Ecolab Chameleon PLUS BW3 User manual

Service Manual........................................................1 - 25
Booster Advanced / Professional
BW3 - BW4 - BW7
BF3 - BF4 - BF8

Content EN
1. Description.............................................................................................................3
1.1 Layout Professional Wall Booster BW3...........................................................4
1.2 Operation Diagrams Professional Wall Booster BW3 .....................................5
1.3 Layout Wall Booster BW4 - BW7 ....................................................................6
1.4 Operation Diagrams Wall Booster BW4 - BW7...............................................7
1.5 Layout Floor Booster BF3 - BF4 - BF8............................................................8
1.6 Operation Diagrams Floor Booster BF3 - BF4 - BF8 ......................................9
2. Maintenance .......................................................................................................10
2.1 Filter .............................................................................................................10
2.2 Long stops ....................................................................................................10
3. Start .................................................................................................................... 10
3.1 New system ..................................................................................................10
4. Daily Operation ...................................................................................................10
4.1 Start ..............................................................................................................10
4.2 Stop ..............................................................................................................10
5. Service ................................................................................................................11
5.1 Components .................................................................................................11
5.1.1 Pump / Motor....................................................................................11
5.1.2 Control system .................................................................................11
5.1.3 Flow trigger ......................................................................................11
5.1.4 Non-return valve/intake side ............................................................11
5.2 Recycling and scrapping...............................................................................11
6. Trouble Shooting ................................................................................................12
6.1 The unit does not start .................................................................................12
6.2 The "Δ"- lamp on the control panel is on ......................................................13
6.3 Too low or unstable pressure .......................................................................13
7. Recommended Spare Parts ...............................................................................14
8. Specications .....................................................................................................14
9. Electric diagram...................................................................................................15
10. Pump curve .........................................................................................................17
11. Declaration of Conformity ....................................................................................19

3
Fig. 1 110001493
Fig. 2 110001494
2
1
2
1. Description
The Booster in the Chameleon
Plus range is a completely functio-
ning pumping station that supplies
pressurised water to connected
satellite hygiene stations. There-
fore the Booster must be supplied
with water in sufcient quantity and
power according to specications.
The station is then ready for hygi-
ene duties.
The Booster is tted with a fre-
quency controlled pump which en-
sures a constant working pressure
independent of usage pattern.
Important: Do not use the water
from the system for applications
other than cleaning.
A typical Floor Booster installation
is shown in g. 2
· Booster (1)
· Satellite (2)
A typical Wall Booster installation
is shown in g. 1
Booster (1)
· Mixing system (2)
· Satellite (3)

4
Fig. 3 110001495
Fig. 4 110001496
1.1 Booster BW3
(Fig. 4).
1. Water inlet
2. Manifold inlet
3. Trigger sensor, ow sensor
4. Pump
5. Manifold outlet
6. Outlet pipe
7. Display
8. El-box
9. Operation panel
10. Pressure sensor (Outlet)
11. • OPushbutton.Stop
12. • I Pushbutton.Start
13. • ΔLamp. Alight by error

5
0627268
1.2 Operating Diagrams
acc. ISO14617
BW3 Booster
B. Ball valve.
F. Filter.
FST. Flowsensor and -trigger.
C. Check valve.
PE. Pressure sensor.
TE. Temperature sensor.
CP. Centrifugal pump.
D. Outlet.
W. Water inlet.
SN : Socket no.

6
Fig. 5 110001497
Fig. 6 110001498
1.3 Advanced Booster BW4 - BW7
(Fig. 5).
1. Water inlet
2. Manifold inlet
3. Trigger sensor, ow sensor
4. Pump
5. Manifold outlet
6. Outlet pipe
7. Display
8. El- box ( BW4)
8a. Inverter box
8b. Filter box (only used on BW7)
9. Operations panel
10. Navigation buttoms
11. Pressur sensor (Outlet)
12. Pressur sensor (Inlet)
13. Label
14. Name Label
15. • OPushbutton.Stop
16. • I Pushbutton.Start
17. • ΔLamp. Alight by error

7
0627269
1.4 Operating Diagrams acc.
ISO14617
Advanced Booster BW4 - BW7
B. Ball valve.
F. Filter.
FST. Flowsensor and -trigger.
C. Check valve.
PE. Pressure sensor.
TE. Temperature sensor.
CP. Centrifugal pump.
D. Outlet.
W. Water inlet.
SN : Socket no.

