Wilo BF Series User manual

Read all warnings and instructions before using.
Improper use may result in serious or fatal illness
or injury.
This product was made by the client’s order
Please, check the name plate.
WILO Pumps Booster system
(
BF/BP Series
)

2
C ontents
Thank you for purchasing WILO Pumps products.
Please read carefully for your safety & convenience.
Section Subject page
0 Contents ························································ 2
1Safety precautions (Make sure to read & follow carefully!)
·············3
2Introduction ····················································· 4
3Characteristics of products ·································· 4
4Application ······················································ 4
5Specification ··················································· 4
6Transport and Intermediate Storage ······················· 5
7Components of product ······································ 5
8Installation ······················································ 8
9Operating principle ··········································· 11
10 Commissioning ··············································· 13
11 Maintenance ·················································· 15
12 Trouble - shooting ············································ 17
13 Control unit ···················································· 20
14 Installation of the system operating data ················· 24
15 Operating data and Setup ·································· 25
16 Identification Code and Data ······························· 30

3
Safety precautions
( Make sure to read & follow carefully! )
1
These instructions contain basic references which must be strictly adhered to. It is therefore imperative for the
installer and the operator to carefully read these instructions prior to installation and commissioning. Please
observe, not only the safety directions under the main heading and safety precautions, but also those added and
specifically marked under the following headings.
1.1)Safety marks contained in these instructions
Following safety marks explain the grades of human and property damage when users ignore the instruction.
1.2)Personnel qualification
The personnel installing the pump must have the appropriate qualification for this work.
1.3)Dangers if the safety indication are not followed.
Failure to observe the safety indications can endanger persons and the installation. Failure to abide
by the safety indications will nullify your right to any claims for compensation.
In particular, failure to observe these indications can, for example, create the following dangers:
•failure of important functions in the installation.
•dangers to persons caused by electrical and mechanical effects.
1.4)Safety instructions for the operator.
Local regulations for the prevention of accidents must be observed. Dangers resulting from electrical
energy are to be prevented . National /local energy supply company regulations must be observed.
1.5)Safety indications for inspection and assembly work
The operator must ensure that all inspection and assembly is carried out by authorized and qualified
specialist who has studied the operating instructions in detail.
In principle, work may only be carried out with the pump/plant switched off and at complete stand-still.
1.6)Unauthorized modification and manufacture on spare parts
Changes to the pump/installation may only be made in agreement with the manufacturer. The use of
original spare parts and accessories authorized by the manufacturer will ensure safety. The use of any
other parts may invalidate claims invoking the liability of the manufacturer for any consequences.
1.7)Improper operating modes
The operational safety of the appliance is only guaranteed if it is used as intended in accordance
with the operating instructions. The operational tolerance limitations stated in the
catalogue/data sheet must not be exceeded under any circumstances.
Warning
When not following indications marked by the warning signal
Death or serious Injury could happen.
Caution
When not following indications marked by the caution signal
Human damage or property damage could happen.
Caution
This signal warns the electric hazard.
Therefore, follow the indications of the warning signal or the instructions carefully.

