IOM Manual - American
Installation, Operation &
Maintenance Manual
For
Series 1000
Neptune Booster Systems
Copyright © 2011 American-Marsh Pumps
Water Systems Group
Engineered Process Group
www.american-marsh.com
Series 1000
Model: Neptune Booster Systems
Edition 1
25 October 2011
IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
Installation, Operation & Maintenance Manual
Table of Contents
3 ...............SAFETY CONSIDERATIONS
4 ...............WARRANTY
4...............GENERAL INSTRUCTIONS
4...............MANUFACTURER
4...............TYPE OF PUMP
4...............INSTALLATION, OPERATION & MAINTENANCE MANUAL IDENTIFICATION
5 ...............HANDLING AND TRANSPORT
5 ...............METHOD OF TRANSPORT
5...............INSTALLATION
5 ...............STORAGE
5...............SHORT-TERM STORAGE
5 ...............LONG-TERM STORAGE
6 ...............INSTALLATION & ALIGNMENT
6...............SYSTEM RECEIPT
6...............INSTALLATION
6...............BASE PLATE INSTALLATION
6...............NEW GROUTED BASE PLATES
7...............COUPLING
8...............SYSTEM INTEGRATION
8 ...............PUMP OPERATION
8...............ROTATION CHECK
8...............PRE START-UP CHECKS
8...............ENSURING PROPER NPSHA
9...............MINIMUM FLOW
10...............REDUCED CAPACITY
10...............REDUCED HEAD
10...............OPERATION IN SUB-FREEZING CONDITIONS
10 ...............OPERATION
11 ...............SUPPLEMENTAL INFORMATION
12 ...............APPENDIX A
13 ...............APPENDIX B
14 ...............APPENDIX C
15 ...............APPENDIX D
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IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
Installation, Operation & Maintenance Manual
SAFETY CONSIDERATIONS
proper prime (flooded system).
Never operate the pump(s) for more than a short interval with
the discharge valve closed. The length of the interval depends
on several factors including the nature of the fluid pumped and
its temperature. Contact American-Marsh Engineering for additional support if required.
The American-Marsh Neptune Booster System has been
designed and manufactured for safe operation. In order to
ensure safe operation, it is very important that this manual be
read in its entirety prior to installing or operating the system.
American-Marsh Pumps shall not be liable for physical injury,
damage or delays caused by a failure to observe the instructions
for installation, operation and maintenance contained in this
manual.
Never operate the system with a closed suction valve.
Excessive pump noise or vibration may indicate a dangerous operating condition. The pump(s) must be shutdown immediately.
Remember that every pump has the potential to be dangerous,
because of the following factors:
Do not operate the pump and/or the system for an extended
period of time below the recommended minimum flow.
• Parts are rotating at high speeds
• High pressures may be present
• High temperatures may be present
• Highly corrosive and/or toxic chemicals may be present
It is absolutely essential that the rotation of the motor be
checked before starting any pump in the system. Incorrect rotation of the pump(s) for even a short period of time can cause
severe damage to the pumping assembly.
Paying constant attention to safety is always extremely important. However, there are often situations that require special
attention. These situations are indicated throughout this book
by the following symbols:
If the liquid is hazardous, take all necessary precautions to avoid
damage and injury before emptying the pump casing.
Residual liquid may be found in the pump casing, suction and
discharge manifolds. Take the necessary precautions if the liquid is hazardous, flammable, corrosive, poisonous, infected, etc.
Always lockout power to the driver before performing pump
maintenance.
DANGER - Immediate hazards which WILL result in severe
personal injury or death.
Never operate the pump without the coupling guard (if supplied) and all other safety devices correctly installed.
Do not apply heat to disassemble the pump or to remove the
impeller. Entrapped liquid could cause an explosion.
If any external leaks are found while pumping hazardous product, immediately stop operations and repair.
WARNING – Hazards or unsafe practices which COULD result
in severe personal injury or death.
CAUTION – Hazards or unsafe practices which COULD result
in minor personal injury or product or property damage.
Maximum Lifting Speed: 15 feet/second.
If in a climate where the fluid in the system could freeze, never
leave liquid in the booster system. Drain the system completely.
During winter months and cold weather, the liquid could freeze
and damage the system components.
Do not run the equipment dry or start the pump without the
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IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
Installation, Operation & Maintenance Manual
PUMP IDENTIFICATION
WARRANTY
American-Marsh Pumps guarantees that only high quality materials are used in the construction of our pumps and that machining and assembly are carried out to the highest standards.
MANUFACTURER
American-Marsh Pumps
185 Progress Road
Collierville, TN 38017
United States of America
The pumps are guaranteed against defective materials and/or
faulty craftsmanship for a period of one year from the date of
shipment unless specifically stated otherwise.
TYPE OF PUMP
Replacement of parts or of the pump itself can only be carried
out after careful examination of the pump by qualified personnel.
The American-Marsh Neptune Booster System can consist
of many different types of pumps. This manual is intended to
cover the integration of these pumping assemblies into a common skid. Individual pump specific Installation, Operation
& Maintenance manuals will be supplied in addition to this
manual to supplement specific pump construction.
The warranty is not valid if third parties have tampered with
the pump and/or if the pump warranty seal has been removed
without PRIOR written consent.
This warranty does not cover parts subject to deterioration or
wear and tear (mechanical seals, pressure and vacuum gauges,
rubber or plastic items, bearings, etc.) or damage caused by
misuse or improper handling of the pump by the end user.
DATE OF MANUFACTURE
The date of manufacture is indicated on the pump data plate.
Parts replaced under warranty become the property of American-Marsh Pumps.
INSTALLATION, OPERATION &
MAINTENANCE MANUAL IDENTIFICATION
Prepared: October 25, 2011
Revision: Contact the American-Marsh Pumps’ factory:
American-Marsh Pumps
185 Progress Road
Collierville, TN 38017
United States Of America
Edition: 01
Date of Revision:
Phone:
(901) 860-2300
Fax:
(901) 860-2323
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NAMEPLATE INFORMATION
GENERAL INSTRUCTIONS
The pump and motor unit must be examined upon arrival to
ascertain any damage caused during shipment. If damaged
immediately notify the carrier and/or the sender. Check that
the goods correspond exactly to the description on the shipping
documents and report any differences as soon as possible to the
sender. Always quote the pump type and serial number stamped
on the data plate.
FIGURE 1 – Pump Data Plate
SERIAL NUMBER:
Serial Number of pump unit (issued by Production Control)
SIZE:
Size designation of pump (3x4-10)
TYPE:
Pump type (REF, REC or REI)
RPM:Speed of pump
GPM:
Rated capacity of pump
TDH:
Rated Total Dynamic Head of pump
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The pumps must be used only for applications for which the
manufacturers have specified:
4
•
The construction materials
•
The operating conditions (flow, pressure, temperature, etc.)
•
The field of application
IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
Installation, Operation & Maintenance Manual
4. After a performance test, if required, the pump is tipped on
the suction flange for drainage (some residual water may
remain in the casing). Then, internal surfaces of ferrous
casings, covers, flange faces, and the impeller surface are
sprayed with Calgon Vestal Labs RP-743m, or equal. Exposed shafts are taped with Polywrap.
