SPECIALIZED PUMP COMPANY INC. Booster Systems · SPECIALIZED PUMP COMPANY INC. 1 1.0 Installation...

SPECIALIZED PUMP COMPANY INC. Booster Systems

System Manual

Version

1.6

S P E C I A L I Z E D P U M P C O M P A N Y I N C .

Booster Systems

© Specialized Pump Company Inc. P. O. Box 3805

Hollywood, Florida 33083 Phone 954.967.2071 • Fax 954.967.2074

Email: [email protected]: WWW.SpecializedPump.com

mailto:[email protected]


Table of Contents

C H A P T E R 1 Installation Receiving Your System Temporary Storage Location Concrete Bases (Pads) Anchoring Electrical Emergency Generator Piping Start-up C H A P T E R 2 Overview System Features Warranty C H A P T E R 3 Model Overview System Piping Pump Types Bladder Tanks Pump Sequencing Overview Control Panel Upgrade Simplex Systems Simplex Temporary Pumps Duplex Systems Pump Sequencing Triplex 3 Systems Pump Sequencing Triplex 1-2 Systems Pump Sequencing Triplex 2-1 Systems Pump Sequencing Quadplex 4 Systems Pump Sequencing Quadplex 2-2 Systems Pump Sequencing Quadplex 1-1-2 Systems Pump Sequencing Quadplex 1-3 Systems Pump Sequencing Penta 5 Systems Pump Sequencing Penta 1-4 Systems Pump Sequencing Penta 2-3 Systems Pump Sequencing Penta 3-2 Systems Pump Sequencing Penta 1-2-2 Systems Pump Sequencing Penta 1-3-1 Systems Pump Sequencing Hex 2-2-2 Systems Pump Sequencing Hex 6 Systems Pump Sequencing Hex 1-5 Systems Pump Sequencing Hex 3-3 Systems Pump Sequencing Hex 4-2 Systems Pump Sequencing Hex 2-4 Systems Pump Sequencing C H A P T E R 4 Protection Devices Overview Motor Fault and Overload Control Fault and Overload Pump Over Temperate Protection Transient Voltage Suppressors (TVS) C H A P T E R 5 Programmable Controller Overview DA-105 PLC DA-05 PLC DA-06 PLC Analog Card LED Status PLC Inputs / Outputs Delay Time Settings C H A P T E R 6 Terminal T1 Connections Terminal To PLC Connections 105 to T1 29 Terminal To PLC Connections 05 to T1 Terminal To PLC Connections 06 to T1 Hybrid System Connections C H A P T E R 7 Operator Controls H-O-A Switches Constant-Variable Switch Main Disconnect PLC-Bypass Switch Time Clock Alarm Display

C H A P T E R 9 Displayed Messages Normal Operation – Lead Pump On Normal Operation – Lag On No Flow Shutdown Displaying Elapsed Time Displaying PSI-GPM Low Supply Level Emergency Generator Transfer Low City Pressure High System Pressure Analog Signal Loss C H A P T E R 9 Option List C H A P T E R 1 0 Dry Contacts Remote Alarm Console C H A P T E R 1 1 Pressure Reducing Valves C H A P T E R 1 2 Pressure Switches C H A P T E R 1 3 Troubleshooting Motors Pumps Pressure Regulating Valves Pump Sequencing (Pressure Switch) Pump Sequencing (Transducer) Pressure Gauges Temp Probes and Purge Valves Transducer Display Programmable Logic Controller (PLC) C H A P T E R 1 4 Programming Identifying your PLC Using Display Buttons to Program Programming the 105 PLC Programming the 05 PLC Programming the 06 PLC Programming the CT Depth System C H A P T E R 1 5 Preventive Maintenance Start up Preventive Maintenance Daily Preventive Maintenance Weekly Preventive Maintenance Monthly Preventive Maintenance Yearly Preventive Maintenance Lubrication C H A P T E R 1 6 Appendixes Appendix A – Time Clock Appendix B – Pressure Switch Appendix C – Transducer Type 1 Appendix D – Transducer Type 2 Appendix E – 105 Program Record Sheet Appendix F – 05 Program Record Sheet Appendix G – 06 Program Record Sheet Appendix H – CT II Program Record Sheet Appendix I – Power Supply Data Sheet Appendix J – Display Data Sheet Appendix K – Analog Card Data Sheet Appendix L – Modem Data Sheet Appendix M – Temp Purge Valve Data Sheet Appendix N – Temp Purge Valve Data Sheet Appendix O – Temp Purge Valve Data Sheet Appendix P – Baldor VFD Appendix Q – AquaVar II VFD Appendix R – AquaVar CPC VFD Appendix S – Expansion Tanks Fiberglass (Non-ASME) Appendix T – Expansion Tanks Steel (ASME)


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1.0 Installation of your Water Booster System 1.1. Receiving

1) Specialized Pump Company performs complete electric and hydraulic tests on the booster system at the factory prior to shipping. Check your system for any signs of mishandling or breakage in transit. If any problems are found notify the carrier immediately.

2) Caution: Never use the motor lifting rings to lift the entire weight of the system. The SPC Booster System and be easily handled

by a forklift or by hoisting by the base

3) Isolators and springs may be shipped with the system .If the system is not to be immediately installed ensure that these components are secured in a safe place

.

1.2 Temporary Storage

1) If your SPC system is not to be installed immediately upon arrival, the system should not be exposed to excess moisture or extreme weather conditions, for this reason we recommend it be kept in a clean dry location

2) The System should be covered during storage and care taken to ensure that debris cannot enter the intake or discharge piping.

1.3 Location

1) Provide an area for installation that would allow a 36-inch clearance in front of the control panel as required by National Electric Code.

2) Ensure there is ample room for removal and servicing of the pumps and motors.

3) Pumping systems do discharge water…there must be a floor drain located adjacent to the booster system. This drain must be

kept clear and clean to receive the various discharges from the system. Inadequate drainage may result in significant water damage.

4) Temporary Pump Systems with the Variable Speed Drive- Must be shelter from weather.

1.4 Concrete Base (Pad)

1) Suggested Concrete Base Size: a. Duplex - Length 44” Width 25” Height 8” Spring Depth 4” Spring Type CT b. Triplex - Length 64” Width 50” Height 10” Spring Depth 8” Spring Type UW c. Quad - Length 80” Width 50” Height 12” Spring Depth 12” Spring Type CT

2) To Determine Springs = Base Length X Base Width X Depth, Assume Pump System weight at ¾ of Total weight of Pad

3) Bases should never be less than 8” Thick

Chapter 1


1.5 Anchoring

If the Optional Inertia Base springs are used: Type UW Spring Flex Mounting: Mounting Max Spring Defl Size Load Const Inches Lbs lbs/in UW-200 125 1001.3 UW-400 400 3031.3 UW-600 700 6201.1 UW-100010609521.1 UW-1300 13001300 1.0 UW-1600 160016001.0 UW-1625 205020501.0 UW-1628 250025001.0 Notes: Foundation to be raised 1” before Spring Flex Mountings are installed

BT Springs Type Max Defl Size Load Inches BT-11 90 1.3 BT-121001.3 BT-131851.3 BT-142651.0 BT-163700.5 BT-174500.5 BT-187000.5

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1.6 Electrical

1) Specialized Pump Company recommends the use of a qualified electrician to comply with the National Electrical Code and local codes.

2) Specialized Pump Company recommends copper stranded wire.

3) Specialized Pump Company systems are prewired and tested prior to shipment. Normally the Only wiring required is the power source Connection to the main power block. An earth ground must also be connected to the terminal lug provided

4) When utilizing the Dry Alarm Relay for remote motorizing of system warnings, ensure that alarm devices activated through these

contacts must not exceed the voltage or current rating listed on the relay

5) When utilizing the Emergency Generator Connection verify that the generator circuit is capable of handling the total number of amps for the control circuit and the pumps selected.

1.7 Piping

1) Connecting pipes of two dissimilar metals will increase the rate of rate corrosion. If incompatible metals are used, Specialized Pump Company recommends the use of dielectric isolation devices be used to prevent electrical corrosion.

2) Specialized Pump Company recommends the use of Flanged rubber sphere isolators for suction and discharge manifolds to further

reduce normal transmitted vibration

3) The suction and discharge piping should be independently supported and aligned properly so that there is no strain transmitted to the pumps

4) All temp purge lines should be piped to a floor drain to avoid flooding

5) Pump Base should be level

6) See Appendix O for Expansion Joint Information

. 1.8 Start Up

1) Once the system is fully installed contact Specialized Pump Company at least 48 hours in advance to arrange for our representative to come out to the site to start the system and training.

2) Note: System must be ready for Start-Up, if not and a second start-up call is required the second Trip will be billed as a normal service call

Chapter 2 S P E C I A L I Z E D P U M P C O M P A N Y I N C .

2.0 Overview 2.1 Specialized Pump Company System Features

1) High Pressure Mechanical Seal Pumps 2) To maintain constant system pressure, regardless of varying flow demands or

suction fluctuations, a pressure reducing valve for each pump. The valves are Watts epoxy coated, self adjusting, pilot operated pressure reducing valves with non-slam, reversing-reversing features, with stainless steel main seats. (except on Full Variable Speed Systems)

3) All Pumps Are Mounted On A Steel Base. 4) The entire assembly will have two coats of top grade marine epoxy paint. 5) Complete electric and hydraulic tests to be performed at the factory 6) The System is complete with all necessary shut off valves, gauges, and

flanges, so repairs and maintenance can easily be completed. 7) Control Panels equipped with the Programmable Controller feature:

a. Digital message/operator interface and display, for all functions and alarms

b. Display module is UL approved and NEMA 4X rated. c. Full system trouble shooting guide, and Help Center with a 24 hour Emergency Contact Phone number within

the display. d. Customer Programmable Features, Pump Alternation, Run Times and Time Delays.

8) The Specialized Pump Company control panel shall include:

a. Circuit Breakers or Motor Circuit Controllers (MCC) b. Magnetic Contactors With Adjustable Thermo Overloads c. Programmable Minimum Run Time Delays d. Programmable Lag Run Times e. Hand-Off-Automatic Selector Switches f. Pump Run Pilot Lights For Each Pump g. Seven Day Programmable Time Clock h. Fused Transformer With 115 VAC Fused Secondary i. Main Power Terminal Block j. U.L. Listed Controller. k. Steel Control Panel Enclosure is NEMA 3R rated and UL approved

2.2 Specialized Pump Company Warranty

1) From Time of Delivery, Specialized Pump Company, Inc. will warrant each water

pumping system against defects in materials and workmanship under normal use and service for a period of One (1) year

2) From Time of Delivery, Specialized Pump Company, Inc. will warrant each water pumping system against defects in materials and workmanship under normal use and service for a period of One (1) year.

3) From Time of Delivery Each pre-pipe S.P.E.C. electrical control panel will be covered by a One (1) year warranty on all internal electrical

controls

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3.0 Model Over View 1) Our Pump Systems are Designed to handle a wide range of applications , such as Pressure boosting, Domestic

water supply, Water Fountains, Cooling systems, Air-conditioning systems and Light irrigation

3.1 System Piping 1) Our Pump Systems are available with a variety of configurations and materials to meet your specific application,

Specialized Pump Company can provide custom solutions when requested. 3.2 Expansion Tank 1) Our Systems are available with a variety of configurations and materials for your tank to meet your specific application, 2) Steel ASME Rated Tanks - Appendix T 3) Fiberglass Non-ASME Rated – Appendix S 4) Locations – Mounted on Base – Rooftop or remote

3.3 Pump Types 1) End-Suction Centrifugal Pumps

Cast Iron and Bronze construction in both self priming and standard configurations. Close coupled, frame mounted and SAE engine drive options available. Flows up to 5,000 GPM and 400 feet TDH.

2) Multi-Stage Pumps Horizontal and vertical configuration high pressure pumps for water boost applications in both surface and tank mount environments. Stainless steel with variable suction and discharge orientation. Flows to 350 GPM and 800 feet TDH. Designed to handle a wide range of filtration, pressure boost, wash system and boiler feed applications

3.4 Pump Sequencing

1) Pump sequencing in all Systems is determined by number of pumps in a system and by the output of those pumps. The PLC is programmed to determine which pumps are cycled on at a particular time to meet the buildings requirements in the most efficient manner possible. Depending on the System the program can use up to seven lag functions to provide a constant water pressure to the building.

2) The PLC constantly monitors the flow rate or Pressure; it will then determine which pump or combination of pumps

will be activated to meet the demand. The PLC takes in a number of factors to determine the most economical and efficient to use the pumps to meet the demand.

3) There is no Customer Input for Pump Sequencing.

3.5 Control Pane Upgrade

1) The Digital Upgrade utilizes your existing starters and breakers/fuses, and pumps. 2) The Digital Upgrade incorporates a micro-processor and software specific to your pump configuration resulting in

the benefits enjoyed by our complete systems: a. Pumps stage as needed as per demand determine by your pump configuration b. Protect against low city pressure (high system pressure available) c. Lead pump fail, d. High flow-start of standby e. Remote alarm annunciation. f. The Digital Upgrade has a built in information message center which acts like an “on-board”

maintenance manual prompting you through the correct steps for the current situation. The Message Center displays:

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g. Current Status Via Digital Display and PSI readout h. Problem Status (alarms) i. Problem resolutions - how to correct it j. System Restart Instructions k. Records and Displays previous error counts

3) This complete unit with individual Illuminated Hand-Off-Auto selector switches is in a Nema 3R steel enclosure. 10” (W) X 12” (L) X 6” (H). The Digital Upgrade is available for Duplex Triplex and Quad Systems

3.6 Simplex System - Control Panel and One Pump

1) Commonly Used for Cooling Towers, Irrigation, Pool Fill and Temporary Pumps. 2) Systems use either End Suction or SS Multistage Vertical Pumps. 3) Single Pump Systems have no Alternation 4) Pressure Switch Control on non-VSD systems

3.7 Simplex System - Temporary Booster Pump System

1) Temporary Simplex-Vertical Pump Station 2) Conditions: 30GPM@50 PSI at the Top of Building

a. No Less than 20 PSI incoming Pressure b. 208-230/460 VAC - Three Phase

3) Features: a. Vertical Multi-Stage Pump, ITT-Goulds Model 3SV b. Control Panel c. Low City Pressure Alarm d. High System Pressure Cutout e. 2" Suction and 2" Discharge Ball Valves f. 2" In-Line Strainer g. 2" Pressure Reducing Valve (2" Check Valve on Variable Speed Systems) h. Suction and Discharge Copper Piping with Fittings i. System mounted on a steel base j. Fiberglass Pressure Tank, 119 Gallons, 125 PSI, Non-ASME

4) Sizing:

a. For Buildings up to 25 Stories - 5 Horsepower System b. For Buildings up to 40 Stories - 7.5 Horsepower System c. For Buildings up to 60 Stories - 10 Horsepower System ....... ( Variable Speed Drive)

3.8 Simplex System - Temporary Simplex Jet Pump System

1) Temporary Simplex-Jet Pump Station 2) Conditions:

a. 15GPM@20 PSI at the Top of Building b. No less than 20 PSI incoming Pressure c. 10/230 VAC - Single Phase

3) Features: a. Jet Pump, ITT-Goulds Model J15S b. Low City Pressure Alarm c. High System Pressure Cutout d. Suction and Discharge Ball Valves e. In-Line Strainers f. Fiberglass Pressure Tank, 86 Gallons, 125 PSI, Non-ASME