4
Introduction
2
Characteristics of product
3
Application
4
Specification
5
▶These instructions contain information on the WILO Pumps Booster system. Before using your Booster system, you should read
and understand this operating instruction. Make special note of all danger, warning and caution statements. Keep the
instructions for using as a reference.
▶If not observing these operating instructions, a serious injury or a death could happen by
electric hazard.
▶Always keep these operating instructions with the booster system. In this case, the
using purpose and installing condition should be appropriate.
Use after necessary treatments (example, Reset the operating data)
▶Don’t use except the normal purpose and installing conditions. If not, It could cause
troubles or accidents. In that case, customers could have responsibility about that.
▶If you have any question or inquiry of these operating instructions, please contact our
agents or the head office.
In situations where it is vital, also install spare products at the special place where serious damages could be
happened by no water suppy caused by product troubles.
▶The system automatically starts as water pressure is low.
▶Can check the condition of booster system by a panel. ▶Automatically distribute load to each pump.
Non-operating pump is excluded from the rotating sequence.
▶Pressurized water supply and pressure boosting in residential, commercial and public buildings, hotels,hospitals,department
stores and for industrial and process engineering.
※Only use this product with clean water!
※Excessively high or heavily fluctuating inlet pressure will require the provision and installation of a pressure
reducing valve to maintain a constant inlet pressure level. Max. tolerable fluctuation: 1.0 bar
Refer to the name plate about capacity, pressure head, voltage, power of a booster system.
Standard specifications are as follows. (Some specifications could be changed by option)
▶Product classification : BP Series Step control system BF Series Inverter control system
※Power source could vary in each product. Therefore, check the name plate surely.
Example of a model name)
B F C 2 W 0 8 3 L 5
- BF : Inverter (1~2nd : Control type)
- C : 3Phase, 380 V, 60 Hz (3rd : Power source)
- 2 : 2Pump system (4th : Numbers of pumps)
- W083 : MVI-0803 (5~8th : Pump type)
- L : Dry running protector (9th : Option)
- 5 : 500L Pressure tank (10th : Pressure tank capacity)
liquid Clean water ( 0 ~ 70 ℃)
Surrounding temp. 0 ~ 40 ℃
Humidity Under RH 85 % (Over dew point)
Pump type Centrifugal pump
Location Indoor
Suction condition Pressurized
Protector for a motor Overload relay
Pump power source ※ 3Phase, 380V, 50Hz(Standard)
Control power source ※ 1Phase, 220V, 50Hz(Standard)

5
Transport and Intermediate storage
6
The pump must be protected from any damage at all times during transport & intermediate damage.
Caution
Transport of the unit requires proper preparation and handling. Always make sure
that the pumps and unit remain in horizontal position during transport and don’t let
slip out of the transport suspension arrangement. If the pump/unit slip out of the
suspension arrangement, It may cause personal injury or property damage.
Caution
Avoid extreme temperature variation and humidity when keeping at a warehouse.
Condensed water caused by severe humidity could cause the damage of metal
components Admitted temperature = -10 ~ 50 ℃/ Admitted humidity = under RH 85 %
Caution
Keep the motor cable out of any stress during delivery.
If cables are damaged, it could cause a electric shock, a leakage and a fire.
No. Components Amounts
1 Control unit 1
2 Pump 1~4
3 Bed 1
4 Manifold for suction 1
5 Manifold for discharge 1
6 Isolating valve 2/pump
7 Check valve 1/pump
8 Anti-vibration damper 4~12
Components of product
7
Fig. 1
*Shape of components could be changed without prior notice.
2
7
4
68
3
5
1
7.1)BP Series
No. Components Amounts
1 Control unit 1
2 Pump 1~4
3 Bed 1
4 Manifold for suction 1
5 Manifold for discharge 1
6 Isolating valve 2/pump
7 Check valve 1/pump
8 Anti-vibration damper 4~12
Fig. 2
2
7
4
6
8
3
5
1
7.2)BF Series

Fig. 4 BF control unit inside (Direct starting, 2-3Pumps)
6
Transport and Intermediate storage
7
7.3)BP Control unit
Fig. 3 BP control unit inside (Direct starting, 2-4Pumps)
7.3)BF Control unit
*Shape of components could be changed according to models.
Breaker for pump power
& Overload protector Fuse for control circuit Breaker for control power Emergency operation key
Terminal block
Terminal block
Magnetic contactor for pump operation
Inverter
Magnetic contactor for pump operation
Breaker for control circuit Breaker for inverter Emergency operation key
Breaker for pump power
& Overload protector

Fig. 5 BF control inside (Direct starting,4Pumps)
Fig. 6 BF control unit inside (star-delta starting, 2-4Pumps)
7
Components of product
7
*Shape of components could be changed according to models.
Breaker for a control circuit
Breaker for inverter
Inverter
Breaker for a control circuit Emergency operation keyBreaker for pump power
& Overload protector
Magnetic contactor for pump operation
Magnetic contactor for pump operation
Breaker for pump power
& Overload protector
Breaker for inverter
Terminal block
Terminal block
Inverter Emergency operation key

