FLOWTECH flowboost F.H User manual

1
First Publication Date: 01/09/2020
Revision:
Revision Date:
OPERATION AND
MAINTENANCE MANUAL
F.H Pump Manual

CONTENTS
OPERATION & MAINTENANCE
General Information 3
Safety Information 4
Safety Warnings & Precautions 5
Customer / Contractor Responsibilities 6
Technical 7
Intended use 7
Improper use 7
Marking 7
Technical data 7
Operating conditions 8
General provisions 8
Transportation 8
Handling 9
Installation Dimensions 9
Unpacking 9
Installation 9
Pipes 9
Suction pipe 10
Delivery pipe 10
Electrical connection 10
Start-up and Operation 11
Maintenance 12
Disposal 12
Spare-parts request 12
Troubleshooting 13
2

Definitions of Safety Warnings and
Precautions
WARNING!
Indicates a potentially hazardous situation which, if
not avoided, can result in serious injury or death.
 CAUTION!
Indicates a potentially hazardous situation which, if
not avoided. Can result in minor to moderate injury, or
serious damage to the product.
General
Information
These instructions are to assist in the installation of the flowboost F.H Pump please follow
them carefully.
If, having read this Operation & Maintenance Manual, there is any doubt about any aspect of
the installation please don't hesitate to contact our technical team.
flowboost F.H Pump Manual
3

Safety
Information
It is essential that correct and safe working practices are adhered to at all times when installing,
operating and/or maintaining any piece of equipment. Always consult safety data sheets, operating
and maintenance manuals, Health & Safety legislation and recommendations and specific
requirements of any equipment manufacturer, site controller, building manager or any other persons
or organisation relating to the procurement, installation, operation and/or maintenance of any piece
of equipment associated or in conjunction with any product provided by flowech Water Solutions.
This document is intended for ALL installers, operators, users and persons carrying out maintenance
of this equipment and must be kept with the equipment, for the life of the equipment and made
available to all persons at all times. Prior to carrying out any work associated with the set it is essential
that the following sheets are read, fully understood and adhered to at all times.
Equipment must only be installed, operated, used, and/or maintained by a competent person. A
competent person is someone who is technically competent and familiar with all safety practices
and all of the hazards involved.
Any damage caused to any equipment by misapplication, mishandling or misuse could lead to risk of
Electrocution, Burns, Fire, Flooding, death or injury to people and/or damage to property dependent
upon the circumstances involved. flowech Water Solutions accepts no responsibility or liability for
any damage, losses, injury, fatalities or consequences of any kind due to misapplication, mishandling
or misuse of any equipment, or as a result of failure to comply with this manual.
Failure to install, operate, use or maintain the equipment in accordance with the information contained
within this document could cause damage to the equipment and any other equipment subsequently
connected to it, invalidating any warranties provided by flowech Water Solutions to the buyer.
4

Safety Warnings &
Precautions
These instructions should be read and clearly understood before working on the system. Please
read this manual carefully and all of the warning signs aached before installing or operating the
equipment keep this manual handy for your reference. This equipment should be installed, adjusted
and serviced by trained and qualified personnel. Failure to observe this precaution could result in
bodily injury.
WARNING! - Install an emergency stop key separately from the isolator. Rotating
shas can be hazardous.
WARNING! - This equipment has a high leakage current and must be permanently
fixed to earth.
WARNING! - Do not aach or remove wiring or connectors when the power is applied.
Do not check signals during operation. When the power is turned on and the running
command is on, the motor will start rotating. The stop key is only eective when the
function is set. If there is a power failure and an operation instruction is given the unit
may start automatically when the power is reinstated.
WARNING! - Make sure that the input voltage is correct. Be sure to install the unit in
a room that is not exposed to direct sunlight and is well ventilated.
Avoid environments which have a high ambient temperature, high humidity or
excessive condensation. Avoid dust. Corrosive gas, explosive gas, inflammable gas,
grinding-fluid mist and salt damage, etc.
WARNING! - Do not connect the power source to any terminals except power
connectors.
WARNING! - Motor control equipment and electronic controllers are connected to
hazardous line voltages. When servicing drives and electronic controllers, you may be
exposed to components at or above the line potential. Extreme care should he taken
to protect against shock. Dangerous voltage may exist aer the power light is o.
Wait more than 5 minutes aer turning o the power supply before performing
maintenance or inspection. Hazard of electric shock. Disconnect incoming power
before working on this unit.
WARNING! - The inverter should be protected separately against ground fault.
Observe the regional regulations for electrical installation!







