Dutypoint VG 2HM3ZT, VG 2HM5ZT, VG 2HM7ZT, VG 4HM5ZT, VG 4HM9ZT Twin Pump Booster Set User Guide

VG
Variable Speed
Twin Pump Booster Sets
FULL USER GUIDE
© Manual Copyright Dutypoint Systems 2013
The contents, information and copyright of this manual are the sole property of Dutypoint Systems. No part of this manual may be copied,
reproduced, stored or transmitted in any form, or be translated into any language without prior written permission of the owners.
Every effort has been made to ensure the accuracy of this manual at the time of printing, however our policy of continuous improvement
means that specifications and instructions may change without notice.
Please Note: If the sytem that you have purchased has been modified, updated or otherwise altered from
the Dutypoint standard range, additional information applicable to the change(s) will be provided in
Appendix E at the end of this manual.
DUTYPOINT SYSTEMS
SHEPHERD ROAD GLOUCESTER
GL2 5EL
UK
Tel: 44 (0) 1452 300592
Fax: 44 (0) 1452 303691
Email: [email protected]
www.dutypoint.com
Dutypoint Part Number VG - M03
Iss.4 - Aug 2013
Contents
VG Iss.4 - Aug 2013
Iss.4 - Aug 2013
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User Guide - VG Variable Speed Twin Pump Booster Sets
SAFETY
Important Health & Safety Information
User Guide - Document Conventions .........................................................................6
United Kingdom Health & Safety at Work Act 1974 .................................................... 7
Dutypoint responsibility ...................................................................................7
Customer / Contractor responsibility ...............................................................7
Pump Servicing ..........................................................................................................7
Electrical Safety ..........................................................................................................7
High voltages ...................................................................................................7
Electronic safety devices .................................................................................8
High voltage testing may damage electronic components .............................. 8
Operating Limits For Standard Dutypoint Pumpsets ..................................................9
Section 1
Introduction
Welcome .....................................................................................................................12
VG Series Overview ...................................................................................................13
Technical features ...........................................................................................13
Options ............................................................................................................13
Pump Overview ..........................................................................................................13
Teknospeed Variable Speed Drive .............................................................................14
Pressure Vessels ........................................................................................................14
Control Panel Overview ..............................................................................................15
Commissioning and Post-Installation Help .................................................................15
Commissioning ................................................................................................15
Post-Installation Help ...................................................................................... 15
Section 2
Specifications, Configurations & Dimensions
Identifying Your Pump ................................................................................................18
General Specifications ................................................................................................18
Performance & Control ....................................................................................18
Construction ....................................................................................................18
Dimensions .................................................................................................................19
Electrical Specifications ..............................................................................................19
Pump Performance .....................................................................................................20
2HM Series Pumps - Operating Characteristics @ 2850rpm 50Hz ................20
4HM Series Pumps - Operating Characteristics @ 2850rpm 50Hz ................21
Section 3
The Control Panel
Control Panel
..............................................................................................................24
Section 4
Installation, Commissioning and Routine Maintenance
Installationand Commissioning Overview ...................................................................30
Installation and Pre-Commissioning Checks ..............................................................30
Pipework and mechanical components ...........................................................30
Electrical ..........................................................................................................30
Final checks before commissioning ................................................................ 31
Pressure Vessel Precharging .....................................................................................31
Venting Pumps ...........................................................................................................31
Procedure for flooded suction .........................................................................31
Procedure for lift suction ..................................................................................32
Operational and Performance Tests ........................................................................... 32
Duty/Standby sets ...........................................................................................32
Duty/Assist sets ...............................................................................................32
Commissioning/Handover Check ...............................................................................33
Routine User Maintenance .........................................................................................33
Recommended user weekly checks ................................................................ 33
Recommended user quarterly checks .............................................................33
Recommended user 6 monthly checks ...........................................................33
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Contents
Essential 12 monthly (maximum interval) service ........................................... 34
Detailed Pump Maintenance ...................................................................................... 34
Detailed Controller Maintenance ................................................................................ 34
Detailed Accessory Maintenance ............................................................................... 34
Section 5
Troubleshooting
First Step When a Fault Occurs ................................................................................. 36
General Pump Troubleshooting ................................................................................. 36
Technospeed Controller Troubleshooting .................................................................. 37
Appendix A
Manufacturer’s Guide - CEA-CA, HM-HMS Electric Pumps
General User Guide ....................................................................................................... 40
Failure Analysis System Procedure ............................................................................... 47
Appendix B
Manufacturer’s Guide - Teknospeed
Instructions for Installation and Use............................................................................... 58
Troubleshooting .......................................................................................................... 67
Appendix C
Manufacturer’s Guide - FAM Pressure Vessel
General ....................................................................................................................... 84
Installation Safety Notes ............................................................................................. 84
Periodic Maintenance ................................................................................................. 84
General Maintenance and Repair .............................................................................. 84
Precharge instructions .................................................................................... 85
Diaphragm replacement .................................................................................. 85
Installing a Replacement Vessel ................................................................................ 86
Appendix D
Miscellaneous Technical Information
Net Positive Suction Head (NPSH) ............................................................................ 88
Cavitation ........................................................................................................ 88
Calculating NPSH ........................................................................................... 88
Convertion Factors ..................................................................................................... 89
Variable Speed Flow, Head and Power Calculations ................................................. 90
General Operating Limits (Standard Dutypoint Pumpsets) ........................................ 90
Appendix E
Additional Information
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User Guide - VG Variable Speed Twin Pump Booster Sets
4
VG Iss.4 - Aug 2013
SAFETY
Important Health & Safety
Information
Please read this section before attempting to use
or work on your VGPumpset as it contains
important Safety Information and the System
Operating Limitations.
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User Guide - VG Variable Speed Twin Pump Booster Sets
User Guide - Document Conventions
Throughout this manual, text may be accompanied by one of the following icons.
Where these occur the conventions shown below are applied.
In general these conventions will also apply to OEM Manufacture’s manuals that are
included within this User Guide, however variations may occur, but these will be
redefined at the beginning of their manual.
DANGER
Denotes attention to the possibility of the risk of personal injury or
damage to adjacent property if the information is ignored.
ELECTRIC Denotes attention to the possibility of life-threatening electric shock if
SHOCK
the information is ignored.
WARNING
Denotes attention to a condition that may result in under-performance or
damage to the equipment if the information is ignored.
NOTE
Denotes attention to an important factor applicable to the action being
performed.
or
WARNING
PLEASE READ THE FOLLOWING INFORMATION WHICH IS PROVIDED FOR YOUR SAFETY
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VG Iss.4 - Aug 2013
Important Health & Safety Information
United Kingdom Health & Safety at Work Act 1974
Dutypoint responsibility
Section 6(a) of this Act requires manufacturers to advise their customers on the safety
and the handling precautions to be observed when installing, operating, maintaining
and servicing their products. The user’s attention is therefore drawn to the following:
• The appropriate sections of this manual must be read before working on the
equipment.
• Installation, operating and maintenance must only be carried out by suitably
trained/qualified personnel.
• Normal safety precautions must be taken and appropriate procedures
observed to avoid accidents.
Refer to DUTYPOINT SYSTEMS for any technical advice or product information.
Customer / Contractor responsibility
It is the responsibility of the customer and/or the contractor:
• To ensure that anyone working on the equipment is wearing all necessary
protective gear/clothing.
• Is aware of appropriate health & safety warnings
• has read the information in this section of the manual.
Pump Servicing
Before attempting to open any unit or service a pump:
• Familiarise yourself with the relevant contents of this manual.
• Installation, maintenance and repair work must only be carried out by
trained, skilled and suitably qualified personnel.
• Disconnect or lock-out the power source to ensure that the pump(s) will
remain inoperative.
Locking out the equipment by switching off the release mechanism or
set value WILL NOT prevent accidental starting of the motor.
• Allow the pump(s) to cool if over-heated.
• CLOSE the isolating valves on the suction and discharge connections of
the affected pump(s).
• VENT the pump(s) slowly and cautiously – Refer to Section 4 of this
manual.
• DRAIN the pump(s).
Electrical Safety
High voltages
Especially applicable when Variable Speed Controllers (Inverters) are fitted.
• When the inverter variable speed drive head is connected to the power
supply the components of the power unit – as well as certain components of
the master control unit – are also connected to the power supply.
TOUCHING THESE COMPONENTS CAN SERIOUSLY ENDANGER LIFE!
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User Guide - VG Variable Speed Twin Pump Booster Sets
• Before removing the frequency inverter cover, the system must be
disconnected from the power supply. After switching off the power supply
wait at least 5 minutes before starting work on or in the inverter drive head
– the capacitors in the intermediate circuit must be given time to discharge
completely via the discharge resistors.
Up to 800 volts can be present – if there are faults this can be higher.
• All work carried out when the frequency inverter is open must be performed
only by suitably qualified and properly authorised personnel.
When connecting external control wires care must be taken not to short
circuit adjacent components. Bare cable ends which are not in use must be
insulated.
THE SYSTEM MUST ONLY BE OPERATED WHEN IT HAS BEEN CORRECTLY
EARTHED AND PIPES BONDED TO EARTH IN ACCORDANCE WITH IEE
REGULATIONS
Electronic safety devices
• The inverter drive heads used in Dutypoint Systems Pumpsets contain
electronic safety devices which switch off the control element in the event of
a fault developing.
The motor will have zero current but will remain energised as it stops.
• The motor can also be stopped by ‘mechanical blocking’.
• If it is switched off electronically, the motor is disconnected from the mains
voltage supply via the electronics in the frequency converter.
The motor is not voltage-free in the circuit itself.
• Voltage fluctuations and power failures (temporary outages) can cause the
motor to switch itself off.
Repair of faults can cause the motor to start up again unexpectedly!
High voltage testing may damage electronic components
• High voltage tests of the inverter or the motor may damage the electronic
components.
Bridge before the incoming/outgoing terminals L-L2-L3 and U-V-W.
• To avoid incorrect metering by capacitors incorporated in the electronic
circuits, isolate the motor from the inverter drive head.
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VG Iss.4 - Aug 2013
Important Health & Safety Information
Operating Limits For Standard Dutypoint Pumpsets
Type of pumped liquids.
Maximum pumped liquids temperature.
Water with
substances.
no
gas
or
aggressive
+35°C for domestic uses.
(EN 60335-2-41).
40°C for other purposes.
Minimum pumped liquid temperature.
1°C to avoid icing.
Operating ambient temperature.
+5°C to 40°C for indoor installation.
(CEI EN 60439-1).
Relative humidity.
Max 50% at 40°C.
Air impurities.
The air must be clean and free of acid
vapours, corrosive gases and excessive
amounts of dust.
Storage temperature.
+5°C to 50°C.
Suction Conditions.
Refer to notes on Net Positive Suction Head
(NPSH) included in Appendix D
VG Iss.4 - Aug 2013
Minimum positive pressure 0.1 Bar,
Maximum positive pressure 0.5 Bar.
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User Guide - VG Variable Speed Twin Pump Booster Sets
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1
Introduction
This Section introduces the VG Variable Speed
Twin Pump Booster Sets and provides an
overview of the Pumps and Controllers.
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User Guide - VG Variable Speed Twin Pump Booster Sets
Welcome
Thank you for purchasing one of the DUTYPOINT VG Variable Speed Twin Pump
Booster Sets.
Dutypoint Systems is a Division of Elmbridge Pumps Company and manufactures
pressure boosting pump systems. Since its beginnings as a supplier of pumpsets to
the water industry the name 'Dutypoint' has become synonymous with unrivalled
quality, service and reliability.