8
Installation
8
Check whether products are complete or not!
■Ascertain the same product as you’ve ordered by a name plate and perhaps, if any, damage on delivery.
■Ascertain all components of pumps are complete. (refer to the structure of products)
Warning
A booster system is connected to a pressure tank which has proper capacity and is connected to
the discharge manifold. Especially, the step control type must use a pressure tank, otherwise, it
could cause failures by severe pressure fluctuation and frequent repetition of the start and stop.
8.1)Install location
• A booster system is for the indoor usage, nevertheless, if installed outdoor, keep the system from rich, wind and extreme temperature.
•The suction of a pump should be pressurized. (recommended suction pressure : 0.2 ㎏f/㎠)
Caution
Water level of a reservoir always keep higher than the top of a pump’s suction part to avoid dry running.
Keep over min. pressure at the suction of a pump.
Especially, must vent air after cleaning a reservoir entirely! And fluctuation of the suction
pressure should be below 1.0 ㎏f/㎠!
• Install where to be without direct sun light, dirty & humidity and corrosive and inflammable gas whereas, keep pump from
where to have good ventilation.(Admitted surrounding temperature is 0 ~ 40℃.)
• Install the pump in an easily accessible position to faciliate later inspections or maintenance. Make booster system
handled by a qualified personnel.
• Install where is close to water source and the length of a suction pipe should be short.
• If there is a possibility to be frozen to burst, use special complements to avoide freezing.
Warning
Obviously, make facilities for drain to avoid submergence damage by water leakage on
installation, replacement, repair, and pump’s failure!
8.2)Plumbing
• Pump must remain free of stress from adjoining pipework.
• Make a suction pipe short and not bent as much as possible.
• Use a strainer for prevent pumps from a foreign matter interrupting normal pump operation.
• Recommend to attach flexible joints or valves at a suction/discharge pipe conveniently to disassemble.
• Recommend to attach a flow pipe at a discharge pipe for conveniently checking.
• Equip device to avoid water hammer at discharge pipe.
Warning
Enlarge a suction pipe over one level more than standard in case suction is over 10m or bent over
two times. If not so, the fluctuation of discharge pressure could be severe or the protector of dry
operation doesn’t work at suction side. Also, do as the above in case that electric valves attach
to discharge or water demand severely!
Caution
8.3)Electric wiring
Electric Wiring should be performed by a licensed & qualified electrician. In order to prevent electric shock,
the breaker against electric leakage and the grounding should be installed.
• Electric wiring of the main parts of this production has already been completed.
• The main(R.S.T) and earth(E) should be wired in accordance with the wiring diagram inside of the control unit.
• Don’t connect the earth wire with gas pipes, or it could be the cause of an explosion.
• Please check the following items
①Is a breaker for the electric leakage proper?
②Is the electric wiring proper? ( about the connecting state and the diameter of lines)
③Notice that three terminals of a motor should be firmly assembled.
• Please check the rotating direction of a pump! The direction is marked on a motor or a pump. Don’t run the pump reversely.
• Ovserve pump name plate data.

9
Installation
8
Warning
Don’t diverge pump main power terminal for anther usage.It could cause troubles.
On electric wiring, be careful to keep a control unit from any foreign matters.
Don’t exceed over ±10 % of admitted voltage.
Terminal name Function
E Ground terminal
R, S, T Input terminal for pump power
L1, L2 Input terminal for control power
EC Common terminal for EA, 1R, 2R, 3R (4R)
EA Terminal for signal output of faults, after faults are removed, automatically, return at normal state.
(Normal state:『EC-ER』is open , Fault state:『EC-ER』is closed.)
1R, 2R, 3R Terminal for pump running.
1R ; 1s t pump operation status terminal output (On operating,『EC-1R』is closed.
2R ; 2nd pump operation status terminal output (On operating,『EC-2R』is closed.
3R ; 3rd pump operation status terminal output (On operating,『EC-3R』is closed.
※Wiring could be changed by an option or a power source.
Please, refer to the wiring diagram attached to products for the detail information.
Fig. 7 Wiring diagram (It is a standard. It could be changed by an option)
warning
Wiring lines has already been wired.
Please refer to the wiring diagram
1s t pump
Alarm for fault
User Scope
Ground
2n d pump 3r d pump
EC EA 1R 2R 3RE R S T L1 L2
~ ~
Ground
terminal
Input terminal of pump supply power (standard: 3 ~ 380V, 50Hz)
Input terminal of control supply power (standard: 1 ~ 220V, 50Hz)
Common terminal
Terminal for signal output of faults
(potential-free, 1a contact rating : AC 250V/5A)
Terminal for pump running
(potential-free, 1a contact rating : AC 250V/5A)