8
Fig. 7 110001499
Fig. 8 110001500
1.5 Advanced Booster BF3 - BF4 - BF8
(Fig. 6).
1. Water inlet
2. Manifold inlet
3. Trigger sensor, ow sensor
4. Pump
5. Manifold outlet
6. Outlet pipe
7. Display
8. El- box ( BF3 - BF4)
8a. Inverter box
8b. Filter box (only used on BF8 and bigger)
9. Operations panel
10. Navigation buttoms
11. Pressur sensor (Outlet)
12. Pressur sensor (Inlet)
13. Label
14. Name Label
15. • OPushbutton.Stop
16. • I Pushbutton.Start
17. • ΔLamp. Alight by error

9
0627269
1.6 Operating Diagrams acc.
ISO14617
Advanced Booster BF3 - BF4 - BF8
B. Ball valve.
F. Filter.
FST. Flowsensor and -trigger.
C. Check valve.
PE. Pressure sensor.
TE. Temperature sensor.
CP. Centrifugal pump.
D. Outlet.
W. Water inlet.
SN : Socket no.

10
Fig. 13 0627106
Fig. 16 110001503
Fig. 14 0627131
Fig. 17 110001504
Fig. 18 0627117
2. Maintenance
The Booster unit is maintenance
free. However, we recommend
cleaning the booster unit in con-
nection with the occasional clean-
ing of the other equipment in the
area. The lter must be cleaned at
convenient intervals (approx. every
1-3 months) depending of the
amount of impurities in the water.
2.1 Filter
1. Press “0” on the control panel
to stop the Booster.
2. Interrupt the master switch
(Fig. 13).
3. Close the water inlet .
4. Open a tap to release the
system of pressure.
5. Remove the lter (A, Fig. 18)
and place it in a descaling
solution.
Note: MB systems are not
delivered with a factory
mounted lter. In case a lter
2.2 Before a longer
production stop
If long production stops are
planned (more than 6 months) and
the pump is drained, it is recom-
mended that the pump is secured
as follows:
1. Remove the coupling safety
guard.
2. Spray a couple of drops of sili-
cone oil onto the axle between
the top section and the cou-
pling.
Carefully follow the instructions
given in the manual provided by
the pump supplier.
3. Start
3.1 New system
In order to ensure a problem-free
start up of a new system the pipe
system must be ushed and bled.
Bleeding the pipe system
1. Turn on the water supply to
rinse and bleed the entire sys-
tem. If satellites are installed
open the tap furthest away
until no air or dirt comes out.
Then rinse and bleed the next
tap and continue until the tap
closest to you has been rinsed
and bled.
2. Mount satellites, if any
Bleeding the pump
3. Press “0” on the control panel
to stop the Booster.
4. Loosen the relief plug (A, Fig
14) 1-2 revolutions until water
and air begin to ow out.
Note. Never loosen the relief
plug while the pump is running
as this may damage the pack-
ing and cause personal injury.
5. Tighten the relief plug again
6. Start the pump so that all re-
maining air pockets are forced
up to the top of the pump.
7. Stop the pump.
8. Loosen the relief plug 1-2
revolutions again and bleed
the system until only water
ows out.
9. Tighten the relief plug once
more.
The Booster is now ready for
operation. Press “I” on the control
panel. (see g. 16 and 17).
4. Daily operation
4.1 Start
1. Check that water supplies for
the system are open.
2. Press “I” on the control board
in order to start up the unit.
4.2 Stop
1. Press “0” on the control panel
to stop.
2. Turn off the water supply.
3. Switch off the air supply.
Note. Due to the following it is very
important always to switch off both
water and air supply after use:
• If the air supply is open when
the main station or satellites are
not in use, air might leak into
the water line. If this happens,
the system must be bled once
more.
• The water separator, which is a
part of the air regulator, is only
to be emptied when the air sup-
ply is closed.
After a long time production stop
is mounted in a MB system,
the descaling procedure is ex-
actly the same until the scale
is dissolved.
6. Rinse the cleaned lter thor-
oughly and remount.