This manual is compiled as a composite to include both the Dutypoint package
information and the specific manufacturer’s information necessary for the installation,
safe operation and user maintenance of your pumps.
Please read and familiarise yourself with the contents of this manual.
MCB Control
Panel
Pressure Vessels
Pressure
Transducers
Isolation
Valves
Teknospeed
Controllers
Non-Return
Valves
HM-HMS Series
Pumps
Anti-vibration Feet
Fig. 1-1 A Typical VG Variable Speed Twin Pump Booster Set
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VG Iss.4 - Aug 2013
Section 1 Introduction
VG Series Overview
The VG Series of variable speed twin pump sets provides a selection of compact,
efficient systems based on ITT Lowara manufactured pumps with Teknospeed®
speed control.
These quiet pressure pump sets have been designed for use where space is limited,
and provides ease of maintenance and reliability. They are ideal for installation in
residential property.
Technical features
• Twin variable speed pumps.
• Teknospeed intelligent control.
• Cyclic duty changeover
• Integrated adjustable pressure control.
• System pressure gauge.
• Low water cut-out contacts.
• Motor thermistor protection.
• Pressure setpoint adjustment.
• Local electrical isolation with MCB protection.
• Anti-vibration feet.
• Individual alarm warning LED.
• Power Factor controller circuit to maintain the required pressure in the
event of mains voltage fluctuations (sinusoidal).
• Common fault volt-free contacts.
Options
• Flexible expansion joints.
• Low level float switch.
Pump Overview
The VG Series uses ITT Lowara HM Series Horizontal Centrifugal Electrical Pumps.
Full details of the pumps are given in the manufacturer’s manual republished in
Appendix A of this manual.
Fig. 1-2 ITT Lowara HM-HMS Series Pumps
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User Guide - VG Variable Speed Twin Pump Booster Sets
Teknospeed Variable Speed Drive
The Teknospeed (designed and developed by ITT industries) is a simplified air-cooled
control attached to the pump which adjusts motor speed so as to constantly provide
users with the same pressure, even when demand for water changes.
The controller relies on a 4-20mA signal to maintain a preset pressure. The required
pressure set-point can be adjusted by a potentiometer on the side of the unit.
Contacts for a low water floatswitch and for alarm condition are incorporated and a
small panel provides Power, Run and Alarm leds. The rate of flash of the Alarm led
identifies up to seven different types of fault condition.
Full details of Teknospeed system is given in the manufacturer’s manual republished
in Appendix B of this manual.
Fig. 1-3 ITT Teknospeed Controller
Pressure Vessels
Pressure Vessels are fitted to the
discharge manifold of the pump sets to
maintain the pressure in the system
when there is no demand and the pumps
are stopped.
Full details of vessels used given in the
manufacturer’s manual republished in
Appendix C of this manual.
Fig. 1-4 The Pressure Vessel
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VG Iss.4 - Aug 2013
Section 1 Introduction
Control Panel Overview
The Power Control Panel for the VG
Pumpset is a simple unit supporting
Power Connection, a local Electrical
Isolator, and MCB protection.
Control
adjustment
and
status
monitoring
is
provided
on
the
Teknospeed control unit.
Full details of the Control Panel is given
in Section 3 of this manual.
Fig. 1-5 The Control Panel
Commissioning and Post-Installation Help
Dutypoint Systems is a Division of Elmbridge Pumps, a long-established firm of
Pumping Engineers specialising in packaged Booster Pumpsets. Operating from our
works and offices in Gloucester with easy access to the national motorway network,
Dutypoint is strategically placed to provide prompt and efficient Commissioning and
Maintenance service all over the UK
Commissioning
Before shipment, all Dutypoint booster sets are pre-commissioned. Whilst important
procedures such as venting and rotational direction checks need to be carried out on
site, parameters including pressure settings and delay timers are adjusted to suit the
site conditions as advised.
In practice, a system can almost invariably be made to perform more efficiently if
correctly commissioned on site.
Please note that engineer visits are priced at one visit to commission one pump set.
If there are multiple units on a site, special terms can be negotiated.
To arrange a commissioning visit, please call the Technical Service Help line shown
below.
Post-Installation Help
For any assistance required, call the Technical Service Help line shown below.
TECHSERVICE HELPLINE 01452 300590
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2
Specifications,
Configurations &
Dimensions
This Section lists specifications and specific
details for available variants of VG Pumpsets.
• Identifying Your Pump
• General Specifications
• Dimensions
• Electrical Specifications
• Pump Performance
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User Guide - VG Variable Speed Twin Pump Booster Sets
Identifying Your Pump
Attached to each pump is a label (fig 2-1) that identifies the type and specification.
Speed
Pump Model No.
V = Variable
Control Type
Z = Teknospeed
Number of
Pumps
V G 2
I
2HM5
L
Z M
Pump Manufacturer
Rating
L = Lowara (ITT)
M = 230v/1phase/50Hz
T = 400v/3phase/50Hz
Fig. 2-1 Pump Labelling
General Specifications
Performance & Control
Flow range
0.1 - 3.6Litres/sec.
Pressure range
2.0 - 5.0
Control type
Teknospeed ®
Construction
Base
Mild steel Galvanised BS729.
Manifolds
AISI 304.
Pressure Vessels
AISI 304/Butyl.
PED 97/23/C Certified.
WRAS Approved.
Vessel Isolation Valves
PTFE/EN12165 Cu Zn Pb25n.
Pump Isolation Valves
PTFE/EN12165.
Non-Return Valves
EN12165.
Fasteners
BZP BS 3643.
Antivibration Mountings
Integral.
Pumps
18
Casings AISI 316.
Impellers Thermoplastic.
Max System Pressure
10 Bar.
Max System Temp.
40°C.
VG Iss.4 - Aug 2013
Section 2 Specifications, Configurations & Dimensions
Dimensions
A(mm) B(mm) C(mm) D(mm)
Weight
(kg)
Model
Pump
VG2-2HM3-LZM
2HM3ZT
241
520
149
419
62
VG2-2HM5-LZM
2HM5ZT
306
594
149
419
65
VG2-2HM7-LZM
2HM7ZT
331
625
149
419
65
VG2-4HM5-LZM
4HM5ZT
281
569
149
419
70
VG2-4HM9-LZM
4HM9ZT
331
670
141
411
70
Electrical Specifications
VG Iss.4 - Aug 2013
Voltage/
Phase/
Frequency
Full
Load
Current/
Pump
Full
Load
Current
Total
Model No.
Controller
Motor
Rating
VG2-2HM3-LZM
Teknospeed
0.30kW
230/1/50
2.30A
4.60A
VG2-2HM5-LZM
Teknospeed
0.55kW
230/1/50
3.50A
7.00A
VG2-2HM7-LZM
Teknospeed
0.75kW
230/1/50
4.90A
9.80A
VG2-4HM5-LZM
Teknospeed
0.55kW
230/1/50
3.50A
7.00A
VG2-4HM9-LZM
Teknospeed
1.10kW
230/1/50
6.80A
13.60A
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User Guide - VG Variable Speed Twin Pump Booster Sets
Pump Performance
2HM Series Pumps - Operating Characteristics @ 2850rpm 50Hz
The performances are valid for liquids with density = 1.0 kg/dm3 and kinematic viscosity L= 1 mm2/sec.
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VG Iss.4 - Aug 2013
Section 2 Specifications, Configurations & Dimensions
4HM Series Pumps - Operating Characteristics @ 2850rpm 50Hz
The performances are valid for liquids with density = 1.0 kg/dm3 and kinematic viscosity L= 1 mm2/sec.
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User Guide - VG Variable Speed Twin Pump Booster Sets
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VG Iss.4 - Aug 2013
3
The Control Panel
This Section provides information on the Control
Panel fitted to the range of VG Variable Speed
Twin Pump Booster Sets.
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User Guide - VG Variable Speed Twin Pump Booster Sets
Control Panel
The User Control Panel on the VG pumpsets is a simple unit, providing a basic power
connection point with MCB-protected local isolation, fig 3-1.
Control adjustment for the transducer-based monitoring system and pumpset status
monitoring is provided on the fitted Teknospeed Control Unit.
Full details of the Teknospeed® system operation, local connections and status
indicators, is given in the manufacturer’s manual republished in Appendix B of this
manual.
Fig. 3-1 The Control Panel
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Fig. 3-2 Control Panel Wiring Diagram
Section 3 The Control Panel
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User Guide - VG Variable Speed Twin Pump Booster Sets
Fig. 3-3 Control Panel Low Water
Relay Connection
Fig. 3-4 Control Panel
Connection Layout
26
VG Iss.4 - Aug 2013
Fig. 3-5 Control Panel Terminal Diagram
Section 3 The Control Panel
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27
Fig. 3-6 Control Panel External Cables
User Guide - VG Variable Speed Twin Pump Booster Sets
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4
Installation, Commissioning
and Routine Maintenance
This Section gives general information on
installation,
commissioning
and
routine
maintenance procedures for the VG range of
Pumpsets.
• Installation and Pre-Commissioning Checks
• Pressure Vessel Precharging
• Venting Pumps
• Operational and Performance Tests
• Commissioning/Handover Check
• Routine User Maintenance
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User Guide - VG Variable Speed Twin Pump Booster Sets
Installationand Commissioning Overview
Before shipment, all Dutypoint pumpsets are pre-commissioned. Whilst important
procedures such as venting and rotational direction checks need to be carried out on
site, initial parameters including pressure settings and delay timers will be adjusted to
suit the site conditions previously advised to Dutypoint.
In practice, a system can almost invariably be made to perform more efficiently if
further re-commissioning is carried out on site.
NOTE
Please note that engineer visits by Dutypoint are priced at one visit to
commission one pump set. If there are multiple units on a site, special
terms can be negotiated. To arrange a commissioning visit, please call
the Technical Service Help line 01452 300590.
Installation and Pre-Commissioning Checks
The following checks should be carried out at the initial installation on site BEFORE
any run tests are carried out.
DANGER
Ensure that you have read and understood the SAFETY section at the
front of this manual before proceeding.
Pipework and mechanical components
1. Ensure that the mounting area and any associated groundwork provides
adequate support for the pumpset.
2. Ensure all supports/brackets are in place and secure.
3. Verify all pipe joints are sealed and tight.
Electrical
ELECTRIC
These checks MUST be carried out by a competent electrician.
SHOCK
1. Check the motor voltage and frequency information on all the motor nameplates
and on controllers etc. correspond with that of the source power supply.
WARNING
Ensure that the power source is sufficient to allow the running of two
pumps together. (Refer to Section 2 of this manual).
2. Check that all electrical connections are correctly made and secure. Pay
particular attention to Earth and bonding connections.
3. Carry out specific checks for Earth bonding.
4. Carry out NICEIC certification checks as required for the installation, e.g Earth
Loop Impedance, Insulation Tests, etc.
5. Carry out any other pre-start checks recommended by the pump manufacturer.
Refer to the pump manual in Appendix A of this manual. DO NOT POWER UP
AT THIS STAGE.
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VG Iss.4 - Aug 2013
Section 4 Installation, Commissioning and Routine Maintenance
Final checks before commissioning
1. Re-check all equipment for any accidental damage caused during installation.
2. Carry out the Precharging and Venting procedures described next.
Pressure Vessel Precharging
Before commissioning starts the precharge of the pressure vessels should be
checked.