10
Installation
8
8.4)Connecting electric rods for detecting the water level in a suction reservoir(Option)
Install a electric rod as shown in the fig.8 for detecting the water level in a suction
reservoir to avoid dry running.
(A electric rod is set by a user. If an electric rod is not required,
『FC-F1』should be connected with a wire. Otherwise, it is impossible
to operate system because the system recognizes as no water in a
reservoir.
•If the water level down below a electric rod(F1) for detecting water
shortage (D.W.S), a system recognizes as the dry operating state.
And the『ERROR』lamp blinks and, Pumps stop in sequence.
(At that time, if checking『ERROR MESSAGE』,『E.dr』(dry operation)
is displayed.
•In order to return to the normal state, go up the water level until
a electric rod (F2) detects the normal water level (N.W.L).
8.5)Dry running protector (Option)
The wiring of dry running protector has already been completed in the factory.
Warning! On the improper suction condition, an electric rod could work abnormally.
Before installing, please check whether the suction condition is proper or not!
This protector may be assembled inside or outside of a control unit.(It is different to use what kind of models.)
Caution
( The place impossible to use an electric rod )
If a suction pipe is too long or bent too many times, the function against dry operation
does not work normally, because air is suctioned together with water on operating.
If abnormal noise is detected at the suction, stop the system, and after improving the
suction condition, operate the system again.
Don’t use the system at the place where air is apt to be suctioned with water.
If not, the components for rotating are apt to be broken.
Fig. 8
FC F1 F2
Normal
Water
Level
Water
Shortage
Level
Suction
Reservoir
At the suction, an electric rod is assembled for avoiding dry operation
A-type
An electric rod
Bushing for air vent
A key for air vent
plug
(Caution to miss it)
B-type
A kit for avoiding dry operation.
Connect two line of a electric rod
to a terminal for『Electric rod』
Fig. 9 Dry running protector Fig. 10 circuit board of dry running protect

11
Operating principle
9
9.1)Step control type
According to the shifts of water demand, the booster system controls numbers of constant speed pumps to satisfy the
required water demand. Absolutely, connect a pressure tank to a outlet pipe to avoid severe on/off repetition.
•According to the water demand, the pressurized water in a tank is supplied and if the discharge pressure down below
the on-pressure which have been already set, the pump which was stopped for longest is started to satisfy the water
demand.
•Nevertheless, if the water demand is still increasing, the other pump runs sequentially for satisfying the water demand.
•If the discharge pressure approaches to the off-pressure by decreasing the water demand.
The pumps which is running for longest is stopped.
•A pump should be stopped in the minimum operating time and the stop interval time.
< example of 3pumps >
①One of pumps is on/off. (One of 3pumps is on by turns)
②One of pumps is on. (As water capacity is increasing, one of1,2&3 is on continuously)
③One or two of Pumps is(are) on (One or two among 3pumps is(are) on by turns.)
④Two of pumps are on(As water capacity is increasing, two of 3pumps are on continuously)
⑤Two or three of pumps are on/off (two or three of 3pumps are on by turns.)
⑥Three pumps are on (As water capacity is increasing, all pumps are on continuously)
Operating by turns and on/off repeatedly
- Pump stopped for longest, is on
- Pump working for longest, is off
Pump on working, continuously work.
󱈻
Pressure
Capacity 󱈺
Off-pressure
On-pressure
Supply
the water
In a pressure
tank
Pump 1
operation Pump 1 operation
Pump 2 ~ 4
operation
(in sequence)
Water demand increasing
Water demand decreasing
① ② ③ ④ ⑤ ⑥