In case of doubt, contact the manufacturer.
HANDLING AND TRANSPORT
METHOD OF TRANSPORT
5. Flange faces are protected with plastic covers secured with
plastic drive bolts. 3/16 in (7.8 mm) steel or 1/4 in (6.3
mm) wood covers with rubber gaskets, steel bolts, and nuts
are available at extra cost.
The Neptune Booster System must be transported in the horizontal position.
INSTALLATION
6. All assemblies are bolted to a wood skid which confines the
assembly within the perimeter of the skid.
During installation and maintenance, all components must
be handled and transported securely by using suitable slings.
Handling must be carried out by specialized personnel to avoid
damage to the pump and persons. The lifting rings attached to
various components should be used exclusively to lift the components for which they have been supplied.
7. Assemblies with special paint are protected with a plastic
wrap.
8. All assemblies having external piping (seal flush and cooling water plans), etc. are packaged and braced to withstand
normal handling during shipment. In some cases components may be disassembled for shipment. The pump must
be stored in a covered, dry location.
LONG-TERM STORAGE
Maximum lifting speed: 15 feet/second
Long-term storage is defined as more than two months, but less
than 12 months. The procedure American-Marsh follows for
long-term storage of pumps is given below. These procedures
are in addition to the short-term procedure.
STORAGE
SHORT-TERM STORAGE
Solid wood skids are utilized. Holes are drilled in the skid to
accommodate the anchor bolt holes in the base plate, or the casing and bearing housing feet holes on assemblies less base plate.
Tackwrap sheeting is then placed on top of the skid and the
pump assembly is placed on top of the Tackwrap. Metal bolts
with washers and rubber bushings are inserted through the skid,
the Tackwrap, and the assembly from the bottom of the skid and
are then secured with hex nuts. When the nuts are “snugged”
down to the top of the base plate or casing and bearing housing feet, the rubber bushing is expanded, sealing the hole from
the atmosphere. Desiccant bags are placed on the Tackwrap.
The Tackwrap is drawn up around the assembly and hermetically (heat) sealed across the top. The assembly is completely
sealed from the atmosphere and the desiccant will absorb any
entrapped moisture. A solid wood box is then used to cover the
assembly to provide protection from the elements and handling.
This packaging will provide protection up to twelve months
without damage to mechanical seals, bearings, lip seals, etc. due
to humidity, salt laden air, dust, etc. After unpacking, protection will be the responsibility of the user. Addition of oil to the
bearing housing will remove the inhibitor. If units are to be idle
for extended periods after addition of lubricants, inhibitor oils
and greases should be used.
Normal packaging is designed to protect the pump during shipment and for dry, indoor storage for up to two months or less.
The procedure followed for this short-term storage is summarized below:
Standard Protection for Shipment :
1. Loose unmounted items, including, but not limited to, oilers, packing, coupling spacers, stilts, and mechanical seals
are packaged in a water proof plastic bag and placed under
the coupling guard. Larger items are packaged and metal
banded to the base plate. All parts bags and cartons are
identified with the American-Marsh sales order number,
the customer purchase order number, and the pump item
number (if applicable).
2. Inner surfaces of the bearing housing, shaft (area through
bearing housing), and bearings are coated with Cortec
VCI-329 rust inhibitor, or equal.
Note: Bearing housings are not filled with oil prior to shipment.
3. Regreasable bearings are packed with grease (Royal Purple
NLGI#2).
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IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
Installation, Operation & Maintenance Manual
Every three months, the shaft should be rotated approximately
10 revolutions.
INSTALLATION & ALIGNMENT
SYSTEM RECEIP T
When the Neptune Booster System is received it is very important that the system and components are checked for signs of
damage during shipment.
INSTALLATION
BASE PLATE INSTALLATION
FIGURE 2 – Base Plate Foundation
NEW GROUTED BASE PLATES
3. After leveling the system, base plate, tighten the anchor
bolts. If shims were used, make sure that the base plate was
shimmed near each anchor bolt before tightening. Failure to do this may result in a twist of the base plate, which
could make it impossible to obtain final alignment. Check
the level of the base plate to make sure that tightening the
anchor bolts did not disturb the level of the base plate. If
the anchor bolts did change the level, adjust the jackscrews
or shims as needed to level the base plate. Continue adjusting the jackscrews or shims and tightening the anchor bolts
until the base plate is level.
1. The pump foundation should be located as close to the
source of the fluid to be pumped as practical. There should
be adequate space for workers to install, operate, and
maintain the pump. The foundation should be sufficient to
absorb any vibration and should provide a rigid support for
the pump and motor. Recommended mass of a concrete
foundation should be three times that of the pump, motor and base. Note that foundation bolts are imbedded in
the concrete inside a sleeve to allow some movement of the
bolt.
4. Check initial alignment. If the pump and motor were
removed from the base plate proceed with step 5 first, then
the pump and motor should be reinstalled onto the base
plate using American-Marsh’s Factory Preliminary Alignment Procedure, and then continue with the following. As
described above, pumps are given a preliminary alignment
at the factory. This preliminary alignment is done in a way
that ensures that, if the installer duplicates the factory
conditions, there will be sufficient clearance between the
motor hold down bolts and motor foot holes to move the
motor into final alignment. If the pump and motor were
properly reinstalled to the base plate or if they were not
removed from the base plate and there has been no transit
damage, and also if the above steps where done properly,
the pump and driver should be within 0.015 in (0.38 mm)
FIM (Full Indicator Movement) parallel, and 0.0025 in/in
(0.0025 mm/mm) FIM angular. If this is not the case first
check to see if the driver mounting fasteners are centered
in the driver feet holes. If not, re-center the fasteners and
perform a preliminary alignment to the above tolerances by
shimming under the motor for vertical alignment, and by
moving the pump for horizontal alignment.
2. Level the Neptune Booster System base plate assembly. If
the base plate has machined coplanar mounting surfaces,
these machined surfaces are to be referenced when leveling
the base plate. This may require that the pump and motor be removed from the base plate in order to reference
the machined faces. If the base plate is without machined
coplanar mounting surfaces, the pump and motor are to
be left on the base plate. The proper surfaces to reference
when leveling the pump base plate assembly are the pump
suction and discharge flanges. DO NOT stress the base
plate. Do not bolt the suction or discharge flanges of the
system to the piping until the base plate foundation is
completely installed. If equipped, use leveling jackscrews
to level the base plate. If jackscrews are not provided, shims
and wedges should be used (see Figure 2). Check for levelness in both the longitudinal and lateral directions. Shims
should be placed at all base anchor bolt locations, and in
the middle edge of the base if the base is more than five feet
long. Do not rely on the bottom of the base plate to be flat.
Standard base plate bottoms are not machined, and it is not
likely that the field mounting surface is flat.
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5. Grout the base plate. A non-shrinking grout should be
used. Make sure that the grout fills the area under the base
plate. After the grout has cured, check for voids and repair
them. Jackscrews, shims and wedges should be removed
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IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
Installation, Operation & Maintenance Manual
SUCTION PIPING
from under the base plate at this time. If they were to be
left in place, they could rust, swell, and cause distortion in
the base plate.