On variable speed systems the precharge air pressure for vessels should be 90% of
the maximum pressure generated by the pump in the pipework system
e.g: If the max. pressure generated by the pump in a system is 6 bar.
This will require a pre-charge pressure of 6 x 90% = 5.4 bar.
Refer to the following table:
Required Pressure
Precharge Pressure
Fig. 4-1 Pump PreCharge Pressure Calculator
To verify the precharge pressure.
1. First check that the expansion or pressure vessel(s) are totally drained of water,
and that the system is switched off and no electrical parts are live.
2. Locate the charging valve on each vessel, accessed by removing the plastic
cover on the top of the vessel.
3. Connect a portable pressure gauge with a measuring range compatible with the
expected pressures in your application, which has a flexible hose and Schradertype connector to the charging valve.
4. Check the pre-charge pressure above the diaphragm in each pressure vessel
[Accumulator]. correspond to criteria given in the text above.
5. If necessary, release or add additional air to correct.
Venting Pumps
It is important to bleed all air from the pump body before initial start-up.
Procedure for flooded suction
Flooded Suction is defined as the condition where there is positive pressure on the
suction (inlet) side of the pump(s) as is the case where the storage tank water level
is at the same or higher level than the pump bleed point.
This procedure should be carried out individually for each pump in the Pumpset.
1. Close any valve on the discharge manifold outlet to the system.
2. Open all valves on the suction (inlet) side of the pump.
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User Guide - VG Variable Speed Twin Pump Booster Sets
3. Using the vent screw at the top of the pump (refer to Appendix A to locate), allow
any air in the pump body and suction pipework to vent to atmosphere.
4. When water (under pressure from the storage tank feeding the pump on the
suction side) escapes through the vent screw hole - and no more air bubbles can
be seen - close the vent screw.
5. Switch on the electrical supply to the pump motor and start the pump in AUTO
mode.
As each motor starts verify that the direction of rotation correctly corresponds
with the direction of the arrow shown on the body of the pump. If rotation is
backward STOP, switch off the pump and investigate.
6. Slowly open the valve on the discharge manifold outlet to the system allowing
water to be pumped into the system.
7. Switch off, re-close the discharge valve and repeat steps 3 to 6 several times to
ensure that all air is released from the pump body and local pipework.
8. The above procedure should be carried out individually for each pump in the
Pumpset.
Procedure for lift suction
Lift Suction is defined where the water storage tank is at a lower level than the
pumpset. In this case a negative pressure condition may exist at the pump suction.
The “Lift Suction” mode of operation requires specific venting
WARNING procedures. Please call Dutypoint Technical Support on 01452 300592
for advice before attempting to vent the pump(s).
The advised procedure should then be carried out individually for each pump in the
Pumpset.
Operational and Performance Tests
Having checked that the Pumpset is installed, precharged, vented in accordance with
the procedures set out earlier, carry out the following running tests before handing
over the Pumpset for operational use.
Duty/Standby sets
1. On Duty/Standby sets, wait for a normal stop to take place (or create the
conditions where this would happen) and check that the ‘Duty’ pump stops.
Whilst stopped simulate a fault by inhibiting the ‘Duty’ pump and then recreate
the conditions for a normal start to take place.
Check that the ‘Standby’ Pump now starts and runs in place of the inhibited ‘Duty’
pump and observe the pressure values.
2. Wait for a normal stop to take place (or create the conditions where this would
happen) and check the ‘Standby’ pump stops. Whilst stopped undo the inhibit to
the ‘Duty’ pump which should now return to normal.
Duty/Assist sets
1. For ‘Duty/Assist’ applications, run the system up to pressure using the ‘Duty’
Pump only, then deliberately create the condition(s) which will require the ‘Assist’
Pump to operate as well. (e.g: open taps to reduce the pressure in the system to
a point where one pump only cannot maintain the required output.
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VG Iss.4 - Aug 2013
Section 4 Installation, Commissioning and Routine Maintenance
Verify that the ‘Assist’ Pump starts and runs together with the ‘Duty’ Pump and
that the desired pressure is duly restored and maintained.
2. Close the taps again (thereby reducing the demand) and check the ‘Assist’ Pump
slows down and stops, allowing the ‘Duty’ Pump to continue on its own.
Commissioning/Handover Check
1. Record any indicated voltage / amperage / pressure data / controller passwords
for future reference.
2. Re-check all isolating valves are fully open and replace any cover(s).
With all the isolators ON and the switches and/or control programs set to
AUTO, the pumpset is now fully operational in automatic control mode.
NOTE
No manual operation or attendance is required other than for routine
servicing and maintenance checks.
Other than for maintenance purposes, the supply to the Controller(s) and
the Pump motor(s) should never be switched off
Routine User Maintenance
Dutypoint Pumpsets have been designed to keep major maintenance requirements
to a minimum. Planned maintenance of the pumps and other principal components
should therefore be undertaken at the intervals recommended in the manuals
referenced below.
It is essential that a full test following the Pre-Commissioning procedure on
page 30 is carried out on an annual basis.
In addition, the operator in charge should routinely make visual checks of the
equipment during use, noting particularly any unusual noises or vibrations. This will
give an immediate indication of any irregularity in the operation of the system.
DANGER
DO NOT COMMENCE ANY MINTENANCE WORK UNTIL:
1. YOU HAVE READ THE SAFETY SECTION AT THE BEGINNING OF THIS
MANUAL.
2. ARE DRESSED IN THE CORRECT PROTECTIVE CLOTHING.
3. HAVE ALL NECESSARY SAFETY EQUIPMENT TO HAND.
Refer to the appropriate manufacturer’s information that is provided in
the appendices of this manual for the equipment being serviced.
Recommended user weekly checks
1. Visually check the complete pumpsets system.
2. Observe the running of the pump(s) and note any unusual vibration, etc.
Recommended user quarterly checks
1. Visually check the complete pumpsets system.
2. Observe the running of the pump(s) and note any unusual vibration, etc.
3. Operate each manual isolating valve three times to ensure continued efficient
working.
Recommended user 6 monthly checks
The pressure vessel should be drained and the pre-charge pressure checked.
Refer to page 31 of this section for details.
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User Guide - VG Variable Speed Twin Pump Booster Sets
Essential 12 monthly (maximum interval) service
Carry out the full Pre-Commissioning procedure to verify correct safe operation. Refer
to page 30 of this section for details.
Detailed Pump Maintenance
Please refer to the Manufacturer’s document which you can find in Appendix A and
Appendix C of this manual.
Detailed Controller Maintenance
Please refer to the appropriate Manufacturer’s document which you can find in
Appendix B of this manual.
Detailed Accessory Maintenance
If you have purchased additional accessories for your system, please refer to the
appropriate manufacture’s document supplied.
34
VG Iss.4 - Aug 2013
5
Troubleshooting
This Section provides general troubleshooting
tips applicable to the Dutypoint range of
pumpsets.
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User Guide - VG Variable Speed Twin Pump Booster Sets
NOTE
The information in this section is common to all Dutypoint centrifugal
pumps. For more detailed troubleshooting information that is specific to
the type and model of Pump and Controller used in the VG pumpsets,
please refer to the Manufacturer’s literature located in the appendices of
this manual.
First Step When a Fault Occurs
When a fault first occurs, turn off the main power to the pumpset and leave off
for around 1 minute.
Switching power back on and re-energising the system may be sufficient to
clear the fault.
General Pump Troubleshooting
Item/Fault
Possible Cause(s)
Recommended Action
1. No electrical power.
1. Check and rectify.
2. Blown fuse(s).
2. Check and rectify.
3. Overload trip.
3. Check and (if necessary) reset the
overload trip value.
Pump will not
start.
For Control Panel information refer to
Section 3 of this manual.
For Pump and Controller manufacturer’s
information refer to the appendices to this
manual.
Low (or zero)
output
(discharge rate).
1. The rotating part(s) of
the
pump
is(are)
partially or completely
obstructed
e.g: impeller obstructed
by foreign matter
1. Strip the pump to inspect and rectify.
2. Pump not primed WARNING: running the
pump ‘dry’ can cause
serious damage to the
mechanical seal.
2. Having first checked the mechanical
seal for damage, prime and air-bleed
the pump and try again
3. Valve
in
suction
pipework closed or
partially closed.
3. Check all appropriate valves are fully
open.
4. Incorrect pump rotation
4. Check and rectify.
For Pump and Controller manufacturer’s
information refer to the appendices to this
manual.
36
VG Iss.4 - Aug 2013
Section 5 Troubleshooting
Item/Fault
Pump vibrates
and/or is noisy
Pump runs
continuously
Possible Cause(s)
Recommended Action
1. Pump is cavitating.
1. Increase
the
discharge
back
pressure slightly by progressively
closing a manual isolating valve on
the discharge side until the cavitation
stops.
2. Motor bearings worn.
2. Check and rectify
3. The rotating part(s) of
the
pump
is(are)
partially or completely
obstructed.
e.g: impeller obstructed
by foreign matter.
3. Strip the pump to inspect and rectify.
1. If the pump has a “Hand
Control” option on it’s
control panel.
1. Switching to “Auto” should restore
normal control.
If normal control is not returned an
immediate service visit is required.
2. Pump has no “Hand
Control” option.
2. An immediate
required.
1. Pipework or the pump
chamber has a partial
blockage.
1. Check and rectify
2. Momentary loss of one
phase of power supply.
2. Check and try again.
3. Discharge flow rate too
high.
3. Reduce by the discharge flow rate by
increasing the discharge back
pressure
slightly,
progressively
closing a manual isolating valve on
the discharge side: then try again
4. Overload trip setting
too low for rated duty
4. Check and (if necessary) reset the
overload trip value
Overload Trip
For Pump and Controller manufacturer’s
information refer to the appendices to this
manual.
service
visit
is
For Pump and Controller manufacturer’s
information refer to the appendices to this
manual.
Technospeed Controller Troubleshooting
If you suspect your problem is possibly caused by the Technospeed Controller, please
refer to the troubleshooting information on page 27 of the manufacturer’s manual
located in Appendix B.
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38
VG Iss.4 - Aug 2013
A
Appendix A
Manufacturer’s Guide CEA-CA, HM-HMS Electric
Pumps
This Section contains a facimile copy of the
Installation
Safety,
Operating
and
Troubleshooting instructions provided by ITT
Lowara for their CEA-CA and HM-HMS Electric
Pumps:
• General User Guide
• Failure Analysis System Procedure
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General User Guide
40
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Appendix A Manufacturer’s Guide - CEA-CA, HM-HMS Electric Pumps
VG Iss.4 - Aug 2013
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42
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Appendix A Manufacturer’s Guide - CEA-CA, HM-HMS Electric Pumps
VG Iss.4 - Aug 2013
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44
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Appendix A Manufacturer’s Guide - CEA-CA, HM-HMS Electric Pumps
VG Iss.4 - Aug 2013
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User Guide - VG Variable Speed Twin Pump Booster Sets
46
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Appendix A Manufacturer’s Guide - CEA-CA, HM-HMS Electric Pumps
Failure Analysis System Procedure
Lowara
Failure Analysis System Procedure
CEA-CA, HM-HMS Electric
Pumps
1) Electric pump applications
CA-CEA made with AISI 304 and HM
• Pumping of water and liquids chemically and mechanically not aggressive.
• Water storing;
• Irrigations;
• Water circulation (cold, hot, chilled)
CA-CEA made with AISI 316 and HMS
• Reverse osmosis
• Industrial washings
• Swimming pool
• Gold industry
• Wine production
2) Critical items of application
2.1) Electrical supply:
• In running condition, max variation of supply voltage: ± 10%.