12
Operating principle
9
9.2)Inverter control type
According to the water demand, booster system control the pump speed. At maximum. speed, if not satisfying the water
demand, constant speed pumps are started to satisfy the water demand.
•According to the water demand, the pressurized water in a tank is supplied and if the discharge pressure goes down
below the on-pressure which have been already set, VSP’s speed is increased for satisfying the water demand.
•If the discharge pressure does not approach to the on-pressure at maximum. speed, the CSP that was stopped for
longest, starts.
•If the discharge pressure is over the off-pressure by decreasing the water demand, VSP’s speed is decreased. If the
discharge pressure is over the off-pressure at minimum. speed, the CSP that is running for longest is stopped.
Additionally, VSP is stopped at the zero flow.
•A pump should be stopped in the minimum operating time and the stop interval time.
•If VSP is running continuously for the set time, VSP is changed from current pump to next order pump after all pumps
are stopped.
•VSP’s alternation
BF Series : After all pumps are stopped, VSP ( Pump which is controlled by a inverter) is changed to
another pump.
BI Series : The inverter can control 1st or 2nd Pump. After the designated time, VSP is automatically changed to
next order pump and then former VSP runs as CSP.
If the schedule mode is available. The on-pressure is automatically changed at the designated time (BI Series).
< example of 3pumps >
①Only VSP is operating
BF Series (at zero flow, one of 3pumps is on by turns)
BI Series (at zero flow in the designated time, one of #1 & #2 is on by turns)
②1VSP and 1CSP are operating
BF Series (one of 3pumps is a VSP, one is a CSP –alternation operating )
BI Series (one of #1 & #2 is a VSP , pump#3 is a CSP )
③1VSP and 2CSP are operating
BF Series (one of 3pumps is a VSP, 2pumps are CSPs )
BI Series (one of #1 & #2 is a VSP, 2pumps are CSPs )
Only VSP operate
- The speed of VSP is adjusted according
to capacity
VSP(1set) and CSP operate
- The speed of VSP is adjusted according
to capacity
- CSP(over 1pump) is running
󱈻
Pressure
Capacity 󱈺
Off-pressure
On-pressure
① ② ③
*VSP : The pump is operated with an inverter
*CSP : The pump is operated without an inverter

13
Commissioning
10
Warning Close the door of a control unit on operating for avoiding electric accidents by high
voltage and hazards caused by the water leakage of pumps and pipes.
Besides, electric appliances around a system should be treated in the same way.
Caution Care not to block the motor ventilator with foreign materials on operating.
It could cause a fire, damages of a product.
10.1)Initial operating order
①Check a main power breaker and a protector capacity
②Check the cable square of main power.
③Check a main power voltage.
④Check connecting state of pipes and electric cables.
⑤Check water level in a suction reservoir.
At each pump, close a isolating valve in the suction and
release a air vent plug and slowly open a isolating valve.
Water and air come out together.
If air vent sufficiently, fasten the plug again and open the isolating valve completely.
(The operation with a isolating valve close could cause dry operation and troubles.
①Supply power ( Pump power / Control power )
②Turn on all breakers (MCCB & CP) in a control unit.
At that time,『Emergency operating key』should be off.
If the emergency operating key turns on, only the selected pump operates continuously.
(it is impossible to operate automatically at this situation.)
By the『Emergency operating key』, check the rotating direction of a pump as operating each pump
in a short term. the rotating direction of a pump is marked on the motor or the pump. If the direction
is reverse, replace two of pump power lines (R.S.T).
(If the『Emergency operating key』is on, the selected pump operates and the control circuit is off.
Therefore, after checking the rotating direction, let the『emergency operating key』be off for the
automatic operation.
Caution When wiring electric lines again from a control unit to motors, must keep the
same order as before. If not, the rotating direction under a Inverter control
could be different from that under manual operation. It will cause troubles.
Set operating data for the automatic operation.
(The setup of operating data for each items refers to『Operating data and Setup』
(★, the mark is adapted to a inverter control type.)
①Essential operating data :
On-pressure, Off-pressure, Minimum speed (★), Shut-off pressure
②Ancillary operating data :
Discharge pressure (For resetting the zero point of a pressure transmitter).
Max. pressure (For stopping a system in order to protect from severe overpressure).
Delay time (For avoiding frequent on/off).
(★) Control type (For changing the inverter control type to the step control type).
If pressing the『AUTO/ STOP』key, the left lamp is on and the system is operated in accordance
with operating data. If pressing again the『AUTO/ STOP』key, the left lamp is off and the system
is stopped. Please, check operating state and whether it work normally or not.
At initial operation, Must vent the air which stayed inside pipes or pumps as opening an air vent plug.
If air does not vent sufficiently, even if opening a tap, water could not come out.
On operating, check whether pressure, vibration, and noise are normal or not.
Fig. 11
Motor
supporter
Air vent
plug
Ready to operate
Air vent
Supply power
Check the direct
of rotation
Install operating
data
Automatic
operating