4) Sizing: For Buildings up to 10 Stories - 1.5 Horsepower System

mailto:30GPM@50PSI

mailto:30GPM@50PSI


3.9 Duplex System - Control Panel and Two Equal Sized Pumps

1) Commonly Used for Domestic Water, Redundant Cooling Towers, Irrigation, and hot water re-circulators. 2) Systems use either End Suction or SS Multistage Vertical Pumps. 3) One Alternation Cycle 4) One Lag Function 5) All Duplex Systems utilize a PLC and PSI Transducer for Pump Controls except for the Duplex Hot Water

Recirculator 6) Variable Speed Drive Available

a. Standard One Drive for Each Pump b. SP142 Common One Drive System

7) Options Available See Chapter 8 8) Pump Workload Ratio ≈ 50/50 or 100/100 9) Pump Sequencing as follows:

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First Alternation Duplex Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 On Off

Pumps 1+2 Off On Second Alternation

Pump 2 On Off Pumps 1+2 Off On

3.10 Triplex Systems 3 Three Equal Sized Pumps

1) Commonly Used for Domestic Water, Towers, Irrigation, Pump Systems. 2) Advantage – Alternation allows even wear on each pump 3) Systems use either End Suction or SS Multistage Vertical Pumps. 4) Three Alternation Cycles 5) Two Lag Functions 6) All Triplex Systems utilize a PLC and PSI Transducer for Pump Controls 7) Variable Speed Drive Available

a. Standard One Drive for Each Pump 8) Options Available See Chapter 8 9) Pump Workload Ratio ≈ 33/33/33 10) Pump Sequencing as follows:

First Alternation Triplex 3 Lead L1 L2

L3 L4 L5 L6 L7

Pump 1 On Off Off

Pumps 1+2 Off On Off

Pumps 1+2+3 Off Off On

Second Alternation

Pump 2 On Off Off Pumps 2+3 Off On Off

Pumps 1+2+3 Off Off On Third Alternation

Pump 3 On Off Off Pumps 1+3 Off On Off

Pumps 1+2+3 Off Off On


3.11 Triplex 1- 2 One Lead Pump and Two equal size LAG Pumps

1) Commonly Used for Domestic Water, Irrigation Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical or a Combination of the two Types of Pumps 3) Two Alternation Cycles 4) Three Lag Functions 5) All Triplex Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available

a. Standard One Drive for Each Pump b. One VS Drive on the lead Pump

7) Options Available See Chapter 8 8) Pump Workload Ratio ≈ 20/40/40 9) Pump Sequencing as follows:

First Alternation

Triplex 1-2 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 On Off Off Off Pump 2 Off On Off Off

Pumps 1+2 Off OPT Off Off Pumps 2+3 Off Off On Off

Pumps 1+2+3 Off Off Off On

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Second Alternation

Pump 1 On Off Off Off Pump 3 Off On Off Off

Pumps 1+3 Off OPT Off Off Pumps 2+3 Off Off On Off

Pumps 1+2+3 Off Off Off On 3.12 Triplex System 2-1 Two Lead Pumps and One LAG Pump

1) Commonly Used for Domestic Water, Irrigation Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical or a Combination of the two Types of Pumps 3) Two Alternation Cycles 4) Three Lag Functions 5) All Triplex Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available

a. Standard One Drive for Each Pump 7) Options Available See Chapter 8 8) Pump Workload Ratio ≈ 25/25/50 9) Pump Sequencing as follows:

First Alternation Triplex 2-1 Lead L1 L2 L3 L4 L5 L6 L7


Pump 1+3 Off Off On Off Pump 1+2+3 Off Off Off On

Second Alternation


Pump 2+3 Off Off On Off Pump 1+2+3 Off Off Off On


3.13 Quad System 4 Four Equal size Pumps

1) Commonly Used for Domestic Water, Irrigation Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical 3) Four Alternation Cycles 4) Three Lag Functions 5) All Quad Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available

b. Standard One Drive for Each Pump 7) Options Available See Chapter 8 8) Pump Workload Ratio ≈ 25/25/25/25 9) Pump Sequencing as follows:

First Alternation

Quad 4 Lead L1 L2 L3

L4 L5 L6 L7 Pump 1 On Off Off Off

Pumps 1+2 Off On Off Off Pumps 1+2+3 Off Off On Off

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3.14 Quad System 1-2-1 One Lead and Two equal size LAG Pumps One Large Pump

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical or a combination of both 3) Four Alternation Cycles 4) Five Lag Functions 5) All Quad Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available

a. Standard One Drive for Each Pump b. Single Drive for Lead Pump

7) Options Available See Chapter 8 8) Pump Workload Ratio ≈ 15/25/25/35 9) Pump Sequencing as follows:

Pumps 1+2+3+4 Off Off Off On

Second Alternation Pump 2 On Off Off Off

Pump 2+3 Off On Off Off Pumps 2+3+4 Off Off On Off

Pumps 1+2+3+4 Off Off Off On Third Alternation

Pump 3 On Off Off Off Pumps 3+4 Off On Off Off

Pumps 1+3+4 Off Off On Off Pumps 1+2+3+4 Off Off Off On

Fourth Alternation Pump 4 On Off Off Off

Pumps 1+4 Off On Off Off Pumps 1+2+4 Off Off On Off

Pumps 1+2+3+4 Off Off Off On

First Alternation Quad1-2-1 Lead L1 L2 L3 L4 L5 L6 L7

Pump 1 On Off Off Off Off Off Pump 2 Off On Off Off Off Off

Pumps 1+2* Off OPT Off Off Off Off Pumps 2+3 Off Off On Off Off Off Pumps 2+4 Off Off Off On Off Off

Pumps 2+3+4 Off Off Off Off On Off Pumps 1+2+3+4 Off Off Off Off Off On

Second Alternation Pump 1 On Off Off Off Off Off Pump 3 Off On Off Off Off Off

Pumps 1+3* Off OPT Off Off Off Off Pumps 2+3 Off Off On Off Off Off Pumps 3+4 Off Off Off On Off Off

Pumps 2+3+4 Off Off Off Off On Off On Pumps 1+2+3+4 Off Off Off Off Off


3.15 Quad System 2-2 Two Lead Pumps and Two equal size LAG Pumps

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical Pumps 3) Two Alternation Cycles 4) Five Lag Functions 5) All Quad Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available

a. Standard One Drive for Each Pump 7) Options Available See Chapter 8 8) Pump Workload Ratio ≈ 10/10/40/40 9) Pump Sequencing as follows:

First Alternation Quad 2-2 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 On Off Off Off Off Off Pump 3 Off On Off Off Off Off

Pumps 1+3 Off Off On Off Off Off Pumps 3+4 Off Off Off On Off Off

Pumps 1+3+4 Off Off Off Off On Off Pumps 1+2+3+4 Off Off Off Off Off On

Second Alternation Pump 2 On Off Off Off Off Off Pump 4 Off On Off Off Off Off

Pumps 2+4 Off Off On Off Off Off Pumps 3+4 Off Off Off On Off Off

Pumps 2+3+4 Off Off Off Off On Off

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Pumps 1+2+3+4 Off Off Off Off Off On

3.16 Quad System One Lead Pump and One LAG Pump and Two Larger Lag Pumps

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical Pumps 3) Two Alternation Cycles 4) Five Lag Functions 5) All Quad Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available

a. Standard One Drive for Each Pump 7) Options Available See Chapter 8 8) Pump Workload Ratio ≈ 5/15/40/40 9) Pump Sequencing as follows:

First Alternation

Quad1-1-2 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off Off Pump 2 Off ON Off Off

Off Off

Pumps 1+2* Off OPT Off Off

Off Off Pumps 2+3 Off Off ON Off Off Off Pumps 3+4 Off Off Off ON Off Off

Pumps 2+3+4 Off Off Off Off ON Off Pumps 1+2+3+4 Off Off Off Off Off ON

Second Alternation Pump 1 ON Off Off Off

Off Off

Pump 2 Off ON Off Off

Off Off Pumps 1+2* Off OPT Off Off Off Off Pumps 2+4 Off Off ON Off Off Off Pumps 3+4 Off Off Off ON Off Off

Pumps 2+3+4 Off Off Off Off ON Off

Pumps 1+2+3+4 Off Off Off Off Off ON


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3.17 Quad System1-3 One Lead Pump and Three LAG Equal Sized Lag Pumps

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical Pumps 3) Three Alternation Cycles 4) Five Lag Functions 5) All Quad Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available

a. Standard One Drive for Each Pump b. Single Variable Speed Drive for Lead Pump

7) Options Available See Chapter 8 8) Pump Workload Ratio ≈ 10/30/30/30 9) Pump Sequencing as follows:

First Alternation Quad1-3 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off Pump 2 Off ON Off Off Off

Pumps 1+2* Off OPT Off Off Off Pumps 2+3 Off Off ON Off Off

Pumps 2+3+4 Off Off Off ON Off Pumps 1+2+3+4 Off Off Off Off ON

Second Alternation Pump 1 ON Off Off Off Off Pump 3 Off ON Off Off Off



Third Alternation Pump 1 ON Off Off Off Off Pump 4 Off ON Off Off Off




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3.18 Penta 5 System Five Equal Sized Pumps

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical Pumps 3) Five Alternation Cycles 4) Four Lag Functions 5) All Penta Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available

a. Standard One Drive for Each Pump 7) Options Available See Chapter 8 8) Pump Workload Ratio ≈ 20/20/20/20/20 9) Pump Sequencing as follows:

First Alternation Penta5 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off

Pumps 1+2 Off ON Off Off Off Pumps 1+2+3 Off Off ON Off Off

Pumps 1+2+3+4 Off Off Off ON Off Pumps 1+2+3+4+5 Off Off Off Off ON

Second Alternation Pump 2 ON Off Off Off Off



Third Alternation Pump 3 ON Off Off Off Off



Fourth Alternation Pump 4 ON Off Off Off Off



Fifth Alternation Pump 5 ON Off Off Off Off




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3.19 Penta System 1-4 One Lead Four Equal Sized Lag Pumps

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical Pumps 3) Four Alternation Cycles 4) Five Lag Functions 5) All Penta Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available


7) Options Available See Chapter 8 8) Pump Workload Ratio ≈ 12/21/21/21/21 9) Pump Sequencing as follows:

First Alternation

Penta 1-4 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off Off Pump 2 Off ON Off Off Off Off

Pumps 1+2 Off OPT Off Off Off Off Pumps 2+3 Off Off ON Off Off Off

Pumps 2+3+4 Off Off Off ON Off Off Pumps 2+3+4+5 Off Off Off Off ON Off

Pumps 1+2+3+4+5 Off Off Off Off Off ON Second Alternation

Pump 1 ON Off Off Off Off Off Pump 3 Off ON Off Off Off Off



Pumps 1+2+3+4+5 Off Off Off Off Off ON Third Alternation




Pumps 1+2+3+4+5 Off Off Off Off Off ON Fourth Alternation




Pumps 1+2+3+4+5 Off Off Off Off Off ON


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3.20 Penta System 2- 3 Two Leads Three Equal Sized Lag Pumps

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical Pumps 3) Six Alternation Cycles 4) Six Lag Functions 5) All Penta Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available


First Alternation

Penta 2-3 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off Off Off Pump 3 Off ON Off Off Off Off Off

Pumps 1+3 Off Off ON Off Off Off Off Pumps 3+4 Off Off Off ON Off Off Off

Pumps 3+4+5 Off Off Off Off ON Off Off Pumps 1+3+4+5 Off Off Off Off Off ON Off

Pumps 1+2+3+4+5 Off Off Off Off Off Off ON Second Alternation

Pump 2 ON Off Off Off Off Off Off Pump 4 Off ON Off Off Off Off Off



Pumps 1+2+3+4+5 Off Off Off Off Off Off ON Third Alternation




Pumps 1+2+3+4+5 Off Off Off Off Off Off ON Fourth Alternation




Pumps 1+2+3+4+5 Off Off Off Off Off Off ON Fifth Alternation




Pumps 1+2+3+4+5 Off Off Off Off Off Off ON Sixth Alternation




Pumps 1+2+3+4+5 Off Off Off Off Off Off ON


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3.21 Penta System 3-2 Three Leads Two Equal Sized Lag Pumps



First Alternation

Penta3-2 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off Off Off Pump 4 Off ON Off Off Off Off Off



Pumps 1+2+3+4+5 Off Off Off Off Off Off ON Second Alternation




Pumps 1+2+3+4+5 Off Off Off Off Off Off ON Third Alternation




Pumps 1+2+3+4+5 Off Off Off Off Off Off ON Fourth Alternation




Pumps 1+2+3+4+5 Off Off Off Off Off Off ON Fifth Alternation




Pumps 1+2+3+4+5 Off Off Off Off Off Off ON Sixth Alternation




Pumps 1+2+3+4+5 Off Off Off Off Off Off ON


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3.22 Penta System 1-2-2 One Lead Two Sized Lag Pumps and Two Larger Sized Lag Pumps




First Alternation

Penta1-2-2 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off Off Off Off Pump 2 Off ON Off Off Off Off Off Off

Pump 1+2* Off OPT Off Off Off Off Off Off Pumps 2+3 Off Off ON Off Off Off Off Off

Pumps 2+3+4 Off Off Off ON Off Off Off Off Pumps 4+5 Off Off Off Off ON Off Off Off

Pumps 2+4+5 Off Off Off Off Off ON Off Off Pumps 2+3+4+5 Off Off Off Off Off Off ON Off

Pumps 1+2+3+4+5 Off Off Off Off Off Off Off ON Second Alternation

Pump 1 ON Off Off Off Off Off Off Off Pump 3 Off ON Off Off Off Off Off Off

Pumps 1+3 Off OPT Off Off Off Off Off Off Pumps 2+3 Off Off ON Off Off Off Off Off

Pumps 2+3+5 Off Off Off ON Off Off Off Off Pumps 4+5 Off Off Off Off ON Off Off Off

Pumps 3+4+5 Off Off Off Off Off ON Off Off Pumps 2+3+4+5 Off Off Off Off Off Off ON Off

Pumps 1+2+3+4+5 Off Off Off Off Off Off Off ON


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3. 23 Penta System 1-3-1 Lead 3 Lag Pumps and 1 Larger Sized Lag Pump

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical Pumps 3) Three Alternation Cycles 4) Six Lag Functions 5) All Penta Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available



First Alternation

Penta 1-3-1 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off Off Off Pump 2 Off ON Off Off Off Off Off

Pumps 1+2 Off OPT Off Off Off Off Off Pump 5 Off Off ON Off Off Off Off

Pumps 2+5 Off Off Off ON Off Off Off Pumps 2+3+5 Off Off Off Off ON Off Off

Pumps 2+3+4+5 Off Off Off Off Off ON Off Pumps 1+2+3+4+5 Off Off Off Off Off Off ON

Second Alternation Pump 1 ON Off Off Off Off Off Off Pump 3 Off ON Off Off Off Off Off




Third Alternation Pump 1 ON Off Off Off Off Off Off Pump 4 Off ON Off Off Off Off Off





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3.24 Hex System 2-2-2 Two Equal Sized Leads 2 Equal Sized Lags Two Larger Lags

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical Pumps 3) Two Alternation Cycles 4) Seven Lag Functions 5) All Penta Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available

a. Standard One Drive for Each Pump 7) Options Available See Chapter 8 8) Pump Workload Ratio ≈ 10/10/15/15/25/25 9) Pump Sequencing as follows:

Firs t Alternation

Hex2-2-2 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off Off Off Off Pump 3 Off ON Off Off Off Off Off Off Pump 5 Off Off ON Off Off Off Off Off

Pumps 3+4 Off Off Off ON Off Off Off Off Pumps 3+4+5 Off Off Off Off ON Off Off Off

Pumps 3+4+5+6 Off Off Off Off Off ON Off Off Pumps 1+3+4+5+6 Off Off Off Off Off Off ON Off