flowboost F.H Pump Manual
5

Customer / Contractor
RESPONSIBILITIES
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
and/or clothing.
• Is aware of appropriate health & safety warnings.
• Has read the information in this section of the manual.
CAUTION! - It is strongly recommended that all electrical equipment conforms
to National Electrical Codes and local regulations. Only qualified personnel should
perform installation, alignment and maintenance. The manufacturer reserves the right
to alter the technical data in order to make improvements or update information.
CAUTION! - Failure to observe these rules will render the guarantee invalid. The same
applies to repair jobs and/or replacement. Your legal rights are not aected.
CAUTION! - The manufacturer declines all responsibility in the event of damage or
injury caused as a result of tampering with the equipment.
CAUTION! - Do not switch on/o power supply to run/stop the motor/system! Start
the unit only by using run buon or external run command.




6

Technical
Horizontal Multi-Stage Close Coupled Pumps in stainless steel.
Intended use
For clean liquids: non-explosive and non-flammable, non-hazardous for health or the environment, non-
aggressive for pump materials, not containing abrasives, solid or fibrous particles.With seal rings in EPDM the
pump is not suitable for use with oil.
Liquid temperature from - 15°C to + 110 °C.
Improper use
The device is designed and built only for the purpose described. Improper use of the device is forbidden,
as is use under conditions other than those indicated in these instructions. Improper use of the product
reduces the safety and the eciency of the device, Flowtech shall not be responsible for failure or accident
due to improper use. Do not use in ponds, tanks or swimming pools or where people may enter or come into
contact with the water.
Marking
The following picture is a copy of the name-plate that is on the external case of the pump
Technical data
Dimensions and weight (see technical catalogue).
Nominal speed 2900/3450 rpm
Protection IP 54
Supply voltage / Frequency:
up to 240V 1~ 50/60 Hz
up to 480V 3~ 50/60 Hz
Check that the mains frequency and voltage correspond to the electrical characteristics shown on the
indicator plate. The electric data marked on the label are referred to the nominal power of the motor.
Sound pressure: < 70 dB (A).
Max. Starts per hour: 30 at regular intervals (15 for 206-406, 20-32-48).
Maximum permissible pressure in the pump casing: 80m (8 bar), 100 m (10 bar) for 20-32-48.
The max. Inlet water pressure: PN (Pa) - Hmax (Pa).
flowboost F.H Pump Manual
7

Operating conditions
Installation in well ventilated location protected from the weather, with a max ambient temperature of 40°C.
General provisions
Before using the product it is necessary to know all the safety indications.
Carefully read all operating instructions and the indications defined for the dierent steps: from transportation
to disposal.
The specialized technicians must carefully comply with all applicable standards and laws, including local
regulations of the country where the pump is sold.
The device has been built in conformity with the current safety laws. The improper use could damage people,
animals and objects.
The manufacturer declines any liability in the event of damage due to improper use or use under conditions
other than those indicated on the name-plate and in these instructions.
Follow the routine maintenance schedules and the promptly replace damaged parts, this will allows the
device to work in the best conditions.
Use only original spare parts provided from Flowtech or an Authorised distributor.
Don’t remove or change the labels placed on the device.
Do not start the device in case of defects or damaged parts.
Maintenance operations, requiring full or partial disassembly of the device, must be done only aer
disconnection from the supply.
Safety devices
The device has an external case that prevents any contact with internal parts.
Residual Risks
The appliance designed for use when inline with the design and safety rules, doesn’t have residual risks.
Information and Safety signals
For this kind of product there will not be any signals on the product.
Individual protection devices
During installation, starting and maintenance it is suggested to the authorized operators to consider the use
of individual protection devices suitable for described activities.
During ordinary and extraordinary maintenance interventions, safety gloves are required.
Signal individual protection device
Hand Protection - Gloves for protection against chemical, thermal and mechanical risks.
Transportation
The product is packed to maintain the content intact.
During transportation avoid to stack excessive weights.
Ensure that during the transportation the box cannot move.
8