14
Commissioning
10
10.2)Automatic operation
The system is designed to automatically operate by the set operating data.
After properly setting the operating data, press the『AUTO/ STOP』key, and the indicator lamp is on and the system
operates in“auto operation”mode. press The『AUTO/ STOP』key again, and a indicator lamp is off and a system is in
“stop”mode. (About the automatic operation of a system, refers to“Operating principle”)
(In case of a inverter control type,“automatic operation”does not work on Min.speed set mode.
Must cut off『Min.speed set mode』the“automatic operation”.)
Warning
Previously should change the pre-loading pressure of tank in case of changing
on-pressure. It is impossible to check the pre-loading pressure on operating.
Therefore, after stopping a system, check it out. (pre-loading pressure in a tank
refers to“maintenance”)
10.3)Emergency operation (E.O.)
In case of the initial operation for checking the rotating direction of a motor or the fault of
a circuit board, it is possible to operate each pump manually.
In that case, as to change to“Emergency operation key”mode,
it could operate pumps manually.
If turning on the“Emergency operation key”, a control circuit is off and a selected
pump which is on, continuously operate. (No automatic control)
※For the automatic operation, all emergency operation key should be off.
10.4)Inverter manual operation (in case of the inverter control type)
For the setup of『shut-off pressure』and『shut-off velocity』, the system could be operated manually.
If pressing a『SPEED SETUP』key, an arbitrary pump start to operate at low speed. On automatic
operation,『SPEED SETUP』key is not on.
After a『AUTO/ STOP』key is off,『SPEED SETUP』is possible to be set. At that time, the value is displayed
on a indicator window is not“speed”but“discharge pressure”. The speed is displayed as the frequency value on the
indicator window of a inverter in the control unit.
(If the frequency is 60.0, the speed value is 100 percent.)
At this mode, if pressing the『▲』key, the speed of a inverter is increasing and the speed of a pump is
also increasing. Oppositely, if pressing the『▼』key, the speed is decreasing.
※If operating a pump at too low speed, overheat or severe vibration could be happened.
At that case, stop a pump or go up a speed.
Fig. 11
『AUTO/ STOP』key is a toggle type.
AUTO
STOP
※Indicator is off
:“STOP”mode
AUTO
STOP
※Indicator is off
:“AUTO”mode

Fig. 13 membrane tank
15
Maintenance
11
Warning
When repairing or checking the system, must cut off all powers and make pumps
stop for safety. On automatically operating, there is hazards that a pump could be
operated abnormally.
11.1)General check
•In case that on-pressure, off-pressure, electric current and noise are higher than normal value, refer to『trouble
- shooting』.
•If a mechanical seal is normal, there is little not leakage.
If the leakage is too much, replace it with new one.
•Check up leakage and damage of pipes.
11.2)Adjustment of the on-pressure
adjust the on-pressure only in case that the discharge pressure is too high or low.
11.3)Maintenance in the winter
In the winter, when not using for long time to avoid being frozen to burst, use thermal insulations for pipes and
manifolds or drain water from pumps and manifolds through plugs.
11.4)Charging the pressure tank.
On checking up the pressure tank, if the pre-loading pressure of a tank is too low, charge air as the following way.
After completely draining the water in the tank, open the cap on the top of a tank and charge air with a air
compressor. Be careful not to charge the oil, which is mixed with air, to the pressure tank.
If the pre-loading pressure is too low, the pressure tank does not normally work. Oppositely, if the pre-loading
pressure is higher than the on-pressure, the on/off of the pump is too much repeated. in that case, vent air as
pressing a part popped out in the center of a air valve.
※The pre-loading pressure is set as the 90% of on-pressure or“on-pressure - 0.5㎏f/㎠ ”(deviation ±10 %)
Air Valve
Valve Stopper
Cap