To avoid NPSH and suction problems, suction pipe sizes must
be at least as large as the pump suction connection. Never use
pipe or fittings on the suction that are smaller in diameter than
the pump suction size. An ideal piping configuration should
have a minimum of 10 pipe diameters between the source and
the pump suction manifold. In most cases, horizontal reducers
should be eccentric and mounted with the flat side up as shown
in figure 6 with a maximum of one pipe size reduction. Never
mount eccentric reducers with the flat side down. Horizontally
mounted concentric reducers should not be used if there is
any possibility of entrained air in the process fluid. Vertically
mounted concentric reducers are acceptable. In applications
where the fluid is completely deaerated and free of any vapor or
suspended solids, concentric reducers are preferable to eccentric
reducers.
6. Run piping to the suction and discharge of the pump.
There should be no piping loads transmitted to the pump
after connection is made. Recheck the alignment to verify
that there are no significant loads.
7. Perform final alignment. Check for soft-foot under the
driver. An indicator placed on the coupling, reading in the
vertical direction, should not indicate more than 0.002 in
(0.05 mm) movement when any driver fastener is loosened.
Align the driver first in the vertical direction by shimming
underneath its feet. When satisfactory alignment is obtained the number of shims in the pack should be minimized. It is recommended that no more than five shims be
used under any foot. Final horizontal alignment is made by
moving the driver. Maximum pump reliability is obtained
by having near perfect alignment. American-Marsh recommends no more than 0.002 in (0.05mm) parallel, and
0.0005 in/in (0.0005 mm/mm) angular misalignment.
Avoid the use of throttling valves and strainers in the suction
line. Start up strainers must be removed shortly after start up.
When the pump is installed below the source of supply, a valve
should be installed in the suction line to isolate the pump and
to permit pump inspection and maintenance. However, never
place a valve directly on the suction nozzle of the pump.
8. Operate the pump for at least an hour or until it reaches
final operating temperature. Shut the pump down and
recheck alignment while the pump is hot. Piping thermal
expansion may change the alignment. Realign pump as
necessary.
Refer to the American-Marsh Pump Engineering Manual and
the Centrifugal Pump IOM Section of the Hydraulic Institute
Standards for additional recommendations on suction piping.
DISCHARGE PIPING
PIPING CONNECTION – SUCTION &
DISCHARGE MANIFOLDS
Install a valve in the discharge line. This valve is required for
regulating flow and/or to isolate the pump for inspection and
maintenance.
All piping must be independently supported, accurately aligned
and preferably connected to the pump by a short length of flexible piping. The pump should not have to support the weight of
the pipe or compensate for misalignment. It should be possible
to install suction and discharge bolts through mating flanges
without pulling or prying either of the flanges. All piping must
be tight. Pumps may air-bind if air is allowed to leak into the
piping. If the pump flange(s) have tapped holes, select flange
fasteners with thread engagement at least equal to the fastener
diameter but that do not bottom out in the tapped holes before
the joint is tight.
When fluid velocity in the pipe is high, for example, 10 ft/s (3
m/s) or higher, a rapidly closing discharge valve can cause a
damaging pressure surge. A dampening arrangement should be
provided in the piping.
COUPLING
A direction arrow is cast on the front of the casing and on the
Bearing Housing. Make sure the motor rotates in the same
direction before coupling the motor to the Pump.
It is absolutely essential that the rotation of the motor be
checked before connecting the shaft coupling. Incorrect
rotation of the pump, for even a short time, can dislodge the
impeller which may cause serious damage to the pump. All RE
pumps turn clockwise as viewed from the motor end or, conversely, counterclockwise when viewed from the suction end.
Piping Forces: Take care during installation and operation to
minimize pipe forces and/or moments on the pump casing.
The coupling should be installed as advised by the coupling
manufacturer. Pumps are shipped without the spacer installed.
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IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
Installation, Operation & Maintenance Manual
PRE START-UP CHECKS
If the spacer has been installed to facilitate alignment, then it
must be removed prior to checking rotation. Remove protective material from the coupling and any exposed portions of the
shaft before installing the coupling.
Prior to starting the pump it is essential that the following
checks are made.
SYSTEM INTEGRATION
•
Pump and Motor properly secured to the base plate
After the system has been mounted and supported properly the
step of wiring the panel into the building’s power supply can be
started.
•
All fasteners tightened to the correct torques
•
Coupling guard in place and not rubbing
1. Ensure that the Neptune Booster System disconnect is in
the OFF position.
•
Rotation check, see above
THIS IS ABSOLUTELY ESSENTIAL.
2. Ensure that each H-O-A (Hand-Off-Auto) switch is in
the OFF position as well. This will stop a pump within the
system from energizing accidentally.
3. Have a qualified electrician route power to the system control panel. Be sure that local electrical codes are followed as
they can vary greatly region to region.
4. Grout the Neptune Booster System skid to the concrete
foundation with a non-shrink grout as specified above.
5. Route Neptune Booster System thermal relief valves, if
equipped, to the appropriate floor drain.
6. If American-Marsh supplied an optional, remotely mounted hydro-pneumatic tank, install the tank in a suitable location and connect it to the Neptune Booster System with the
supplied remote connection.
•
Shaft seal properly installed
•
Seal support system operational
•
Bearing lubrication
•
Bearing housing cooling system operational
•
Impeller clearances properly set
•
Pump instrumentation is operational
•
Pump is primed
•
Rotation of shaft by hand
As a final step in preparation for operation, it is important to
rotate the shaft by hand to be certain that all rotating parts
move freely, and that there are no foreign objects in the pump.
ENSURING PROPER NPSHA
Net Positive Suction Head – Available (NPSHA) is the measure
of the energy in a liquid above the vapor pressure. It is used to
determine the likelihood that a fluid will vaporize in the pump.
It is critical because a centrifugal pump is designed to pump a
liquid, not a vapor. Vaporization in a pump will result in damage to the pump, deterioration of the Total Differential Head
(TDH), and possibly a complete stopping of pumping.
The hydro-pneumatic tank is shipped from the factory with the
isolation valve in the closed position. The hydro-pneumatic
tank MUST be pre-charged to system pressure with air PRIOR
to opening the isolation valve and admitting fluid.
PUMP OPERATION
Net Positive Suction Head – Required (NPSHR) is the decrease
of fluid energy between the inlet of the pump, and the point
of lowest pressure in the pump. This decrease occurs because
of friction losses and fluid accelerations in the inlet region of
the pump, and particularly accelerations as the fluid enters the
impeller vanes. The value for NPSHR for the specific pump
purchased is given in the pump data sheet, and on the pump
performance curve.
ROTATION CHECK
It is absolutely essential that the rotation of the motor be
checked before connecting the shaft coupling. Incorrect rotation of the pump, for even a short time, can dislodge and damage the impeller, casing, shaft and shaft seal.
For a pump to operate properly the NPSHA must be greater
than the NPSHR. Good practice dictates that this margin
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IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
Installation, Operation & Maintenance Manual
should be at least 5 ft (1.5 m) or 20%, whichever is greater.