It is not necessary to use any special vehicle to transport the packaged device.
The transport vehicles must comply, for the weight and dimensions, with the chosen product (see technical
catalogue dimensions and weights).
Handling
Handle with care, the packages must not receive impacts.
Avoid to impact onto the package materials that could damage the pump.
If the weight exceeds 25 Kg the package must be handled by two person at the same time.
Raise the pump-motor unit slowly, making sure it does not move from side to side in an uncontrolled way, to
avoid the risk of imbalance and tipping up.
Installation Dimensions
For the dimensions of the device (see technical catalogue).
Ambient requirements and installation site dimensions
The customer has to prepare the installation site in order to guarantee the right installation and in order to fulfil
the device requirements (electrical supply, etc.).
The place where the device will be installed must fulfil the requirements.
It’s absolutely forbidden to install the machine in an environment with potentially explosive atmosphere.
Unpacking
Inspect the device in order to check any damages which may have occurred during transportation.
Package material, once removed, must be discarded/recycled according to local laws of the destination
country.
Installation
The pumps must be installed with the rotor axis in the horizontal position and with the feet under the pump.
Place the pump as close as possible to the suction source.
Provide space around the pump for motor ventilation, to allow for checking of sha rotation, for filling and
draining the pump and to allow for collection of the liquid to be removed (especially for draining liquids which
are harmful or have to be removed at temperatures higher than 60°C).
Pipes
Ensure the insides of pipes are clean and unobstructed before connection.
ATTENTION: The pipes connected to the pump should be secured to rest clamps so that they do not
transmit stress, strain or vibrations to the pump.
Tighten the pipes or union coupling to the extent sucient to ensure a tight seal.
Excessive torque may cause damage to the pump.
When the pipe or union coupling is mounted, keep the pump casing connection blocked with a second
wrench, making sure the connection is not deformed by excessive tightening.
The pipe diameters must not be smaller than the pump connections.
flowboost F.H Pump Manual
9

Suction pipe
If the suction pipe is longer than 10m, use an internal pipe diameter larger than the pump suction connection.
The suction pipe must be perfectly airtight and be led upwards in order to avoid air pockets.
With a pump located above the water level (suction li operation) fit a foot valve with strainer which must
always remain immersed.
If operating with flexible hoses use a reinforced spiral suction hose, in order to avoid the hose narrowing due
to suction vacuum.
With the liquid level on the suction side above the pump (inflow under positive suction head, fit an inlet gate
valve.
For suction from a storage tank fit an anti-backflow valve. Follow local specifications if increasing network
pressure.
Install a strainer on the suction side of the pump to prevent foreign particles from entering the pump.
Delivery pipe
Fit a gate valve in the delivery pipe to adjust delivery and head.
Install a pressure gauge.
With a geodetic head at outlet over 15m fit a check valve between the pump and the gate valve in order to
protect the pump from water hammering.
Electrical connection
Electrical connection must be carried out only by a qualified electrician in accordance with local regulations.
Follow all safety standards.
The unit must be properly earthed (grounded).
Connect the earthing (grounding) conductor to the terminal with the marking.
Compare the frequency and mains voltage with the name-plate data and connect the supply conductors to
the terminals in accordance with the appropriate diagram inside the terminal box cover.
ATTENTION: never allow washers or other metal parts to fall into the internal cable opening between
the terminal box and stator.
If this occurs, dismantle the motor to recover the object which has fallen inside. If the terminal box is provided
with an inlet gland, use a flexible power supply cord of the H07 RN-F type. If the terminal box is provided with
an inlet bushing, connect the power supply cord through a conduit. For use in swimming pools (not when
persons are in the pool), garden ponds and similar places, a residual current device with IN not exceeding
30 mA must be installed in the supply circuit.
Install a device for disconnection from the mains (switch) with a contact separation of at least 3mm in all
poles.
With a three-phase motor install an overload protection device with curve D appropriate for the rated current
of the pump.
Single-phase are supplied with a capacitor connected to the terminals and (for 220-240 V - 50 Hz) with an
incorporated thermal protector.
ATTENTION: When the pump is fed by a frequency converter, the minimum frequency should not fall below
25Hz and in any case the total head of the pump should never be lower than 3m.
10

