Xylem Lowara GHV1 User manual

Break Tank Cold Water Booster Sets
GHV1-4 Hydrovar Variable Speed
1
Operating, Installation and Maintenance Instructions
EC Declaration of conformity
Xylem Water Solutions UK Limited declare that the GHV Booster set conforms to the requirements of the
Machinery Safety Directive 2006/42/EC.
Electromagnetic compatibility (EMC) Directive 2014/30/EU
Conforming to the UK Health & Safety Requirements 2008 No. 1597
Water supply (Water fittings) regulations 1999
Signed: Position: Engineering manager Date: 20-04-2016 Revision B
Clive Willmott
Introduction
This leaflet contains information to enable the safe installation and operation of the products mentioned.
The following instructions must be read and understood by all persons responsible for the installation, operation
and maintenance of this product.
Warning Symbols
Safety instructions where noncompliance would affect safety.
Safety instructions where electrical hazard is involved.
Safety instructions where noncompliance could cause damage to the equipment.
Instruction for safe use
This product has been designed for boosting cold water in potable water installations to the
operating conditions shown.
This product should not be installed until this leaflet has been studied carefully and understood.
Handling, transportation and installation of this equipment should only take place with the proper
use of lifting equipment. This product must be stored in a frost-free dry environment.
50Hz 2900 min-1 LpA (dB+/-2) SV Pumps
P2 (KW) 1 Pump 2 Pump 3 Pump 4 Pump
2.2 <70 <70 <70 <70
3 <70 <70 <70 <70
4 <70 <70 <70 <70
5.5 <70 <70 <70 <70
7.5 71 74 76 77
11 - 22 73 76 78 79
Noise Emissions
Operating limits Fluid temperature 0˚C to 40˚C
Ambient temperature 0˚C to 40˚C
Operating pressure Max 8bar, 10bar, 16bar depending on set type
Protection class Motor and Electrical panel IP55
Hydrovar IP55

GHV 20
/
10SV06F022T
/
M
/
2000F
2
Identification code
Series
10 = 1 pump
20 = 2 pumps
30 = 3 pumps
40 = 4 pumps
Set WRAS approval
M = Single phase
Set supply T = Three phase
No digit above 2.2kW Three phase
Pump type & motor supply
Installation
The cold Water booster set is despatched mounted on a wooden pallet and covered in a protective film, it is
recommended that the unit be retained in the protective packaging until the product is to be installed. The unit
will arrive pre-packaged and wired ready for installation. This product has been fully run tested
at our works under simulated site conditions. The unit should be thoroughly checked for
physical damage that may have been caused during transit. If the unit is found to have
damage it must be reported immediately and should not be installed. The unit should be sited
in a ventilated, dry frost free position also ensuring adequate room for general maintenance
and service. The set should be fixed in position directly to the floor, if vibration separation is
required then cork mats should be used supplied by others.
Generally the water tank is constructed to have a weir slot (Cat 5) as required by the water bylaws to prevent
back flow contamination, if the inlet ball valve suffered a catastrophic failure the overflow may not be able to
keep up with the inflow in which case excess water will be ejected through the weir slot and onto the plant room
floor, if this is not acceptable then consideration should be given to fitting the break tank set onto a tray with
overflow to drain.
Electrical connections
The electrical connections must be carried out by a competent electrician in accordance with local regulations.
The cable used for the incoming supply must be of adequate size to carry the motor full load
current of all pumps as they are able to operate at the same time. Motor
ratings are shown on the set duty plate. All non power cable should be limited to 1.5mm².
All connections must be made using the appropriate wiring drawings for the equipment being
installed; with particular attention being paid to the supply voltages. The supply voltage is shown
on the set duty plate.
Never operate this product with isolation panels removed or the control panel door in the open position.
These Sets are fitted with variable speed drives which include large capacitors so wait at least 8 minutes
after the supply has been removed before opening or removing covers.
It is essential that this equipment is earthed to the building earth system.
All metal parts must be earth bonded directly to the building earth system.
Nominal power
(kW) 1 pump
GHV10 - 20 1 single phase
Absorbed current (A)
1 x 230V
GHV10 - 20 three phase
Absorbed current(A)
3 x 400V
GHV30 three phase
Absorbed current(A)
3 x 400V
GHV40 three phase
Absorbed current(A)
3 x 400V
kW GHV10 GHV20 GHV10 GHV20 GHV30 GHV40
0.75 6.3 12.6 - -- -
1.1 8.14 16.28 2.36 5.0 7.4 9.9
1.5 10.8 21.6 2.97 6.2 9.4 12.5
2.2 15.7 31.4 4.33 9.1 13.6 18.2
3 6.07 12.7 19.1 25.5
4 7.63 16.0 24.0 32.0
5.5 10.4 21.8 32.8 43.7
7.5 14.0 29.4 44.1 58.8
11 20.3 42.6 63.9 85.3
15 26.0 54.6 81.9 109.2
Electrical data GHV20/30/40
UK WR
//
United Kingdom
Tank size & mtg type
F=Frame B=Base
Never run pumps dry
Ensure the pumps are filled with water before switching the electrical supply on.

