EPS POWERBOOST PRO E Series User manual

POWERBOOST
Clean Water
Booster
Sets
Flow Range O&M Manual

2
POWER BOOST
by EPS Group
Table of Contents
General 3
Installation Checklist 4
Location Consideration 5
Installation Information & Diagrams 5
Commissioning 6
Pressure Vessel 7
Pump Specifi cation 8
Controller Specifi c Instructions & Troubleshooting 9
Declaration of Conformity 11

3
POWER BOOST
by EPS Group
General
Delivery and Handling
The weight and size of the POWERBOOST unit may require the aid of lifting equipment and
must be handled in a safe manner. The unit must be lifted only by the base and not the pipe
work, pumps or vessel.
Inspection
On delivery, the POWERBOOST unit should be inspected thoroughly and any damage reported
to the supplier as soon as possible. This should be conrmed in writing within 48 hours.
Applications
The POWERBOOST FLOW range of cold water booster units are designed for domestic and light
commercial pressure boosting.
The POWERBOOST unit should not be installed in areas that are classied as hazardous or
where there is a risk of an explosion or harm to people. The manufacturer does not accept
responsibility if the unit is used to pump liquids other than clean water unless suitability has
previously been agreed in writing.
Warranty
All mechanical components of the POWERBOOST unit are covered by a 12 month warranty
against manufacturing defects. In case of failure please contact the relevant technical
department on one of the following:
Site Storage
Should a POWERBOOST unit need to be stored before installation it should be in a safe place
away from moisture, dust and frost.
ROI 094 963 3500
NI 028 9181 8347
UK 01543 415200

4
POWER BOOST
by EPS Group
Installation Checklist
1. Check the unit for any visual defects. Contact your supplier immediately if any are found.
2. Choose a suitable location for installation. Please ensure the unit is tted in accordance
with these instructions.
3. Connect the inlet and outlet pipe work as per the installation diagram.
• The POWERBOOST Unit is designed to be gravity fed from a cold water storage
tank.
• The inlet pipe work should be sized according to minimise friction & turbulence
maintaining a suction velocity of less than 2m/s and in any case should be at least
the size of the inlet manifold.
• Good quality full bore Isolation Valves should be tted before and after the unit to
allow for reliable service or repair.
4. Fit the supplied pressure vessel to the discharge manifold (See Page 7).
5. In accordance with the latest IEE regulation all electrical connections should be carried
out by a qualied electrician. The booster unit must be earthed. It is recommended that a
residual current device (RCD) is tted on the incoming electrical supply.
6. Once all mechanical and electrical connections have been made the following steps
should be followed before the unit is powered up:
• Fully close all isolation valves on the outlet side of the booster set;
• Ensure there is sucient water in the supply tank;
• Fully open all isolation valves on the inlet side of the booster set;
• Open bleed screw at the top of each pump in turn and fully de-aerate the pumps.

5
POWER BOOST
by EPS Group
Location Consideration
The POWERBOOST unit should be installed in a dry, well- ventilated area where it is not exposed to
extreme temperature or frost.
Reasonable access to all parts of the set and adequate service work space must be provided.
Provision for lifting equipment is recommended for units incorporating large pumps. There should
ideally be adequate lighting in the location of the POWERBOOST unit for ease of maintenance.
All system pipe work should be aligned and self supporting preventing any strain or distortion
within the unit. All pipe work that may be exposed to freezing conditions should be fully protected.
Provision should be made for the disposal of water drained from the system.
Foundation & Mounting
The POWERBOOST unit must be mounted on a solid foundation to support the weight of the unit.
Surfaces must be rm and level in all directions, the recommended surface is a concrete plinth or
oor and points are provided for oor xing if desired. Isolation mounts are provided and should
be tted if required.
Outlet Manifold
NB: Pipe Work connections can be made to either end of the inlet & outlet Manifold to suit your
site layout. Blanking Caps are supplied loose to close any open ends.
Installation Information & Diagrams
3.
0
General Notes
ALL ITEMS TO BE TAGGED WITH EPS TAG STATING;
EPS, DRAWING No, PURCHASE ORDER No.
1st ANGLE
PROJECTION
FOR HANDRAIL DETAILS SEE EPS DRAWING;
EPS/A-L/HANDRAILING/RAILFAB.
REMOVE ALL SHARP EDGES AND BURRS
IF IN DOUBT ASK DO NOT SCALE OFF THIS DRAWING
Drawn By:
Cost Code:
Checked By: Date:
Revision Suffix:
Drawing No.:
Job No.:
Drawing Title:
Scale:
reproduced in any form without the prior written consent of E.P.S. Pumping & Treatment Systems.
This drawing is protected by copyright and must not be
[e-mail]
022-31250
022-31200
Quartertown Industrial
Co. Cork.
Job Title:
Email:
Phone:
Fax:
Mallow,
Estate,
COPYRIGHT
094-9630761
094-9630226
Mountrath, Co. Laois.
Ballyhaunis, Co. Mayo.
0502-32518
0502-32279
Fax:
Phone:
Phone:
Fax:
QtyItem No. Material Finish
NOTES
2.
4.
1.
BOOSTER SETS
POWERBOOST FLOW-V
CR RANGE
LC0000046
*PB0010*
*PB0010*
TOS
27/05/2016
LC0000046
Sheet 1 of 2
N.T.S.
123
FINISH:
MATERIAL :
ELEVATION
Inlet Manifold