Ensuring that NPSHA is larger than NPSHR by the suggested
margin will greatly enhance pump performance and reliability. It will also reduce the likelihood of cavitation, which can
severely damage the pump.
Never operate pump with both the suction and discharge valves
closed. This could cause an explosion.
2. Slowly open the Neptune Booster System supply from the
building.
MINIMUM FLOW
3. A standard centrifugal pump will not move liquid unless
the pump is primed. A pump is said to be “primed” when
the casing and the suction piping are completely filled with
liquid. Open discharge valve a slight amount. This will
allow any entrapped air to escape and will normally allow
the pump to prime, if the suction source is above the pump.
When a condition exists where the suction pressure may
drop below the pump’s capability, it is advisable to add a low
pressure control device to shut the pump down when the
pressure drops below a predetermined minimum.
Minimum continuous stable flow is the lowest flow at which the
pump can operate and still conform to the bearing life, shaft
deflection and bearing housing vibration limits. Pumps may be
operated at lower flows, but it must be recognized that the pump
may not conform to one or more of these limits. For example,
vibration may exceed the limit set by the ASME standard. The
size of the pump, the energy absorbed, and the liquid pumped
are some of the considerations in determining the minimum
flow.
Typically, limitations of 10% of the capacity at the best efficiency point (BEP) should be specified as the minimum flow.
However, American-Marsh has determined that several pumps
must be limited to higher minimum flows to provide optimum
service. To confirm what minimum flows are required please
contact the American-Marsh engineering department.
4. All cooling, heating, and flush lines must be started and
regulated.
5. Open all petcocks on pumps and system manifolds to allow
air to bleed from the system.
6. Turn the Neptune Booster System panel disconnect to the
ON position.
Note: “Minimum intermittent flow” value of 50% of the “minimum continuous flow” as long as that flow is greater than the
“minimum thermal flow.”
7. Jog PUMP # 1 in order to confirm correct rotation. If rotation is incorrect take corrective action as required.
All pumps also have a “Minimum Thermal Flow.” This is defined
as the minimum flow that will not cause an excessive temperature rise. Minimum Thermal Flow is application dependent.
8. Jog PUMP # 2 in order to confirm correct rotation. If rotation is incorrect take corrective action as required.
Do not operate the pump below Minimum Thermal Flow, as
this could cause an excessive temperature rise. Contact an
American-Marsh Sales Engineer for determination of Minimum Thermal flow.
9. Continue this action to confirm that all system pumps have
correct rotation.
10. Turn PUMP # 1 H-O-A switch to the HAND position.
Bleed air from the Pressure Reducing Valve (PRV ), if
supplied, at the highest point on the valve by opening any
fitting.
STARTING THE SYSTEM
1. Open all system isolation valves to the full open position.
This includes all suction and discharge isolation valves. It
is very important to leave the suction valve open while the
pump is operating. Any throttling or adjusting of flow must
be done through the discharge valve. Partially closing the
suction valve can create serious NPSH and pump performance problems.
11. Turn PUMP # 1 H-O-A switch to OFF position.
12. Turn PUMP # 2 H-O-A switch to the HAND position.
Bleed air from the Pressure Reducing Valve (PRV ), if
supplied, at the highest point on the valve by opening any
fitting.
13. Continue this action to confirm that all system PRV’s have
all air bled from system.
14. After all air is bled from the Neptune Booster System, place
the system into operation by placing all H-O-A switches to
AUTO position.
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IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
Installation, Operation & Maintenance Manual
REDUCED CAPACITY
Avoid running a centrifugal pump at drastically reduced capacities or with discharge valve closed for extended periods of time.
This can cause severe temperature rise and the liquid in the
pump may reach its boiling point. If this occurs, the mechanical
seal will be exposed to vapor, with no lubrication, and may score
or seize to the stationary parts. Continued running under these
conditions when the suction valve is also closed, can create an
explosive condition due to the confined vapor at high pressure
and temperature. Thermostats may be used to safeguard against
over heating by shutting down the pump at a predetermined
temperature.
Safeguards should also be taken against possible operation with
a closed discharge valve, such as installing a bypass back to the
suction source. The size of the bypass line and the required
bypass flow rate is a function of the input horsepower and the
allowable temperature rise.
REDUCED HEAD
Note that when discharge head drops, the pump’s flow rate
usually increases rapidly. Check motor for temperature rise as
this may cause overload. If overloading occurs, adjust your set
points on your system panel.
OPERATION IN SUB-FREEZING
CONDITIONS
When using the pump in sub-freezing conditions where the
pump is periodically idle, the pump should be properly drained
or protected with thermal devices which will keep the liquid in
the pump from freezing.
OPERATION
American-Marsh Neptune Booster Systems are tested and
adjusted PRIOR to shipment. System pressure set points are
factory adjusted based on specifications supplied to AmericanMarsh Pumps at time of order. Confirmation of proper system
operation is the responsibility of the end user.
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Failure to properly vent the complete Neptune Booster System
could result in erratic or sluggish operation due to air trapped in
the system PRV’s.
WITH HYDRO-PNEUMATIC TANK
When the H-O-A switches are placed in the AUTO position
the lead pump will run continuously to maintain the system set
pressure as entered into the Neptune Interactive Display (NID).
To adjust the low pressure suction set point, confirm the system
pressure with the lead pump running (PUMP # 1). The low suction pressure transducer is typically set at the factory at 5 PSI
OFF and 20 PSI ON. The pressure transducer setting can be
adjusted as needed based on field conditions.
When system flow demand increases beyond the pump design
point Neptune Booster System pressure will begin to decrease.
The low system set point is typically set at the factory at 10 PSI
below the system set pressure. The low system transducer setting can be adjusted as needed based on field conditions.
When the Neptune Booster System pressure reaches the predetermined user defined set point, the lag pumps starts in response to the lower pressure. The lag pump will run as required
until flow demand decreases and Neptune Booster System pressure rises above the user defined set point. When the Neptune
Booster System pressure reaches the user defined set point the
lag pump will shutdown automatically and the lead pump will
continue to run. During periods of low system demand or shutoff operation both pumps can be provided with a thermal relief
valve for pump protection.
WITHOUT HYDRO-PNEUMATIC
TANK
When the H-O-A switches are placed in the AUTO position
the hydro-pneumatic tank pressure switch sequences the lead
pump under no flow condition. The tank fills to capacity and
the hydro-pneumatic tank pressure starts to increase. This increase in hydro-pneumatic tank pressure will stop the lead pump
when the user defined set point is reached and after the minimum run time has been satisfied. These parameters are user
defined and are entered into the Neptune Interactive Display
(NID). The tank will supply demand for the system under lower
flow conditions and stop the system from nuisance tripping due
to low demand. As the hydro-pneumatic tank pressure continues to drop as system demand continues, the lead pump will
start after a minimum time delay. The system pressure trans-
10
IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
Installation, Operation & Maintenance Manual
ducer will continue to cycle the lead and lag pumps as required
to maintain hydro-pneumatic tank and system demands.