Pumps 1+2+3+4+5+6 Off Off Off Off Off Off Off ON Second Alternation

Hex2-2-2 Lead L1 L2 L3 L4 L5 L6 L7 Pump 2 ON Off Off Off Off Off Off Off Pump 4 Off ON Off Off Off Off Off Off Pump 6 Off Off ON Off Off Off Off Off

Pumps 3+4 Off Off Off ON Off Off Off Off Pumps 3+4+6 Off Off Off Off ON Off Off Off

Pumps 3+4+5+6 Off Off Off Off Off ON Off Off Pumps 2+3+4+5+6 Off Off Off Off Off Off ON Off

Pumps 1+2+3+4+5+6 Off Off Off Off Off Off Off ON


19

3.25 Hex System 6 Six Equal Sized Pumps

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical Pumps 3) Six Alternation Cycles 4) Five Lag Functions 5) All Penta Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available


First Alternation

Hex6 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off Off

Pumps 1+2 Off ON Off Off Off Off Pumps 1+2+3 Off Off ON Off Off Off

Pumps 1+2+3+4 Off Off Off ON Off Off Pumps 1+2+3+4+5 Off Off Off Off ON Off

Pumps 1+2+3+4+5+6 Off Off Off Off Off ON Second Alternation

Pump 2 ON Off Off Off Off Off Pumps 2+3 Off ON Off Off Off Off

Pumps 2+3+4 Off Off ON Off Off Off Pumps 2+3+4+5 Off Off Off ON Off Off

Pumps 2+3+4+5+6 Off Off Off Off ON Off Pumps 1+2+3+4+5+6 Off Off Off Off Off ON

Third Alternation Pump 3 ON Off Off Off Off Off



Pumps 1+2+3+4+5+6 Off Off Off Off Off ON Fourth Alternation




Fifth Alternation Pump 5 ON Off Off Off Off Off



Pumps 1+2+3+4+5+6 Off Off Off Off Off ON Sixth Alternation





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3.26 Hex System 1- 5 One Lead 5 Equal Sized Lag Pumps

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical Pumps 3) Five Alternation Cycles 4) Six Lag Functions 5) All Penta Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available


7) Options Available See Chapter 8 8) Pump Workload Ratio ≈ 10/18/18/18/18/18 9) Pump Sequencing as follows:

First Alternation

Hex1-5 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off Off Off Pump 2 Off ON Off Off Off Off Off

Pumps 1+2 Off OPT Off Off Off Off Off Pumps 2+3 Off Off ON Off Off Off Off

Pumps 2+3+4 Off Off Off ON Off Off Off Pumps 2+3+4+5 Off Off Off Off ON Off Off

Pumps 2+3+4+5+6 Off Off Off Off Off ON Off Pumps 1+2+3+4+5+6 Off Off Off Off Off Off ON

Second Alternation Pump 1 ON Off Off Off Off Off Off Off Pump 3 Off ON Off Off Off Off Off




Third Alternation Pump 1 ON Off Off Off Off Off Off Pump 4 Off ON Off Off Off Off Off




Fourth Alternation Pump1 ON Off Off Off Off Off Off Pump5 Off ON Off Off Off Off Off



Pumps 2+34+5+6 Off Off Off Off Off ON Off Pumps 1+2+3+4+5+6 Off Off Off Off Off Off ON

Fifth Alternation Pump 1 ON Off Off Off Off Off Off Pump 6 Off ON Off Off Off Off Off





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3.27 Hex System 3-3 Three Equal Sized Lead Pumps 3 Equal Sized Lag Pumps

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical Pumps 3) Three Alternation Cycles 4) Seven Lag Functions 5) All Penta Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available


First Alternation

Hex3-3 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off Off Off Off Pump 4 Off ON Off Off Off Off Off Off

Pumps 1+4 Off Off ON Off Off Off Off Off Pumps 4+5 Off Off Off ON Off Off Off Off

Pumps 4+5+6 Off Off Off Off ON Off Off Off Pumps 1+4+5+6 Off Off Off Off Off ON Off Off

Pumps 1+2+4+5+6 Off Off Off Off Off Off ON Off Pumps 1+2+3+4+5+6 Off Off Off Off Off Off Off ON

Second Alternation Hex3-3 Lead L1 L2 L3 L4 L5 L6 L7 Pump 2 ON Off Off Off Off Off Off Off Pump 5 Off ON Off Off Off Off Off Off




Third Alternation Hex3-3 Lead L1 L2 L3 L4 L5 L6 L7 Pump 3 ON Off Off Off Off Off Off Off Pump 6 Off ON Off Off Off Off Off Off





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3.28 Hex System 4-2 Four Equal Sized Lead Pumps Two Equal Sized Lag Pumps

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical Pumps 3) Four Alternation Cycles 4) Seven Lag Functions 5) All Penta Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available


First Alternation Hex 4-2 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off Off Off Off Pump 5 Off ON Off Off Off Off Off Off












Fourth Alternation Hex4-2 Lead L1 L2 L3 L4 L5 L6 L7 Pump 4 ON Off Off Off Off Off Off Off Pump 6 Off ON Off Off Off Off Off Off





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3.29 Hex System 2-4 Two Equal Sized Lead Pumps Four Equal Sized Lag Pumps

1) Commonly Used for Domestic Water, Pump Systems. 2) Systems use either End Suction or SS Multistage Vertical Pumps 3) Four Alternation Cycles 4) Seven Lag Functions 5) All Penta Systems utilize a PLC and PSI Transducer for Pump Controls 6) Variable Speed Drive Available


7 Lag Functions, 4 Alternations, Lead Pump “On” Options

First Alternation Hex 2-4 Lead L1 L2 L3 L4 L5 L6 L7 Pump 1 ON Off Off Off Off Off Off Off Pump 3 Off ON Off Off Off Off Off Off












Fourth Alternation Hex 2-4 Lead L1 L2 L3 L4 L5 L6 L7 Pump 2 ON Off Off Off Off Off Off Off Pump 6 Off ON Off Off Off Off Off Off





4.0 Protection Devices

1) Motor Fault and Overload

a. Each Pump motor is protected by its’ own Circuit breaker. b. Each Pump motor is protected by its’ own adjustable thermal overload with reset buttons

2) Control Fault and Overload

a. The Control Circuit is protected by its’ own fuse b. The Control Circuit Transformer primary is fused. c. The Fuse for the Circuits are:

1) For AC Voltages Less than or equal too 400 use Fuse Type: MEN 1.0 Amp 2) For AC Voltages Great than 400 use Fuse Type: MEN 0.5 Amp

3) Mechanical Pump Over Temperate Protection

a. Standard-Temperature Purge for each Pump-Mechanical Type b. Optional-Temperature Sensor and Purge Solenoids for each Pump

4) Transient Voltage Suppressor (TVS)

a. Provides surge protection between the motor contactor and the PLC.

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5. 0 Programmable Logic Controller (PLC) 5.1 PLC Overview

1) Specialized Pump Company utilizes three models of Programmable Logic Controllers (PLC)The DA105, the DA 05 and the DA06. All are easily identified and although different, they all share similar logic and are invisible to the user.

5.2 DA105 The DA105 does not have any slots for the analog card and will not be used where a transducer is required. The program logic is based on pressure switches.

. 5.3 DA05 The DA 05 utilizes an analog board for the input of a pressure transducer. The program logic is based on the use of a transducer and PSI. This is the only plc to require the use of an external DC power supply.

5.4 DA06 The DA 06 utilizes an analog board for the inputs of a transducer. The program logic can be based on a number of transducers both for Flow (GPM) and Pressure (PSI). The 06 is also the controller used for variable speed pumps.

25


5.5 The Analog board

1) Analog Card used on Both the 05 and 06 PLC’s

26


27

5.6 PLC LED Status

1) Status-Run–ON-CPU is in RUN Mode-Normal a. -Run–OFF–CPU is in Program Mode–Call Service b. -Pwr–ON–CPU Power Good c. -Pwr–OFF–CPU Power Failure d. -CPU–OFF–CPU is OK

2) CPU–ON–CPU internal diagnostics has detected an error–Call Service 5.7 PLC Inputs/Outputs

1) DA105 9 Inputs 8 Outputs 2) DA05 8 Inputs 6 Outputs 3) DA06 20 Inputs 16 Outputs

105 05 06 Inputs Outputs 06 05 105

Clock Clock Clock X0 Y0 Hand Hand HandLCP LCP LCP X1 Y1 Pump1 Pump1 Pump1HSP HTS-P1 HTS X2 Y2 Pump2 Pump2 Pump2Lag2 HTS-P2 OPS X3 Y3 Pump3 Pump3 Pump3Lag1 PRG PRG X4 Y4 Pump4 Pump4 Pump4NS Var Spd Var Spd X5 Y5 Pump5 Alarm Pump5

Lag3 NS NS X6 Y6 Pump6 N/A OpenLag4 E RST E RST X7 Y7 Alarm N/A AlarmPRG N/A CBP X10 Y10 Light N/A N/A

E RST N/A P1FB X11 Y11 VPump1 N/A N/A N/A N/A P2FB X12 Y12 VPump2 N/A N/A N/A N/A P3FB X13 Y13 VPump3 N/A N/A N/A N/A P4FB X14 Y14 VPump4 N/A N/A N/A N/A P5FB X15 Y15 V-Stop N/A N/A N/A N/A P6FB X16 Y16 V-Preset N/A N/A N/A N/A V-P2 On X17 Y17 Open N/A N/A N/A N/A Open X20 N/A N/A Open X21 N/A N/A Open X22 N/A N/A Open X23

Note: Both the "PWR" and the "RUN" LED's on all model PLC's should be lit

when in operation 5.8 Pre-Programmed Default Delay Time Settings

1) Low City Pressure .≅ 5SecondTimeDelay 2) Low City Pressure .≅ 2-Minute Automatic Reset Limit. 3) High System Pressure ≅ 5 Second Time Delay 4) No Flow Shutdown.≅ 5SecondTimeDelay 5) Master Reset(X10) ≅15SecondTimeDelay


6.0 Terminal Connections

6.1 T1 Connections: The T1 Terminal can be located near the bottom of the panel

Chapter 6

+ Plus Wire of the Transducer (PSI) STD-PLC - Minus Wire of the Transducer (PSI) STD-PLC A Low City Pressure Switch STD-ALL B Low City Pressure Switch STD-ALL 4a Program Safety Interlock Jumper STD-PLC 4b Program Safety Interlock Jumper STD-PLC ER External Reset STD-PLC ER External Reset STD-PLC RC Remote Alarm Dry Contact (Normally Closed) STD-ALL C Remote Alarm Dry Contact (Common) STD-ALL

RO Remote Alarm Dry Contact (Normally Open) STD-ALL Y Alarm STD-ALL N AC Neutral STD-ALL E Emergency Generator Connection 105 PLC G Emergency Generator Connection 105 PLC T1 Heat Sensor Pump 1 Optional T1 Heat Sensor Pump 1 Optional T2 Heat Sensor Pump 2 Optional T2 Heat Sensor Pump 2 Optional 5 No Flow Pressure Switch 105 PLC 6 No Flow Pressure Switch 105 PLC

G+ Plus Wire of the Transducer (GPM) Optional G- Minus Wire of the Transducer (GPM) Optional V1 To Variable Speed Drive 1 Optional V2 To Variable Speed Drive 2 Optional V3 To Variable Speed Drive 3 Optional V4 To Variable Speed Drive 4 Optional H High Flow Flow Switch 105 PLC F High Flow Flow Switch 105 PLC 1 High System Pressure Switch 105 PLC 2 High System Pressure Switch 105 PLC 3 High City Pressure Switch Optional 4 High City Pressure Switch Optional 5 No Flow Pressure Switch Optional 6 No Flow Pressure Switch Optional 7 Temp Sensors Optional 8 Temp Sensors Optional 9 High Flow Pressure Switch Optional 10 High Flow Pressure Switch Optional 11 Lead Pump Failure Switch Non PLC 12 Lead Pump Failure Switch Non PLC M1 Upgrade Panel connection to P1 Contactor Upgrade Only M2 Upgrade Panel connection to P2 Contactor Upgrade Only M3 Upgrade Panel connection to P3 Contactor Upgrade Only M4 Upgrade Panel connection to P4 Contactor Upgrade Only

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6.2 105 PLC to T1 Connections


29



6.5 Variable Speed Hybrid Connections

30


Chapter 7 7.0 Operation and Diagnostics 7.1 Operator Controls

1) Hand-Off Automatic (H-O-A) Switch a. Each pump will have a H-O-A switch b. The Switch will illuminate when the pump is running. c. Placing the switch in “Hand” position will operate the pump in the

manual mode. d. Placing the switch in the “Off” position will turn the pump off. e. Placing the switch in the “Auto” position will place the pump in a

stand-by condition to be run automatically when required

2) Constant- Variable Switch a. In Hybrid Systems only, the Constant-Variable Switch allows the

user to choose the mode the system will operate in. b. Left – Variable c. Center – Off d. Right - Constant

3) Main Disconnect Switch a. All MCC Controlled Systems will have a Main Disconnect switch

which disables the power when in the off position and to open the panel the switch must be in the off position

b. Left – Off c. Center – On d. On Systems with the Emergency Generator Connection a 6 pole

switch is used to disconnect both city and emergency power.

4) PLC-By-Pass Switch a. In the event of a problem with the PLC. By-Pass switch

allows the use of the system by removing the PLC from the circuit.