- a too high voltage generates overheating and overload;
- a too low voltage generates starting problems.
• Max frequency of start: 40 start/h
- an excessive number of starting generates overheating and overload of motor;
- frequents start and stop of pump can generate a rupture of the motor tie rods.
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2.2 Liquid
• Pumps made in standard configuration must pump clean water or condensate.
Temperature limits and standard configurations:
- CEA-CA pumps: -10°C, +85°C,
with mechanical seal ceramics/coal/NBR;
- CEA(N)-CA(N) pumps: -10°C, +85°C,
with mechanical seal ceramics/coal/EPDM;
- HM pumps: -10°C, +60°C,
with mechanical seal ceramics/coal/EPDM;
- HMS pumps: -10°C, +110°C,
with mechanical seal ceramics/coal/EPDM.
• In case of applications with bigger range of temperature and pumping of other liquids, pumps must be
configurated with attention.
Main configurations realized, based on the type of application, are wrote in the following table:
Application
Deionized water
Advised seal (*)
Silicon carbide/Special
coal/EPDM oFPM
Note
Suitable for waters witch have just undergone
by process of direct or reverse osmosis
Demineralized water
Silicon carbide/Special
coal/EPDM oFPM
Pasteurizing systems
Ceramica/Coal/NBR or FPM or Pumping of water with Tmax ≤ 100°C
EPDM
Washing of systems for
the food industry
Widia/Special coal/EPDM
Mixture of water and hard caustic: max conc.
20%, Tmax 80°C.
Generics washing
systems
Widia/Special coal/EPDM
Products to alkaline base with Ph between 8
and 10. For greater Ph it is advised
Widia/Silicon carbide/EPDM
Refrigeration systems
Widia/Special coel/EPDM or
Widia/Silicon carbide/EPDM
Mixture of water and glycol with concentration
from 10% to 100% and temperature from -55°C
to +40°C
It is advised to contact the sale Large tipology of acids
Transfer/pumping of
generic chemical products net
(*) Rotating part/fixed part/O-Ring
• If is pumped an abrasive liquid with CEA pump, it is advised to use the pump with the seal holding disc without
the 3 indents.
• Pumping of diesel oil or others inflammable liquids is concurred only with use of special version pumps and
equipped with Atex motor.
• Pumping of sea water, brackishwater or with a great concentration of chlorine is not adviced because of
priming of corrosive phenomena in hydraulic part.
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Appendix A Manufacturer’s Guide - CEA-CA, HM-HMS Electric Pumps
Lowara
2.3) Installation:
• Max environement temperature: 40°C.
• Max operating pressure: 8 bar.
• Installation of pump inside of environements with a great humidity causes damaging of motor bearings.
• If the pump is used in refrigeration systems, it is advised to remove the condensate evacuation plugs of the
motor for facilitate her evacuation.
• In case of pump with negative water head, or in case of pumping of hot liquids it is necessary check the
difference in height between the axias pump and the level of water can guarantee the correct working of pump
without cavitation (check NPSH value).
• Pump must never operates without water to avoid damages of mechanical seal and hydraulic part.
• The pump mustn't operates when the delivery outlet is closed (overheating of pumped liquid and motor).
• 1~ motors with power until 1.5 kW of CEA-CA pumps and 1~ motors of HM-HMS pumps have an internal
motor protection but they cannot operate without a operator supervision or insertion of additional protections
inside of control board.
• For 1~ motor with power >1,5 kW of CEA-CA pumps and all 3~ motor, must be protect with a circuit breaker
installed by a Customer (it is adviced use of Lowara control board).
• It is necessary guarantee a correct air flow to cool the motor. It is necessary the ventilation grid is not partially
or totally obstructed; otherwise it generates overheating and overload of motor.
• Pump must be positioned correctly so that permit the disassembly of the motor and the hydraulic part without
remove the pump body from pipe so that performe ease an inspection.
• Pump must be positioned and anchored to a plane surface. Moreover, suction and delivery pipes must be
anchored to a wall and they mustn't charge to pump body; otherwise, suction and delivery pump cupling can
break.
• It is necessary insert a non return valve inside of delivery for protect the pump from water hammer and reverse
rotation.
• To get a correct priming of pump, in starting condition, it is necessary to fill the pump body and the delivery
pipe with water; otherwise, the performance will be low and will generates damages of hydraulic part.
• If the performances of pump are greater than witch previewed, or if it pumps a dense, viscous liquids, is
possible change their by turning of impeller.
• Normally the pump is installed with horizontal axis; it can be installed with vertical axis too, but the motor must
be positioned over the hydraulic part to avoid the contact with water (in case ok leaks) or condensate witch can
be on the pump body.
2.4) Operation with inverter
• Operation with inverter positioned inside of the control board not present particular limits (see the inverter
handbook).
• Installation of our equipment TKS directly is possible only for 3~ pump with power until 1.1kW.
3) Equipments and tools required
• Megaohmeter 500 - 1000 Vdc;
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4) Inspection of defected product
4.1) Preliminary information
On receving of defective product, requirements from Customer:
• purchase date (if possible, confirmed by bill or sale slip);
• installation date;
• conditions of installation and operating.
4.2) External visual inspection
Check the external condition of product, in a particular manner check on the surface of pump body the
presence of weld defects, and integrity of aluminum motor casing.
4.3) Preliminary inspections
• Data in plate:
- type of product and code;
- series number;
- manufacturing date;
• Based on type of application witch is subject the pump, check if the configuration is right or wrong (see the
table in 2.2).
• Condition of capacitor (if present) and connections on terminal board.
4.4) Electrical resistence of windings
Check electrical continuity of windings and find possible interruptions or burnings.
4.5) Measure of insulation resistance
Performed in accordance with european standard EN 602 04-1 (500 Vdc between conductors and ground).
Test is passed if insulation resistance is ≥ 10 MΩ.
5) Disassembly and analysis
N.W. The pictures refer to HM pump.
• Remove the protection grid, depending on the motor type, extract the
fan with 2 screwdriver or unsrew the screws on the hub and check:
- the condition of fan;
- the free rotation of the shaft with screwdriver.
• Unscrews the screws, remove the pump body (HM-HMS-CEA) or
suction flange (CA) and check:
- conditions of his internal surface (presence of wear, defects of
welds);
- the presence of initial disc inserted for interference (this disc is
necessary to keep close the stages in the HM-HMS pumps);
- conditions of O-Ring positioned between pump body and suction
flange (CA);
- the presence of foreign matters.
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Lowara
• Unscrew the lock nut and extract one by one the stages (diffuser +
impeller) and check:
- the presence of wear or defects of welds (stainless steal impellers);
- presence of wear in the bush of plastic impeller (HM).
• Remove O-Ring from his seat (on seal holding disc):
- check the presence of wear or cuts.
• Extract the mechanical seal from shaft, taking care of not damage it,
and remove the seal housing:
- check condition of her surface and condition of wear;
- positioning of fixed part of mechanical seal on the seal holding disc
(if the mechanical seal is not positioned correctly, it reduces her
operating life and her efficiency);
- if inside of CEA pumps there are the three indents on the seal
holding disc, check their wear condition (possible wear indicates the
pumping of abrasive liquid).
• Extract the rotor and check the conditions of
bearings.
• Performe an heads visual analysis for finding possible problems with following cases:
a) all motors:
- one or more winding coils burnt ----> shorted coil;
b) 1~ motor:
- run winding OK and start winding KO ----> capacitor defected;
- run winding KO and start winding OK ----> motor could not start;
- both windings faulty ----> overload;
c) 3~ motor:
- 1 phase fine and 2 phases burnt ----> powered with only 2 phases;
- all phases burnt ----> overload;
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Lowara
6) Check list
Type of problem
Pump data
Does not delivery water
Low performance
Does not starts
Noisy
Grounded motor
Excessive power input
Runs slowly
Further:
Type:
Code:
Series number:
Installation date:
Manufacturing date:
Liquid pumped:
Temperature:
Note:
CEA-CA-HM-HMS pumps failure causes required for claim opening
Where
100 Electric motor
100 Electric motor
100 Electric motor
100 Electric motor
101 Motor shaft
What
100 Flooded/full of water
Why
106 Uncorrect assembly/testing of components
110 holes of drain condensate, obstructed/closed
111 Pinched gasket screws
112 Not complying components tooling
100 Further (supply detailed description of failure)
103 Not complying/unsuitable applications
119 Normal wear
120 Excessive wear
101 Further:
101 Excessive power input / 102 Motor shaft locket
104 Wrong internal electrical connections
overheating / burnt
106 Uncorrect assembly/testing of components
107 Bursted / unconnected capacitor
108 Short circuit for contact with mobile parts
109 Short circuit between coils/windings
114 Hydraulic rotating part locked
115 Presence of external matters between windings
100 Further (supply detailed description of failure)
121 Inadequate power supply
103 Not complying/unsuitable applications
113 Inadequate size of motor
116 Inadequate cooling
119 Normal wear
120 Excessive wear
101 Further:
102 Runs slowly / does not st 106 Uncorrect assembly/testing of components
107 Bursted / unconnected capacitor
117 Defected/wrong rotor
118 Not operating level sensors
119 Water full level sensors
100 Further (supply detailed description of failure)
121 Inadequate power supply
103 Not complying/unsuitable applications
113 Inadequate size of motor
101 Further:
105 Defected/not operating electrical/electronic components
103 Does not stops
118 Not operating level sensors
100 Further (supply detailed description of failure)
103 Not complying/unsuitable applications
101 Further:
104 Noisy / locked / vibrate 102 Locked motor shaft
106 Uncorrect assembly/testing of components
(ok windings)
112 Not complying components tooling
114 Hydraulic rotating part locked
100 Further (supply detailed description of failure)
103 Not complying/unsuitable applications
119 Normal wear
120 Excessive wear
101 Further:
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Section Manufacturer’s Guide - CEA-CA, HM-HMS Electric Pumps
Lowara
112 Not complying components tooling
100 Further (supply detailed description of failure)
103 Not complying/unsuitable applications
119 Normal wear
120 Excessive wear
101 Further:
112 Not complying components tooling
100 Further (supply detailed description of failure)
103 Not complying/unsuitable applications
119 Normal wear
120 Excessive wear
101 Further:
105 Defected/not operating electrical/electronic components
200 Lack of technical / commercial information
118 Not operating level sensors
119 Water full level sensors
100 Further (supply detailed description of failure)
121 Inadequate power supply
103 Not complying/unsuitable applications
119 Normal wear
120 Excessive wear
101 Further:
106 Uncorrect assembly/testing of components
112 Not complying components tooling
300 Wrong rating plate/packing
100 Further (supply detailed description of failure)
103 Not complying/unsuitable applications
119 Normal wear
120 Excessive wear
101 Further:
106 Uncorrect assembly/testing of components
112 Not complying components tooling
114 Hydraulic rotating part locked
100 Further (supply detailed description of failure)
103 Not complying/unsuitable applications
119 Normal wear
120 Excessive wear
101 Further:
106 Uncorrect assembly/testing of components
112 Not complying components tooling
100 Further (supply detailed description of failure)
103 Not complying/unsuitable applications
119 Normal wear
120 Excessive wear
101 Further:
106 Uncorrect assembly/testing of components
112 Not complying components tooling
100 Further (supply detailed description of failure)
103 Not complying/unsuitable applications
119 Normal wear
120 Excessive wear
101 Further:
106 Uncorrect assembly/testing of components
112 Not complying components tooling
100 Further (supply detailed description of failure)
103 Not complying/unsuitable applications
119 Normal wear
120 Excessive wear
101 Further:
106 Uncorrect assembly/testing of components
101 Motor shaft
Shaft / toothing jut
101 Motor shaft
401 Broken/cracked
200 Control device
200 Not operate
300 Total hydraulic
300 Low performance
300 Total hydraulic
104 Noisy / locked / vibrate
403 Pump sleeve
400 Leak
404 OR/Mechanical seal
400 Leak
408 Pump shaft/joint
401 Broken/cracked
600 Product
600 Wrong rating plate
packing
601 Wrong product
200 Lack of technical / commercial information
document
602 Not acknowledgment of 600 Out of legal warranty period
601 Product tampering
warranty
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8) Faq
Problem founded
Pump does not start
Possible causes of the problem
Power supply problems:
• no power;
• unconnected or damaged cable;
• supply voltage too low;
Hydraulic locked.