11
(holidays etc) it might be necessary
to bleed the piping system and the
booster unit again.
5. Service
Service may only be carried out by
authorized and qualied personnel.
Warning: The system must only be
serviced when there is no voltage
or pressure on the system.
1. Turn off the main switch at the
control box (Fig. 13)
2. Open a water outlet to depres-
surise the system.
5.1 Components
5.1.1 Pump / motor
Pump/motor are maintenance free,
see section 2.2
5.1.2 Control system
Maintenance free
If defective: Call service technician
5.1.3 Flow trigger
Maintenance-free.
If defective, replace the ow switch.
Installation instructions, see Appen-
dix 110001767.
5.1.3.1 Adjustments of ow switch
1. Press "0" on the control panel
to stop the system.
2. Remove the cover.
3. Turn the "rinse/foam" handle
to foam position.
4. Activate the spray handle on
the outlet hose so water runs
out.
5. Check that the ow switch is
turned the correct way (the
wire must follow the ow direc-
tion).
6. Turn the brass screw at the
bottom of the hole until a
green diode lights up.
7. Close the spray handle again
and check that the red diode
lights up.
8. Mount the cover.
5.1.4 Non-return valve / inlet
side
Maintenance - free.
If defective, replace the non-return
valve.
5.2 Recycling and scrap-
ping
Recycle the wrapping and scrap
the machine according to recom-
mendations from the local authori-
ties.

12
6. Troubleshooting
6.1 The unit does not start
Is there voltage
to the unit? Reconnect voltageNo
Is the ’Δ’ lamp
flashing?
Yes
Go to section 6.2Yes
No
Go to setup→settings
menu → Startup
method, and set it to
pressure
Does the unit start
Call a service
technician
Yes
No
Set unit back to
Flow start in setup
menu
Try to readjust
flow switch
(chapter 5.1.3.1)
Can the unit start?No
OK
Yes

13
6.2 The "Δ"- lamp on the control panel is on
6.3 If the inlet pressure is low or unstable
Check the display
for error
messages
Press ”0" wait for a few
seconds and then
press ”I” on the control
panel to restart the
system.
Does the error
come back
Go to
softwaremanual
Start using the unit
again
Yes
No
Check the inlet
pressure is
between 2-8bar, at
maximum water
consumption
Is the pump leaking
or making jarring
sounds?
Call a service
technician
Is there sufficient
water supply?
Yes
Is the filter
Clogged Clean the filter
Yes/no
No Yes
Secure higher inlet
pressure
No

14
7. Recommended spare parts
Technical Data Booster/Main station.
Advanced* Proff.**
Water Unit. 3 (4 kW) 3 (4 kW) 4 (5.5 kW) 7 (10 kW)** 8 (11 kW)*
Max. Outlet pressure. bar 25 25 25 22 25
Consumption during rinsing. 1) L/min 90 90 120 210 240
Consumption during foaming. L/min 30 30 40 80 80
Min. supply pressure. bar 2 2 2 2 2
Max. supply pressure. bar 8 8 8 8 8
Min. water supply. L/min 100 100 135 265 265
Max. water temp. °C 70 70 70 70 70
Pipe dimension inlet Ø inch 1.1/4" 1.1/4" 1.1/4" 2" 2"
Pipe dimension outlet Ø inch 1.1/4" 1.1/4" 1.1/4" 2" 2"
Electricity
Supply voltage V 3/PE 400 V ±10%
Frequency Hz 50/60 Hz 48 0%…62 +0%
Motor load (kW) kW 4 4 5.5 10 10
Installation to EN 60204-1
Nominal current A 10.6 10,6 14.2 27 27
Fuse A 16 16 20 35 35
L1, L2, L3, PE mm2 2.5 2.5 2.5 6 6
General
Sound level ISO 11202 dB Below 70 Below 70 Below 70 Below 70 Below 70
Dimensions mm 1070 x 550 x 375 785 x 550 x 375 1074 x 557 x 382 1074 x 557 x 382 990x535x364
Weight (kg) kg 85 60 75 75 80
All specications are based on 5 bar supply pressure
Note:
* Pump pressure 20 bar + inlet pressure max. 25 bar
** Pump pressure 20 bar + inlet pressure max. 22 bar
1) 1 user per 30l/min.
8. Specications
The recommended spare parts are marked with * in the spare part manual.

