOSS OF PRIME FAULT Cause Cure Normally used on end-suction centrifugal pumps System has lost prime or air is trapped in system. Check the system for prime lead in the foot valve or suction line. Probe is dirty, corroded, or failed.
(located at wire terminal strip). If the power is good, replace the fan. There is no water flow through heat exchanger. Make sure both ball valves are open. Water is leaking at the heat exchanger. Repair or replace the coil. Fault code 2 – DC overvolt (intermediate circuit DC voltage is excessive). To be performed by a qualified person only. Check the input voltage (AC) to the drive. If high, contact the power company. Fault code 6 – DC undervolt (intermediate circuit DC voltage is insufficient).
GLOSSARY OF TERMS AC Alternating Current. The voltage, and therefore current, constantly oscillates positive and negative. For North America, the line frequency is 60 Hz. Some other areas of the world use 50 Hz. Across-the-line (XL) Applying 100% of line voltage to a motor during startup and run. A simple large relay with a contact for each power phase (for 3 phase) is used to control the motor OFF/ON.
DC Direct Current. Such as a battery. The voltage is stable, and does not oscillate (at least intentionally). Digital A simple ON/OFF condition. For example, the presence or lack of a 120VAC signal on a wire is a digital condition. DSR Downstream Relief Valve is used to limit the maximum allowable downstream pressure. Equal HP pumps Also referred to as interchangeable pumps. Defines which pumps are available to start based on lowest run time. VSPs and XL pumps are defined in the PLC program.
Lift This refers to how high water must be "lifted" to reach the pump suction. Lift stations have even harsher NPSHR than Flooded Suction systems. Loss of prime safety is an excellent choice for these systems. Auto-re-prime systems are available to help maintain a full suction line (CRD reprime, vacuum pumps). Lock-out A system which limits the pump systems available pumps and or limits the speed of a variable speed pump during user-defined time of day or day of week.
Relay This is a normally open or normally closed device that changes output state when it is energized or de-energized, and sends or removes a 120VAC signal to the PLC. SCADA Supervisory Control And Data Acquisition. Sequential alternation One of several methods of selecting which pump to use first. This method simply picks #1 the first time, #2 the next and so on. Once all pumps have been selected as "lead" once, the method starts over at #1. Setpoint The desired situation for a control variable.
APPENDIX A — FINAL CHECK LIST £ £ £ £ £ £ Is the base unit properly leveled and secured? Are all lubrication points properly lubricated? Is the shut-off valve on to the pump suction open? Is the shut-off valve on the discharge line open? Is the piping properly supported so as to prevent strains on the unit? Is the distribution system purged of debris and air? Is the system filled? CAUTION: Stuffing Box Damage Do not run pumps dry. Fill and vent the pump volute prior to operation.
APPENDIX B — ELECTRICAL WIRING AND CONTROL SETTINGS FINAL CHECKLIST £ Does the feeder line voltage correspond to the unit voltage? Check the unit nameplate or motor terminal connection. WARNING: Electrical Shock Hazard Inspect all electrical connections prior to powering the unit. Wiring connections must be made by a qualified electrician in accordance with all applicable codes, ordinances, and good practices.
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