Fuses burnt.
Circuit breaker tripped/not calibrated.
Capacitor too small or damaged (1~ motor).
2 phases powered (3~ motor).
Motor is burnt because of insulation defected, overheating or
overload (unsuitable liquid)
Pump does not delivery water
Non return valve clogged
Delivery outlet obstructed because of foreign matters;
Not primed pump.
Pump operates in cavitation
Incorrect performance
Delivery outlet partially clogged
Pump run in the opposite way
Pump is undersized
Wrong size of the motor
Wrong diameter of pump impeller
Clogged non return valve
Unsuitable liquid (density or specific weight)
Wear of hydraulic part
Difference in height and/or flow resistence too highs
System leaks
Noisy
Pump operates in cavitation condition
Pump is primed incorrectly
Motor bearings damaged cause by condensate
Presence of foreign matters
Runs slowly
Run and start windings exchanged on control panel (1~ motor)
Wrong windings connections inside the motor (3~ motor)
Grounded motor
Generation of condensate inside of the motor
Insulation defected
Presence of foreign matters (swarfs or bolts and screws)
7
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Lowara
Excessive power input
Uncorrect voltage
Windings defected
Motor supplied with 2 phases instead of 3 (3~ motor)
Unsuitable liquid
Wrong size of impeller/motor
Defected pump
Defected bearings
Too high frequency of startings
Hydraulic locked
Unsuitable liquid
Presence of foreign matters inside of the pump
Tolerance of tooling beyond the limits
O-ring out of seat
Overheating/overload
Too high pumped liquid temperature
Too high frequency of startings
Wrong supply voltage
Wrong size of pump/motor
Defected pump
Thrust bearings damaged/seized
Lack of adequate protection inside of control board (for motors
without internal protection, see 2,3)
Lack of ventilation of the motor
Too high environment temperature
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55
56
Wrong size of
impeller/motor
Supply voltage too low
Defect of insulation
Overheating / overload
Motor burnt
Hydraulic locked
2 phases supplied (3~)
Too small or damaged
capacitor (1~ motor)
Circuit breaker
tripped/not calibrated
System leaks
Difference in height
and/or flow resistence
Hydraulic wear
Unsuitable liquid
Clogged non return
valve
Pump run in the
opposite way
Cable unconnected or
damaged
Fuses burnt
Pump operates in
cavitation condition
Delivery outlet partially
clogged
No power
Not primed pump
Obstructed delivery
outlet
Clogged non return
valve
PUMP DOES NOT
DELIVERY WATER
Presence of foreign
matters inside of pump
Motor bearings
damaged
Pump is primed
incorrectly
NOISY
INCORRECT
PERFORMANCE
DOES NOT STARTS
Too high frequency of
starting
Damaged bearings
Defected pump
Wrong size of
impeller/motor
Overload
Unsuitable liquid
Motor supplied with 2
phases instead of 3 (3~
Windings defected
Uncorrect voltage
EXCESSIVE POWER
INPUT
7) Failure tree (CEA-CA-HM-HMS pumps)
VG
Weld defected
O-Ring damaged
Mechan. seal damaged
LEAKS OF
HYDRAULIC PART
Wrong windings
connections (3~)
Run and start windings
exchanged on control
RUNS SLOWLY
Presence of foreign
matters
Insulation defected
Condensate inside of
the motor
GROUNDED MOTOR
User Guide - VG Variable Speed Twin Pump Booster Sets
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B
Appendix B
Manufacturer’s Guide Teknospeed
This Appendix contains a facimile copy of the
Installation Safety and Configuration instructions
provided by ITT Lowara for the Teknospeed®
Controller.
• Instructions for Installation and Use
• Troubleshooting
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User Guide - VG Variable Speed Twin Pump Booster Sets
Instructions for Installation and Use
TKS SERIES ELECTRIC PUMP WITH
TEKNOSPEED SPEED VARIATOR
Instructions for installation and use
Keep this manual for future reference
Page numbers below refer to manufacturer’s original manual
1 Overview ................................................................................................... page 19
2
Preliminary inspection .............................................................................. page 19
3 Applications ............................................................................................... page 19
4 Working limits ........................................................................................... page 19
5 Installation ................................................................................................. page 20
6 Start-up ..................................................................................................... page 21
7 Maintenance .............................................................................................. page 26
8 Troubleshooting ........................................................................................ page 27
9 Spare parts ............................................................................................... page 30
10 Disposal..................................................................................................... page 30
11 Warranty ................................................................................................... page 30
Page numbers below refer to this Dutypoint manual
12 Tables and drawings.................................................................................. page 71
13 Declaration of conformity........................................................................... page 82
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Appendix B Manufacturer’s Guide - Teknospeed
en
English
1. Overview
The purpose of this manual is to provide the necessary information for proper installation, operation
and maintenance of the TEKNOSPEED converter connected to a LOWARA electric pump.
Read this manual before using the product.
Improper use may cause personal injury and damage to property, and lead to the forfeiture of the
warranty coverage.
For information regarding the electric pumps, refer to the relevant manuals.
The instructions and warnings provided below concern the standard version.
Please refer to the sale contract for any modifications or special version characteristics.
Always specify the exact model identification code and construction number when requesting technical
information or spare parts from our Sales and Service department.
For instructions, situations or events not considered in this manual or in the sale documents, please contact our Service Center nearest you.
2. Preliminary Inspection
2.1 Visual Inspection
Upon delivery, check the integrity of the packaging.
If the packaging is damaged, unpack the product and inspect it visually to make sure it has suffered no
damage during transport.
Should the product be damaged, inform our dealer within 8 days from delivery.
2.2 Handling and Storage
The product is delivered in a cardboard box or wooden case. During transport and storage, protect it
from humidity, heat sources and possible mechanical damage (impacts, falls, etc). Lift and handle the
product carefully using suitable hoisting equipment.
Refer to chapter 4 for further information.
3. Applications
The TKS system consists of a three-phase electric pump, the TEKNOSPEED single-phase converter and
an electronic pressure transmitter (also known as pressure sensor).
The TEKNOSPEED single-phase converter is suitable for the control of a three-phase electric pump according to the conditions described in this manual and the supply voltage / frequency specified in the rating plate.
The converter controls the operation of the pump in order to ensure a constant delivery pressure based
on the signal received from the electronic pressure transmitter.
The TKS system can be used for domestic water supply, irrigation and pressure boosting applications.
For further information refer to chapter 12.
4. Working Limits
For storage :
• Ambient temperature: -5°C to +40°C .
For operation :
For information regarding electric pumps refer to the relevant manuals.
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4.1 TKS system (TEKNOSPEED mounted on the electric pump)
Do not use the product in environments where corrosive and/or flammable powders, acids,
gases, etc. are present.
Do not use the electric pump to handle dangerous or flammable liquids.
• Ambient temperature: +0°C to +40°C
• Maximum relative humidity : 50 % at + 40°C provided no condensation occurs
• Maximum height above sea level: 1000 meters
• Protection class : IP 55 (if installed on motors with at least IP55 protection)
• Maximum operating pressure : refer to the operating instructions for the electric pump
The standard version features a transmitter with 10 bar full scale (chapter 4.2)
• Temperature of pumped liquid : + 1°C to + 40 °C
• Nature of pumped liquid : water containing no chemically aggressive substances or
suspended solids
• Maximum rated power of electric pump connected to the converter : 1.1 kW
• Converter supply voltage : 1 x 230 V ± 10 % 50/60 Hz
• Converter output voltage (corresponding to the motor supply voltage) :
3 x 230 V ± 10 % 12-50 Hz (these values vary according to the converter’s
voltage/frequency curve)
• Converter’s rated input current : 6.8 A
• Converter’s rated output current: 4.6 A
• Maximum number of starts per hour, evenly distributed : read the operating instructions for
the electric pump
4.2 Pressure transmitter
The sensor for this transmitter is a piezo-resistive silicon element which is sensitive to pressure. It is
mounted on a small flexible printed circuit (TAB) and is immersed in an oil chamber. The pressure is transmitted to the sensor through a steel diaphragm located in the oil chamber.
• Pressure range : 0 to 10 bar
• Power supply : 21 Vdc from TEKNOSPEED
• Output signal : 4 to 20 mA
• Connection : 1/4” male, made of nickel plated brass
• Electrical connector : removable, provided with 2-meter shielded cable
• Protection class : IP 55
For ambient conditions other than those specified above, please contact our Sales and Service
Department.
5. Installation
Information for installers
The installation operations must be carried out by skilled and qualified personnel.
Use adequate equipment and protections. Observe the accident prevention regulations in force.
Before proceeding with the installation, read these operating instructions and the manual for the
electric pump.
If the product shows evident signs of damage, do not proceed with installation but contact our Customer
Service Center.
Install the product in a sheltered location protected from the weather and freezing temperatures;
observe the working limits in order to guarantee adequate motor cooling. For further information
refer to chapters 4 and 12.
Observe all the safety standards and accident prevention regulations in force.
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6. Start-up
Information for installers
The start-up operations must be performed by skilled and qualified personnel. Use adequate
equipment and protections. Observe the accident prevention regulations in force.
Before starting the unit, read these operating instructions and the manual for the electric pump.
6.1 Hydraulic Connection of Electric Pump
The hydraulic connections must comply with current standards and legislation.
The product can be connected directly to the municipal water system or the water can be taken from a
storage tank.
In case of connection to the municipal water system follow the regulations locally in force (issued by City,
utility company, etc.). We suggest that you install a pressure switch on the suction side for deactivation
of the electric pump in the event of low water system pressure (protection against dry running).
Make sure that the water system pressure added to the maximum pressure of the pump does not
exceed the maximum operating pressure value (nominal pressure NP) allowed for the pump.
For example, if the system features a CA 70/33 pump we can calculate that :
Maximum head of the pump :
43 meters (equivalent to a closing contact pressure of approximately 4.3 bar)
Maximum working pressure allowed :
8 bar (NP 8)
Water system pressure (consider the maximum value):
1.5 bar
Resulting maximum working pressure :
4.3 + 1.5 = 5.8 less than the 8 bar limit
When using a storage tank it is necessary to install a float switch for deactivation of the electric pump in
the event of low water (protection against dry running).
You must install a pressure gauge on the delivery side as it may be necessary to modify the factory settings based on the actual installation conditions.
To complete the system, flexible pipes on suction and delivery side, on-off valves on suction and delivery
side, non-return valve and surge tank with diaphragm are normally installed. To avoid having to drain the
system in the event that the diaphragm tank or the pressure gauge or the pressure transmitter need replacing, we advise you to install on-off valves.