15
5 5
4 4
3 3
2 2
1 1
D D C C B B A A
Rubber cable 4 x 2,5mm2 250cm
Brown 1.5mm2 38cm
Black 1.5mm2 38cm
Shield cable 4 x 2,5mm2 105cm
3/PE
400V/ 27A (Nom)
Black 2,5mm2, 30cm Grey 2,5mm2, 30cm Brown 2,5mm2, 30cm
Brown 2,5mm2, 20cm Grey 2,5mm2, 20cm Black 2,5mm2, 20cm
Grey Brown
Yellow/green
Black
Title Size Drawing Number Ver/Rev Date: Sheet of
Init
Nilfisk-ALTO Food Division
Blytaekkervej 2 9000 Aalborg Denmark
Tel: [phone] www.nilfiskfood.com
0601725 G Electrical connections
A4
1126May10
san
Title Size Drawing Number Ver/Rev Date: Sheet of
Init
Nilfisk-ALTO Food Division
Blytaekkervej 2 9000 Aalborg Denmark
Tel: [phone] www.nilfiskfood.com
0601725 G Electrical connections
A4
1126May10
san
Title Size Drawing Number Ver/Rev Date: Sheet of
Init
Nilfisk-ALTO Food Division
Blytaekkervej 2 9000 Aalborg Denmark
Tel: [phone] www.nilfiskfood.com
0601725 G Electrical connections
A4
1126May10
san
DisplayDisplay
Main SwitchMain Switch
1L1 3L2 5L3
2T1 4T2 6T3
L I N E
L O A D
EMC filter 16A
L I N E
L O A D
EMC filter 16A
L1 L2 L3
L1 L2 L3
Controller PCBController PCB
AC1 AC2
JP12
CON10
Black Grey Brown Yellow/green
Black
Grey
Brown
Yellow/green
M
3
Motor 4/5.5kW
M
3
Motor 4/5.5kW
U1
V1
W1
1 2 3 Yellow/green
1 2 3
Yellow/green
Shield Shield
Frequency inverter 4.0/5.5kWFrequency inverter 4.0/5.5kW
L1 L2 L3
B-
B+
U V W
9. Electric diagram9. Electric diagram

16
5 5
4 4
3 3
2 2
1 1
D D C C B B A A
Rubber cable 4 x 6,0mm2 240cm
Shield cable 4 x 6,0mm2 120cm
Shield cable 4 x 4,0mm2 85cm
Brown 1.5mm2 38cm
Black 1.5mm2 38cm
Electrical connections for booster BF8/BW8
3/PE
400V/ 27A (Nom)
Max current 28A
Black 6,0mm2, 40cm Grey 6,0mm2, 40cm Brown 6,0mm2, 40cm
Black Grey Brown
Yellow/green
Title Size Drawing Number Ver/Rev Date: Sheet of
Init
Nilfisk-ALTO Food Division
Blytaekkervej 2 9000 Aalborg Denmark
Tel: [phone] www.nilfiskfood.com
0601726 G Electrical connections
A4
1107Jun10
san
Title Size Drawing Number Ver/Rev Date: Sheet of
Init
Nilfisk-ALTO Food Division
Blytaekkervej 2 9000 Aalborg Denmark
Tel: [phone] www.nilfiskfood.com
0601726 G Electrical connections
A4
1107Jun10
san
Title Size Drawing Number Ver/Rev Date: Sheet of
Init
Nilfisk-ALTO Food Division
Blytaekkervej 2 9000 Aalborg Denmark
Tel: [phone] www.nilfiskfood.com
0601726 G Electrical connections
A4
1107Jun10
san
1 2 3 Yellow/green
1 2 3
Yellow/green
Shield Shield
Frequency inverter 11kWFrequency inverter 11kW
L1 L2 L3
B-
B+
U V W
Black Grey Brown Yellow/green
Black
Grey
Brown
Yellow/green
Main SwitchMain Switch
1L1 3L2 5L3
2T1 4T2 6T3
DisplayDisplay
M
3
Motor 11kW
M
3
Motor 11kW
U1
V1
W1
1 2 3
Yellow/green
1 2 3 Yellow/green
ShieldShield
Controller PCBController PCB
AC1 AC2
JP12
CON10
L I N E
L O A D
EMC filter 30A
L I N E
L O A D
EMC filter 30A
L1 L2 L3
L1 L2 L3