Water supply connection
Connect the incoming water supply to the break tank ball valve. The outlet of the tank will already be connected
to the booster set suction manifold. The tank will generally include a class AB air gap (Category 5 protection) the
tank will also include a low level float switch connected to the booster set to protect against dry running. Connect
the 22mm warning pipe (where fitted) to a position where a discharge will cause a nuisance and be remedied.
Connect the overflow pipe to drain. When the tank has been filled check the water level and adjust ball valve as
necessary.
Ensure the tank is thoroughly flushed through before the set is put on line.
It is the responsibility of the installer to ensure that the overflow is able to keep up with the
incoming water volume, if this is not the case then a pressure reducing valve should be fitted to
reduce the incoming mains water volume.
Discharge pipe work
The discharge pipe work can be connected to either end of the booster set, ensure the blanking cap is fitted to
the end not used. A flexible connector fitted between the booster discharge manifold and the system connection
pipe will help prevent the transmission of noise/vibration. An isolation valve should be provided between the
booster discharge line and the system to aid maintenance. The discharge pipe work should be sized to achieve
a maximum velocity of approximately 2.5m/s.
Pressure vessels
GHV variable speed booster set can operate with relatively small vessels; each set is supplied with 1 x 24lt
vessel for each pump which is more than adequate for the set to function correctly. Larger vessel can be added
if required. If stand alone vessels are added they should have an isolation valve and drain cock fitted to allow
the vessel to be isolated from the system and drained to check the pre-charge pressure.
Hydrovar basic setting details
All standard GHV booster sets are arranged for all the Hydrovars to be set as masters so if one inverter fails
the next Hydrovar will take control. The booster set will come with all basic settings for Cascade
serial mode (multi-pump applications) set as standard. The only parameters that may need changing
are the SET POINT (parameter 2) this will normally have been set to match the pumps fitted but can
be adjusted by pressing the up/down button and the AUTO START (parameter 8) which should be
set to AUTO START see flow chart below for details. The settings entered will
be automatically entered in all remaining pumps. Hydrovar errors are logged and time tagged to
enable sequence of errors to be checked.
NOTE: Never set the maximum frequency above 50Hz as this will lead to inverter overload.
For more advanced settings please see the Hydrovar technical manual.
When the unit is first powered up the default setting will be Auto start off.
Minimum threshold
Minimum threshold can be set (Parameter 605) to a low pressure value which can be used to stop the set if the
pressure falls to this low limit (typically 1 bar) for a period of time (typically 8 seconds) set in (parameter 610).
Note: This time delay also acts on the low water level input.
3