6
POWER BOOST
by EPS Group
Electrical Installation
The POWERBOOST unit is designed for professional installation and should be connected by a
suitably qualied electrician in accordance with the latest IEE regulations.
Ensure that the electrical supply is fully isolated before removing any electrical covers. The
POWERBOOST unit must be earthed and it is recommended that an RCD is tted on the incoming
electrical supply.
Single phase Powerboost units are suitable for voltage supply 230 +/- 10%.The supply cable should
be sized POWERBOOST to its required length allowing for voltage drop with all pumps running
simultaneously and protected by a suitable MCB or fuse.
Wiring Connections
The POWERBOOST unit has provision for an external level switch input and a volt free general
alarm output (BMS connection). Connections for these features are made within the main wiring
box as per the diagrams below.
FLOW-V
Connect incoming power to RCD
Terminals 1 & 2 -
Normally Closed alarm output
Terminals 3 & 4 -
Level switch input, to be looped out if not required
Commissioning
1. Make a visual check to ensure all pipe work and electrical connections are connected in a
safe manner.
2. Ensure the supply tank is suciently full and the pumps have been de-aerated.
3. Ensure that the closest outlet to the booster set is open to allow water to ow once the set
is turned on.
4. Check the main discharge valve after the outlet manifold is closed and all other valves are
fully open.

7
POWER BOOST
by EPS Group
5. Turn on the power supply to the controllers and press the start button on the controllers.
6. Slowly open the discharge valve on the booster unit to gradually ll the delivery main.
7. Once water is owing from the nearest outlet, check the pipe work around the set for leaks.
8. Working away from the set, open each outlet in turn until water ows to purge air from the
system.
9. When all the air has been purged, close all outlets. The pump set will shut off within 10
seconds after building up pressure in the system.
10. The POWERBOOST unit is factory set as per the details on the pump specication page.
11 Please see controller specic instructions for guidance on how to chance the Pressure cut in
and cut out settings of your booster unit if required.
Pressure Vessel
The air pre-charge in the pressure vessel should be set 65% of the pre-set working pressure for maximum
effectiveness. It is recommended to check the tank air pressure every 4-6 months. The vessel can be
charged with an air source via an inlet valve. The pressure can be checked using a suitable pressure
gauge. Air can be added or released as required in order to adjust the percentage of pressure.
In order to check the air pressure in the vessel, it is necessary to release the pressure in the vessel
To do this:
1. The isolation valve below the vessel must rst be closed
2. The drain valve is opened to release water pressure
3. The air pressure is tested with a suitable gauge at the air valve
4. Add or release air depending on the pressure reading
5. When the pressure has been adjusted, close the drain valve and open the isolation valve to
return the set to service
ELEVATION
END VIEW
END VIEW
PLAN
ISOMETRIC
SHORT
MIDDLE
LONG
IF IN DOUBT ASK DO NOT SCALE OFF THIS DRAWING
Title:
Client:
FLOW THRU ISOLATION VALVE
CLEAN WATER BOOSTER SETS
COPYRIGHT
This drawing is protected by copyright and must not be
reproduced in any form without the prior written consent of US.
Isolation Valve
Drain Valve

8
POWER BOOST
by EPS Group
Pump Specication
Pump
Power Amps Per Pump Factory Maximum
kW HP 230V 400V Cut In System
Pressure Flow Pressure
4CR80 0.55 0.75 3.4 2 2 3 80 5.2
5CR80 0.75 1 4.3 2.5 3 4 80 6.7
4CR100 0.75 1 4.5 2.6 2 3 100 5.0
5CR100 1.1 1.5 4.2 2.4 3 4 100 6.3
4CR200 1.5 2 7.3 4.2 3 4 200 5.8
5CR200 1.8 2.5 9.4 5.4 4 5 200 7.3
6CR200 2.2 3 10.2 5.9 5 6 200 8.7
Flow V Variable Speed

9
POWER BOOST
by EPS Group
Starting up: Steadypres
Switch on power to controller
and wait the STARTING time
(approx. 10 sec.)
By pressing START STOP you
put the inverter IN SERVICE
or OUT OF SERVICE.
To increase 0.1 bar press
SIMULTANEOUSLY
To decrease 0.1 bar press
SIMULTANEOUSLY
ENTER
ENTER
P 3.2
P 3.3
P 3.1
Set pressure quick adjustment: Steadypres
Light Signals: Steadypres
Keyboard
ON OFF BLINKING
STATUS
POWER
STEADYPRES does not detect power supply. WARNING: cannot
guarantee the absence of power supply, the electronic board
may be faulty, but under tension
STATUS
POWER
STEADYPRES is live, but the pump is not running (STANDBY)
STATUS
POWER
STEADYPRES is live, and the pump is running
STATUS
POWER
STEADYPRES is live, but out of serivce; the re-arm is only manual
STATUS
POWER
is only manual STEADYPRES is in ALARM mode, re-arm
Controller Speci c Instructions & Troubleshooting
+
+

