Dutypoint VT Booster Set User manual

VTBooster Set
O&M Manual

Table of Contents
1. Important Health & Safety Information ......................................................................................... 3
1.1 Document Conventions................................................................................................... 4
1.2 Health and Safety Information......................................................................................... 6
1.3 Operating Limits for Standard Dutypoint Systems Pumpsets ......................................... 9
2. System Information, Installation and Commissioning................................................................. 10
2.1 Booster Set Components ............................................................................................... 11
2.2 Control Panel Wiring Diagrams..................................................................................... 12
2.3 HAND/OFF/AUTO Switch Operation............................................................................. 16
2.4 Installation and Commissioning VT Booster Sets ......................................................... 17
3. User Maintenance and Troubleshooting..................................................................................... 22
3.1 Routine User Maintenance............................................................................................ 23
3.2 Troubleshooting............................................................................................................. 25
Appendix A- Grundfos CRIE Pumps O&M Details ......................................................................... 28
Ap1.1 Grundfos CR/CRI/CRN Pump O&M ......................................................................... 29
Ap1.2 Grundfos CRE/CRIE, CRNE/SPKE/MTRE/CME Controller O&M (Up to 2.2kW) ..... 30
Ap1.3 Grundfos MGE 71/MGE 80/MGE 90/MGE 132 Controller O&M (More than 2.2kW) 31
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1. Important Health & Safety Information
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1.1 Document Conventions
Throughout this manual, text may be accompanied by one of the following icons. Where these
occur the conventions shown below are applied.
In general these conventions will also apply to OEM Manufacture’s manuals that are included
within this User Guide, however variations may occur, but these will be redefined at the beginning
of their manual.
PLEASE READ THE FOLLOWING INFORMATION WHICH IS PROVIDED FOR YOUR SAFETY
Danger: Denotes attention to the possibility of the risk of personal
injury or damage to adjacent property if the information is ignored.
Electric Shock: Denotes attention to the possibility of life-
threatening electric shock if the information is ignored.
Warning: Denotes attention to a condition that may result in under-
performance or damage to the equipment if the information is
ignored.
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Note: Denotes attention to an important factor applicable to the
action being performed.
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1.2 Health and Safety Information
Basic safety warnings relating to all products.
United Kingdom Health & Safety at Work Act 1974
Dutypoint Responsibility
Section 6(a) of this Act requires manufacturers to advise their customers on the safety and the
handling precautions to be observed when installing, operating, maintaining and servicing their
products. The user’s attention is therefore drawn to the following:
• The appropriate sections of this manual must be read before working on the equipment.
• Installation, operating and maintenance must only be carried out by suitably trained/
qualified personnel.
• Normal safety precautions must be taken and appropriate procedures observed to avoid
accidents.
Refer to DUTYPOINT SYSTEMS for any technical advice or product information.
Customer / Contractor Responsibility
It is the responsibility of the customer and/or the contractor:
• To ensure that anyone working on the equipment is wearing all necessary protective gear/
clothing.
• Is aware of appropriate health & safety warnings
• has read the information in this section of the manual.
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Hand Control Mode
In the 'HAND' position the pump(s) controlled by the switch will normally run at full speed and
completely independently of any control devices, and can result in pump(s) running against a
closed valve head if there is no draw.
This can cause the system to be maintained at the maximum pressure produced by the pump plus
any incoming pressure and additional pressure caused by water surge and can potentially damage
the pump and other parts of the system.
The 'HAND' option should only be used with a competent operator in attendance, or when
there is a continued demand sufficient to provide constant flow through the pumps to
maintain the running pressure of the system to an acceptable level.
Pump Servicing
• Familiarise yourself with the relevant contents of this manual
• Installation, maintenance and repair work must only be carried out by trained, skilled and
suitably qualified personnel.
• Disconnect or lock-out the power source to ensure that the pump(s) will remain
inoperative. Locking out the equipment by switching off the release mechanism or
set value WILL NOT prevent accidental starting of the motor.