5) Time Clock a. Set Time Clock to Current time and Day b. Pull one pin on face of time clock at the time and day you

want the pumps to alternate. c. Ensure that selector switch on the clock face is in the

center position d. Ensure that System Program is set to “Auto Alternate Off”

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6) Alarm

a. A sonic alarm will sound to give an audible warning if an error condition is present. The alarm can be silenced with either the “Reset” button on the display.

b. The Volume of the alarm can be alter by opening and closing the mechanical shutter located on the bottom of the alarm

7) Displays with Touch Key

a. PLC equipped Control Panels will come with a Digital Display Operator Interface with four touch

keys. Each key is designated a specific function or functions. b. Key 1–HELP–Displays the On board Help Screens When this key is pressed during normal

operation the software Version and Job Number will appear in the display window. When the key is pressed during an alarm situation a help message for that particular alarm is displayed

c. Key 2–EMT–Press this key to display the elapsed Pump Run Time. The display will cycle through the elapsed time reading for each pump in the system before returning to the Standard Display Sequence.

d. Key 3–GMP– Will Alternate the Display To Show Either Gallons per minute (GPM) or Pressure per Square Inch (PSI) the output of selected pump in the gallons per minute (G.P.M.)format. If the System has been ordered with the GPM Option

e. Key 4–Reset–when pressed the key will reset the system after an alarm condition. If the alarm condition is still present, the key will only silence the alarm but will not clear the alarm condition.

f. Hidden Keys s

• HELP and ETM Keys – Places PLC in Program Mode • ETM and GPM Keys – Displays Error Counts • GPM and Reset Keys – Reset Error Count • In Program Mode [GPM] key when enabled allows continuous advancement instead of

a single press single advance. 1) Note: With Each press of a button a beep should be heard

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Chapter 8 8.0 - Display – Messages Overview 8.1 Normal Operation – Displays 8.1.1 Normal Operation - Lead Pump On

Displayed Message → 105 PLC

Displayed Message → 05-06 PLC PSI Mode” Displays Current PSI

Displayed Message →

05-06 PLC GPM Mode” Displays Current GPM Normal Operation - No Help Messages 8.1.2 Normal Operation-LAG ON Will Flash *** Until System Pressure is Met


Displayed Message → 05-06 PLC” Displays Current PSI

Displayed Message → 05-06 PLC” Displays Current GPM Normal Operation - No Help Messages

33


8.1.3 Normal Operation-LAG ON When System Pressure is met Display will count down seconds remaining in runtime.


Displayed Message → 05-06 PLC

Displayed Message → 05-06 PLC Normal Operation - No Help Messages 8.1.4 No Flow System Shut Down Cause–When a "'true" No Flow signal is received, the lead pump is de-activated. A message is displayed indicating normal system shutdown. During shutdown, low flow requirements are met by the hydro-pneumatic bladder tank. Displayed Message- “NORMAL SYSTEM SHUTDOWN”” Action-All Panels–None-Lead pump will automatically restart upon high flow or a drop in normal maintained system pressure. Help Message “Pressure meets demand, Pumps will Automatically Restart when needed 8.1.5 Displaying Elapsed Time Pressing the ETM Button on the Display will cause the Elapsed Time Reading for Each pump to be displayed. Displayed Message All Normal Operation - No Help Messages

34


8.1.6 PSI- GMP Pressing the GPM Button on the Display will causes the display to alternate between PSI and GPM. (If Applicable) Displayed Message 06 GPM Optioned Only Normal Operation - No Help Messages 8.2.0 Warning Messages Passive - Displays 8.2.1 Low Supply Level (cutout)- (If Applicable) Cause-Remote sensor, signals of low level in cistern or reservoir. All pumps are disabled. Displayed Message-“LOW SUPPLY LEVEL” Action-None-Controller resets automatically upon return to safe level. Verify Water level Help Message System Will Restart Automatically When Supply Level Comes Into Operating Range 8.2.2 Emergency Generator Transfer Connection (If Applicable) Cause–Power Failure-Emergency generator power has transferred to generator power from city. Selector inside control panel will start selected pump Displayed Message-“EMERGENCY POWER TRANSFER”” Action-All Panels–None–Upon return of normal power system will automatically transfer back to normal operation. Help Message Emergency Generator Power has transferred Panel will start Selected Pump & Mode System will Resume Normal Operation Automatically When Power is restores

35


8.3.0 Error Messages Active - Displays Note: Any message with Indicates an audible alarm will also be triggered With that alarm. To Silence Alarm Press the RESET Button on the Display 8.3.1 Low City Pressure (Std All) Low City Pressure Attempting Alarm Reset Displayed Message-“LOW CITY PRESSURE Attempting Alarm Reset” Cause–Pressure Switch signals of low city pressure. All pumps are disabled. System disables pumps and checks for correct city pressure. If City pressure returns to a safe level in 2 minutes the system will automatically restart. No further action is required Help Message Verifying Low Pressure System Will Restart Automatically When Pressure Comes Into Operating Range 8.3.2 Low City Pressure (Std All) Low City Pressure Cutout Displayed Message-“LOW CITY PRESSURE CUTOUT” Cause–City Pressure has not returned to a safe level inside the two-minute time frame. All pumps remain disabled. Action–Display Panels- A manual restart is required. To restart throttle all discharge valves then press reset pumps will restart if alarm condition has cleared Non-Display-Manual Restart is required-To restart throttle all discharge valves then press reset pumps will restart if alarm condition has cleared Help Message Pumps Will Not Restart In Hand Or Auto During This Alarm Condition. To RESTART:THROTTLE All Discharge Valves Then Press Reset Pumps Will Restart If Alarm Condition Has Cleared If Further Help Is Required Call: 1-(954) 967-271

36


8.3.3 High System Pressure (Cutout) Cause–Pressure switch signals system pressure has exceeded safe limit. All pumps are disabled. Normally cause by a malfunction in a PR valve. Displayed Message-“HIGH SYSTEM PRESSURE CUTOUT” Action–All Panels-Manual Restart is required-To restart throttle all discharge valves then press reset, pumps will restart if alarm condition has cleared Help Message Pumps Will Not Restart In Hand Or Auto During This Alarm Condition. To Restart:Throttle All Discharge Valves Then Press Reset Pumps Will Restart If Alarm Condition Has Cleared If Further Help Is Required Call: 1-(954) 967-271 8.3.4 Analog Signal Loss Cause–No Signal from Transducer. Possible Failed Transducer or bad or loose connection. Displayed Message-“Analog Signal Loss”” Note Pumps Can be run in the Manual Mode Only Action-All Panels–Check Transducer Connections. Call for Service Help Message Manual Mode Only Service Required .

37


9.0 DOMESTIC BOOSTER SYSTEM OPTIONS

Panel Options - Description PLC Systems Non PLC Systems #

Audible Alarm with silencer-A horn will acknowledge any alarm condition. Also includes a Dry Contracts for remote monitoring of system alarms. STD STD 1)

Low City Pressure (Std All)Low City Pressure Cut-Out STD STD 2) Programmable PLC-All control functions will be sequenced through a programmable controller. With status indicator lights for each input and output. Volatile-volatile memory, computer link and networking capabilities. Remote Communications to factory via cell phone line.

STD N/A 3)

Elapsed Time Meter -Elapsed Time Meter Display for reach Pump STD OPT 4) Dry Contacts (Remote Alarm)-Dry Contacts for Remote communications of alarm conditions.* STD OPT 5)

Phase Monitor P.M.-Upon phase loss, low voltage, and high voltage or phase regeneration, Monitor will disable all motors. Monitor will reset automatically .L.E.D. monitors normal mode

OPT OPT 6)

Digital Flow Indicator-A paddle wheel flow transducer produces a frequency proportional to the flow rate. The LCD display will provide G.P.M. flow readout. OPT N/A 7)

Variable Speed Drive – Configures your pump motors into variable speed motors. OPT OPT 8)

Motor Circuit 1 - Motor Circuit Controller System – Main Disconnect STD STD 9) Emergency Generator Ready – Panel configured to accept Emergency Generator Power Connection OPT OPT 10)

High City Pressure Normal Shutdown-H.C.P. pressure switch signals city pressure is above buildings minimum pressure requirements. If signal exceeds 20 seconds (adj.) the lead pump is deactivated. A displayed message will indicate this condition. Upon a pressure drop to an unacceptable level, the lead pump is restarted. Required with Option 5

▲ OPT 11)

High Flow/Flow Switch-Direct acting flow switch signals high flow demand. After a (adj.) time delay the high flow lag pump is sequenced on .A minimum run (adj.) time delay holds in lag pump against varying flow fluctuations. Flow switch will de-activate lag pump upon return to normal flow conditions

▲ OPT 12)

13)

High Flow/Pressure Switch-H.F.P. pressure switch signals high flow demand at the point that the lead pumps capacity is exceeded. After a (adj.) time delay, the lag pump is sequenced on. A minimum run (adj.)time delay holds in the lag pump against flow demand fluctuations. Pressure switch will de-activate lag pump.

▲ OPT

14) High System Pressure (Cutout)-pressure switch signals system pressure has exceeded safe limit (adjustable). All pumps are disabled. A displayed message will indicate this condition. A manual reset will restart system

▲ OPT

15) Low Supply Level(cutout)-Remote sensor, signals of low level in cistern or reservoir. All pumps are disabled. A displayed message will indicate this condition. Controller rests automatically upon return to safe level.

OPT OPT

16)

No Flow System Shut Down(normal)-Controller constantly monitors pressure and flow. When a "'true" No Flow signal is received, the lead pump is de-activated. A message is displayed indicating normal system shutdown. During shutdown, the hydro-pneumatic bladder tank meet slow flow requirements. Lead pump will restart upon high flow or a drop in normal maintained system pressure. System must also include a Hydro-Pneumatic Bladder Tank

OPT

OPT

Highly Recommended

Highly Recommended

Phase Monitor P.M.-Upon phase loss, low voltage, and high voltage or phase regeneration, Monitor will disable all motors. Monitor will reset automatically .L.E.D. monitors normal mode

OPT OPT 17)

Gauge Board ( 2) (panel mounted)-Industrialgradea,3½-diameter back flange mount, back Connection. Gauge board panel mounted. OPT 18) OPT

19) Gauge Board (3) (panel mounted)-Industrialgradea,3½-diameter back flange mount, back Connection. Gauge board panel mounted. OPT OPT

20) Modem – Connects your System to a remote computer via a phone line. OPT N/A

▲ Function Standard with PLC unit but controlled with readings from transducer instead of a pressure switch

38


39

# System Piping Options - Description PLC Systems Non PLC Systems

21)

Full Size By Pass-A silent check valve is installed between the suction and discharge manifolds .During periods when city supplied pressure is adequate to satisfy building requirements, pump and pressure reducing valves are bypassed providing a path of least friction loss (Recommended with High City Pressure Shutdown Pressure Switch.)

OPT OPT

22) Inertia Base Springs-Steel spring mountings with ribbed neoprene skid pads and leveling bolts to be installed under/in concrete in inertia absorbing base. OPT OPT

23) Temp Purge Solenoids Each Pump-Temperature Sensor and Purge Solenoids for each Pump

Highly Recommended for pumps over 20Horsepower OPT OPT

24) Temp Purge for each Pump-Temperature Purge for each Pump-Mechanical Type STD STD

25) Hydro-Pneumatic Bladder Tank – Fiberglass - Non ASME Rated-Mounted and piped on pump system/remote-roof/roof-roof. Select capacity and maximum pressure range.

OPT OPT

26) Hydro-Pneumatic Bladder Tank – Steel - ASME Rated-Mounted and piped on pump system/remote-roof/roof-roof. Select capacity and maximum pressure range.

OPT OPT

27) Flanged Isolators (Rubber Sphere)-Flanged rubber sphere isolators for suction and discharge manifolds to further reduce normal transmitted vibration. See accessories option section.

OPT OPT

28) Butterfly Valves – used instead of standard Ball valves OPT OPT 29) Hose Bib – Hose connection install in system piping OPT OPT

30) Piping -Copper-Pump will be piped in copper type L/type K. See pressure ratings-product specifications STD STD

31) Piping – Copper with Stainless Steel Headers-Pumps will be piped in Stainless Steel schedule 304/316. See pressure ratings product specifications. OPT OPT

32) Piping - Stainless Steel-Pumps will be piped in Stainless Steel schedule 304/316. See pressure ratings product specifications. OPT OPT

33) Piping - Galvanized-Pumps will be piped in galvanized steel schedule 40. See pressure ratings product specifications OPT OPT

34) Piping - P.V.C.-Pumps will be piped In PVC schedule 80. See pressure ratings products specifications OPT OPT

35) Piping - Steel-Pumps will be piped in Steel. See pressure ratings product specifications OPT OPT


10. 0 Remote Alarm - Dry Contacts

10.1 Dry Contact Terminals

10.2 Remote Alarm Console (Optional)

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13.0 Pressure Reducing Valves 13.1 Valve Description

1) Each pump will have its’ own valve except where the pump has a variable Speed Drive 2) Maintains constant system pressure, regardless of varying flow demands or suction fluctuations. Valves are

equipped as follows: a. Hydraulic check features to prevent reverse flow up on pressure reversal. b. The valves are 100% epoxy coated inside and out c. Self adjusting, pilot operated pressure reducing valves d. Slam-slam, Reversing-reversing features e. Stainless steel main seats

13.2Functional Description

1) Pressure Reducing Function –The pressure reducing function is controlled by the 263AP or 263SS control. The 263 are a normally open, adjustable control set to respond to outlet/down stream pressure changes. An Increase in pressure above this point throttles the control towards closed. The main valve modulates towards a closed position. When pressure drops, the control throttles s towards open, modulating the main valve towards the open position. A constant outlet/down stream pressure is maintained.

a. Turning the adjustment screw CLOCKWISE (IN) increases the outlet/down stream pressure.

b. Turning the adjustment screw COUNTER-CLOCLWISE (OUT) decreases the outlet/down stream pressure.

2) Opening Speed Control–F.C.– An adjustable flow control adjacent to the valve cover port,

determines the opening speed of the main valve. It allows free flow in to the cover and restricted flow out of the cover.

a. COUNTER-CLOCKWISE adjustment for faster opening, b. CLOCKWISE for slower opening. c. Complete closure prevents the main valve from opening.

3) Hydraulic Check Feature–When the main valve outlet pressure exceeds inlet pressure, fluid is directed from the outlet to the main valve cover. This causes the main valve to close until the inlet pressure/flow is again greater than the outlet pressure/flow.

4) Valve Configuration a. Threaded b. Flanged c. Straight (Globe) d. Angled (90°)

41


42


12.0 Pressure Switches 12.1 Ratings:

1) V3 - 0 thru 100 PSI 2) V4 – 0 thru 200 PSI 3) V5 – 0 thru 300 PSI

12.2 Switch Name ON OFF

1) PS1 Low City Pressure LCP PSI 2) LS1 Low Supply Level LSP Ft. Ft. 3) PS2 High System Pressure HSP PSI 4) PS3 Lead Pump Failure LPF PSI 5) PS4 High City Pressure HCP PSI 6) PS5 No Flow NF PSI 7) PS6 High Flow Pressure Switch HF PSI 8) FS1 High Flow Switch FS1 ON/GPM 9) FS2 High Flow Switch FS2 ON/GPM

43


Chapter 13 13.0 TROUBLESHOOTING The following troubleshooting information should be used as a guide in determining the cause of the most common problems you may encounter. It is not intended to be a cure-all for problems you may encounter with your system. Should you be unable to correct a specific problem by use of this guide? Contact Specialized Pump for assistance..

13.1.0 System Operation - System Error Faults

1) No Flow System Shut Down

a. Displayed Message- “NORMAL SYSTEM SHUTDOWN”” or White Warning Light b. Cause–When a "'true" No Flow signal is received, the lead pump is de-activated. A message is

displayed indicating normal system shutdown. During shutdown, low flow requirements are met by the hydro-pneumatic bladder tank.

c. Action-All Panels–None-Lead pump will automatically restart upon high flow or a drop in normal maintained system pressure.

2) Low Supply Level (cutout)- (If Applicable)

a. Displayed Message-“LOW SUPPLY LEVEL” b. Cause-Remote sensor, signals of low level in cistern or reservoir. All pumps are disabled. c. Action-None-Controller resets automatically upon return to safe level. Verify Water level

3) Low City Pressure (Std All)

a. Displayed Message-“LOW CITY PRESSURE Attempting Alarm Reset” b. Cause–Pressure Switch signals of low city pressure. All pumps are disabled. System disables pumps

and checks for correct city pressure. If City pressure returns to a safe level in 2 minutes the system will automatically restart.

c. Action -No further action is required

4) Low City Pressure (Std All) a. Displayed Message-“LOW CITY PRESSURE CUTOUT” or Red Warning Light b. Cause–City Pressure has not returned to a safe level inside the two-minute time frame. All pumps

remain disabled. c. Action–Display Panels- A manual restart is required. To restart throttle all discharge valves then press

reset pumps will restart if alarm condition has cleared Non-Display-Manual Restart is required-To restart throttle all discharge valves then press reset pumps will restart if alarm condition has cleared

5) High System Pressure (Cutout) or Red Warning Light

a. Displayed Message-“HIGH SYSTEM PRESSURE CUTOUT” b. Cause–Pressure switch signals system pressure has exceeded safe limit. All pumps are disabled.