If you install a check valve on the pump’s delivery side, position the pressure transmitter downstream
from the valve. We advise you to install a test tap to be used during the TKS system’s calibration stage
(chapter 6.3.3) unless a water drawing point is already present in the vicinity of the pump .
For further information refer to chapter 12.
6.1.1 Surge Tank (Diaphragm Tank)
A diaphragm tank must be installed on the delivery side of the electric pump to maintain pressure in the
system when there is no water demand, in order to prevent continuous pump operation.
With the TEKNOSPEED converter there is no need for a large capacity tank. The nominal capacity of the
tank, in liters, must be at least 5% of the maximum flow rate (liters per minute) of one pump, with a minimum of 8 liters of nominal capacity.
Example :
maximum flow rate of pump = 60 liters per minute
nominal volume of tank = 60 x 0.05 = 3 liters ➞ 8 liters
maximum flow rate of pump = 150 liters per minute
nominal volume of tank = 150 x 0.05 = 7.5 liters ➞ 8 liters
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Make sure that the surge tank can handle the maximum pressure of the system.
Check and adjust the precharge pressure before connecting the surge tank to the system.
If the surge tank is already connected, you will have to drain the system before you check and adjust the
precharge pressure. To avoid doing this, we suggest that you install an on-off valve between the connection to the tank and the system’s pipe.
To determine the precharge value for the surge tank you can use the following formula:
if in bar ➞ work pressure – 0.2 = precharge pressure
if in kPa ➞ work pressure – 20 = precharge pressure
6.2 Electrical Connection of Pump
The electrical connections must comply with current standards and regulations.
Make sure that the type of power source, the supply voltage and frequency match the ratings of
the TKS system shown in the rating plate. Provide suitable general protection against short circuits on the electrical power line.
WARNING : although the TKS system has single-phase power supply, the pump’s motor is always a
three-phase motor connected to 230 V. The missing phases are created by the converter. For further
information refer to chapter 12.
Before proceeding with these operations, make sure that all the connections (even those that are
potential-free) are voltage-free. Always disconnect the TEKNOSPEED converter from the power
supply before carrying out any operations on the system’s electrical or mechanical components.
After disconnection from the power source, wait at least 1 minute before carrying out any work on
TEKNOSPEED to allow the condensers in the internal circuit to discharge.
6.2.1 Differential Magneto-thermal Switch
If local regulations require the installation of a differential magneto-thermal switch, make sure it is of a
type that is suited to the system. Suitable switches are those having the characteristic curve for unidirectional alternate and pulsating DC fault current (type A or C).
They can be identified by the presence of the following symbol:
6.2.2 Version with Cable and Plug
The TKS system is equipped with power cord and plug.
When installing the pump, make sure that the plug and corresponding outlet are easily accessible in case the system needs to be deactivated.
If the power cord is damaged, it must be replaced at a service center or by qualified personnel.
6.2.3 Input Filter
The TEKNOSPEED converter is equipped with an input filter according to the EMC directive.
6.2.4 Motor Overload Protection
The TEKNOSPEED converter has an incorporated overload protection which guarantees absolute protection when it is connected to motors featuring the same nominal protection as that of the converter. For
lower power motors an auxiliary protection is used (see chapter 6.2.5)
6.2.5 Motor Overtemperature Protection (PTC)
Some models may feature an extra protection (thermistor) in addition to the overload protection incorporated in the converter. The thermistor (PTC) is attached to the base of the terminal board and connected
through cables and mini-fastons. The corresponding dip-switch will be in the PTC Y position.
For further information refer to chapter 12.
6.2.6 Converter overtemperature protection
The TEKNOSPEED converter has an incorporated overtemperature protection.
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6.2.7 Protection against dry running (float switch)
The TEKNOSPEED converter can be connected to an external device for protection against pump dry
running (see chapter 6.1). The most conventional method consists in the use of a float switch installed in
the suction tank.
To connect the cable of the external device you must remove the converter’s radiator using a no. 5 Allen
wrench (maximum torque 6 Nm). Turn the radiator upside down, paying attention to the connections with
the removable terminal board. The terminal board may have to be extracted. Replace an M 16 x 1.5 plug
with one of the cable glands supplied. Lay the float switch cable and connect it to the terminals corresponding to LOW 1 and LOW 2 (suitable for 0.5÷1 mm2 conductors). Screw down the cable fastening
plate and tighten the cable gland to secure the cable. If you connect the suction side of the pump to the
municipal water system, you can use a pressure switch that opens its contact when the pressure drops
below the set point.
If you are not using any device, two terminals must be connected with a jumper.
Use the slotted blade screwdriver (2.5 mm) provided with the TKS system for the connections on
the converter’s terminal board.
For further information refer to chapter 12.
6.2.8 External Enable Device
You can connect a switch instead of the float switch (chapter 6.2.7). This external device can be used to
enable or disable the system. We recommend using a shielded cable. The stripping of the cable should
allow the shielding to be in contact with the cable fastening plate.
Use the slotted blade screwdriver (2.5 mm) provided with the TKS system for the connections on
the converter’s terminal board.
For further information refer to chapter 12.
6.2.9 Alarm Relay
The TEKNOSPEED converter has a contact that can be used to obtain an external shutdown or malfunction signal.
This contact is closed when
• the pump is not running due to one of the following causes : no voltage
motor overload (chapter 6.2.5)
motor overtermperature (chapter 6.2.6)
converter overtemperature (chapter 6.2.7)
Probe faulty or disconnected (chapter 6.2.11)
• lack of water on suction side (chapters 6.2.8 and 6.2.9)
To connect the cable you must first take the radiator off the converter using a no. 5 Allen wrench (maximum torque 6 Nm). Turn the radiator upside down, paying attention to the connections with the removable terminal board. The terminal board may have to be extracted. Replace an M 16 x 1.5 plug with one of
the cable glands supplied. Lay the cable and connect it to the terminals corresponding to COM and NC
(suitable for 0.5÷1 mm2 conductors). Screw down the cable fastening plate and tighten the cable gland
to secure the cable.
We recommend using a shielded cable. The stripping of the cable should allow the shielding to be in
contact with the cable fastening plate.
Use the slotted blade screwdriver (2.5 mm) provided with the TKS system for the connections on
the converter’s terminal board.
For further information refer to chapter 12.
6.2.10 Serial Interface
The TEKNOSPEED converter is equipped with a serial interface that can only be used on pumping systems with two pumps.
Do not connect any wires to the COM, TX, RX terminals of the serial interface.
For further information refer to chapter 12.
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6.2.11 Pressure Transmitter
The TKS system comes with pressure transmitter connected to the TEKNOSPEED converter’s terminal
board. The transmitter is equipped with a 2-meter shielded cable. If you need to wind up the cable, do
not coil it but fold it .
For further information refer to chapter 12.
6.2.12 Regulation Dip-switches
The TEKNOSPEED converter is equipped with a series of microswitches (dip-switches) that determine its
operating cycle.
Do not modify the factory setting; you could damage the converter or the system on which it is installed.
For further information refer to chapter 12.
6.3 Initial Start-up
6.3.1 Priming
Read the operating instructions for the electric pump.
Fill the pump and suction pipes with water before starting the system. Dry running can damage
the pump.
Start the system with the on-off valve on the delivery side closed. Then open the valve gradually. When
the air in the pipe has been bled off the pump will run smoothly and silently.
6.3.2 Checking the Direction of Rotation of the Motor
There is no need to check the direction of rotation of the motor since it is pre-set at the factory.
6.3.3 Operating Pressure Calibration
A pressure gauge must necessarily be installed on the delivery side as it may be necessary to
modify the factory setting according to the actual installation conditions and system requirements.
The TKS system comes with a factory setting that enables it to be used.
To modify the pressure based on the actual system requirements proceed as follows:
• Increasing the pressure value
- Make sure that the system is pressurized, no user is open and the pump is off. If there are any open
users you can close the on-off valve located on the pump’s delivery side.
- Unscrew the plug that protects the adjusting screw.
- Turn the adjusting screw slowly to the right using a screwdriver.
Use the slotted blade screwdriver (2.5 mm) provided with the TKS system. The adjusting screw
has a limited travel, less than one turn, between the minimum value (0 bar) and the maximum
value (10 bar). Do not force it beyond the limits as you could damage the adjusting screw .
- The pump starts.
- Read the pressure value on the gauge and keep turning the adjusting screw until the gauge pointer
reaches the desired value.
- Make sure that the pressure has stabilized at the desired value.
- If necessary, make slight adjustments by turning the adjusting screw to the right or left. If you need to
lower the pressure setting, we recommend that you open a user partially (see next section “Lowering
the pressure value”).
Make sure that the new value you have selected is within the head range specified in the TKS system’s rating plate.
- The pump stops after approx. 60 seconds. The switch-off pressure may be slightly higher than the
desired value (chapter 6.4.1)
• Lowering the pressure value
- Make sure that the system is pressurized, no user is open and the pump is off.
- Unscrew the plug that protects the adjusting screw.
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-
Open the on-off valve located on the pump’s delivery side.
Open a user or the test tap (chapter 6.1) partially, allowing the pressure to drop slowly.
The pump starts.
Turn the adjusting screw slowly to the left using a screwdriver.
Use the slotted blade screwdriver (2.5 mm) provided with the TKS system. The adjusting screw
has a limited travel, less than one turn, between the minimum value (0 bar) and the maximum
value (10 bar). Do not force it beyond the limits as you could damage the adjusting screw.
- Read the pressure value on the gauge and keep turning the adjusting screw until the gauge
pointer reaches the desired value.
- Make sure that the pressure has stabilized at the desired value.
- If necessary, make small adjustments by turning the adjusting screw to the right or left.
Make sure that the new value you have selected is within the head range specified in the TKS system’s rating plate.
- The pump stops after approx. 60 seconds. The switch-off pressure may be slightly higher than the
desired value (chapter 6.4.1).
For further information refer to chapter 12.
6.3.4 Indicator Lights
On the adhesive plate attached to top of the radiator there are three LED’s with the following functions :
Steady green light
Power
Indicates that the TKS system is powered
Steady yellow light
Run
Indicates that the pump is running
Flashing red light
Alarm
Indicates an alarm has triggered
If an alarm is triggered, the red light will flash more or less rapidly depending on what has caused the system to shut down. Except for lack of water on the suction side, in all other cases the system will automatically start again after 20 seconds. If the cause of the malfunction persists, after three attempts to restart
the system will definitively shut down except in case of lack of water on the suction side.
For further information refer to chapters 8.1 and 12.
6.4 Product Description
Information for users
The TKS system consists of an electric pump operated by an automatic electronic control system (frequency converter known also as speed variator) that enables the delivery of constant pressure by reducing or increasing the flow rate based on the water demand.
6.4.1 Operation
The automatic electronic control system receives a signal from a pressure sensor and compares it with
the set value.
When the system is pressurized the pump is switched off. Water consumption by the users determines a
decrease in system pressure which causes a reduction in the value of the signal. In this case the control
system starts the pump, regulating its speed until the reference or operating pressure is re-established.
If the water consumption increases the control system increases the speed of the pump, while if the water
consumption diminishes the control system decreases the speed of the pump. When the maximum flow
rate of the pump is reached, the control system runs the pump at its maximum nominal speed.
If the pressure increases because of decreased water consumption, the value of the signal from the sensor increases; in this case the control system reduces the speed of the pump.