• Allow the pump(s) to cool if over-heated.
•CLOSE the isolating valves on the suction and discharge connections of the affected
pump(s).
•VENT the pump(s) slowly and cautiously – Refer to the relevant section of this manual.
•DRAIN the pump(s).
High Voltages
Especially applicable when Variable Speed Controllers (Inverters) are fitted.
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• When the inverter variable speed drive head is connected to the power supply the components of
the power unit – as well as certain components of the master control unit – are also connected to
the power supply.
TOUCHING THESE COMPONENTS CAN SERIOUSLY ENDANGER LIFE!
• Before removing the frequency inverter cover, the system must be disconnected from the power
supply. After switching off the power supply wait at least 5 minutes before starting work on or in
the inverter drive head – the capacitors in the intermediate circuit must be given time to discharge
completely via the discharge resistors.
Up to 800 volts can be present – if there are faults this can be higher.
• All work carried out when the frequency inverter is open must be performed only by suitably
qualified and properly authorised personnel.
When connecting external control wires care must be taken not to short circuit adjacent
components. Bare cable ends which are not in use must be insulated.
THE SYSTEM MUST ONLY BE OPERATED WHEN IT HAS BEEN CORRECTLY EARTHED
AND PIPES BONDED TO EARTH IN ACCORDANCE WITH IEE REGULATIONS
Electronic Safety Devices
• High voltage tests of the inverter or the motor may damage the electronic components.
Bridge before the incoming/outgoing terminals L-L2-L3 and U-V-W.
• To avoid incorrect metering by capacitors incorporated in the electronic circuits, isolate the
motor from the inverter drive head.
High voltage testing may damage electronic components
• High voltage tests of the inverter or the motor may damage the electronic components.
Bridge before the incoming/outgoing terminals L-L2-L3 and U-V-W.
• To avoid incorrect metering by capacitors incorporated in the electronic circuits, isolate the
motor from the inverter drive head.
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1.3 Operating Limits for Standard Dutypoint Systems
Pumpsets
Table showing standard operating limits which apply to cold water booster sets.
Table showing standard operating limits
Type of pumped liquids Water with no gas or aggressive substances
Maximum pumped liquids
temperature
+35°C domestic uses. (EN 60335-2-41). 40°C for other purposes
Minimum pumped liquid
temperature
1°C to avoid icing
Operating ambient
temperature
+5°C to 40°C for indoor installation. (CEI EN 60439-1).
Relative humidity Max 50% at 40°C.
Air impurities The air must be clean and free of acid vapours, corrosive gases
and excessive amounts of dust.
Storage temperature +5°C to 50°C.
Suction conditions Minimum positive pressure 0.1 Bar. Maximum positive pressure
0.5 Bar
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2. System Information, Installation and
Commissioning
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2.1 Booster Set Components
VT Booster Set Components
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2.2 Control Panel Wiring Diagrams
Twin Pump Wiring Diagram - Single Phase
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Twin Pump Wiring Diagram - 3 Phase
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VT3 - Single Phase Control Panel Wiring Diagram
VR (VASCO) Cold Water Booster Sets
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VR (VASCO) Cold Water Booster Sets
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VT3 - Three Phase Control Panel Wiring Diagram
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2.4 Installation and Commissioning VT Booster Sets
1. Installation and pre-commissioning checks
2. Pressure vessel pre-charging
3. Venting pumps
4. Programming the controller
5. Operational and performance tests
6. Commissioning/handover check
Installation and Commissioning Overview
Before shipment, all Dutypoint pumpsets are pre-commissioned. Whilst important procedures such
as venting and rotational direction checks need to be carried out on site, initial parameters
including pressure settings and delay timers will be adjusted to suit the site conditions previously
advised to Dutypoint.
In practice, a system can almost invariably be made to perform more efficiently if further re-
commissioning is carried out on site.