Normally cause by a malfunction in a PR valve. c. Action–All Panels-Manual Restart is required-To restart throttle all discharge valves then press

reset, pumps will restart if alarm condition has cleared - Usually cause: by debris in the PR Valves Schedule Service for PRV Cleaning

6) Analog Signal Loss (If Applicable)

a. Displayed Message-“Analog Signal Loss”” b. Cause–No Signal from Transducer. Possible Failed Transducer or bad or loose connection. c. Action-All Panels–Check Transducer Connections both at the (+) & (-) terminals but all ensure that the

plug connector on the Analog card in the PLC is secured. . If all connections are secure Call for Service

7) Emergency Power (If Applicable) a. Displayed Message-“LOW SUPPLY LEVEL” b. Cause-System is Running off the Emergency Generator c. Action-None-Controller resets automatically upon return to normal power

8) High Flow (If Applicable)

a. Displayed Message-“High Flow” b. Cause-Remote sensor, signals of low level in cistern or reservoir. All pumps are disabled. c. Action-None-Controller resets automatically upon return to safe level. Verify Water level

44


45

9) Phase Error (If Applicable)

a. Displayed Message-“ Phase Error” b. Cause- Phase Monitor Detected and Error c. Action-None

10) Low C/T Level (If Applicable)

a. Displayed Message-“LOW C/T LEVEL” b. Cause-PLC detected through the transducer signal that the Cooling Tower water level was below a pre

set minimum condition c. Action- None-Controller resets automatically upon return to safe level. Verify Water level

11) High C/T Level (If Applicable)

a. Displayed Message-“High C/T LEVEL” b. Cause-PLC detected through the transducer signal that the Cooling Tower water level was above a pre

set maximum condition and the pumps are disabled c. Action-Manual Reset is required

12) High Temp Pump 1 (If Applicable)

a. Displayed Message-“High Temp Pump 1” b. Cause-Remote sensor, signals of low level in cistern or reservoir. All pumps are disabled. c. Action-None-Controller resets automatically upon return to safe level. Verify Water level

13) High Temp Pump 2 (If Applicable)

a. Displayed Message-“High Temp Pump 2” b. Cause-Remote sensor, signals of low level in cistern or reservoir. All pumps are disabled. c. Action-None-Controller resets automatically upon return to safe level. Verify Water level

14) Fire Pump Cut-Out

a. Displayed Message-“Fire Pump Cutout” b. Cause-Signal from fire pump dry contacts enables the system to be shutdown while fire pumps are

running. c. Action-None-Controller resets automatically upon shutdown of the fire pump

15) Lead Pump Failure

a. Amber Warning Light b. Cause-Remote sensor, signals of low level in cistern or reservoir. All pumps are disabled. c. Action-None-Controller resets automatically upon return to safe level. Verify Water level

16) High City Pressure

a. Displayed Message-“High City Pressure” b. Cause-City Pressure is higher than expected. Pumps can be shut down until and system run on city

pressure alone until city pressure falls back into the normal range c. Action-None-System automatically starts pumps when required to maintain the set system pressure.

13.3.0 Motors:

1) Motor Fails To Run In “Hand” Position. a. Disconnect in the "Off" position. Place Disconnect in "On" Position b. Pump Circuit Breaker is Tripped Reset Circuit Breaker c. Motor Over Load is tripped. Reset Overload d. A loose power connection Service - Check and Secure Connections e. Failed motor starter coil-starter will not pull in. Service - Replace Started f. Rotor is locked-check for a locked pump shaft caused by foreign debris in the Impeller or the binding of

the impeller in the casing. Service - Disassemble Pump and Clear Debris 2) Motor Runs Hot

a. Inadequate ventilation causing high ambient temperatures Allow Room to Cool and Try Again b. Overload on motor causing excessive amp draw Service Required - Determine Reason for Overloaded

Motor c. Unbalance power supply between phases Service Required - Verify Electrical Phase Problem d. Over greased bearings Service Required - Disassemble Pump and clean Excessive Grease


46

3) Excessive Motor Noise:

a. Lack of bearing lubricant Lubricate Bearings as per Pump Manual b. Worn bearings requiring replacement Service Required - Replace Bearings c. Loose or bent cooling Fan Service Required - Repair or Replace Fan

4) Motor Pulls Excessive Amperage

a. Motor Running Hot See Motor Run Hot Troubleshooting b. Unbalanced power supply or improper voltage Service Required - Verify Electrical Problem c. Rotating elements binding internally Service Required - Repair or Replace Rotating Elements d. Rotating elements binding internally due to external mounting stress. Service Required to Verify

Problem e. Pump operating beyond rated capacity: Service Required to Verify Problem

13.4.0 Pumps:

1) Pump Output Pressure Low: a. Suction isolation valve partially closed Open Suction Side Isolation Valve b. Suction supply pressure lower than specified Check City Pressure c. Loss of prime (Suction lift applications only). Check for Suction Loss and Re Prime d. Motor speed incorrect—check incoming voltage. Service Required to Verify and Correct the Problem e. Clogged vane(s) on impeller(s). Service Required to Verify and Correct the Problem f. Blockage in the suction supply line Service Required to Verify and Correct the Problem g. Incorrect rotation direction Service Required to Verify and Correct the Problem h. Pump is air locked Service Required to Verify and Correct the Problem i. Pump operating beyond rated capacity Service Required to Verify and Correct the Problem j. Impeller(s) loose or binding Service Required to Verify and Correct the Problem

2) Excessive Pump Noise

a. Pump operating beyond rated capacity causing cavitation. Service Required to Verify and Correct the Problem

b. Impeller(s) loose or binding Service Required to Verify and Correct the Problem c. Foreign objects loose in pump casing Service Required to Verify and Correct the Problem d. Suction lifts too high causing cavitation Service Required to Verify and Correct the Problem

3) Excessive Pump Vibration:

a. Bent pump or motor shaft. Service Required to Verify and Correct the Problem b. Worn pump bearing(s). Service Required to Verify and Correct the Problem c. Impeller out of balance Service Required to Verify and Correct the Problem d. Pump operating beyond rated capacity causing cavitation Service Required to Verify and Correct the

Problem e. Misalignment between pumps and motor Service Required to Verify and Correct the Problem f. Bad motor bearings Service Required to Verify and Correct the Problem g. Pressure Regulating Valve Problem Service Required to Verify and Correct the Problem

4) Pumps Leaking

a. Bent pump or motor shaft. Service Required to Verify and Correct the Problem b. Worn pump bearing(s). Service Required to Verify and Correct the Problem

13.5.0 Pressure Regulating Valves:

1) Pressure Too High a. CRD set too high. Service Required to Verify and Correct the Problem b. PRV diaphragm ruptured. Service Required to Verify and Correct the Problem c. CRD diaphragm ruptured. Service Required to Verify and Correct the Problem d. Orifice elbow clogged. Service Required to Verify and Correct the Problem e. Inlet side check valve stuck in the closed position Service Required to Verify and Correct the Problem f. Inlet side strainer is clogged Service Required to Verify and Correct the Problem g. PRV stem sticking in upper or lower guide bearings. Service Required to Verify and Correct the

Problem h. PRV seat surface is worn or damaged. Service Required to Verify and Correct the Problem i. CRD disc retainer worn or damaged. Service Required to Verify and Correct the Problem j. Outlet side check valve (if applicable) stuck open or not seating tight. Service Required to Verify and

Correct the Problem


47

2) Pressure Too Low

a. PRV stem sticking in upper or lower guide bearing. Service Required to Verify and Correct the Problem b. PRV spring misaligned. Service Required to Verify and Correct the Problem c. CRD disc retainer hole is clogged. Service Required to Verify and Correct the Problem d. CRD disc retainer motion is obstructed. Service Required to Verify and Correct the Problem e. CRD set too low. Service Required to Verify and Correct the Problem f. Orifice elbow eroded allowing too high a volume of water in piloting. Service Required to Verify and

Correct the Problem 3) Valve Will Not Check (Applies Only If Valves Are Piloted For Check Feature):

a. Inlet side check valve is stuck open or fails to seat. Service Required to Verify and Correct the Problem b. Outlet side checks valve is stuck closed. Service Required to Verify and Correct the Problem c. Outlet side strainer is clogged. Service Required to Verify and Correct the Problem d. PRV stem is sticking in upper or lower guide bearings. Service Required to Verify and Correct the

Problem e. PRV diaphragm is ruptured. Service Required to Verify and Correct the Problem f. PRV seat is worn. Service Required to Verify and Correct the Problem

4) Modulation: a. Air trapped under PRV cover. Service Required to Verify and Correct the Problem b. Orifice elbow is too large or too small. Service Required to Verify and Correct the Problem c. Inlet or outlet check valve (if applicable) malfunctioning. Service Required to Verify and Correct the

Problem 13.6.0 Pump Sequencing (Pressure Switch) Note: Try to run pump in the hand position. If pump fails to start refer to motor section

1) Pump Fails To Start Automatically a. Pressure switch is improperly wired or the Connections are loose. Service Required to Verify and

Correct the Problem b. Pressure switch mechanism malfunctioning. To check remove the switch and trip switch by hand.

Service Required to Verify and Correct the Problem c. Pressure switch sensing line closed or obstructed. Service Required to Verify and Correct the Problem d. Pressure switch improperly adjusted. Service Required to Verify and Correct the Problem

2) Pump Fails To Stop Automatically When Not Required a. Pressure switch mechanism malfunctioning. To check remove the switch cover and trip switch by hand.

Service Required to Verify and Correct the Problem b. Pressure switch is improperly adjusted—Check for correct flow setting Service Required to Verify and

Correct the Problem c. Pump under control of minimum run timer (if applicable). Service Required to Verify and Correct the

Problem d. Motor starter hung up in operating position will not release. Service Required to Verify and Correct the

Problem 13.7.0 Pump Sequencing (Transducer) Note: Try to run pump in the hand position. If pump fails to start refer to motor section

1) Pump Fails To Start Automatically a. PLC is not in the “Run” mode. Place PLC in the "Run" Mode … See PLC Chapter for Specifics b. Program Interlock Jumper still in position on T1 Remove Jumper

2) Pump Fails To Stop Automatically When Not Required (Transducer) a. Pump under control of minimum run timer (if applicable). Normal Operation No Action Required b. Motor starter hung up in operating position will not release. Service Required to Verify and Correct the

Problem 13.8.0 Pressure Gauges Caution: Pressure must not exceed the gauge rating

1) Gauge provides incorrect pressure reading a. Gauge cock valve partially closed. Ensure that valve is fully opened b. Gauge piloting partially blocked or damaged. Service Required to Verify and Correct the Problem

2) Gauge provides erratic pressure reading a. Air in gauge piloting. Service Required to Verify and Correct the Problem b. Excessive system vibration. Service Required to Verify and Correct the Problem


48

13.9.0 Temperature Probes and Purge Valves

1) Valve purges continuously: a. Pump constantly running against little or no flow. Service Required to Verify and Correct the Problem b. Debris wedged in valve. Service Required to Verify and Correct the Problem c. Temperature probe failure—to check, disconnects power to temperature Probe. Service Required to

Verify and Correct the Problem d. Temperature probe is misadjusted (Adjustable type only). Service Required to Verify and Correct the

Problem 2) Valve does not purge at all:

a. Temperature probe failures to check electrically by pass temperature probe. Service Required to Verify and Correct the Problem

b. Temperature probe is mis-adjusted (Adjustable type only). Service Required to Verify and Correct the Problem

13.10.0 Transducer

1) No Readings a. Transducer is improperly wired or the Connections are loose. Verify all connections are secure and

cables intact. b. No 24VDC – Verify Power Supply Output Service Required to Verify and Correct the Problem

2) Transducer Reading does not match Pressure Gauge a. Display reading is a few pounds lower than Pressure Gauge Calibrate Transducer in software program b. Display is greater that 20 PSI higher than gauge- reseat or replace analog card Service Required to

Verify and Correct the Problem 13.13.0 Display

1) Display Not Working a. By-Pass Switch is in the "By-Pass" position. Place By-Pass Switch in the "Normal" position. b. Display is improperly wired or the Connections are loose Verify Connection are secure c. Display Defective. Service Required to Verify and Correct the Problem

2) Display - Shows “Optimate Series 420 Series Terminal” a. Display lost programming. Service Required to Verify and Correct the Problem b. PLC lost programming. Service Required to Verify and Correct the Problem

3) Display Button not Working a. Display Defective Service Required to Verify and Correct the Problem

4) Display – All LED’s Flashing a. Display Connections are loose. Verify Connection are secure

5) Display – Strange Characters Displayed (#$%?*&) b. V Memory in the PLC needs to be cleared. Service Required to Verify and Correct the Problem

13.12.0 Temperature Probes and Purge Valves

1) Valve purges continuously: c. Debris wedged in valve. Service Required to Verify and Correct the Problem d. Pump constantly running against little or no flow. Service Required to Verify and Correct the Problem e. Temperature probe failures—to check, disconnect power to temperature Probe. Service Required to

Verify and Correct the Problem f. Temperature probe is misadjusted (Adjustable type only). Service Required to Verify and Correct the

Problem

2) Valve does not purge at all: g. Temperature probe failures to check electrically by pass temperature probe. Service Required to Verify

and Correct the Problem h. Temperature probe is mis-adjusted (Adjustable type only). Service Required to Verify and Correct the

Problem 13.13.0. Programmable Logic Controller

1) PLC Not Responding a. PLC not in "RUN" Mode Place PLC in the "RUN" Mode b. PLC Locked Remove power from the PLC to clear the error. If the error clears, you should monitor the

system


49

2) PWR Indicator off

a. Power to the Unit is incorrect or is not applied. Verify Voltage and Replace Fuse b. PLC power supply is faulty. Service Required to Verify and Correct the Problem c. Other component(s) have the power supply shut down. Service Required to Verify and Correct the

Problem

3) PLC will Not Enter the "RUN Mode a. If the CPU will not enter the Run mode (the RUN indicator is off), the problem is usually in the application

program, unless the CPU has a fatal error. A fatal error has occurred; the CPU LED should be on. (You can use programming device to determine the cause of the error.) Service Required to Reprogram or replace the PLC

4) CPU Indicator is OFF

a. If the CPU indicator is on. A fatal error occurred in the CPU. Generally, this is not a programming problem but an actual hardware failure. This problem is sometimes caused by high frequency electrical noise introduced into the CPU from an outside source. Remove power from the PLC to clear the error. If the error clears, you should monitor the system, Check your system grounding and electrical noise filters if the grounding is suspected. Service Required to replace the PLC

5) Communications Problems

a. The cable is disconnected. Secure Cable b. The cable has a broken wire or has been wired incorrect Service Required to Verify and Correct the

Problem c. The cable is improperly terminated or grounded. Service Required to Verify and Correct the Problem d. The device connected is not operating at the correct baud rate (9600 baud) Service Required to Verify

and Correct the Problem e. The device connected to the port is sending data incorrectly. Service Required to Verify and Correct the

Problem f. A grounding difference exists between the two devices. Service Required to Verify and Correct the

Problem g. Electrical noise is causing intermittent errors. Service Required to Verify and Correct the Problem h. The PLC has a bad communication port and should be replaced. Service Required to Verify and Correct

the Problem 13.14.0 Analog Card

a. Wire Harness Clip incorrectly Inserted Verify and Secure Harness b. Card Not Fully Inserted into PLC Turn Power Off and Re-insert Card c. Defective Analog Card Service Required to Verify and Correct the Problem

13.15.0 +24 Volt Power Supply

a. Loose Connections Verify and Secure Connections b. Defective Power Supply Service Required to Verify and Correct the Problem

13.16.0 VARIABLE SPEED DRIVES

a. See Trouble shooting Guide and Error Codes for the appropriate brand of Drive • AquaVar II – See Appendix Q • AquaVar CPC – See Appendix R • Baldor – See Appendix P .