10
POWER BOOST
by EPS Group
Controller Specic Instructions & Troubleshooting
Alarms: Steadypres
OVER
CURRENT %
The current exceeded the allowable tolerance on the current set. The inverter
stops the pump, the rearm is only manual.
CURRENT
LIMIT
Occurs if, in the absence of ow, the pump cannot reach the SET pressure, but can
reach at least a pre-determined percentage of the SET pressure, dened through the
parameter Pd. The inventer does not stop the pump.
I DRY
(Only with ow
sensor)
Occurs if, in the absence of ow, the pump cannot reach the SET pressure, but can
reach at least a pre-determined percentage of the SET pressure, dened through
the parameter Pd. The inventer does not stop the pump.
DRY
RUNNING
(applications WITH
ow Sensor)
Occurs if, in the absence of ow, the pump falls to reach the pressure of the set but
does not even reach a predeterminded percentage of the SET pressure, expressed
by the parameter Pd; the inverter stops the pump . The error is reset after the time TP
and the inventer re-starts in automatic mode.
DRY
RUNNING PF
(only T/T models)
Occurs if the electrical parameter COSFI (power factor) falls to value indicating the
unload operation of engine. the inverter stops the pump. the error is reset after the
time TP.
LOW PRESS Occurs if the pump is running at maximum frequency (50/60 Hz), in the presence
of ow, and the pressure doesn’t reach 0.3 bar; the inverter stops the pump. the
error is reset after the time TP and the inverter re-starts in automatic mode.
VOLTLAGE
ERROR L
A voltage drop has occurred beyond minimum operating threshold. The inverter
stops the pump. The error is reset after one minute, and the inverter re-starts in
automatic mode.
HIGH TEMP.
BOX
(Only T/T models)
The temperature inside the inverter has reached 65°C; is automatically limited
the maximum frequency of 5 Hz but the drive continues to run, the error is reset
below 60°C.
OVER TEMP.
BOX
(Only T/T models)
The temperature Inside the Inverter has reached 80°C, the inverter stops the
pump, the error is reset below 60°C and the drive will restart automatically.
HIGH TEMP.
MOD
The module temperature has reached the rst alarm threshold; the maximum
working frequency is automatically limited, but the drive continues to run, the
error is reset when the module temperature returns below 70°C.
OVER TEMP.
MOD
The module temperature has reached the second alarm threshold, the inverter
stops the pump, the error is reset when the module temperature returns below
70°C and the drive will restart automatically.
INPUT
ERROR
There has been a reversal of the power connections / output to the motor . the in-
verter is locked, the error is reset by connecting the cables correctly in the terminal.
COM ERROR Communication has been interrupted between the control board and the power
board; the cause could be integrity of the cable and the connection ports or an
electronic board fault.
PHASE
ERROR
(Only for models with three-phase output) lack of phase towards the motor during
operation. The inverter stops the pump; reset is manual only.
LOW LEVEL This occurs when the digital input EL is congured as“WATER LEVEL” (level signal)
and there is no signal. When the signal returns, the message disappereas and the
inverter operates normally again.
EXT OFF This occurs when the digital input EL is congured as “EXT ENABLE” (control
enabled from outside) and there is no signal. When the signal returns (external
enabling) the message disappears and the inverter operates normally again.

11
POWER BOOST
by EPS Group
We, EPS Group
of Mallow Business and Technology Park
Quartertown
Mallow
Co Cork P51 AC94
Telephone: [phone]
Email: [e-mail]
Hereby declare that:
Equipment: POWERBOOST PRO E, PRO S, & FLOW V Ranges
Model : All standard models
in accordance with the following Directives:
• Machinery Directive 2006/42/EU
• EMC Directive 2014/30/EU
is in conformity with the applicable requirements of the following documents:
• ISO 12100 (Safety of machinery — General principles for design — Risk assessment and risk reduction)
I hereby declare that the equipment above has been designed, assembled, and tested to comply
with the relevant section of the above referenced specications. The unit complies with all essential
requirements of the directives.
The Technical File is maintained at:
EPS Group
Mallow Business and Technology Park
Quartertown
Mallow
Co Cork P51 AC94
Telephone: [phone]
Email: [e-mail]
DECLARATION OF CONFORMITY
PLEASE KEEP THIS DOCUMENT IN A SAFE PLACE
Signed:
Managing Director, EPS
Date:
02/01/2020

POWERBOOST
by EPS Group
IRL & NI
powerboost.ie
[e-mail]
094 963 3500 (IRL)
028 9181 8347 (NI)
UK
power-boost.co.uk
[email protected].uk
01543 415200