Mechanical Installation, Operation, and Maintenance Manual AquaForce Variable Speed Package System
Table of Contents Table of Contents Introduction and Safety.........................................................................................................................3 Introduction..........................................................................................................................................3 Safety.....................................................................................................................................................
Table of Contents Monthly maintenance.......................................................................................................................19 Troubleshooting...................................................................................................................................21 Pump station troubleshooting.........................................................................................................21 The pump station does not power up.................................
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 WARNING: Radiation Hazard. Do NOT send the product to Xylem if it has been exposed to any nuclear radiation. Electrical installation For electrical installation recycling requirements, consult your local electric utility. 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.
Introduction and Safety • Rinse the components in water after you disassemble the pump. • Do not exceed the maximum working pressure of the pump. • Do not open any vent or drain valve or remove any plugs while the system is pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping. • Never operate a pump without a properly installed coupling guard.
Introduction and Safety Warranty claim Xylem products are high-quality products with expected reliable operation and long life. However, should the need arise for a warranty claim, then contact your local sales and service representative.
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 Storage between use Observe the following for long-term storage of a pump station. • Insure system is drained of any water. • Remove transducers to ensure that they do not freeze. • System may be top-heavy, brace to keep from tipping. Long-term storage If the unit is stored for more than 6 months, these requirements apply: • Store in a covered and dry location. • Store the unit free from heat, dirt, and vibrations.
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 • Serial number • Item numbers of the required parts. 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 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. The pump instruction manual is supplied with the system. Review the wiring diagrams and dimensional drawings before you install and operate the unit. Electrical precautions WARNING: Electrical shock hazard.
Installation Guideline Explanation/comment Make sure that the space around the pump package is sufficient. This facilitates ventilation, inspection, maintenance, and service. If you require lifting equipment such as a hoist or tackle, make sure that there is enough space above the pump package. This makes it easier to properly use the lifting equipment and safely remove and relocate the components to a safe location.
Installation Grout the baseplate Required equipment: • Cleaners: Do not use an oil-based cleaner because the grout will not bond to it. See the instructions provided by the grout manufacturer. • Grout: Non-shrink grout is required. 1. Clean all the areas of the baseplate that will come into contact with the grout. 2. Build a dam around the foundation. 3. Thoroughly wet the foundation that will come into contact with the grout. 4. Pour grout into the baseplate up to top of the base rails.
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: Explosion hazard. Do not short battery terminals together or damage the battery. WARNING: • Failure to follow these precautions before you start the unit will lead to serious personal injury and equipment failure.
Commissioning, Startup, Operation, and Shutdown Checks Checked Check that the drain plugs are installed before filling system. Inspect all piping joints for tightness. Joints can become loose during transit due to vibration and shock. Check all flanged joints for the proper torque. Check that the system is full of liquid. 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.
Commissioning, Startup, Operation, and Shutdown Pump station startup Confirm the job site voltage 1. Check these items before you apply power or close the disconnect: 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.
Commissioning, Startup, Operation, and Shutdown Start the package 1. Close the disconnect in order to apply power to the package. 2. Turn the panel switch to the local position. 3. Watch the screen as the boot-up progresses and note the serial number of the unit. This is the password that you use for the setup menu. 4. If the unit starts, press the Stop button in order to stop the unit. Check the pump rotation 1. Select the hand mode on the controller. 2. Enable the pump with the blinking green light.
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 24 Cause Remedy The diaphragm tank is faulty. Check for a properly installed diaphragm tank. Has the tank failed? Has the tank been charged to the proper operating pressure before installation? (~10 psi below the desired set point) 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.
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 B = 2 in. Chk E = 4 in. Chk C = 2.5 in. Chk F = 6 in.
Technical Reference Fifth character: Supply voltage 2 = 208 V / 1 PH / 60 Hz 6 = 460 V / 3 PH / 60 Hz 3 = 230 V / 1 PH / 60 Hz 7 = 575 V / 3 PH / 60 Hz 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
Technical Reference Pump station with SSH pumps Example product code V 2 HE F 4 P A L 2 BCD Numbering system definitions First character: Variable or constant speed V = 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.
Technical Reference Seventh character: Trim F — — — 4-11/1 6 6-1/8 4-13/1 6 6-3/16 6-1/16 7-1/2 7-1/2 8-1/4 7-15/16 — — G — — — 4-3/8 — 4-7/16 — 5-5/8 7-1/8 7-1/8 — 7-11/16 — — H — — — 4-3/16 — 4-1/4 — — 6-11/1 6 6-7/8 — — — — J — — — 3-7/8 — — — — 6-1/2 6-1/2 — — — — K — — — — — — — — — 6 — — — — L — — — — — — — — — 5-1/2 — — — — Eighth character: Branch size / discharge valve type A = 1.5 in. Chk D = 3 in.
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