16
Maintenance
11
Warning
11.5)Checking the control unit
Don’t arbitrarily change the structure and installation except the operating data.
The personnel checking the control unit must have the appropriate qualifications.
Must turn off the main power before the inspection or the maintenance of a control unit.
•Carefully check up the following items periodically.
①The cooling state of a inverter (only Inverter type).
②The overheat, the abnormal smell, the color deformation of a part in a control box.
③The state of wiring.
④The vibration and the noise.
•Never do a insulation test nor a withstand voltage test. It could breakdown the semiconductors in the control
unit.
•The static electricity that is occurred by touching, damages the electric circuit. Therefore, must handle the
circuit board with care.
•In a inverter type, even after the main power has already been off, It takes 3~4 minutes to completely
discharge a inverter. Therefore, wait until the inverter is completely discharged.
•After turning off the power, check the rust of bolts and nuts. Tighten loosened screws and nuts if you need it.
•In case of a inverter type, when there is a foreign matter by the cooling fan of a inverter, cooling capacity
becomes down. Therefore, removes it, after turning off the main power and completely discharging the inverter.
•check up the rotating troubles of cooling fans, the troubles of magnetic contactors, the abnormal noise, and if
there is any trouble, replace it with new one.
11.6)The replacement time of major components
The expected life of each component is calculated on the normal operating condition. Replace the component by the
following criteria.
•When disposing a printed circuit board or electric components, observe the relevant law.!
•Our product include a printed circuit board. Don’t dispose it at a common garbage can!
Classification Component Life time Criterion of replacement
Pump and motor Mechanical seal 1year Excessive leakage
O-ring and Gasket Each time Whenever disassembling
Motor bearing 3year Abnormal noise or severe noise
Mechanical parts Pressure transmitter 3year When output signal is not correct
Pressure tank 3year Abnormal operation (pressure fluctuation)
Control unit Magnetic contactor 3year Severe contact’s damage or abnormal operation
Relay 3year Severe contact’s damage or abnormal operation
Electrolytic Condenser 3year When capacity is reduced
Inverter cooling fan 2year Abnormal noise
Circuit board 3year Uncertain performance

17
Trouble - shooting
12
12.1)General faults
•Open a valve
•Vent air through a plug
•Repair or replace
•Exchange two of three main power terminals in a
control unit
•Compensate water to a reservoir
•Repair or replace
•Change a operation mode to the“AUTO”
•Repair or replace
•Turn on the MCCB of the pump
•Reset the on-pressure
•Reset the off-pressure
•Replace
•Change the operation mode to『AUTO』
•Repair or replace
•Repair or replace
•Repair or replace
•Repair or replace
•Repair or replace
•Repair or replace
•Reset a on & a off-pressure
•Recharge air to the required pressure.
•Repair pipes (remove air) or install the PRV (pressure
reducing valve)
•Reset a on & a off-pressure
•Recheck water demand (Capacity and head)
•Repair or replace
•Repair or replace
•Repair or replace
•Repair or replace
•Repair or replace
•Repair or replace
•Repair or replace
•Refer to『12.2』(next page)
•Reduce the pipe’s length & enlarge the diameter of
pipes.
•Check pre-loading pressure of a tank and adjust it.
•Install a pressure reducing valve and enlarge
capacity of a pressure tank.
•A discharge valve is closed
•It is not enough to vent air
•Trouble in a pump/ a motor
•A motor rotate reverse
•Water level of a reservoir is low
•Trouble in a pressure transmitter
•Operation mode is in the“stop”.
•Trouble in wiring (Short or snapping)
•Pumps are unselected
•On-pressure is low
•Off-pressure is high
•Trouble in a pressure transmitter
•the Operation mode is『Manual』or
•『Emergency』
•Trouble in a control unit
•leakage in pipes
•The performance of pump is low
•leakage in pipes
•leakage in a check valve
•The gap of on & off-pressure is small
•Trouble in a pressure tank.
•Pressure fluctuation in pipes
•On-pressure is low.
•The selection of a system is fault.
•Pump’s performance is down.
•Trouble in a control unit.
•Trouble in a pressure transmitter
•Trouble in a pump or a motor.
•Short between pumps and power.
•A circuit short or a damaged breaker.
•Power lines are in a short
•Refer to『12.2』(next page)
•A suction pipe is too long or the diameter
is too small.
•Operating without a pressure tank or the
pre-loading pressure is incorrect
•Electric valve works or shifts on water
demand is severely large.
RemedyCauseFault
Even if a tap is open,
water does not flow.
Even if all taps are
closed, pumps don’t stop.
Pump is running without
water flow.
Vibration of pump is
Abnormal.
Water doesn’t reach to
the highest tap.
Pumps don’t work by turns
or in parallel.
The M.C.C.B in a control
unit is tripped.
Error lamp on the window
Is blinking
Pressure fluctuation
is severe