OPERATIONAL H-O-A SWITCHES
CONTROL SELECTOR SWITCH
System discharge pressure transducer high set point must be
lower than the pump shutoff head.
To adjust the low pressure suction set point, confirm the system
pressure with the lead pump running (PUMP # 1). The low suction pressure transducer is typically set at the factory at 5 PSI
OFF and 20 PSI ON. The pressure transducer setting can be
adjusted as needed based on field conditions.
When system flow demand increases beyond the pump design
point Neptune Booster System pressure will begin to decrease.
The low system set point is typically set at the factory at 10 PSI
below the system set pressure. The low system transducer setting can be adjusted as needed based on field conditions.
SUPPLEMENTAL INFORMATION
PRESSURE REGULATED SYSTEMS
The controller uses a solid state pressure transducer to control
the starting and stopping of individual pumps on the Neptune Booster System package. This pressure transducer signal
(4-20 milliampere) is connected to the Programmable Logic
Controller (PLC) which has user defined start and stop set
points. When the system pressure drops below the user defined
pressure set point, usually just below the PRV stem setting,
the controller causes the next pump to start. Rising system
pressure causes the controller to turn the pumps off. This type
of a system also utilizes a Pressure Regulating Valve (PRV )
for each pump and has a constant speed panel. The controller
responds to the system pressure (as adjusted and measured from
the discharge pressure transducer) to start and stop the pump
or pumps. When the system pressure drops below the user
defined set point, usually just below the PRV stem settings, the
controller causes the next pump in line to start. When the pressure in the system rises sufficiently, the controller stops the last
pump started, after a user defined minimum run period. A low
pressure alarm and shutdown is included in the controller logic
standard to protect the pump or pumps in the system from running dry and or cavitating due to insufficient suction pressure.
One selector switch, H-O-A, is included for each motor.
The switch includes a “MAN” (Manual, Hand) position, an
“OFF”(Safety) position, and an “AUTO” (Automatic Control)
position. In the manual position, the Pressure Switch and all
automatic control is bypassed so the contactor coil is continuously energized by the selector switch. The Overload Relay contacts also override the manual position to protect the motor.
“OFF ” (SAFETY ) POSITION
In the “OFF” position, the Motor Contactor coil is de-energized to prevent the motor from running.
“MAN” POSITION (MANUAL CONTROL)
Control power wiring is TAKEN off the incoming power on the
load (down-stream) side of the Line Fuses or Circuit Breaker.
It is routed to the three position (Auto-Off-Manual) selector
switch. In the manual position, the all pressure switches and
all automatic control is bypassed so the contactor coil is continuously energized by the selector switch. The Overload Relay
contacts also override the manual position to protect the motor.
The Minimum Run Timer does not operate with the selector
switch in the MANUAL position.
Use EXTREME care in operating the system in MANUAL
(MAN) position of the control to avoid causing system over
pressure.
“AUTO” (AUTOMATIC CONTROL)
POSITION
In this position, the motor starter is connected to the appropriate output terminal of the PLC (Programmable Logic Controller) which enables automatic control of the pump motor by the
PLC. Note that overload relay operation is independent of the
PLC or any other control circuitry to protect the motor.
MOTOR RUNNING LIGHT(S)
The PUMP # 1 Running light activates when ever the motor
contactor (starter) for Motor # 1 is closed under either manual
or automatic control.
www.american-marsh.com
11
IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
Installation, Operation & Maintenance Manual
APPENDIX A
Clay-Val Information
www.american-marsh.com
12
IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
INSTALLATION / OPERATION / MAINTENANCE
MODEL
90-01/690-01
PRESSURE REDUCING VALVE
The Cla-Val 90-01/690-01 is an automatic control valve designed to
reduce higher inlet pressure to a steady lower downstream pressure
regardless of changing flow rate and/or varying inlet pressure. lt is a
hydraulically operated, pilot-controlled, diaphragm type globe or angle
valve. When downstream pressure exceeds the pressure setting of the
control pilot, the main valve and pilot valve close drip-tight. The control
system is very sensitive to slight pressure changes and immediately controls the main valve to maintain the desired downstream pressure.
Pressure setting adjustment is made with a single adjusting screw that
has a protective cap to discourage tampering.
INSTALLATION
1. Allow sufficient room around the valve assembly to make adjustments
and for servicing.
2. lt is recommended that gate or line block valves be installed on both
ends of the 90-01/690-01 valve assembly to facilitate isolating the valve for
maintenance. At a minimum of one pipe diameter apart.
NOTE: BEFORE THE VALVE IS INSTALLED, PIPE LINES SHOULD BE
FLUSHED OF ALL CHIPS, SCALE, AND FOREIGN MATTER.
3. Place the valve assembly in the line with flow through the valve in the
direction indicated on the inlet plate or by flow arrows. Check all fittings
and hardware for proper makeup and that no apparent damage is evident.
Be sure main valve cover nuts/bolts are tight. As pressure in some applications can be very high, thorough inspection for proper installation and
makeup is strongly recommended.
4. Cla-Val Valves operate with maximum efficiency when mounted in horizontal piping with the cover UP, however, other positions are acceptable.
Due to size and weight of cover and internal components of six-inch and
larger valves, installation with the cover up is advisable and provides greater
accessibility to internal parts for periodic inspection
5. Caution must be taken in the installation of this valve to insure that
wise to decrease pressure. There must be liquid flowing through the valve
during pressure adjustments. When the desired setting has been made,
tighten jam nut and replace cover.
9. To check the operation of the valve, open and close the downstream
gate valve. The downstream pressure should remain constant.
10. If opening and closing speed controls (C or S) are installed in the valve
pilot system, fine tune the opening and closing speed of the main valve
while performing step 9. Turn the CV adjustment screw clockwise on the
opening speed control to make the main valve open slower. Turn the
adjustment screw clockwise on the closing speed control to make the
main valve close slower. When adjustments have been completed,
tighten jam nuts.
MAINTENANCE
1. Cla-Val Valves and Controls require no lubrication or packing and
maintenance, however, should be inspected a minimum of once annually.
2. Repair and maintenance procedures of the Cla-Val Hytrol Main Valve
and pilot control components are included in a more detailed IOM manual.
It can be downloaded from our web site (www.cla-val.com) or obtained by
contacting a Cla-Val Regional Sales Office.
3. When ordering parts, always refer to the catalog number and stock
number on the valve nameplate.
SYMPTOM PROBABLE CAUSE
REMEDY
Main valve
fails to open
No pressure at valve inlet
Check inlet pressure
Main valve diaphragm assembly
inoperative
Disassemble, clean and polish
stem, replace detective parts
Pilot Valve (CRD) not opening:
1. No spring compression
2. Damaged spring
3. Spring guide not in place
4. Yoke dragging on inlet nozzle
1. Tighten adjusting screw
2. Disassemble and replace
3. Assemble properly
4. Assemble properly
galvanic and/or electrolytic action does not take place. The proper use
of dielectric fittings and gaskets are required in all systems using dissimilar metals.