Start-up and Operation
Preliminary checks before start-up of the pump
Do not start-up the device in case of damaged parts.
First starting
ATTENTION: never run the pump dry.
Start the pump aer filling it completely with liquid.
When the pump is located above the water level
Suction li operation or with a positive suction head which is too low (less than 1m) to open the non-return
valve, fill the pump through the priming hole.
When the liquid level on the suction side is above the pump
(inflow under positive suction head, fill the pump by opening the suction gate valve slowly and completely,
keeping the delivery gate valve open to release the air.
Before starting, check that the sha turns by hand. For this purpose use the screwdriver notch on the sha
end on the ventilation side.
When starting, with a three-phase motor, check that the direction of rotation
Is as shown by the arrows on the lantern bracket.
Otherwise, disconnect electrical power and reverse the connections of two phases.
Check that the pump works within its field of performance and that the absorbed current shown on the
name-plate is not exceeded. Otherwise adjust the delivery gate valve or the seing of any pressure switches.
If a priming loss occurs (interruption of delivery flow) or if a pressure oscillation is indicated by the pressure
gauge, make sure all the suction pipe couplings are perfectly sealed and tighten the two sealed plugs on the
pump casing.
Never run the pump for more than five minutes with a closed gate valve.
Prolonged operation without a change of water in the pump causes dangerous increases of temperature and
pressure.
When the water is overheated due to prolonged operation with a closed port, stop the pump before opening
the gate valve.
To avoid any risk of danger to users and the creation of harmful thermal stress in the pump and system due
to large temperature dierentials, wait until the water has cooled inside the pump before starting again.
If the water is overheated on account of prolonged operation with a non-primed or insuciently filled pump
(suction li operation), wait until cool before opening the draining and filling plugs.
Care must be taken when the pumped fluid has a high temperature. Do not touch the fluid when its
temperature is higher than 60°C. Do not touch the pump when the surface temperature is higher than 80°C.
Switch o of the pump
The appliance must be switch o every time there are faults. (See troubleshooting).
The product is designed for a continuous duty, the switch o is performed by disconnecting the power
supply by means the expected disconnecting devices. (See Electrical connection).
flowboost F.H Pump Manual
11