If there is a swift decrease in water consumption (e.g. due to sudden closing of the faucets), the control
system runs the pump at minimum speed for approx. 60 seconds and then stops it. In this case the stopping pressure coincides with the set value.
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If the water consumption decreases gradually, the system runs the pump at a slightly higher pressure for
approx. 60 seconds (with transmitter full scale equal to 10 bar ➞ + 0.2 bar), and then stops it if there is
no further water consumption.
If the system is powered the green (Power) light is on.
When the pump is running the yellow (Run) light is on.
If there is a shutdown or malfunction the red (Alarm) light comes on.
If an alarm is triggered, the red light will blink more or less rapidly depending on the cause of the shutdown. Except for lack of water on the suction side, in all other cases the system will automatically start
again after 20 seconds. If the cause of the malfunction persists, after three attempts to restart the system
will definitively shut down.
Refer to experienced and qualified personnel for any adjustments and/or maintenance operations. Do not attempt to change the settings or open the control system.
Before using the equipment, read the manuals and store them safely.
Store the screwdriver supplied with the TKS system in a safe place.
7. Maintenance
Information for maintenance personnel
Observe the following directions if you need to carry out any service operations on the product .
Maintenance operations must be performed by qualified personnel only.
Before carrying out any maintenance operations, make sure that all the connections (even those
that are potential-free) are voltage-free.
Always disconnect the TEKNOSPEED converter from the power supply before carrying out any
operations on the system’s mechanical or electrical components.
After disconnection from the power source, wait at least 1 minute before carrying out any work on
TEKNOSPEED to allow the condensers in the internal circuit to discharge.
Read this user’s manual and the operating instructions for the electric pump and diaphragm tank
(if installed).
7.1 Routine Maintenance
The TKS system does not require any routine maintenance provided that the working limits described in
chapter 4 are observed.
The pumps do not require any routine maintenance (read the pump’s manual).
Check the air pre-charge in the surge tank, if installed, at least once a year (chapter 6.1.1).
7.2 Extraordinary Maintenance
Use adequate equipment and protections. Observe the accident prevention regulations in force.
Lift and handle the pumps carefully, using suitable hoisting equipment.
Use only original spare parts to replace any worn or faulty components.
WARNING !
Although the TKS system has a single-phase power supply, the pump’s motor is always a three-phase
motor connected to 230 V. The missing phases are created by the converter. For further information refer
to chapter 12.
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Troubleshooting
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8. Troubleshooting
Information for users and maintenance personnel
Read this user’s manual and the operating instructions for the electric pump and diaphragm tank
(if installed).
Maintenance operations must be performed by qualified personnel only.
For further information refer to chapters 7 and 12.
8.1 Visual Signaling Devices
8.1.1 Operation Signals
TKS_M0025_A_OT.XLS
These basic signals are integrated by the alarm signals. Therefore there could be combinations of signals such as green light on (power), yellow light off (pump off) and flashing red light (alarm).
8.1.2 Alarm signals
If an alarm is triggered the red light flashes more or less rapidly (flashing – pause – flashing) depending
on the cause of the system shutdown.
Red light (alarm)
Off
No malfunction
Red light (alarm)
Flashing
Overcurrent shutdown
x2
x2
Red light (alarm)
Flashing
x3
x3
Red light (alarm)
Flashing
x4
x4
Red light (alarm)
Flashing
x5
x5
Red light (alarm)
Flashing
x6
x6
Red light (alarm)
Flashing
x7
x7
Red light (alarm)
Flashing
Converter overtemperature
shutdown
Motor overtemperature
shutdown
Shutdown caused by lack of
water on suction side
Or shutdown caused by open
external switch contact
No signal from transmitter
shutdown
Low voltage (undervoltage)
shutdown
Problems at serial output (for 2pump units)
x8
x8
TKS_M0026_A_OT.XLS
Be careful when servicing the system as it could restart automatically.
Shutdown caused by lack of water on suction side
If the system shuts down because there is not enough water on the suction side, it will restart automatically only if the external device re-enables its operation (float switch or pressure switch or switch ➞ chapters 6.2.7 and 6.2.8).
Shutdown caused by other problems except for lack of water on suction side
In all these cases the system restarts automatically after 20 seconds. If the cause of the malfunction persists, the system will shut down definitively after three attempts to start.
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To reset the system, disconnect the power supply for at least one minute.
If 10 minutes elapse after an alarm without any other malfunctions occurring, the alarm counter is reset
and three new attempts are possible.
If two or more alarms are triggered simultaneously (e.g. due to motor overtemperature and lack of water),
only the first malfunction signal received by the control board is signaled.
WARNING ! The converter does not have a non-erasable alarm log, we therefore recommend that you
observe the flashing frequency carefully before disconnecting the power supply to the TKS
system.
For further information refer to chapters 8.1 and 12.
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8.2 Troubleshooting Guide
PROBLEM
The electric pump does not start
Main switch on
Green light off
The electric pump does not start or
it stops if it is already running
The main switch is on
Green light on
Red light on (*** flashes)
PROBABLE CAUSE
No power supply
POSSIBLE REMEDY
Restore the power supply
Triggering of magneto-thermal
switch
Reset the switch
*** = 2 flashes
Motor overload
Damaged motor stator
*** = 3 flashes
Converter overtemperature
*** = 4 flashes
Motor overtemperature (if the
terminal board is equipped with
the PTC protection)
*** = 5 flashes
Triggering of dry running
*** = 6 flashes
Problems with the pressure
transmitter
*** = 7 flashes
The supply voltage is too low
Users closed
Electric pump running with
speed increasing and
decreasing cyclically
Green light on
Yellow light on
Red light off
Users open
The electric pump does not start
Green light on
Yellow light off
Red light off
The electric pump is running.
There are vibrations in the pump
or near the pump
Frequent starts and stops
The electric pump is running
always at maximum speed
Water leaks through the non-return
valve or in the system
Undersized surge tank
Ruptured surge tank diaphragm
Check the working conditions
of the electric pump
Check the motor
Check to see if anything is
preventing the proper cooling
of the converter
Check the working conditions
of the electric pump
Check the water level
Check the external device and
the related connection cables
Check the transmitter and
the related connection cable
Check the system in order to
locate the leaks.Repair or replace
any faulty components.
Check the working conditions
of the electric pump
Replace the diaphragm
Setting of work point not suitable Modify the system settings
for the system (the value is higher
than the pressure that the pump
is able to deliver)
Setting of work point not suitable Modify the system settings
for the system (the value is equal
to zero)
Setting of work point not suitable
for the system (the value is lower
than the minimum pressure
that the pump can deliver)
There may be problems with the
float switch in the suction tank
There may be problems with the
pressure transmitter
Modify the system settings
Check the float switch and the
tank
Check the hydraulic connection
between the transmitter and the
system
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Triggering of general system
protection
Triggering of differential system
protection (circuit breaker)
Short circuit
Check the connection cables
Ground leakage
Check the insulation of the
electric pump and cables
9. Spare Parts
Information for maintenance personnel
Always state the exact model identification number and construction number when requesting technical
information or spare parts from our Sales and Service Center.
Use only original spare parts when replacing any faulty components.
The use of unsuitable spare parts can cause malfunctions, personal injury and damage to property.
10. Disposal
Information for installers and maintenance personnel
After installing the unit, dispose of packaging according to legislation in force; if possible, re-utilize the
packaging for other purposes.
If the motor needs to be decommissioned and dismantled, observe the current legislation regarding sorted waste disposal.
11. Warranty
Refer to the sales documents for any information.
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12 Tables and Drawings
TKS system composition (chapters 3 and 6.4)
1
2
3
4
5
Radiator (incorporates the electronic control and command board)
Base
Cable and plug
Electric pump
Pressure transmitter
Rating plate (chapters 4 and 9)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Electric pump type
Code
Flow range
Head range*
Rated power
Minimum head*
Frequency
Insulation class and protection class
Motor type
Voltage
Input power
Rated motor power
Current
Converter type
Manufacturing date and Serial number
* note: for water, 10 meters of head are equivalent to almost 1 bar (approx. 100 Kpa)
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Minimum clearance required to ensure proper cooling (chapter 5)
Examples of installation (chapter 6)
1
3
5
7
9
11
72
Reservoir or tank
On-off valve
Flexible pipe
Pressure transmitter
Diaphragm tank
Float switch
2
4
6
8
10
Possible filter
Non-return valve
Electric pump with Teknospeed
Pressure gauge
Test tap
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Suction lift
1
5
7
9
11
Tank
Flexible pipe
Pressure transmitter
Diaphragm tank
Float switch
3
6
8
10
12
On-off valve
Electric pump with Teknospeed
Pressure gauge
Test tap
Foot valve
Non return valve
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Adhesive plate (chapter 6)
1
2
3
4
Power on indicator light
Pump running indicator light
Malfunction indicator light
Warnings
Diagram of TEKNOSPEED converter’s external connections (chapter 6)
1
2
3
4
5
6
7
74
Signalling lights
Pressure adjusting screw
Inlet for pressure transmitter cable (M16 x 1.5 cable gland)
Inlet for external dry running protection device cable (M16 x 1.5 cable gland or plug)
Inlet for serial interface cable (M16 x 1.5 cable gland or plug)
Inlet for malfunction signalling relay cable (M16 x 1.5 cable gland or plug)
Inlet for power supply cable (M20 x 1.5 cable gland)
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TEKNOSPEED converter opening sequence (chapter 6)
How to fasten the cable shielding (chapters 6.2.8, 6.2.9, 6.2.11)
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Diagram of TEKNOSPEED converter’s internal connections (chapter 6)
1
2
3
4
5
6
7
6.35 mm Faston male connectors for motor terminal board cables
Terminal board for transmitter, float switch, serial interface (IN / OUT)
6.35 mm Faston male connectors for phase and neutral (power cord)
Ground screw for power cord
Operating cycle adjustment dip-switch
2.8 mm Faston male connectors for thermistor
Terminal board for malfunction signals (OUT)
Auxiliary terminal board
1
2
3
4
5
6
76
Connection to external device for dry running protection (chapters 6.2.7 and 6.2.8)
Connection to external transmitter (chapter 6.2.11)
Serial interface connection (chapter 6.2.10).