OPERATION AND START-UP
1. Prior to pressurizing the valve assembly, ensure that the necessary
gauges to measure pressure in the system are installed as required by the
system engineer. A Cla-Val X101 Valve Position Indicator may be installed
in the center cover port to provide a visual indication of the valve movement
during start-up.
CAUTION: During start-up and test procedures, a large volume of water
may be discharged downstream. Check that the downstream venting is
adequate to prevent damage to personnel and equipment. All adjustments
in pressure should be made slowly while under flowing conditions.
If the main valve closes too fast, it may cause surging in upstream piping.
2. If isolation valves (B) are installed in pilot system, open these
Flow Control (CV) disc inoperative. Disassemble, clean and polish
Corrosion or excessive scale
stem. Replace worn parts
buildup on stem
Main valve
fails to close
Pilot Valve (CRD) remain open:
1. Spring compressed solid
2. Mechanical obstruction
valves (see schematic).
3. Optional Cla-Val CV Flow Controls (C or S) provide adjustable regulation of flow in and out of the main valve chamber to minimize pulsations
that sometime occur at very low flow rates. If CV Controls are installed,
loosen jam nut and turn adjustment screw counterclockwise from closed
position 3.5 turns for an initial setting.
4. Open the upstream gate or block valve just slightly to allow the main
valve assembly and pilot system to fill with liquid.
5. Carefully loosen tube fittings at highest points and bleed air from pilot
control system. Carefully loosen the plug at top of main valve cover to
bleed air from cover. If an indicator is installed, carefully loosen the air
bleed valve at top of indicator. Tighten tube fittings.
6. Open the upstream gate or block valve fully.
7. Slowly open the downstream gate or block valve. Flow should occur
and pressure should remain constant.
8. Adjust the CRD Control to desired pressure. To change pressure setting,
turn the adjusting screw clockwise to increase pressure, counterclock-
Foreign matter between disc and
seat or worn disc. Scale on stem
or diaphragm ruptured
Flow Clean Strainer plugged
CK2 (isolation valves) closed
3. Worn disc
4. Yoke dragging on inlet nozzle
diaphragm nut
Fails to
regulate
Disassemble main valve, remove
matter, clean parts and replace
defective parts
Remove and clean or replace
Open isolation valves
1. Back off adjusting screw
2. Disassemble and remove
obstruction
3. Disassemble remove and
replace disc retainer assembly
4. Assemble properly
5. Diaphragm damaged or loose
diaphragm nut. Leakage from
vent hole in cover
5. Disassemble. replace
diaphragm and/or tighten nut
Air in main valve cover and/or
tubing
Loosen top cover plug and
fittings and bleed air
Pilot Valve (CRD) yoke dragging
on inlet nozzle
Pilot Valve (CRD) spring not
in correct range to control
Assemble properly
Check outlet pressure
requirements and compare
existing spring with Spring Chart
90-01/690-01 SCHEMATIC
CRD
3.
Pressure Setting
Adjusting Screw
(Turn Clockwise to
Increase Setting)
X140-1
Security Cap
Option
Adjusting Screw
Cap
Jam Nut
Cover
Spring Guide
Cover vent
*Machine Screw
(Fil.Hd) 8 Req'd
Spring
Hex Nut
Belleville Washer
Diaphragm Washer
Diaphragm*
inlet
Yoke
OPTIONAL FEATURES
A X46A Flow Clean Strainer
B CK2 (Isolation Valve)
C Closing Speed Control
D Check Valves with Isolation Valve
S Opening Speed Control
Y X43 “Y” Strainer
BASIC COMPONENTS
1 100-01 Hytrol (Main Valve)
100-20 600 Series Hytrol (Main Valve)
2 X58C Restriction Fitting
3 CRD Pressure Reducing Control
(3/8" NPT)
Body and Seat Assy
Disc Retainer Assy
HYTROL MAIN VALVE
Gasket*
1.
PIPE PLUG
Plug, Body
HEX NUT
COVER
CRD adjust range (psi)
8" and Larger
Spring Color
psi change per turn*
Stainless Steel
2 - 30
Red
15 - 75
Green
30 - 300
* approximate. Use gauge at valve outlet to set
PIPE PLUG
Cover Bolt
6" and Smaller
COVER BEARING
SPRING
3
9
27
STEM NUT
DIAPHRAGM WASHER
X58C
*DIAPHRAGM
X46A
A.
2.
DISC RETAINER
*SPACER WASHERS
*DISC
KO Anti-Cavitation
Trim Option
DISC GUIDE
STEM
**
CK2
B.
KO
DISC GUIDE
CV
C.
STEM
Seat Screw
8" and Larger
SEAT
KO
SEAT
Seat Screw
8" and Larger
**
SEAT O-RING
STUD
8" and Larger
CDC-1
D.
X43
BODY
Y.
PIPE PLUG
(Globe or Angle)
*Repair Parts
** KO ANTI-CAVITATION TRIM CAN BE ADDED TO ANY STANDARD HYTROL VALVE
*SUGGESTED
For a more detailed IOM Manual go to www.cla-val.com or contact a Cla-Val Regional Sales Office.
CLA-VAL
REPAIR PARTS
P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: [email protected] • Website cla-val.com
© Copyright
Cla-Val 2008 Printed in USA Specifications subject to change without notice.
N-90-01/690-01 (R-9/08)
Installation, Operation & Maintenance Manual
APPENDIX B
Vision OPLC Information
For Constant Speed Systems
IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
13
www.american-marsh.com
Vision™ OPLC™
Installation Guide
Vision120™
This guide provides basic information for Unitronics’ Vision120™.
General Description
V120 OPLCs are micro-OPLCs, rugged programmable logic
controllers that comprise an:
On-board I/O configuration
Built-in operating panel containing a graphic LCD
screen and a keypad
Communications
All V120 controllers comprise 2
RS232/485 ports
Certain models comprise a
CANbus port
I/O Options
On-board I/O configuration
Model-dependent; may include
digital, high-speed, and
analog I/Os
I/O Expansion Modules
Via I/O expansion port adapter,
connect up to 128 additional I/Os
per controller
Programming
Write both the HMI and Ladder control application using VisiLogic freeware.
The Vision120 User Guide and the product’s technical specification sheet contain additional
information. These documents are located on the Unitronics’ Setup CD. They may also be
downloaded from the Technical Library at www.unitronics.com.
Standard Kit Contents
V120 controller
Programming cable + RS232 adapter
Mounting brackets (x2)
Rubber seal (mounted in back of panel)
I/O connectors (x2)
Unitronics’ Setup CD
5-pin CANbus connector and CANbus network termination resistor (CANbus models)
Unitronics
1
10/06
Vision™ OPLC™ Vision120™
Danger Symbols
When any of the following symbols appear, read the associated information carefully.
Symbol
Caution
Meaning
Description
Danger
The identified danger causes physical and property damage.
Warning
The identified danger could cause physical and property damage.
Caution
Use caution.
Before using this product, the user must read and understand this document.
All examples and diagrams are intended to aid understanding, and do not guarantee operation.
Unitronics accepts no responsibility for actual use of this product based on these examples.
Please dispose of this product according to local and national standards and regulations.
Only qualified service personnel should open this device or carry out repairs.