4

5
Slow fill mode
All Hydrovar sets are fitted with slow fill controls to help prevent excessive pressures being excreted on system
pipe work when the set comes back on line after a power outage or low water condition.
Slow fill operation
When the set powers up or comes back on line after a low water condition it will automatically inhibit all pumps
except pump 1 which will ramp up slowly and maintain a set point approximately equal to the height of the build-
ing (system pressure – 2 bar) it will remain at this set point until the delay timer normally set for two minutes (ad-
justable) times out and resets the Hydrovars to set point one allowing pump one to speed up to the normal
system set point and release all other pumps to cascade in as required.
Commissioning
With the main power isolated check:
1.The break tank feeding the set is filled with water.
2.The set/system vessels have been charged with Nitrogen to the correct pressure (set point -0.2 bar).
3.Open suction line isolation valve where fitted.
4.Open suction and discharge pump isolation valves.
5.Close main discharge isolation valve.
6.Open the pump vents at the top of each pump.
7.Allow all air to escape until water flows freely.
8.Close pump vent valves.
9.Open discharge valve.
10.Ensure all vessel valves are open.
11.Switch the main power supply on.
12.Check the set point is as required.
13.Switch the inverters to the on position by pressing the up button Note: only 1 pump will be allowed to run in
the first two minutes of power up after which all other pumps will be released to run.
Once the system pressure has been satisfied the last pump should ramp down and after a short while
stop completely until a demand is placed on the system again.
Operation
The booster set is designed to maintain a constant system pressure with varying flows.
Each Hydrovar head has its own 4-20ma transducer which monitors the system pressure at all times.
If one Hydrovar or transducer fails the next Hydrovar will take on the master function. All Hydrovars talk to
each other through a RS485 serial coms link. Each Hydrovar head is fitted with four function keys: Up/Down
Left/Right these are used to navigate through the parameters and change as appropriate. Three LEDs are
provided to indicate: Power-Run-Error.
When a demand is placed on the system, water will be supplied from any vessels that are fitted to the system,
once this supply is depleted the system pressure will start to fall, when the pressure falls 0. 15 bar (par 0510)
below the system set point the first Hydrovar will start to ramp up to maintain the set point, if demand in-
creases and the first Hydrovar reaches maximum speed and again the system pressure falls 0.15 bar blow
set point the next Hydrovar will be called in to ramp up and assist the first pump, the set point will have been
raised by 0.35 bar (par 0505) to give a differential between pumps. All the time demand increases, further
Hydrovars will be called in to assist until all Hydrovars are running. When demand reduces the last Hydrovar
to be called in will start to ramp down and eventually stop, if demand continues to decrease the next Hydrovar
will start to ramp down and stop, this will continue until all Hydrovars have stopped. The next time the
pressure falls the same sequence as above will operate except the first Hydrovar to operate will have been
rotated so all Hydrovars have even usage. See Fig1 below
On sets where a Jockey pump is fitted the sequence will be for the jockey pump to be the first to operate on
all occasions and it will not be connected to the main Hydrovars with a coms link.
If a low level in the break tank occurs all pumps will be stopped until the water supply has been reinstated,
the pumps will then be automatically released to resume normal operation.
The booster set has a remote inhibit facility allowing the set to be stopped/started from a remote source (open
contact to inhibit) See electrical drawing for connection details.

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Volt Free Contacts
Volt free Change/over contacts are available for Run & fault conditions for each Hydrovar. See electrical drawing
for connection details.
Remote inhibit
A remote normally closed contact can be used to remotely inhibit the booster set. (open to inhibit) See electrical
drawing for connection details.
Caution
This booster set is an automatic machine; the pumps may start up automatically without prior
warning.
The set contains pressurised water; reduce the pressure to zero before servicing.
List of main components
Item Component
1 Electric panel
2 Pump suction isolation valve
3 Pump discharge isolation valve
4 Vessel isolation valve & drain
5 Discharge manifold
6 Suction manifold
7 Non return valve
8 Pump
9 Hydrovar inverter
10 Vessel 24lt
11 Flexible Connector
Note:
The use of spare parts not supplied by
Lowara will invalidate the guarantee.
Pump operating sequence
P1 P1+2 P1+2+3
Fig 1.
SV Pump Set See specific pump O&Ms for more in depth pump detail