Maintenance
Before any operations it’s necessary to disconnect the power supply. If required ask to an electrician or to an
expert technician.
Every maintenance operations, cleaning or reparation executed with the electrical system under voltage, it
could cause serious injuries to people.
If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified
persons in order to avoid a hazard.
In case of extraordinary maintenance, or maintenance operations that require part-removing, the operator
must be a qualified technician able to read schemes and drawings.
It is suggest to register all maintenance operation executed.
During maintenance keep particular aention in order to avoid the introduction of small external parts that
could compromise the device safety.
It is forbidden to execute any operations with the direct use of hands. Use water-resistant, anti-cut gloves to
disassemble and clean the filter or in other particular cases.
During maintenance operations external personnel is not allowed.
Maintenance operations that are not described in this manual must be made only by special personnel
authorized by Flowtech.
For further technical information regarding the use or the maintenance of the device, contact Flowtech.
Routine maintenance
Before every maintenance operations disconnect the power supply and make sure that the device could not
accidentally operate.
In the case of water containing chloride (chlorine, sea water), the risk of corrosion increases in stagnant water
conditions (also with an increase in temperature and decrease of pH value). In these cases, if the pump
remains inactive for long periods, it must be emptied completely and, preferably, dried.
For good measure, as in the case of temporary operation with dirty liquids, run the pump briefly with clean
water to remove deposits. When the pump remains inactive it must be emptied completely if there is a risk of
freezing.
Before restarting the unit, check that the sha is not jammed and fill the pump casing completely with liquid.
Dismantling the pump
Close the suction and delivery gate valves and drain the pump casing before dismantling the pump. For
dismantling and re-assembly see construction in the cross section drawing. By removing the screws and the
square nuts (2,4,8) the motor can be taken out complete, with all internal parts of the pump, without removing
the pump casing and the pipes.
Disposal
The final disposal of the device must be done by specialised company. Make sure the company follows the
classification of the material parts for the separation.
Observe the local regulations and dispose the device accordingly with the international rules for environment
protection.
Spare-parts request
When ordering spare parts, please quote their designation, position number in the cross section drawing and
rated data from the pump name plate (type, date and serial number).
12

Troubleshooting
WARNING: Turn o the power supply before performing any operations.
Do not allow the pump or motor to run when dry even for a short period.
Strictly follow the user instructions and if necessary contact an authorised service centre.
Problem Probable Causes Possible Remedies
The motor does not
start
1a. Unsuitable power
supply
1a. Check that the mains frequency and voltage
correspond to the electrical characteristics shown on the
indicator plate
1b. Incorrect electrical
connections
1b. Connect the power supply cable to the terminal board
correctly. Check that the thermal overload protection is
set correctly (see data on the engine indicator plate) and
make sure that the fuse board up line of the engine has
been properly connected
1c. Engine overload
protective device cuts in
1c. Check the power supply and make sure that the pump
sha is turning freely. Check that the thermal overload
protection has been set correctly (see engine indicator
plate)
1d. Blown or defective
fuses
1d. Replace the fuses, check the electric power supply
and points a) and c)
1e. Sha blocked 1e. Remove the cause of blockage as indicated in the
“Blocked pump” instruction booklet
1f. If the above causes
have already been
checked the engine may
be malfunctioning
1f. Repair or replace the engine by applying to an
authorised service center
Pump blocked 2a. Prolonged periods of
inactivity with formation of
rust inside the pump
2a. Rotation may be started directly from the pump sha
or from the joint (remember to turn o the electricity
supply first ) or contact an authorised service centre
2b. Presence of solid
bodies in the pump rotor
2b. If possible, dismantle the pump casing and remove
any solid foreign bodies inside the rotor, if necessary
contact an authorised service centre
2c. Bearings seized 2c. If the bearings are damaged replace them or if
necessary contact an authorised service centre
The pump functions
but no water comes
out
3a. Possible infiltration
of air from suction tube
connections, drain plugs
or filling of pump or from
the gaskets of the suction
pipe
3a. Check which part is not tight and seal the connection
adequately
3b. Foot valve blocked
or suction pipe not fully
immersed in liquid
3b. Clean or replace the boom valve and use a suction
pipe suitable for the application
3c. Suction filter blocked 3c. Clean the filter, if necessary, replace it. See point 2a)
also.
flowboost F.H Pump Manual
13