17
10
15
20
25
Pressure [bar]
Pumpecurve CRN5-9+ (10kW)
0
5
10
0 33 66 99 132 165 198 231 264
Flow [l/min]
BW7+ (10 kW) @ 2 bar supply
20
25
30
b
ar]
PumpecurveCRN3‐9(4.0‐ 5.5kW)
0
5
10
15
0 33 66 99 132 165 198 231
Pressure[
b
Flow[l/min]
BF/BW4(5.5kW)@4barsupply
BW3(4.0kW)@4barsupply
BF3(4.0kW)@4barsupply
1100000455
10. Pump curve

18
15
20
25
30
Pressure [bar]
Pumpcurve CRN5-14 (11kW)
0
5
10
0 33 66 99 132 165 198 231 264
Flow [l/min]
BF8 (11kW) @ 4 bar supply
1100000455

19

BF3, BF4, BF8, BW3, BW4, BW7

Declaration of Conformity
Konformitätserklärung
Déclaration de Conformité
Dichiarazione di Conformità
Declaración de Conformidad
Declaração de Conformidade
Δήλωση Συμμόρφωσης
Overeenkomstigheidsverklaring
Försäkran om överensstämmelse
Vaatimustenmukaisuusvakuutus
Overensstemmelseserklæring
Deklaracja zgodności
Декларация осоответствии
Megfelelőségi nyilatkozat
Izjava o skladnosti
Izjava o usklađenosti
Deklaracija o konformitetu
Declaraţie de Conformitate
Декларация за съответствие
Prohlášení o shodě
Prehlásenie o konformite
Uygunluk Bildirgesi
Vastavusdeklaratsioon
Atitikties deklaracija
Paziņojums par atbilstību prasībām
Свідчення про відповідність вимогам