14.0 PROGRAMMING 14.1 Programming Overview

1) Identify your PLC 2) To View Program Settings, Enter the Program Mode 3) Press the [Help] and [ETM] buttons Simultaneously. 4) To Advance through the settings Press the [Reset] Button. 5) To Exit the Program Mode, press and hold the [Reset] Button for 10 Seconds. 6) To Change Program Settings a Jumper must be in place between 4A and 4B on Terminal 1 7) Record your settings using the appropriate data sheet found in the appendix

a. Appendix E for the 105 PLC Domestic Systems b. Appendix F for the 05 PLC Domestic Systems c. Appendix G for the 06 PLC Domestic Systems d. Appendix H for the 05 PLC 5660Cooling Tower Systems

Programming Mode Screen

14.2 Programming Display Functions

1) Using the Display Buttons to Program the PLC’s Display Buttons Button Function

[Help ↑] & [ETM ↓] Enters Program Mode

[Help ↑] When in Programming mode – Moves Up through selections

[ETM ↓] When in Programming mode – Moves Down through selections

When in Programming mode- Allow Continuous Advancement [GPM] of Keys 1 & 2 When in the Program Mode Depress advance through Programming selections When in the Program Mode Depress and hold for 10 Seconds to Exit [Reset]

Program Mode.

Display Buttons

50


DESCRIPTION

105 05 06

ACTION

Programming Mode

• To enter the Program Mode, Press the [Help] and [ETM] buttons on the display.

Select Model • Select System Your System Model • Using the [Help] and [ETM] buttons, when selected Press the

[Reset] button to advance to the next choice

Set System PSI • Set the System Operating PSI • Using the [Help] and [ETM] buttons, then selected Press the

[Reset button to advance to the next choice ↓

↓ Calibrate Trans (PSI) • Calibrate the Transducer to the pressure gauge. • Using the [Help] and [ETM] buttons, adjust the PSI reading until

it matched the PSI shown on the gauge. When both Match Press the [Reset] button to advance to the next choice.

↓ Set HSP On • Set the PSI to trigger the High System Pressure Alarm. • Using the [Help] and [ETM] buttons, when selected Press the


↓ Set NS On • Set the PSI to trigger Normal Shutdown. • Using the [Help] and [ETM] buttons, when selected Press the


↓ *Ext NF PS Enable” *Ext NF PS Disable”

• *Ext NF PS Enable” When Enabled this mode allows the No-Flow Circuit to be controlled by an External Pressure Switch.

• *Ext NF PS Disable” in this mode the No-Flow works off the Transducer reading Press the [Help] button to toggle between the choices. Press the [Reset] button to advance.

↓ *Low City Pressure” *Low Supply Level”

• Low City Pressure” When Enabled this mode allows the Low City Pressure is monitored by al Pressure Switch.

• *Low Supply Level” in this mode a float switch monitors the level of a cistern or holding tank. Press the [Help] button to toggle between the choices. Press the [Reset] button to advance.

Auto Alternate Off

• Select Pump Alternation Mode • “Auto Alternate Off” Select this if you use the time clock or do

not require pump alternation. • “Auto Alternate On – L1” Select this for pumps to alternate

after a completion of Lag1 • “Auto Alternate On – NS” Select this for pumps to alternate on

Normal Shutdown

↓ Select Mode

• "Mode 0", Normal - Transducer, Low City Pressure, PSI Activated Normal Shutdown. "

• "Mode 1" Island Mode" Modified Lag Enabled • "Mode 2" Variable Speed - X5 activates Normal Shutdown

while screen Displays "Variable Speed Mode • "Mode 3" GPM Mode Enables lag by GPM and not PSI

↓ ↓ Set GPM • Set the System Operating GPM • Using the [Help] and [ETM] buttons, when selected Press the


↓ ↓ Calibrate GPM Transducer

• Calibrate the Transducer to the pressure gauge. • Using the [Help] and [ETM] buttons, adjust the PSI reading until

it matched the GPM shown on the gauge. When both Match Press the [Reset] button to advance to the next choice

51


DESCRIPTION Continued

105 05 06

ACTION

Lead Off - Lag • Select If the Lead Pump runs with Lag1 Pump. • Lead Off- Lag Lead Pump will cycle off during Lag1 • Lead ON- Lag Lead Pump will stay on during Lag1

↓

Set Lag 1 PSI Set Lag 1 PSI

Or GPM

• Set the PSI/GPM the Lag 1 pump should start, • using the [Help] and [ETM] buttons, when selected Press the

[Reset] button to advance to the next choice If Applicable If Applicable

↓ ↓ Set Lag 1 Off

GPM If Applicable

• Set the GPM the Lag 1 pump should turn off • Using the [Help] and [ETM] buttons, when selected Press the


Set Lag 1 Delay

• Set the Lag 1 Delay in Seconds, • this is the number of seconds the pump waits from the time the

LAG1 PSI/GPM is reached to the time the pump starts. Using the [Help] and [ETM] buttons, when selected Press the [Reset] button to advance to the next choice

Set Lag 1 Runtime

• Set the Lag 1 Run Time in Minutes, • Number of minutes the pump will run after the System PSI/GPM

returns to the preset System PSI/GPM. Using the [Help] and [ETM] buttons, when selected Press the [Reset] button to advance to the next choice

↓ Set Lag 2 PSI Set Lag 2 PSI

Or GPM

If Applicable

• Set the PSI/GPM the Lag 2 pump should start, If Applicable • Using the [Help] and [ETM] buttons, when selected Press the



GPM If Applicable



Set Lag 2 Delay If Applicable

• Set the Lag 1 Delay in Seconds, • number of seconds the pump waits from the time the LAG2

PSI/GPM is reached to the time the pump starts. Using the [Help] and [ETM] buttons, when selected Press the [Reset] button to advance to the next choice

Set Lag 2 Runtime If Applicable



↓ Set Lag 3 PSI Set Lag 3 PSI

Or GPM

If Applicable

• Set the PSI/GPM the Lag 3 pump should start, If Applicable • Using the [Help] and [ETM] buttons, when selected Press the



GPM If Applicable



Set Lag 3 Delay If Applicable

• Set the Lag 3 Delay in Seconds, • Number of seconds the pump waits from the time the LAG3


Set Lag 3 Runtime • Set the Lag 3 Run Time in Minutes, • Number of minutes the pump will run after the System PSI/GPM

returns to the preset System PSI/GPM. Using the [Help] and [ETM] buttons, when selected Press the [Reset] button to advance to the next choice.

If Applicable

Set Lag 4 PSI

If Applicable

Set Lag 4 PSI Or

↓ GPM If Applicable

• Set the PSI/GPM the Lag 4 pump should start, • Using the [Help] and [ETM] buttons, when selected Press the


52



105 05 06

ACTION


GPM If Applicable



Set L4 Delay If Applicable



Set L4 Runtime If Applicable

• Set the Lag 4 Run Time in Minutes, • this is the number of minutes the pump will run after the System

PSI/GPM returns to the preset System PSI/GPM. Using the [Help] and [ETM] buttons, when selected Press the [Reset] button to advance to the next choice.

↓ Set Lag 5

PSI Set Lag 5 PSI

Or GPM

If Applicable

• Set the PSI/GPM the Lag 5 pump should start,

If Applicable • Using the [Help] and [ETM] buttons, when selected Press the



GPM If Applicable



Set L5 Delay If Applicable



Set L5 Runtime If Applicable



↓

Set Lag 6 PSI Or

GPM If Applicable

• Set the PSI/GPM the Lag 6 pump should start, • Using the [Help] and [ETM] buttons, when selected Press the

[Reset] button to advance to the next choice ↓


GPM If Applicable



↓ ↓ Set L6 Delay

If Applicable



↓ ↓ Set L6

Runtime If Applicable



↓

Set Lag 7 PSI Or

GPM If Applicable

• Set the PSI/GPM the Lag 7 pump should start,, • Using the [Help] and [ETM] buttons, when selected Press the

[Reset] button to advance to the next choice. ↓

Set Lag 7 Off GPM

If Applicable

• Set the GPM the Lag 7 pump should turn off ↓ ↓ • Using the [Help] and [ETM] buttons, when selected Press the


↓ ↓ Set L7 Delay

If Applicable



53



105 05 06 ACTION

• Set the Lag 7 Run Time in Minutes,

Set L7 • Number of minutes the pump will run after the System PSI/GPM returns to the preset System PSI/GPM. Using the [Help] and [ETM] buttons, when selected Press the [Reset] button to advance to the next choice

Runtime ↓ ↓ If Applicable

END • Press the [Reset] button to begin again or Hold the [Reset] button For 10 seconds to exit the programming mode.

14.3 Special Programming for Transducer Depth 5660Cooling Tower Systems

Description Action

Set T Delay: 0 Min • Set Time Delay for Pumps to Start 0-15 Minutes Min%. Using the [Help] and [ETM] buttons, when selected Press the [Reset] button to advance to the next choice

Set Lead On: XX% • This is the percentage at which the Lead pump turns ON 75%. Using the [Help] and [ETM] buttons, when selected Press the [Reset] button to advance to the next choice

Set Lag On: XX% • This is the percentage at which the LAG pump turns ON 50%. Using the [Help] and [ETM] buttons, when selected Press the [Reset] button to advance to the next choice

Set Pumps Off: XX% • This is the percentage at which the pumps turn OFF . Using the [Help] and [ETM] buttons, when selected Press the [Reset] button to advance to the next choice 90%

Set Low Warn: XX% • This is the percentage at which the Low Water Alarm comes on 10%. Using the [Help] and [ETM] buttons, when selected Press the [Reset] button to advance to the next choice

Set High Warn: XX% • This is the percentage at which the High Water Alarm comes . Using the [Help] and [ETM] buttons, when selected Press the [Reset] button to advance to the next choice on 95%

Cooling Tower Depth • This is the actual depth of the cooling tower 6”,12”,18”,24”,30” and 36”

END • Press the [Reset] button to begin again or Hold the [Reset] button For 10 seconds to exit the programming mode

54

Chapter 15S P E C I A L I Z E D P U M P C O M P A N Y I N C .

15.0 PREVENTIVE MAINTENANCE

1) Startup a. two to three hours after starting the system clean all strainers in the suction line (if

applicable). If there is any debris present a more thorough cleaning of the valve may be necessary.

2) Daily

a. Check and record all pressure gauge readings. b. Check for leaks in the mechanical seals and pilot tubing. c. Check connections to the gauge board (if applicable).

3) Weekly

a. If lag pumps do not usually run, operate them in the “hand” position for approximately ten minutes each..

4) Monthly

a. Check motor bearings and lubricate if required b. Clean strainers and all pressure regulating valves. c. Test all alarms. d. On Systems with Variable Speed Drives, Check fan guard and heat sink for dust and dirt

build up. If found to be dirt blow dry clean with compressed air.

5) Yearly a. Check the system sequencing by generating sufficient flow in the building to automatically

activate flow-sensing devices. b. Clean and/or rebuild pressure-regulating valves.

6) Lubrication

a. Some small motors have pre-greased bearings and require no maintenance. b. Note: Refer to specific component bulletins for motor lubrication instructions.

55


APENDEXES

Appendix A – Time Clock Appendix B - Pressure Switch Appendix C - Pressure Transducer Type PT3 Appendix D - Pressure Transducer Type PT4 Appendix E – 105 Program Settings Sheet Appendix F – 05 Program Settings Sheet Appendix G – 06 Program Settings Sheet Appendix H – CTII Settings Sheet Appendix I – Power Supply Specifications Appendix J – Display Specifications Appendix K – Analog Card Specifications Appendix L – Modem Specifications Appendix M – Temp Purge Appendix N – Depth Transducer Appendix O – Expansion Joints (Isolators) Appendix P – Baldor Variable Frequency Drive Appendix Q – AQUAVAR II Variable Frequency Drive Appendix R – AQUAVAR CPC Variable Frequency Drive Appendix S – Expansion Tank Fiberglass Non ASME Appendix T – Expansion Tank Steel ASME

56


Appendix A – Time Clock

57


Appendix A – Time Clock

58


Appendix B – Pressure Switches

59


Appendix C – Transducer Type PT3

60


Appendix D – Transducer Type PT4

Transducer Connections Pin #3 Brown Wire +24 VDC Pin #1 White Wire 4-20 mA Output Pin #2 Do not connect Pin #4 is wider for orientation – Do not Connect Plug can be mounted in only one position

61


62

Appendix E – 105 Program Data Sheet

105 PROGRAMMING SETTINGS PRESSURE SWITCHES DESCRIPTION PROGRAM SETTINGS Select Model Set to

Auto Alternate Set to Lead Off - Lag Set to

Select EG Mode Set to Set L1 Dly Set to

Set L1 Runtime Set to Set L2 Dly Set to




Set L5 Runtime Set to


63

Appendix F – 05 Program Data Sheet

05 PROGRAMMING SETTINGS PSI DESCRIPTION PROGRAM SETTINGS Select Model Set to

Set System PSI Set to Calibrate Transducer Adj to

Set HSP Set to Set NS On Set to “Ext NF PS” Set to

Low City Pressure Set to Auto Alternate Set to Select Mode Set to

Lead Off - Lag Set to Set L1 PSI Set to Set L1 Dly Set to

Set L1 Runtime Set to Set L2 PSI Set to Set L2 Dly Set to



Set L4 Runtime Set to Set L5 PSI Set to

Set L5 Dly Set to



64

Appendix G – 06 Program Data Sheet

06 PROGRAMMING SETTINGS PSI - GPM DESCRIPTION PROGRAM SETTINGS Select Model Set to

Set System PSI Set to Calibrate Transducer Adj to

Set HSP Set to Set NS On Set to “Ext NF PS” Set to

Low City Pressure Set to Auto Alternate Set to Select Mode Set to

Set System GMP Set to

Calibrate GPM Transducer Adj to

Lead Off - Lag Set to Select EG Mode Set to

Set L1 GPM Set to Set L1 Dly Set to

Set L1 Runtime Set to Set L2 GPM Set to Set L2 Dly Set to








65

Appendix H – CT5660 Program Data Sheet

CT5660 PROGRAMMING SETTINGS (DEPTH)

DESCRIPTION PROGRAM SETTINGS Set T Delay Set to

Set Lead On: Set to Set Lag On Set to

Set Pumps Off: Set to Set Low Warn: Set to Set High Warn: Set to

C/T Depth = Set to


Appendix I – Power Supply Specifications 05 PLC Systems Only

66


Appendix J – Display Specifications

67


Appendix K – Analog Card Specifications

68


Appendix L – Modem Specifications

69


Appendix M – Temp Purge Valve

70


71

Appendix N – WL400 WATER LEVEL SENSOR Submersible Pressure Transducer for Level & Pressure FEATURES