Insucient flow 4a. Pipes and accessories
with diameter too small
causing excessive loss of
head
4a. Use pipes and accessories suitable for the specific
application
4b. Presence of deposits
or solid bodies in the
internal passages of the
rotor
4b. Clean the rotor and install a suction filter to prevent
other foreign bodies from entering
4c. Rotor deteriorated 4c. Replace the rotor, contact Flowtech
4d. Worn rotor and pump
case
4d. Replace the rotor and the pump casing
4e. Excessive viscosity of
the liquid pumped (if other
than water)
4e. The pump is unsuitable
4f. Incorrect direction of
rotation
4f. Invert the electrical connections on the terminal board
or control panel
4g. Suction head
excessive in relation to the
suction capacity of pump
4g. Try to close the feeder gate partially and/or reduce
the dierence in level of the pump and the liquid being
aspirated
4h. Suction pipe too long 4h. Bring the pump closer to the suction tank so as to use
a shorter pipe. If necessary use a pipe of a wider diameter
Noise and vibrations
from the pump
5a. Rotating part
unbalanced
5a. Check that no solid bodies are obstructing the rotor
5b. Worn bearings 5b. Replace the bearings
5c. Pump and pipes not
firmly aached
5c. Anchor the delivery and suction piping as needed
5d. Flow too strong for the
diameter of the delivery
pipe
5d. Use bigger diameters or reduce the pump flow
5e. Functioning in
cavitation
5e. Reduce the flow by adjusting the feeder gate and/or
using pipes with a bigger internal diameter. See point 4g)
too
5f. Unbalanced power
supply
5f. Check that the mains voltage is right
5g. Incorrect alignment of
pump-motor unit
5g. If necessary, the unit must be re-aligned
Leakage from the
mechanical seal
6a. The mechanical seal
has functioned when dry
or has stuck
6a. Make sure that the pump casing (and the suction pipe
if the pump is not self-priming) are full of liquid and that all
the air has been expelled. See point 5 e) too.
6b. Mechanical seal
scored by presence of
abrasive parts in the liquid
pumped
6b. Install a suction filter and use a seal suited to the
characteristics of the liquid being pumped.
6c. Mechanical seal
unsuitable for the type of
application
6c. Choose a seal with characteristics suitable for the
specific application
6d. Slight initial drip during
filling or on first start-up
6d. Wait for the seal to adjust to the rotation of the sha. If
the problem persists, see points 6a), 6b) or 6c) or contact
an authorised service center.
In cases 6a), 6b) and 6c), replace the seal, if necessary contact an authorised service center
14

flowboost F.H Pump Manual
15

contact us
FOR FURTHER INFORMATION OR ASSISTANCE
Flowtech Water Solutions are experts in water services and water booster sets.
We have continuously supplied a wide range of standard and custom products since
being founded in 1996.
TELEPHONE : [phone] TELEPHONE : [phone]
MANUFACTURE & SUPPLY SERVICE & MAINTENANCE
ADDRESS : Unit 1 Lock Flight Buildings, Wheatlea Industrial Estate,
Wigan, Greater Manchester WN3 6XP United Kingdom
EMAIL: [e-mail] EMAIL: [e-mail]
WEBSITE: .flowtech.org.uk
REGISTERED
ISO
9001 :2015
Certificate No. 185352020Membership No. 700106
This section of the flowech©website holds
information exclusively for members. Members will
need to log in to gain access to these pages.
Our member’s will be granted exclusive access to
our technical resource library. Within this resource
is a wide range of product information including
data sheets, technical drawings, O&M Manuals
and training videos
At flowech©we operate a network of Service
Engineers located throughout the UK who are
supported by our oces located in and Greater
Manchester. The distribution of engineers means
that in the majority of cases we are less than 4
hours away from aending a customer call out.
We place great emphasis on providing technical
back up to support our Service Engineers in
resolving some dicult operational and technical
issues. We pride ourselves on completing a
project on time, within budget and never leaving
a problem unresolved, or a customer waiting.
This quality of service has made us the first
choice for our customers.
Copyright © 2020 • All Rights Reserved • Flowtech Water Solutions Limited • Company Number: 05125479 • VAT Number: 836 8024 19