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Maintenance
Routine check (6 monthly intervals)
1. Check all pumps produces the correct pressure.
2. Check that the pump operates without undue noise or vibration.
3. Check the break tank is clean and that the correct water level has been maintained.
4. Check that all screws are tight on electrical components.
5. Check that the earth connections are tight and making good contact.
6. Check that the gas pre charge is at the correct pressure, this should be done by isolating
the vessel from the system and draining water out of the vessel via the isolation valve drain point.
Once the water has been discharged, a tyre gauge can be connected to the pre charge valve to display the vessel
pre charge pressure. Recharge as necessary with Nitrogen or dry air.
Any other expansion vessels connected to the system can be checked in the same manner.
Clean any filters that may be connected to suction/discharge lines and ensure the mesh is in good condition.
Yearly intervals
Drain the break tank and using clean water only, clean all internal surfaces using non-metallic equipment and
tools. Remove any debris found in the tank. Check and clean filters in overflow/warning pipe (If accessible)
Refill the tank with clean fresh water, disinfect and leave to stand for 60 minutes. Test water for correct PPM
levels.
Item Component
1 Electric panel
2 Pump suction isolation valve
3 Pump discharge isolation valve
4 Vessel isolation valve & drain
5 Discharge manifold
6 Suction manifold
7 Non return valve
8 Pump
9 Hydrovar inverter
10 Vessel 24lt
11 Flexible Connector
List of main components
HM Pump Set
Note:
The use of spare parts not supplied by
Lowara will invalidate the guarantee.
See specific pump O&Ms for more in
depth pump detail

Xylem Water Solutions UK Limited
Millwey Rise Industrial Estate, Axminster, Devon EX13 5HU - UK
Tel: [phone] Fax: [phone]
e-mail: [email protected]
www.lowara.co.uk www.xyleminc.com
Lowara is a trademark of Xylem Inc. or one of its subsidiaries. © 2016 Xylem, Inc.
Lowara reserve the right to make modifications without prior notice.
Code UKLIT0141 P04/16
Fault Possible Cause Remedy
Pump fails to start
Power supply failure
Control panel fuse blown,
MCB tripped
Remote inhibit active
Low water level
Reinstate incoming power supply
Replace power supply fuse
Reset MCB
Turn remote inhibit off
Reinstate water supply
Pump fails to stop
Set point set too high
Manual operation selected
System pressure low due
to large leak
Lower set point
Select Auto operation
Switch unit off until leak is repaired
Pump switches on and off
quickly
Air in system
Vessel pre-chargeincorrect
Purge air from pumps and pipework
Check vessel pre-charge and Charge as
necessary with Nitrogen or dry air
Pump runs but will not
make pressure
Pump air locked
Non-return valve jammed
Incorrect rotation
Passing too much water
Open pump bleed screw and vent pump
Clean/ replace valve
Check pump internal connections
Check system for leaks
Pump overheating Pump partially seized Remove pump and check for
foreign objects
Pump set frequently
starting. (pressure falls
to cut in point)
Newly installed system with
large amount of air in pipe
work
Leaks in system pipe work
Vessel pre-charge incorrect
Bleed system to remove air
Repair leaks
Isolate vessel and pre-charge with
Nitrogen as appropriate
Break tank overflowing Leaking ball valve
Non-return valve letting by
Replace ball valve seal
Replace/clean non-return valve
Pump leaks water
Defective mechanical seal
Undue mechanical stress on
pump
Replace seal
Support the pipe work
General fault finding guide
Disposal
Disposal of this product should be carried out in accordance of local codes and regulation pertaining to the
disposal of waste, including packaging materials.
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