• High accuracy and reliability • Completely submersible pressure transducer and

cable • Compact, rugged design for easy installation • Minimal maintenance and care • Water level sensor compatible with most monitoring

equipment • 4-20mA output

• Vented cable for automatic barometric compensation • Multiple level ranges available from 3' to 250' • Wet-wet water level sensor eliminates vent tube

concerns • Dynamic temperature compensation system • Submersible pressure transducer not affected by

foam, wind, or rain

Product Description Global Water's WL400 Water Level Sensor provides highly accurate water level measurement for a wide variety of applications, including those in severe environments. The submersible pressure transducers have a dynamic temperature compensation system, enabling high accuracy measurements over a wide temperature range. The water level sensor is easily adapted to all data loggers, telemetry, monitoring equipment, and displays. Each of the water level sensors consist of a solid state submersible pressure transducer encapsulated in a stainless steel 13/16" diameter housing. The water level sensor has a molded-on waterproof cable and a two-wire 4-20 mA high level output for connection to a monitoring device. A 25' cable is standard, and optional cable lengths are available up to 500'. The Water Level Sensor's submersible pressure transducer is fully encapsulated with marine-grade epoxy so that moisture can never leak in or work its way down the vent tube to cause drift or level sensor failure (as is the case with other pressure sensors). The water level sensor uses a unique, highly flexible silicon diaphragm to interface between water and the sensing element. This silicon diaphragm protects the water level sensor's electronics from moisture and provides each sensor with exceptional linearity and very low hysteresis. The design of the submersible pressure transducers eliminates the issues associated with metal foil diaphragms, which tend to crinkle and stretch out over time causing drift, linearity, and hysteresis problems. The water level sensor is also has automatically barometric compensation due to the attached vent cable and protected by a stainless steel micro-screen cap, which makes fouling with silt, mud, or sludge virtually impossible. The water level sensor's design is great for all saltwater applications including tide level monitoring, floating docks, and others. Pressure transducer level ranges of 0-3' low-level range is ideal for measuring shallow flows or small water level changes like those encountered in sewers, storm drains, weirs, and flumes. The 0-3' water monitoring sensor accurately measures small changes in water, even when the water's depth is only a few inches deep. Other metal foil-type water level sensors typically have serious problems at low-level ranges because of sensor crinkling, stretching, and drifting. Each submersible pressure transducer has a two-wire 4-20 mA output signal that is linear with water depth. From 10 to 36 VDC is required to operate the water level sensor, so the level sensors can be operated from common 12 VDC battery systems. The 4-20 mA signal can run up to 3,000' from the submersible pressure transducer to the logging device. Common twisted pair or electrical extension cord wire may be spliced to the vented cable once the cable is out of the water. The 4-20 mA signal may be converted to 0.5 to 2.5 VDC by dropping the current signal across a 125 ohm resistor. Specifications Sensing Element Sensor Element: Silicone Diaphragm, Wet/Wet Transducer Pressure Range: 0-3', 0-15', 0-30', 0-60', 0-120',0-250' Linearity and Hysteresis: ±0.1% FS Accuracy: ±0.1% of full scale at constant temperature, ±0.2% over 35°F to 70°F range Overpressure: Not to exceed 2 x full scale range Resolution: Infinitesimal (Analog) Outputs: 4-20 mA or 0.5 to 2.5 VDC across 125 ohms Supply Voltage: 10 to 36 VDC Current Draw: Same as sensor output Warm Up Time: 10 ms minimum Operating Temperature: -40° to +185°F Compensation: Uses dynamic temperature compensation 30-70 F. Automatic barometric pressure compensation Weight: 1/2 lb Housing Material: 304L Stainless Steel, SS microscreen (hundreds of holes to prevent fouling), electronics are fully encapsulated in marine grade epoxy, guaranteed not to leak Size: up to 5 1/2" long x 13/16" diameter (small enough for a 1" well) Cable Conductors: 4 each 22 AWG Jacket Material: Marine Grade Polyurethane Vent Tube Material: HD Polyethylene Shield: Aluminum Mylar Outer Diameter: .307" Temperature Range: -22° to +185°F Weight: 0.7 oz/ft Length: Standard 25' (up to 500' from the factory)


Appendix N – WL400 WATER LEVEL SENSOR (Continued)

Installation The submersible pressure sensor may be placed slightly below the lowest expected water level. Water level sensor level ranges of 0-3', 0-15', 0-30', 0-60', 0-120' and 0-250' are available. When ordering, select the level sensor range that will cover the maximum water level change (this is not necessarily the total depth of water). Selecting the smallest water level range possible will ensure the greatest accuracy. The 4-20 mA signal can run up to 3,000' from the water level sensor to the logging device. Common twisted pair or electrical extension cord wire may be spliced to the vented cable once the cable is out of the water. The 4-20 mA signal may be converted to 0.5 to 2.5 VDC by dropping the current signal across a 125 ohm resistor.

72


Appendix O – Expansion Isolators

73


Appendix P – Baldor Variable Frequency Drive

Baldor Variable Frequency Drive

74


75


76


77


78

Variable Speed Drive - Baldor Error Codes POSSIBLE CAUSE CORRECTIVE ACTION

1) Command Select a. Incorrect operating mode programmed. Change Operating Mode in the Level 1 input block to one that

does not require the expansion board. b. Need expansion board. Install the correct expansion board for selected operating mode.

2) Bus Overvoltage Trip Over voltage a. Excessive dynamic braking power. Check dynamic brake Watt and resistance parameter values.

Increase the DECEL time. Add external dynamic braking assemblies: RGA resistor kit RBA transistor assembly.

b. DECEL Rate set too low a value Lengthen DECEL time. Add external dynamic braking resistors or module.

c. Overhauling Motor-load Correct problem with motor load. Add external dynamic braking resistors or module.

d. Dynamic; brake mis-wired. Check dynamic brake hardware wiring. e. Input voltage too high. Verify proper AC line voltage. Use step down transformer if needed. Use line

reactor to minimize spikes. 3) Bus Under voltage

a. Input voltage too low. Verify proper AC line voltage. Use step up transformer if needed. Check power line disturbances (sags caused by start up of other equipment). Monitor power line fluctuations with date and time print to isolate power problem Disconnect dynamic brake hardware and repeat operation.

4) External Trip a. Motor ventilation insufficient. Clean motor air intake and exhaust. Check external blower for operation.

Verify motor’s internal fan is coupled securely b. Motor draws excessive current. Check motor for overloading. Verify proper sizing of control and motor c. Volts' Hertz ratio is wrong. Adjust the Volts Hz parameter value. Adjust the Base Frequency. Adjust the

Max Output Voltage. d. No thermostat connected. Connect thermostat. Verify connection of all external trip circuits used with

thermostat. Disable thermostat input at control. e. Poor thermostat connections. Check thermostat connections. f. External trip parameter incorrect. Verify connection of external trip circuit at J4-1 6.Set external trip

parameter to ‘OFF” if no connection made at J4-16. 5) Hardware Protect

a. Fault duration too short to be identified. Reset control. Check for proper grounding of power wiring and shielding of signal wiring. Replace control board.

6) Heat sink Temp a. Motor Overloaded. Correct motor loading. Verify proper sizing of control and motor. b. Ambient temperature too high. Relocate control to cooler operating area. Add cooling fans or air

conditioner to control cabinet. c. Verify fan operation. Remove debris from fan and heat sink surfaces. Replace fan or check fan wiring.

Built-in fans are ineffective or inoperative. 7) HW Desaturation

a. Accel/Decel rate set too short. Torque Boost set too high Electrical noise in logic circuits Motor overloaded, Lengthen Accel/Decel rate. Reduce torque boost value . Check for proper grounding of power wiring and shielding of signal wiring Verify proper sizing of control and motor or reduce motor load

8) HW Power Supply a. Power supply malfunction Check internal connections Replace logic power board.

9) HW Ground Fault a. Output current (motor current) leakage to ground. Disconnect wiring between control and motor. Retry

test. If GND FLT is cleared:. reconnect motor leads and retry the test. Repair motor if internally shorted Replace motor lead wire with low capacitance cable. If GND FLT remains contact Baldor.

10) Invalid Base ID a. Control does not recognize hp and Voltage configuration Press “RESET” key on Keypad If fault remains

access ‘Diagnostic Info and compare reported ID number with Table 5-2, If different. call Baldor. 11) Line REGEN

a. Fault in Line REGEN Converter Series 21H Line REGEN Inverter only


79

Variable Speed Drive - Baldor Error Codes (Continued) POSSIBLE CAUSE CORRECTIVE ACTION

12) Motor Will Not Start a. Not enough starting torque. Increase Current Limit setting. b. Motor overloaded Check for proper! motor loading Check couplings for binding. Verify proper sizing of

control and motor. c. Motor may be commanded to run below minim urn frequency setting. Increase speed command or lower

minimum frequency setting. d. Incorrect Command Select parameter r. Change Command Select parameter to match wiring at J4 e. Incorrect frequency command. Verify control is receiving proper command signal at J4.

13) Motor Will Not Reach Maximum Speed a. Max Frequency Limit set too low Adjust Max Frequency Limit parameter value. b. Motor Overloaded .Check for mechanical overload. If unloaded motor shaft does not rotate freely, check

motor bearings. c. Improper speed command. Verify control is receiving proper command signal at input terminals Verify

control is set to proper op operation mode to receive your speed command . d. Speed potentiometer. failure. Replaced potentiometer.

14) Motor Not Stop Rotation a. MIN Output Speed set too high. Adjust \1IN input speed parameter value b. Improper speed command. Verify control is receiving proper command signal at input terminals. Verify

control is set to receive your speed command. c. Speed potentiometer failure, Replace potentiometer

15) Motor runs rough at low speed a. Torque boost too high. Adjust torque boost parameter value. b. Misalignment of coupling Check motor/load coupling alignment c. Faulty motor. Replace with a Motor.

16) New Base ID a. Replaced Control or Circuit board. Restore parameters to factory settings. Reset control.

17) No Display a. Lack of input voltage. Check input power for proper Voltage b. Loose Connections Check Input power termination. and operator keypad c. Adjust display contrast. See Adjust Display Contrast.

18) NV Memory Fail a. Memory fault occurred. Turn the unit off for at least 30 seconds and then back on. If the error is

displayed again, then Service is Required 19) Sec Overload

a. Peak output current exceeded 3 sec rating. Check PK Current Limit parameter in the Level 2‘:I’utput Limits block Check motor for overloading Increase ACCEL time. Reduce motor load Verify proper sizing ::f control and motor.

b. 1 Min Overload Peak output current exceeded 1riinute rating Check ‘K Current Limit parameter in the Level 2 Output Limits block. Check motor for overloading. Increase ACCEL/DECEL times. Reduce motor load. Verify proper sizing of control and motor.

20) Over Speed a. Motor exceeded 110% of MAX Output Freq parameter value. Check Max Output Freq in the Level 2

Output Limits block. 21) Param Checksum

a. Memory fault occurred Press Reset key on keypad. Restore parameter values to factory settings. If fault remains, call Service

22) Regen RES Power a. Incorrect dynamic brake parameter. Check Resistor Ohms and Resistor Watts parameters in the Level 2

Brake Adjust block b. Regen power exceeded dynamic brake resistor rating. Add external dynamic braking assemblies: RGA

resistor kit or RBA transistor assembly Increase Decel Time. 23) Unknown Fault Code

a. Microprocessor detected a fault that is not defined in the fault code table Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is Required

24) Unstable Speed a. Oscillating load. Unstable input power. Slip compensation too high. Correct motor load. Correct input

power. Adjust slip compensation


80

Variable Speed Drive - Baldor Error Codes (Continued) POSSIBLE CAUSE CORRECTIVE ACTION

25) uP Reset

a. A software watchdog timer has reset the processor because a process has timed out. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is Required

26) FLT Log MEM Fail

a. Corrupt data in fault log (may occur on older systems only). Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is Required.

27) Current SENSFLT

a. Failure to sense phase current. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is Required

28) Bus Current SENS

a. Failure to sense bus current. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is Required

29) Lack of Water

a. This error message will be displayed when a switch has indicated that the incoming water pressure or water level in a suction tank falls below the required NPSH of the pump. If suction conditions or water level in a suction tank falls below the required NPSH of the pump. If suction conditions appear to be correct, check the pressure switch or float switch to make sure it is operating properly. When the suction conditions have returned to normal, the pump will restart automatically. This message will also appear if terminals 6 and 7 on terminal block Xl are not bridged.

30) Conveyor Control (Value Range Control)

a. The drive is not able to obtain the minimum required value set in the conveyor limit setting. Look for potential reasons for the low signal or lower the “CONVEYOR CONTROL” or increase the “DELAY TIME” settings.

31) Error 1 EPROM Error

a. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is Required

32) Error 2 Security Software Protection Error


33) Error 4 Keyboard Error

a. Check pushbuttons for proper actuation, or buttons may be held down by the cover being on too tight. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is Required

34) Error 5 EPROM Error


35) Error 6 Watchdog Error


36) Error 7 Processor Pulse Error

a. (Failure of oscillator for processor) Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is Required

37) Error 8 Invalid Processor Command Error

a. Power wires and motor leads may be too close to the control board or communication ribbon. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is Required


Appendix Q – AQUAVAR III Variable Frequency Drive

.

81

Panel Found on Inside of the Front Door Panel

84

86

AquaVar II Errors

1) Pressure Sensor Error a. The pressure or flow sensor is out of order, not connected properly, not zeroed properly, or the cable is

damaged. Check the sensor and zero object and then turn the unit back on. If the error is displayed again, then Service is Required

2) Actual Value Sensor Error (Act. Val. Sons. Error)

a. The AQUAVAR does not receive a 4-20 mA signal from transmitter. Check transducer wiring, connections and for the 4-20 mA signal. Once corrected, turn power off for at least 30 seconds to restart. If the error is displayed again, then Service is Required

3) Inverter Error a. A problem or error has occurred in the internal drive. Check the active fault history on internal display,

page 70. Press SHIFT ± ENTER keys to read fault history and fault codes, If the error is displayed again, then Service is Required

AquaVar II Error Codes POSSIBLE CAUSE CORRECTIVE ACTION

1) 01 - Watch Dog Trip a. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is

Required 2) 02 - Cowor Bridge ID

a. Ribbon Cable not correctly seated between the power and control boards. Electrical noise Ensure that the ribbon cable is correctly seated• Determine the source of the noise and eliminate it

3) 03 - Current Calibr a. Current sensor have cc offset problem Turn the unit off for at least 30 seconds and then back on. If the

error is displayed again, then Service is Required 4) 16 - Motor Over Temp (Fault) a. The drive’s motor temperature model detected motor overheating severe enough to cause a fault. Decrease

motor loading. If the motor is not overheated, check the temperature model parameters. 5) 17 - Output Fault

a. The output sensor detected an error. Check motor wiring. Check for and remove any capacitive load. Check the motor and cabling for shorts to ground.

6) 18 - Over current a. The drive has measured excessive current in the motor output. This may be caused by: Sudden heavy

load increase, Short circuit in the motor cables. Unsuitable motor. Check the load, motor size, and cables, Check the load, motor size, and cables. Review the settings for acceleration and deceleration times.

7) 19 - Drive Over Temp a. Temperature of the drive’s heat sink is too high. Check the air flow. Check that the heat sink is not clogged

Check the ambient temperature. Check that the switching frequency is not too high compared to ambient temperature and load.

8) 20 - Motor Overload a. Excessive load on the motor (for example, a jammed load.) Check the motor and load.

9) 21 - Drive Under Temp a. Temperature of the drive's heat sink is below 0°C (32°F).Ribbon cable not correctly seated between the

power and control boards. Increase the ambient temperature. Ensure that the ribbon cable is correctly seated.

10) 22 - Motor Stall (Fault) a. The motor’s stall protection sensed a stall severe enough to cause a fault. Check the motor.

11) 23 - Motor Under load a. The load on the motor is insufficient (for example, a broken conveyor belt) that a fault occurs. Check the

motor and load. 12) 24 - Tsp 10 V Ref

a. 10 V reference for the analog input is overloaded, ensure that the total load on the ±10 terminal does not exceed 20 mA dc. Check for correct connection of devices to the ± 10 terminal. Check for short circuits associated with devices connected to the ±10 terminal Consult factory.

13) 25 - EE Ref Checksum a. Parameter restoring error due to interference fault or component failure. Reset the fault and attempt a

restart. If fault persists, contact the factory.

87

AquaVar II Error Codes (Continued) POSSIBLE CAUSE CORRECTIVE ACTION 14) 26 - EE Par Checksum

a. Parameter restoring error due to interference fault or component failure. Reset the fault and attempt a restart. If fault persists, contact the factory.