Failure to comply with appropriate safety guidelines can cause severe injury or property damage.
Do not attempt to use this device with parameters that exceed permissible levels.
To avoid damaging the system, do not connect/disconnect the device when power is on.
Environmental Considerations
Do not install in areas with: excessive or conductive dust, corrosive or flammable gas,
moisture or rain, excessive heat, regular impact shocks or excessive vibration, in accordance
with the standards given in the product’s technical specification sheet.
Ventilation: 10mm space required between controller’s top/bottom edges & enclosure walls.
Do not place in water or let water leak onto the unit.
Do not allow debris to fall inside the unit during installation.
Install at maximum distance from high-voltage cables and power equipment.
2
Unitronics
Installation Guide
10/06
Mounting
Dimensions
Panel mounting
Before you begin, note that the
mounting panel cannot be more
than 5 mm thick.
1. Make a panel cut-out
measuring 92 x 92 mm
(3.622” x 3.622”).
2. Slide the controller into the
cut-out, ensuring that the
rubber seal is in place.
3. Push the 2 mounting brackets
into their slots on the sides of
the controller as shown in the
figure to the right.
4. Tighten the bracket screws
against the panel. Hold the
bracket securely against the
unit while tightening the
screw.
5. When properly mounted, the
controller is squarely situated
in the panel cut-out as shown
in the figure to the right.
Unitronics
3
10/06
Vision™ OPLC™ Vision120™
DIN-rail mounting
1. Snap the controller onto the DIN rail
as shown in the figure to the right.
2. When properly mounted, the
controller is squarely situated on the
DIN-rail as shown in the figure to
the right.
I/O Modules
The controllers offer an on-board I/O configuration that differs according to the controller model; I/O
wiring diagrams are in the controller’s technical specification sheet.
Additional I/Os may be integrated into the system via I/O Expansion Modules that you plug into the
controller’s I/O expansion port. Note that the relevant wiring diagrams are in the module’s technical
specification sheet, and that an I/O adapter is required for most modules.
Wiring: General
Do not touch live wires.
Unused pins should not be connected. Ignoring this directive may damage the device.
Caution
To avoid damaging the wire, do not exceed a maximum torque of 0.5 N·m (5 kgf·cm).
Do not use tin, solder, or any substance on stripped wire that might cause the wire
strand to break.
Use crimp terminals for wiring; use 26-14 AWG wire (0.13 mm 2–2.08 mm2).
1. Strip the wire to a length of 7±0.5mm (0.250–0.300”).
2. Unscrew the terminal to its widest position before inserting a wire.
3. Insert the wire completely into the terminal to ensure a proper connection.
4. Tighten enough to keep the wire from pulling free.
Power Supply
The controller requires an external 12 or 24VDC power supply, according to the controller model.
Exact information may be found in the controller’s technical specification sheet.
A non-isolated power supply can be used if a 0V signal is connected to the chassis.
4
Unitronics
Installation Guide
10/06
You must use an external circuit protection device.
Install an external circuit breaker. Guard against shortcircuiting in external wiring.
Double-check all wiring before turning on the power
supply.
Do not connect either the ‘Neutral or ‘Line’ signal of the
110/220VAC to device’s 0V pin.
In the event of voltage fluctuations or non-conformity to
voltage power supply specifications, connect the device
to a regulated power supply.
Earthing the Power Supply
To maximize system performance, avoid electromagnetic interference by:
Mounting the controller on a metal panel.
Earthing the controller’s power supply: connect one end of a 14 AWG wire to the chassis
signal; connect the other end to the panel.
Note: The wire used to earth the power supply must not exceed 10 cm in length. If your
conditions do not permit this, do not earth the power supply
Communication Ports
This series comprises 2 serial ports that may be set to either RS232 or RS485. Certain models also
comprise CANbus ports. Check your controller’s technical specifications.
Turn off power before making communications connections.
Caution
Signals are related to the controller’s 0V; the same 0V is used by the power supply.
Always use the appropriate port adapters.
Serial Communications
The serial ports are type RJ-11 and may be set to either RS232 or RS485 via jumper as described
on page 6. By default, the ports are set to RS232.
Use RS232 to download programs from a PC, and to communicate with serial devices and
applications, such as SCADA.
Use RS485 to create a multi-drop network containing up to 32 devices.
The serial ports are not isolated. If the controller is used with a non-isolated external
Caution
device, avoid potential voltage that exceeds ± 10V.
Pinouts
The pinouts below show the signals between the adapter and port.
RS232
RS485
Controller Port
Pin #
Description
Pin #
Description
1*
DTR signal
1
A signal (+)
2
0V reference
2
(RS232 signal)
3
TXD signal
3
(RS232 signal)
4
RXD signal
4
(RS232 signal)
5
0V reference
5
(RS232 signal)
6*
DSR signal*
6
B signal (-)
Pin #1
*Standard programming cables do not provide connection points for pins 1 and 6.
Unitronics
5
10/06
Vision™ OPLC™ Vision120™
RS232 to RS485: Changing Jumper Settings
Ports can be set to either RS232 or RS485 according to jumper settings.
To access the jumpers, you must open the controller, and then remove the module’s
PCB board. Before you begin, turn off the power supply, disconnect and dismount the
controller.
When a port is adapted to RS485, Pin 1 (DTR) is used for signal A, and Pin 6 (DSR)
signal is used for signal B.
If a port is set to RS485, and flow signals DTR and DSR are not used, the port can also
be used to communicate via RS232; with the appropriate cables and wiring.
Before performing these actions, touch a grounded object to discharge any electrostatic
charge.
Avoid touching the PCB board directly. Hold the PCB board by its connectors.
1. Turn power off before opening
the controller.
2. Locate the 4 slots on the sides
of the controller.
3. Using the blade of a flat-bladed
screwdriver, gently pry off the
back of the controller.
4. Gently remove the top PCB
board:
a. Use one hand to hold the topmost PCB board by its top
and bottom connectors.
b. With the other hand, grasp
the controller, while keeping
hold of the serial ports; this
will keep the bottom board
from being removed together
with the top board.
c. Steadily pull the top board off.
5. Locate the jumpers, and then
change the jumper settings as
required. Jumper settings are
shown on page 7
6
Unitronics
Installation Guide
10/06
6. Gently replace the PCB board.
Make certain that the pins fit
correctly into their matching
receptacle.
a. Do not force the board into
place; doing so may damage
the controller.
7. Close the controller by snapping
the plastic cover back in its
place. If the card is placed
correctly, the cover will snap on
easily.
RS232/RS485 Jumper Settings
Jumper Settings
RS485 Termination
Jumper
RS232*
RS485
Jumper
ON*
OFF
COM 1
1
A
B
3
A
B
2
A
B
4
A
B
COM 2
5
A
B
7
A
B
6
A
B
8
A
B
*Default factory setting.
Unitronics
7
10/06
Vision™ OPLC™ Vision120™
CANbus
These controllers comprise a CANbus port. Use
this to create a decentralized control network of
up to 63 controllers, using either Unitronics’
proprietary CANbus protocol or CANopen.