Nilfisk-ALTO Food Division
Blytækkervej 2
9000 Aalborg
Danmark




11. Declaration of Conformity

20

Declaration of Conformity
We Nilfisk-ALTO, declare under our sole responsibility that the
products BF3+, BF4+, BF8+, BW3+, BW4+,BW7+, to which this
declaration relates, are in conformity with these Council directives
on the approximation of the laws of the EC menber states:
Function: Pumping Station
Model/Type: BF3+, BF4+, BF8+, BW3+, BW4+, BW7+.
Serial number: All
Machinery Directive (2006/42/EC:2006-05-17).
Standard used: EN 60335-2-41/A2:2010
EMC Directive (2004/108/EC:2004-12-15).
Standard used: EN 55014-1/A1:2009 and EN 55014-2/A2:2008
Standard used: EN 61000-3-2/A2:2009 and EN 61000-3-3:2008
Konformitätserklärung
Nilfisk-ALTO, als alleinverantwortlich, erklären hiermit, dass: BF3+,
BF4+, BF8+, BW3+, BW4+,BW7+, in Übereinstimmung mit den
Richtlinien zur Angleichung der Rechtsvorschriften der Mitgliedstaaten
ist:
Funktion: Pumpenstation
Modell/Typ: BF3+, BF4+, BF8+, BW3+, BW4+, BW7+
Seriennummer: Alle
Maschinendirektive (2006/42/EC:2006-05-17).
Standarden: EN 60335-2-41/A2:2010
EMC Direktive (2004/108/EC:2004-12-15).
Standarden: EN 55014-1/A1:2009 og EN 55014-2/A2:2008
Standarden: EN 61000-3-2/A2:2009 og EN 61000-3-3:2008
Déclaration de conformité
Nous, Nilfisk-ALTO, déclarons sous notre propre responsabilité que
les produits BF3+, BF4+, BF8+, BW3+, BW4+, BW7+. auxquels se
réfère cette déclaration, sont conformes à ces directives du Conseil
sur le rapprochement des législations des États membres :
Fonction : Station de pompage
Modèle/Type : BF3+, BF4+, BF8+, BW3+, BW4+, BW7+.
Numéro de série : Tous
Directive 2006/42/CE du 17 mai 2006 relative aux machines
Normes appliquées : EN 60335-2-41/A2:2010
Directive CEM (2004/108/CE:2004-12-15).
Normes appliquées : EN 55014-1/A1:2009 et EN 55014-2/A2:2008
Normes appliquées : EN 61000-3-2/A2:2009 et EN 61000-3-3:2008

Dichiarazione di conformità
Nilfisk-ALTO dichiara sotto la sua esclusiva responsabilità che i prodotti
BF3+, BF4+, BF8+, BW3+, BW4+, BW7+. ai quali fa riferimento la
presente dichiarazione, sono conformi alle direttive del Consiglio
concernenti il riavvicinamento delle legislazioni degli stati membri della
UE:
Funzione: Stazione di pompaggio
Modello/Tipo: BF3+, BF4+, BF8+, BW3+, BW4+, BW7+.
Numero di serie: Tutti
Direttiva Macchine (2006/42/CE:2006-05-17).
Standard utilizzato: EN 60335-2-41/A2:2010
Direttiva EMC (2004/108/CE:15.12.04).
Standard utilizzato: EN 55014-1/A1:2009 ed EN 55014-2/A2:2008
Standard utilizzato: EN 61000-3-2/A2:2009 ed EN 61000-3-3:2008
Declaración de Conformidad
Nosotros, Nilfisk-ALTO, declaramos bajo nuestra única
responsabilidad que los productos BF3+, BF4+, BF8+, BW3+,
BW4+, BW7+, a los que se refiere esta declaración cumplen con las
directivas de este Consejo sobre la legislación de los estados
miembros de la CE:
Función: Estación de bombeo
Modelo/tipo: BF3+, BF4+, BF8+, BW3+, BW4+, BW7+.
Número de serie: All
Directiva sobre máquinas (2006/42/EC:2006-05-17).
Normativa usada: EN 60335-2-41/A2:2010
Directiva CEM (2004/108/EC:15.12.04).
Normativa usada: EN 55014-1/A1:2009 y EN 55014-2/A2:2008
Normativa usada: EN 61000-3-2/A2:2009 y EN 61000-3-3:2008
Declaração de Conformidade
A Nilfisk-ALTO declara, por sua exclusiva responsabilidade que os
produtos BF3+, BF4+, BF8+, BW3+, BW4+, BW7+, referidos nesta
declaração, se encontram em conformidade com estas diretivas do
Conselho relativas à aproximação das disposições legislativas dos
Estados-Membros da CE:
Função: Estação de bombagem
Modelo/Tipo: BF3+, BF4+, BF8+, BW3+, BW4+, BW7+.
Número de série: Todos
Diretiva relativa às máquinas (2006/42/CE:2006-05-17).
Norma utilizada: EN 60335-2-41/A2:2010
Diretiva CEM (2004/108/CE:2004-12-15).
Norma utilizada: EN 55014-1/A1:2009 e EN 55014-2/A2:2008
Norma utilizada: EN 61000-3-2/A2:2009 e EN 61000-3-3:2008
110002635A_BF&BW_2012