15) 27 - EEPROM Checksum a. Parameters restoring error due to interference fault or component failures Reset the fault and attempt a

restart. If fault persists, contact the factory. 16) 28 - Output Phase Loss

a. Current measurement detected a motor phase with no current. Check motor cables. 17) 29 - Precharge Fault


18) 30 - TRIN Fit (ASIC) a. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is

Required 19) 31 - Satur FIt (ASIC)


20) 32 - Empty Trp (ASIC) a. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is

Required 21) 33 - AppI Change


22) 34 - High Unbal Curr a. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is

Required 23) 35 - MCP Software


24) 36 - Loss of Ref(Fault) a. The drive detected the loss of the reference signal. Restore the reference signal.

25) 37 - Loss of Ref(Warning) a. The drive detected the loss of the reference signal. Restore the reference signal.

26) 38 - Broken Wire Trip (Fault)) a. The drive detected a broken wire to Analog Input 1. Check the control wiring for a broken wire and

replace. 27) 39 - Broken Wire Trip (Warning)

a. The drive detected a broken wire to Analog Input 1. Check the control wiring for a broken Wire and replace.

28) 40 - Loss of Keypad a. Communication with the keypad is lost while keypad control is active. Investigate and correct

communication problem. 29) 41 - Ext Fit/Warning (Warning)

a. The configured input sensed an external fault. Investigate why the external fault 30) 42 - Ser Link Timeout

a. Watchdog timer for Modbus serial communications timed out. Reset and restore serial link communications

31) 43 - DI Logic Not Set a. Dl active logic is not set. Set Dl active logic via Active Logic parameter.

32) 44 - DI Logic Changed a. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is

Required 33) 50 - Fan Fault

a. The cooling fan on the drive's enclosure is drawing too much current, which indicates the fan is jammed or has failed. Remove obstruction. Replace fan.

34) 51 - Fan Warning a. The cooling fan on the drive's enclosure is drawing excessive current, but not enough to generate a fault.

This may indicate that the fan is jammed. Remove obstruction. 35) 52 - Motor Over Temp (Warning)

a. The drive’s motor temperature model detected motor overheating, but not severe enough to generate a fault. Decrease motor loading. If the motor is not overheated, check the temperature model parameters.

88

AquaVar II Error Codes (Continued) POSSIBLE CAUSE CORRECTIVE ACTION

36) 53 - Motor Stall (Warning)

a. The motors stall protection sensed a stall I. but not severe enough to cause a fault. Check the motor. 37) 54 - Motor Underload (Warning)

a. The load on the motor is insufficient but not so low that a fault occurs. Check the motor and load. 38) 55 - DeviceNet timed Out Fault

a. No Device communications has occurred in the specified amount of time Reset and restore DeviceNet Communications. See the Device Net manual for further information.

39) 56 - DeviceNet Timed Out (Warning) a. No DeviceNet Communication has occurred in the specified amount of time; Reset and restore

DeviceNet communications; See the Device Net manual for further information. 40) 57 - Network Ext Fault

a. The external communication network delivered a command to the drive (which is forcing a system-wide error.) Reset and restore DeviceNet communication,

41) 58 - Ext Link Timeout (Warning) a. The programmed value or parameter Comm. Timeout was exceeded Reset and restore serial link

communications ions,

Appendix R– AQUAVAR CPC Variable Frequency Drive

89

93

AquaVar CPC Error Codes POSSIBLE CAUSE CORRECTIVE ACTION

1. OVERCURRENT a. Output current is excessive. Check for and correct: Excessive motor load, pump overload. Insufficient

acceleration time (parameters 1301 Ramp 1 and1302 Ramp 2). Faulty motor, motor cables or connections.

2. DC OVERVOLT a. Intermediate circuit DC voltage is excessive. Check for and correct: Static or transient over voltages in the

input power supply. Insufficient deceleration time (parameters 1302 Ramp 2, increase to at least 8 seconds). 3. DEV OVERTEMP

a. Drive heat sink is overheated. Temperature is at or above 1150 C (239° F). C heck for and correct: Fan failure. • Obstructions in Air Flow Dirt or dust coating on the heat sink. Excessive ambient temperature. Excessive motor load ambient temperature. Altitude

4. SHORT CIRC a. Fault current. Check for and correct: A short-circuits in the motor cable(s) or motor. Supply disturbances.

5. OVERLOAD a. Inverters overload condition. The drive output current exceeds the ratings given in “Ratings” on pages

142-145 of this manual. 6. DC UNDERVOLT

a. Intermediate circuit DC voltage is not sufficient. Check for and correct: Missing phase in the input power supply. Blown fuse/check input wiring. Under voltage on mains.

7. All LOSS a. Analog input 1 loss. Analog input value is less than A1 MIN (1604) Check for and correct: Source and

connection for analog input. Parameter settings for All MIN (1604). 8. Al2 LOSS

a. Analog input 2 loss. Analog input value is less than SENSOR MIN (1 506). Check for and correct: Source and connection for analog input. Parameter settings for All MIN (1604). TRANSDUCER MIN.

9. MOT OVERTEMP a. Motor is too hot, based on either the drive’s estimate or temperature feed back device. Check for

overloaded motor. Adjust the parameters used for the estimate; Check the temperature sensors and parameters Check motor wiring and connections. Possible MOTOR phase loss.

10. PANEL LOSS a. Panel communication is lost; Check for and correct: Drive is in local control mode (the control panel

displays LOC) or Drive is in remote control mode (REM) and is programmed to accept start/stop, direction or reference from the control panel. To correct check: Communication lines and connections for control panel. Parameter 2401 KEYPAD FAILURE. Parameters in Group 10: Command Inputs and Group 11: Reference Select (if drive operation is REM).

11. ID RUN FAIL a. The motor ID run was riot completed successfully. Check for and correct: Motor connections, wiring.

12. MOTOR STALL a. Motor or process stall. Motor is operating in the stall region. Check for and correct: Excessive load,

insufficient motor power, Blocked pump. 13. RESERVED Not used 14. 16 - EARTH FAULT

a. The load on the input power system is out of balance; Check for and correct: in the motor or motor cable. Verify that motor cable does not exceed max. Specified length.

15. 17 - UNDERLOAD a. Motor load is lower than expected. Check for and correct: Disconnected load, Drive oversized.

16. 18 - THERM FAIL a. Internal fault. The thermistor measuring the internal temperature of the drive is open or shorted. Turn

the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is Required

17. 19 - OPEX LINK a. Internal fault. A communication-related problem has been detected on the fiber optic link between the

OITF and OINTboards. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is Required

18. 20 - OPEX PWR a. Internal fault. Low voltage condition detected on OINT power supply. Turn the unit off for at least 30

seconds and then back on. If the error is displayed again, then Service is Required

94

AquaVar CPC Error Codes (Continued) POSSIBLE CAUSE CORRECTIVE ACTION

19. 21 - CURR MEAS

a. Internal fault. Current measurement is out of range. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is Required

20. 22 - SUPPLY PHASE a. Ripple voltage in the DC link is too high. Check for and correct: Missing mains phase. Blown fuse. Input

wiring/connections 21. 23 – RESERVED-Not used 22. 24 - OVERSPEED

a. Motor speed is greater than 120% of the larger (in magnitude) of1402 MINIMUM SPEED or 1401 MAXIMUM SPEED. Check for and correct: Parameter settings for 1401 and 1402. Adequacy of motor braking torque. Applicability of torque control.

23. 25 - RESERVED-Not used 24. 26 - DRIVE ID

a. Internal fault. Configuration Block Drive ID is not valid. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is required

25. 27 - CONFIG FILE a. Internal configuration file has an error. Turn the unit off for at least 30 seconds and then back on. If the

error is displayed again, then Service is Required 26. 28 - SERIAL 1 ERR

a. Field bus communication has timed out. Check for and correct: Fault setup (2409 COMM FAULT FUNC and 2410 COMM FAULT TIME). Communication settings (Group 31 or 32 as appropriate). Poor connections and/or noise on line.

27. 29 - EFB CON FILE a. Errors in reading the configuration file for the field bus adapter. Turn the unit off for at least 30 seconds

and then back on. If the error is displayed again, then Service is required 28. 30 - FORCE TRIP

a. Fault trip forced by the field bus. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is Required

29. 31 - EFB 1 a. Fault code reserved for the EFB protocol application. The meaning is protocol dependent. Turn the unit

off for at least 30 seconds and then back on. If the error is displayed again, then Service is required 30. 32 - EFB 2

a. Fault code reserved for the EFB protocol application. The meaning is protocol dependent. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is required

31. 33 - EFB3 a. Fault code reserved for the EFB protocol application. The meaning is protocol dependent. Turn the unit

off for at least 30 seconds and then back on. If the error is displayed again, then Service is required 32. 34 - MOTOR PHASE

a. Fault in the motor circuit. One of the motor phases is lost. Check for and correct: Motor fault. Motor cable fault. Motor wiring, connections. Internal fault.

33. 35 - OUTP WIRING a. Error in power wiring suspected. . Check for and correct: Input power wired to drive output. Ground

faults 34. SERF CORRUPT

a. Error internal to the drive. Turn the unit off for at least 30 seconds and then back on. If the error is displayed again, then Service is required

35. 102 - SERF IITFILE a. Error internal to the drive. Turn the unit off for at least 30 seconds and then back on. If the error is

displayed again, then Service is Required 36. 103 - SERF MACRO


37. 104 - SERF EFBPROT a. Error internal to the drive. Turn the unit off for at least 30 seconds and then back on. If the error is

displayed again, then Service is required 38. 105 - SERF BPFILE


95

AquaVar CPC Error Codes (Continued) POSSIBLE CAUSE CORRECTIVE ACTION

39. 201 - DSP Ti OVERLOAD


40. 202 - DSP 12 OVERLOAD a. Error internal to the drive. Turn the unit off for at least 30 seconds and then back on. If the error is

displayed again, then Service is required 41. 203 - DSP 13 OVERLOAD


42. 204 - DSPSTACK ERROR a. Error internal to the drive. Turn the unit off for at least 30 seconds and then back on. If the error is

displayed again, then Service is required 43. 205 - DSPREVERROR


44. 206 - OMIOIDERROR a. Error internal to the drive. Turn the unit off for at least 30 seconds and then back on. If the error is

displayed again, then Service is required 45. 1000 - PAR HZRPM

a. Parameter values are inconsistent. Verify Parameter Settings 46. 1001 - PAR PFCREFNG

a. Parameter values are inconsistent. Verify Parameter Settings 47. 1003 - PAR AI Scale

a. Parameter values are inconsistent. Verify Parameter Settings 48. 1004 - PAR A0 Scale

a. Parameter values are inconsistent. Verify Parameter Settings 49. 1005 - PAR PCU 2

a. Parameter values are inconsistent. Verify Parameter Settings 50. 1007 - PAR FBUS

a. Parameter values are inconsistent. Verify Parameter Settings 51. 1009 - PAR PCU 1

a. Parameter values are inconsistent. Verify Parameter Settings 52. 2001 - Reserved Not used 53. 2002 - Reserved Not used 54. 2003 - Reserved Not used 55. 2004 - DIR LOCK

a. The change in direction being attempted is not allowed. Either: • Do not attempt to change the direction of motor rotation.

56. 2005 - I/O COMM a. Field bus communication has timed out. Check for and correct: • Fault setup (2411 COMM FAULT FUNC

and 2412 COMM FAULT TIME). • Communication settings (Group 31 or 32 as appropriate). Poor connections and/or noise on the line.

57. 2006 - All LOSS a. Analog Input 1 is lost, or value is less than the minimum setting. Check: • Input source and connections.

• Parameter that sets the minimum (1604). 58. 2007 - TRANSDUCER LOSS

a. Analog Input 2 is lost, or value is less than the minimum setting. Check Transducer, connection and wiring. Input source and connections. Parameter that sets the minimum (1506).

59. 2008 - PANEL LOSS a. Panel communication is lost and either: Drive is in local control mode (the control panel displays LOC),

or Drive is in remote control mode (REM) and is parameterized to accept start/stop, direction or reference from the control panel to correct Communication lines and connections. Parameter 2401 KEYPAD FAILURE.

60. 2009 RESERVED-Not used 61. 2010 - MOTOVERTEMP

a. Motor is hot, based on either the drive’s estimate or on temperature feedback. This alarm warns that a Motor Underload fault trip may be near. Check: Check for overloaded motor, pump.

96

AquaVar CPC Error Codes (Continued) POSSIBLE CAUSE CORRECTIVE ACTION 62. 2011 - UNDERLOAD

a. Motor load is lower than expected. This alarm warns that a Motor Underload fault trip may be near. Check: Motor and drive ratings match (motor is NOT undersized for the drive).

63. 2012 - MOTOR STALL a. Motor is operating in the stall region. This alarm warns that a Motor Stall fault trip may be near. \

64. 2013 - (note 1) AUTORESET a. This alarm warns that the drive is about to perform an automatic fault reset, which may start the motor.

To control automatic reset, use parameter Group 12 AUTOMATIC RESET. 65. 2015 - ALARM 2015PUMPPROTECT

a. Pump protection has been triggered via parameter 2403(protection)

Appendix S– Expansion Tanks (Fiberglass Non-ASME) Corrosion-proof composite construction - From the high density polyethylene inner liner to the fiberglass-wound and epoxy resin-sealed outer shell, WM-Series tanks contain no steel. So they can't rust. Little or no maintenance - Because they contain no steel, there is no paint to scratch or touch up. Longer life, greater flexibility - Our unique air cell offers longer life than the bladders or diaphragms in steel tanks. WM-Series tanks can be installed with a wider range of pressure settings, so you can select the system pressure you want. What's more, the bottom inlet/outlet assembly is pre-installed and comes with system connections to save time and money. Light weight - WellMate tanks are quicker, easier and less costly to install than steel tanks. NSF and/or FDA listed materials - The complete assembly meets stringent US requirements for water components. WellMate tanks are environmentally safe, 100% lead-free. They will not introduce undesirable chemicals or elements into your customers' water. Replaceable air cell - Easy to service in the field. WM-Series Performance Data Model Number

Capacity gal/liter

Max. Operating Pressure psi / kPa / bar

Drawdown 30/50 Setting gal/liter

Diameterinch / cm

Overall Height inch / cm

Height inlet/outlet to floor inch /cm

System Connection

Assembly Weight lb / kg

WM-6 19.8 / 75 100 / 700 / 7.0 5.9 / 22.5 16 / 41 32 / 81 1¾ / 4.4 1" male NPT 17.75 / 8.1 WM-9 29.5 / 112 100 / 700 / 7.0 8.9 / 33.5 16 / 41 44 / 112 1¾ / 4.4 1" male NPT 24.75 / 11.2 WM-12 40.3 / 153 100 / 700 / 7.0 12.1 / 45.8 16 / 41 57 / 145 1¾ / 4.4 1" male NPT 30 / 13.6 WM-14WB 47.1 / 178 125 / 862 / 8.6 14.1 / 53.5 21 / 53 41¼ / 105 2¼ / 5.7 1¼" male NPT 43 / 19.5 WM-20WB 60.0 / 227 125 /862 / 8.6 18.0 / 68.1 24 / 61 41½ / 105 2¼ / 5.7 1¼" male NPT 50 / 22.7 WM-25WB 86.7 / 328 125 / 862 / 8.6 26.0 / 98.5 24 / 61 55¼ / 140 2¼ / 5.7 1¼" male NPT 72.75 / 33.0 WM-35WB 119.7 / 453 125 / 862 / 8.6 35.9 / 135.9 24 / 61 74¼ / 189 2¼ / 5.7 1¼" male NPT 95 / 43.1

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Appendix T– Expansion Tanks (Steel - ASME)

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Appendix T– Expansion Tanks (Steel - ASME)

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SPECIALIZED PUMP COMPANY INC. Booster Systems · SPECIALIZED PUMP COMPANY INC. 1 1.0 Installation...

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