Connection to alarm relay (chapter 6.2.9)
Connection to motor over temperature protection – PTC (chapter 6.2.5)
Operating cycle adjustment dip-switch (chapter 6.2.12)
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Appendix B Manufacturer’s Guide - Teknospeed
Connection to motor over temperature protection – PTC (chapter 6.2.5)
Connection to external device for dry running protection (chapters 6.2.7 and 6.2.8)
1
VG Iss.4 - Aug 2013
Float or pressure switch
2
No external device
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Connection to alarm relay (chapter 6.2.9)
* maximum 230 Vac, maximum 1 A of resistive load only
Serial interface connection (chapter 6.2.10)
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Appendix B Manufacturer’s Guide - Teknospeed
Connection to external transmitter (chapter 6.2.11)
b = white
m = brown
How to fold the external transmitter cable (chapter 6.2.11)
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Factory settings of dip-switches for operating cycle adjustment (chapter 6.2.12)
1
2
Version without PTC protection
Version with PTC protection
Factory settings modification procedures (chapter 6.3.3)
1
2
3
4
5
80
On-off valve on delivery side
Test tap
Adjusting screw protection plug
Adjustment screwdriver
Pressure gauge for reading of system pressure value
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Appendix B Manufacturer’s Guide - Teknospeed
Factory setting chart (chapter 6.3.3)
Basic structure of TEKNOSPEED frequency converter (chapter 6.4)
c.a. Alternate current
c.c. Direct current
RAD Rectifier
INT Intermediate circuit
INV Inverter
MOT Motor
CONTR Control circuit
TRASM Transmitter
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13 Declaration of Conformity
y
Lowara srl, with headquarters in Montecchio Maggiore - Vicenza – Italy, hereby declares that the products described below
TKS series electric pumps equipped with Teknospeed frequency converter,
pressure transmitter with two-meter cable and power cord with plug
comply with the provisions of the following European Directives and with the regulations transposing
them into national law
• Machinery 98/37/EEC
• Low Voltage 73/23/EEC and subsequent amendments
• Electromagnetic Compatibility 89/336/EEC and subsequent amendments
and with the following technical standards
• EN 60335-2-41, EN 55014-1, EN 55014-2, EN 61000-3-2, EN 61000-3-3
Montecchio Maggiore – Italy, 31.10.2002
Amedeo Valente
(Director of R&D and Engineering)
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C
Appendix C
Manufacturer’s Guide - FAM
Pressure Vessel
This Appendix contains a modified version of the
Installation, Safety, and Maintenance instructions
provided by FAM Water Technology for their
Pressure Vessels.
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General
This product was designed for use in water lifting systems using submersed and
surface electric pumps. Its function is to absorb and conserve the potential energy of
the pressurised liquid.
Stored energy from liquid under pressure is transferred to the water system when
required and becomes serviceable once again. The interchangeable diaphragm
expansion tanks can also prevent water hammering.
Installation Safety Notes
These notes are taken from the FAM Pressure Vessel Installation Manual.
• This product is designed to hold water up to +110 °C.
• Never exceed the maximum working pressure and temperature of the
expansion tank; ensure appropriate controls are installed for this purpose.
• During installation prepare adequate systems for drainage to limit damage
caused by leakage from the tank, draining and venting.
• During installation the installer should account for external stress such as
traffic, wind and earthquakes.
• Always install the appliance in conformity to current legislation.
• This product must be installed and regularly inspected by qualified
personnel only.
• The manufacturer shall not be held liable for any personal or material
damage caused by the product if installed and/or used improperly or in way
anyhow diversely from manufacturer’s specifications.
• Exceeding temperature and pressure limits specified by the manufacturer
will give cause to cancel any guarantee covering the product as well as any
manufacturer’s liability.
• For fluids other than water, check compatibility before installing.
• The appliance must be installed in a safe place with access for authorized
personnel only.
• The appliance must be protected by an appropriate earthing systems or
isolated from the system by a dielectric joint.
Periodic Maintenance
Periodic maintenance is recommended at least twice a year and should be carried out
by authorised specialised personnel only.
1. First check that the expansion or pressure tank is totally drained of water, and
that the system is switched off and no electrical parts are live.
2. Check and, if necessary reset the precharge pressure, using the procedure in
Section 4 page 31 of this Dutypoint manual. Ensure that the pressure does not
exceed the value specified in the procedure.
General Maintenance and Repair
Disconnect all electrical equipment before starting on any maintenance jobs or
checking the installation pressure and temperature. The precharge pressure should
be checked and if necessary corrected during any maintenance work.
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Appendix C Manufacturer’s Guide - FAM Pressure Vessel
Precharge instructions
Referring to fig C-1:
1. First check that the expansion or
pressure tank is totally drained of
water, and that the system is switched
off and no electrical parts are live.
3
2
2. Remove the air vent cover.
3. Unscrew the air valve cap.
4. Connect a pressure gauge and,
referring to the procedure in Section 4
page 31 of this Dutypoint manual.
verify that the precharge pressure is
correct.
4
If it is low then the vessel precharge
must be corrected by additional
inflation of the diaphragm.
5. When the precharge pressure is
correct replace the air valve cap and
vent cover.
Fig. C-1 Pre-charging a FAM Vessel
Diaphragm replacement
To replace the diaphragm refer to fig C-2.
1. Empty the expansion tank.
2. Remove the pre-charging by releasing the air-vent.
M8 Screws
& Washers
Flange
Diaphragm
Air Vent
Tank
BABY OSMO
Air Vent
Cover
BABY STAR
Fig. C-2 Baby Star & Baby Osmo Components
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3. Loosen the M8 screws fastening the flange.
4. Remove the flange.
5. Extract the diaphragm and replace it.
Installing a Replacement Vessel
Read these instructions carefully before installing the product.
1. Make sure the product is in good condition. If the product is damaged do not start
on installation but take it back to the seller for immediate replacement.
2. The product must be installed in the position (vertical or horizontal) specified in
the technical specifications (see installation diagram).
3. While the system is cold, measure the static pressure with a gauge, at the point
where the tank has to be installed.
4. Set the precharge pressure, using the procedure earlier in this section on
page 85. Ensure that the pressure does not exceed the value specified in the
procedure.
5. The appliance must be supplied with efficient and sufficient safety and control
facilities, in particular the safety valve must be connected to the appliance and be
free from interference and must be gauged to the quantity of fluid to be
discharged.
The safety valve should also be designed to ensure that the pressure does not
permanently exceed the maximum tolerated pressure (a temporary pressure
peak, limited to 10% of the maximum tolerated pressure, is allowed).
6. Make sure the cap of the valve is fitted tightly after pre-loading and that there is
no leakage.
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D
Appendix D
Miscellaneous Technical
Information
This Appendix contains miscellaneous technical
information applicable to Dutypoint equipment.
• Net Positive Suction Head (NPSH)
• Convertion Factors
• Variable Speed Flow, Head and Power
Calculations
• General
Operating
Dutypoint Pumpsets)
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Limits
(Standard
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Net Positive Suction Head (NPSH)
The minimum operating values that can be reached at the pump suction end are
limited by the onset of cavitation.
Cavitation
Cavitation is the formation of vapour-filled cavities within liquids where the pressure
is locally reduced to a critical value, or where the local pressure is equal to, or just
below the vapour pressure of the liquid. The vapour-filled cavities flow with the current
and when they reach a higher pressure area the vapour contained in the cavities
condenses.
The cavities collide, generating pressure waves that are transmitted to the walls.
These, being subjected to stress cycles, gradually become deformed and yield due
to fatigue. This phenomenon, characterised by a metallic noise produced by the
hammering on the pipe walls, is called incipient cavitation.
The damage caused by cavitation may be magnified by electro-chemical corrosion
and a local rise in temperature due to the plastic deformation of the walls. The
materials that offer the highest resistance to heat and corrosion are alloy steels,
especially austenitic steel. The conditions that trigger cavitation may be assessed by
calculating the total net suction head, referred to in technical literature with the code
NPSH (Net Positive Suction Head).
Calculating NPSH
The NPSH represents the total energy (expressed in m) of the liquid measured at
suction under conditions of incipient cavitation, excluding the vapour pressure
(expressed in m.) that the liquid has at the pump inlet.
To find the static height hz at which to install the machine under safe conditions, the
following formula must be verified:
hp + hz ≥ (NPSHr + 0.5) + hf + hpv
Where:
hp
is the absolute pressure applied to the free liquid surface in the suction
tank, expressed in m. of liquid; hp is the quotient between the
barometric pressure and the specific weight of the liquid.
hz
is the difference in height between the pump axis and the free liquid
surface in the suction tank, expressed in m; hz is negative when the
liquid level is lower than the pump axis.
hf
is the friction loss in the suction line and its accessories, such as:
fittings, foot valve, gate valve, elbows, etc.
hpv the vapour pressure of the liquid at the operating temperature,
expressed in m of liquid. hpv is the quotient between the Pv vapour
pressure and the liquid’s specific weight.
0.5 is the safety factor.
The maximum possible suction head for installation depends on the value of the
atmospheric pressure (i.e. the elevation above sea level at which the pump is
installed) and the temperature of the liquid.
To help the user, with reference to water temperature (4°C) and to the elevation above
sea level, the following tables show the drop in hydraulic pressure head in relation to
the elevation above sea level, and the suction loss in relation to temperature.
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Appendix D Miscellaneous Technical Information
Water temp
(°C)
20
40
60
80
90
110
120
Suction loss
(m)
20
40
60
80
90
110
120
Elevation above
sea level (m)
500
1000
1500
2000
2500
3000
Suction loss (m)
0,55
1,1
1,65
2,2
2,75
3,3
Friction loss must be calculated using a recognised formula. To reduce it to a
minimum, especially in cases of high suction head (over 4-5m.) or within the operating
limits with high delivery values, we recommend using a suction line having a larger
diameter than that of the pump’s suction inlet.
It is always a good idea to position the pump as close as possible to the liquid to be
pumped.
Make the following calculation:
Liquid:
water at ~ 15 °C g = 1 Kg/dm3
Delivery required:
30 m3/h
Head for required delivery:
43 m
Suction difference in height: 3,5 m
The selection is a FHE 40-200/75 pump whose NPSH required value
is 2.5m @ 30 m3/h
For water at 15°C the hpv term is: Pv/g = 0.174 m (0.01701 bar)
eh = Pa/g = 10.33 m
The hf friction loss in the suction line with foot valves is 1.2 m.
By substituting the parameters in formula with the numeric values above:
10.33 + (-3.5) ≥ (2.5 + 0.5) + 1,2 + 0.17
6.8 > 4.4. The relation is therefore verified.
Convertion Factors
Flow conversion
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Pressure conversion
L/min.
÷ 60
= L/Sec
m Hd
÷ 10.2
= Bar
m3/hr
÷ 3.6
= L/Sec
Psi
÷ 14.47
= Bar
Gpm
÷ 13.2
= L/Sec
Kpa
÷ 100
= Bar
Kg/Sec
÷ 1.0
= L/Sec
Kg/cm3
÷ 1.02
= Bar
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Variable Speed Flow, Head and Power Calculations
V1
= Full speed
V2
= Reduced speed
Q1
= Flow rate at full speed
Q2
= Flow rate at reduced speed
H1
= Head at full speed
H2
= Head at reduced speed
P1
= Power at full speed
P2
= Power at reduced speed
V2
Q 2 = ⎛ --------⎞ Q 1
⎝ V 1⎠
2
V2
H 2 = ⎛ --------⎞ H 1
⎝ V 1⎠
2
V2
P 2 = ⎛ --------⎞ P 1
⎝ V 1⎠
General Operating Limits (Standard Dutypoint Pumpsets)
Type of pumped liquids
Water with no gas or aggressive substances
Maximum pumped liquids
temperature
+35°C for domestic uses (EN 603352-41) 40°C for other purposes
Minimum pumped liquid temperature
Operating ambient temperature
Relative humidity
Air impurities
Storage temperature
Suction Conditions
90
1°C to avoid icing
+5°C to 40°C for indoor installation
(CEI EN 60439-1)
Max 50% at 40°C
The air must be clean and free of acid
vapours, corrosive gases and excessive amounts of dust
+5°C to 50°C
Minimum positive pressure 0.1 Bar,
Max 0.5 Bar
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E
Appendix E
Additional Information
If the system that you have purchased has been
modified, updated or otherwise altered from the
Dutypoint standard range, this Appendix will
contains additional information applicable to the
change(s).
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DUTYPOINT SYSTEMS
SHEPHERD ROAD GLOUCESTER
GL2 5EL
UK
Tel: 44 (0) 1452 300592
Fax: 44 (0) 1452 303691
Email: [email protected]
www.dutypoint.com