18
Trouble - shooting
12
Normal state(No fault)
Pump 1(2,3,4) electric troubles
•overload or over current
•Phase failure
•A motor power short
•A breaker is off
•Troubles in a pressure transmitter
•Wires is cut off
Dry running operation (water lack in
a suction reservoir)
•No water in a suction pipe
•The water level of a reservoir is
lower than the setting value on a
electric rod for detecting
Max.(or Off)pressure setting
Error
[Off-pressure≥Max.pressure-0.2]
Excessive pressure in the discharge.
•Max.pressure value is low.
•Line short in a pressure
transmitter.
•Electronic valve works
•Shift of water demand is large
•Trouble in the pressure tank
•Inverter power is off.
•Trouble in a inverter.
12.2)Fault message and Remedy
When the fault indicator lamp blinks or a fault contact works,
press a『ERROR MESSAGE』key and a fault history is displayed on
the window.
When several faults are happened, as pressing the ▲, ▼key,
a fault history is displayed orderly on the window.
Refer to the following table for checking a fault history.
( Only a optional
product )
( Only inverter )
Fault Cause Remedy System states
•Remove causes of
overload(current)
•Check,replace cables or contacts
•Check,replace cables
•Turn on a breaker
•Check, replace the pressure
transmitter
•Check, replace wires
•Keep the water level over required
values by supplying water to a
reservoir.
•Reset max. pressure
•Reset off-pressure
•Reset max. pressure.
•Check,replace the pressure
transmitter.
•Remove external causes.
•Check a membrane tank, and
adjust or replace it.
•Install PRV at discharge
•Turn on a inverter power
•Refer to“Instructions of Inverter ”
A trouble pump stop. Other
pumps operate automatically.
EP1 : No. 1 pump is abnormal.
EP2 : No. 2 pump is abnormal.
EP3 : No. 3 pump is abnormal.
EP4 : No. 4 pump is abnormal.
(Manual recovery)
System is in a stop mode.
(Automatic recovery)
System is in a stop mode.
(Automatic recovery)
System is in a stop mode.
(Automatic recovery)
System is in a stop mode.
(Automatic recovery)
System is in a stop mode.
(Automatic recovery)
When a overload protector (EOCR or thermal relay) works by a overload or phase failure,
After removing trouble causes, turn on the MCCB for a normal operation.
When inverter protecting function works, remove trouble causes and press“RESET”
for recovering to the normal operation mode.
ERROR
MESSAGE
▲
▼

19
Trouble - shooting
12
12.3)In a trouble, system states and recovery.
1) In a trouble, a protecting function works,and outputs a fault signal.
In this case, check the『ERROR MESSAGE』, and remove the causes.
If not finding trouble causes or it repeatedly happens, rapidly contact to our agency or factory.
No Fault state Abnormal system states Recovery and Error message
1“ERROR”lamp blinks Normal :『ERROR』lamp off When removing causes, automatic recovery
Abnormal :『ERROR』lamp on
2Output fault signal Norma : EC-EA terminal open When removing causes, automatic recovery
(potential-free,1a contact) Abnormal : EC-EA terminal close
3Storing『ERROR MESSAGE』Press a『ERROR MESSAGE』key,
messages are displayed on a window.
2) Method to erase the error messages.
①If a fault happen,the relevant error messages are stored into the ROM.
The stored error messages are not erased even if a system is turned off. Additionally, after removing faults’
causes and recovering a system to the normal mode, the error messages remain without erasing it directly.
(“Fault”lamp and“fault signal”are recovered automatically after removing causes.)
②When wanting to remove the error messages, press a『CANCEL』key at the mode to display the relevant fault
causes.
③Even if pressing a『CANCEL』key, the error message is not removed. it means the faults’cause isn’t
removed.
④In case that the error messages are several, as pressing the ▲, ▼key the faults are displayed orderly.
Even if removing fault causes, error
messages are not automatically erased.
Can erase the message by pressing
『CANCEL』key (Even if turning off a system,
error messages remain a memory without
erasing it.)
A pressure transmitter was in trouble. Press a『CANCEL』key, and can remove the
error message after removing the causes.
CANCEL
󱉒
STATE
ERROR
MESSAGE
▲
▼
STATE
ERROR
MESSAGE
▲
▼
Example to remove the error messages