Please note that engineer visits by Dutypoint are priced at one visit to commission one
pump set. If there are multiple units on a site, special terms can be negotiated. To arrange a
commissioning visit, please call the Technical Service Help line 01452 300590.
1. Installation and Pre-Commissioning Checks
The following checks should be carried out at the initial installation on site BEFORE any run tests
are carried out.
Warning
Ensure that you have read and understood the SAFETY section at the front of this manual
before proceeding.
Pipework and mechanical components
1. Ensure that the mounting area and any associated groundwork provides adequate support
for the pumpset.
2. Ensure all supports/brackets are in place and secure.
3. Verify all pipe joints are sealed and tight.
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Electrical
These checks MUST be carried out by a competent electricial. Ensure that the power
source is sufficient to allow the running of two WARNING (twin pump sets) or three (triple
pump sets) pumps together. (Refer to Section 2 of this manual).
1. Check the motor voltage and frequency information on all the motor nameplates and on
controllers etc. correspond with that of the source power supply.
2. Check that all electrical connections are correctly made and secure. Pay particular
attention to Earth and bonding connections.
3. Carry out specific checks for Earth bonding.
4. Carry out NICEIC certification checks as required for the installation, e.g Earth Loop
Impedance, Insulation Tests, etc.
5. Carry out any other pre-start checks recommended by the pump manufacturer. Refer to
the pump manual in Appendix A of this manual. DO NOT POWER UP AT THIS STAGE.
Final checks before commissioning
1. Re-check all equipment for any accidental damage caused during installation.
2. Carry out the Precharging and Venting procedures described next.
2. Pressure Vessel Precharging
Before commissioning starts the precharge of the pressure vessels should be checked.
On variable speed systems the precharge air pressure for vessels should be 90% of the maximum
pressure generated by the pump in the pipework system
e.g: If the max. pressure generated by the pump in a system is 6 bar. This will require a pre-
charge pressure of 6 x 90% = 5.4 bar.
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Refer to the above table.
To verify the precharge pressure:
1. First check that the expansion or pressure vessel(s) are totally drained of water, and that
the system is switched off and no electrical parts are live.
2. Locate the charging valve on each vessel, accessed by removing the plastic cover on the
top of the vessel.
3. Connect a portable pressure gauge with a measuring range compatible with the expected
pressures in your application, which has a flexible hose and Schrader- type connector to
the charging valve.
4. Check the pre-charge pressure above the diaphragm in each pressure vessel
[Accumulator]. correspond to criteria given in the text above.
5. If necessary, release or add additional air to correct.
3. Venting Pumps
It is important to bleed all air from the pump body before initial start-up.
Procedure for flooded suction
Flooded Suction is defined as the condition where there is positive pressure on the suction (inlet)
side of the pump(s) as is the case where the storage tank water level is at the same or higher level
than the pump bleed point.
This procedure should be carried out individually for each pump in the Pumpset.
1. This procedure should be carried out individually for each pump in the Pumpset.
2. Open all valves on the suction (inlet) side of the pump.
3. Using the vent screw at the top of the pump (refer to Appendix A to locate), allow any air in
the pump body and suction pipework to vent to atmosphere.
4. When water (under pressure from the storage tank feeding the pump on the suction side)
escapes through the vent screw hole - and no more air bubbles can be seen - close the
vent screw.
5. Switch on the electrical supply to the pump motor and start the pump in AUTO mode. As
each motor starts verify that the direction of rotation correctly corresponds with the
direction of the arrow shown on the body of the pump. If rotation is backward STOP, switch
off the pump and investigate.
6. Slowly open the valve on the discharge manifold outlet to the system allowing water to be
pumped into the system.
7. Switch off, re-close the discharge valve and repeat steps 3 to 6 several times to ensure
that all air is released from the pump body and local pipework.
8. The above procedure should be carried out individually for each pump in the Pumpset.
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