-
24V Power
Supply
+
Circuit
protection
device
The CANbus port is galvanically isolated.
CANbus Wiring
Use twisted-pair cable. DeviceNet® thick
shielded twisted pair cable is recommended.
121
terminating
resistor
-V
L
PE
H
+V
Network terminators: These are supplied with the
controller. Place terminators at each end of the
CANbus network.
Resistance must be set to 1%, 121R, 1/4W.
-V
Connect ground signal to the earth at only one
point, near the power supply.
The network power supply need not be at the
end of the network
L
PE
H
+V
CANbus Connector
-V
L
PE
H
+V
121
terminating
resistor
The information in this document reflects products at the date of printing. Unitronics reserves the right, subject to all applicable laws, at any time, at its sole
discretion, and without notice, to discontinue or change the features, designs, materials and other specifications of its products, and to either permanently or
temporarily withdraw any of the forgoing from the market.
All information in this document is provided "as is" without warranty of any kind, either expressed or implied, including but not limited to any implied warranties of
merchantability, fitness for a particular purpose, or non-infringement. Unitronics assumes no responsibility for errors or omissions in the information presented in
this document. In no event shall Unitronics be liable for any special, incidental, indirect or consequential damages of any kind, or any damages whatsoever arising
out of or in connection with the use or performance of this information.
The tradenames, trademarks, logos and service marks presented in this document, including their design, are the property of Unitronics (1989) (R"G) Ltd. or other
third parties and you are not permitted to use them without the prior written consent of Unitronics or such third party as may own them
5410-1400-5
8
Unitronics
Installation, Operation & Maintenance Manual
APPENDIX C
VFDC-4000 Information
For VFD Systems
www.american-marsh.com
14
IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
Free Standing Enclosure (optional)
4 Pump Control Configuration
VFDC-4000 Controller Features
Q
Q
Q
Q
Q
VFDC-4000 Controller
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
1 to 4 VFD control
P.I.D. control
Graphic screen display with back-light
System status display
• Operating pressure
• Set pressure
• Auto/Off
• Time and date
• Alarm with time and date
Pump status display
• Pumps in use
• Lead pump
• Pump run/stop
• Pump speed
• VFD fault
Four arrow buttons for easy navigation and setup
Automatic alternation (cycle-based or time-based)
Alarm log
Real time clock
Scheduled pressure setup function
Night time operation (runs smaller pump)
Pressure transmitter setup
Password protection
Serial communication
Idle prevention
Freeze prevention
Low pressure alarm
High pressure alarm
Low suction pressure/low level
VFDC-4000 Panel Standard Features
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
NEMA Type 1 wall mount enclosure (indoor)
Cooling fan + filter and thermostat for VFD ventilation
Panel mounted Variable Frequency Drives
VFDC-4000 pressure booster controller mounted on door
VFD circuit breakers
24 VDC power supply
0-200 PSI pressure transducer
System MAN/OFF/AUTO switch
MANUAL ON/OFF switches
Main terminal blocks
Pump terminal blocks
Pressure transducer terminal blocks
Alarm auxiliary contact
Low water alarm terminal (low suction/level)
Automatic start on low pressure
Q Automatic stop on low pump speed
NEMA 1 Wall Mounted Enclosure (standard)
OPTIONS
Q
Q
Q
Q
Q
Q
Wall Mounted Enclosure with
Optional Line and Load Reactors
Main disconnect
Line reactors
Load reactors
Larger HP VFDs
Free standing enclosures
NEMA 12, NEMA 3R, NEMA 4,
and NEMA 4X enclosures
Duplex, Triplex, and Quad Plex
Models on Reverse Side...
VFDC-4000 Panel Models
APPROX. HP
PUMP MAX AMPS*
DUPLEX
TRIPLEX
QUAD PLEX
208/240V, Single Phase Input / Three Phase Output
3
11.0
D230-1-11.0
T230-1-11.0
Q230-1-11.0
5
17.5
D230-1-17.5
T230-1-17.5
Q230-1-17.5
7.5
27.0
D230-1-27.0
T230-1-27.0
Q230-1-27.0
10
33.0
D230-1-33.0
T230-1-33.0
Q230-1-33.0
15
46.3
D230-1-46.3
T230-1-46.3
Q230-1-46.3
208/240V, Three Phase Input / Three Phase Output
3
11.0
D230-3-11.0
T230-3-11.0
Q230-3-11.0
5
17.5
D230-3-17.5
T230-3-17.5
Q230-3-17.5
7.5
27.5
D230-3-27.5
T230-3-27.5
Q230-3-27.5
10
33.0
D230-3-33.0
T230-3-33.0
Q230-3-33.0
15
54.0
D230-3-54.0
T230-3-54.0
Q230-3-54.0
20
66.0
D230-3-66.0
T230-3-66.0
Q230-3-66.0
25
74.8
D230-3-74.8
T230-3-74.8
Q230-3-74.8
30
88.0
D230-3-88.0
T230-3-88.0
Q230-3-88.0
380-480V, Three Phase Input / Three Phase Output
3
5.5
D480-3-5.5
T480-3-5.5
Q480-3-5.5
5
9.5
D480-3-9.5
T480-3-9.5
Q480-3-9.5
7.5
14.3
D480-3-14.3
T480-3-14.3
Q480-3-14.3
10
17.0
D480-3-17.0
T480-3-17.0
Q480-3-17.0
15
27.7
D480-3-27.7
T480-3-27.7
Q480-3-27.7
20
33.0
D480-3-33.0
T480-3-33.0
Q480-3-33.0
25
37.0
D480-3-37.0
T480-3-37.0
Q480-3-37.0
30
43.5
D480-3-43.5
T480-3-43.5
Q480-3-43.5
40
58.5
D480-3-58.5
T480-3-58.5
Q480-3-58.8
575V, Three Phase Input / Three Phase Output
3
3.9
D575-3-3.9
T575-3-3.9
Q575-3-3.9
5
6.1
D575-3-6.1
T575-3-6.1
Q575-3-6.1
7.5
9.0
D575-3-9.0
T575-3-9.0
Q575-3-9.0
10
11.0
D575-3-11.0
T575-3-11.0
Q575-3-11.0
15
17.0
D575-3-17.0
T575-3-17.0
Q575-3-17.0
20
22.0
D575-3-22.0
T575-3-22.0
Q575-3-22.0
25
27.0
D575-3-27.0
T575-3-27.0
Q575-3-27.0
30
32.0
D575-3-32.0
T575-3-32.0
Q575-3-32.0
40
41.0
D575-3-41.0
T575-3-41.0
Q575-3-41.0
22650 County Highway 6 Q PO Box 1708 Q Detroit Lakes, MN 56502 USA
1-888-DIAL-SJE (1-888-342-5753) Q Phone: 218-847-1317 Q Fax: 218-847-4617
www.sjerhombus.com
©SJE-Rhombus 07/09
Installation, Operation & Maintenance Manual
APPENDIX D
Pump Specific IOM Manual
www.american-marsh.com
15
IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
Installation, Operation & Maintenance Manual
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www.american-marsh.com
IOM Manual: 077-0407-000
Series 1000: Neptune Booster Systems
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