AmeriWater CHIE VARIABLE SPEED BOOSTER PUMP SYSTEM Handbuch

P/N 98-0118 Rev.B

28OCT10

CHIE VARIABLE SPEED BOOSTER

PUMP SYSTEM

OPERATION & MAINTENANCE MANUAL

Manufactured With Pride

In The USA

www.ameriwater.com • 800-535-5585

AmeriWater • 3345 Stop 8 Rd. • Dayton, OH 45414

P/N 98-0118 Rev.B

28OCT10

TABLE OF CONTENTS:

VARIABLE SPEED PUMP SYSTEM INTRODUCTION:

THEORY OF OPERATION……………………………………………….1

INSTALLATION………………………………………………………….…1

SYSTEM DESIGN DRAWING……………………………………….…..4

STARTUP……………………………………...………………………….….5

MAINTENANCE……………………………………………………………..6

PRELIMINARY CHECKS: MEASURING VOLTAGE

& CURRENT………………………………………………………………….6

TROUBLE SHOOTING THE PUMP……………………………………6

VALVES………………………………………………………………………..6

INDICATOR LIGHTS………….……………………………………….…..7

SETTING BY MEANS OF CONTROL PANEL…………………..…..8

SETPOINT SETTING

PUMP IN CONTROLLED OPERATION MODE…………………..….9

SETTING TO MAX. CURVE DUTY…………………………….……....9

SETTING TO MIN. CURVE DUTY…………………………………..…10

START/STOP OF PUMP…………………………………………………..10

FAULT INDICATION……………………………………..……………..…10

REPLACEMENT PARTS DRAWING……..………..…………………..11

VARIABLE SPEED PUMP SYSTEM INTRODUCTION

THEORY OF OPERATION

The variable speed pump controls out going variable pressures of the water for

better equipment operation by maintaining a constant pressure on the system.

The pump is capable of producing 26 GPM or more at a minimum of 30 PSI.

The variable speed pump system is controlled by a VFD controller mounted to

the motor. The unit is set to stop at the set pressure if there is no flow. The

electronics will look at the pressure but will not try to start the motor until it sees

pressure drop.

INSTALLATION

The following guidelines should be met at installation.

1. Mount the variable speed booster pump system on a firm level foundation

by using bolts through the .50 dia. pre drilled holes in the unistrut channel.

2. To insure sufficient cooling of motor and electronics, the following must be

observed:

Place the pump in such a way that sufficient cooling is ensured.

The temperature of the cooling air must not exceed 40 degrees C.

Cooling fins and fan blades must be kept clean.

3. The size of the inlet water supply piping should be 1”.

4. The size of the outlet piping from the variable speed pump system should

be 1”.

5. Follow all local plumbing and electrical codes. The pump is 220-230 volt

single-phase.

Warning: All electric supply circuits must be interrupted before

working in the pump terminal box. Never make any

connections in the pump terminal box unless the

electricity supply has been switched off for at least

5 minutes.

6. A blade or service disconnect isn’t provided. It must be installed. The

pump must be connected to an external all-pole mains switch with a

contact separation of at least 3 mm in each pole according to IEC 364.

Warning: The pump must be earthed and protected against indirect

contact in accordance with national regulations.

Protective earth conductors must always have a .

yellow/green (PE) or yellow/green/blue (PEN) color

marking.

7. If the pump is connected to an electric installation where an earth leakage

circuit breaker is used as additional protection, this circuit must be marked

with the following symbol:

When an earth leakage circuit breaker is selected, the total leakage

current of all the electrical equipment in the installation must be taken into

account.

Earth leakage current < 3.5 mA.

The leakage currents are measured in accordance with EN 60 355-1

8. The motor requires no external motor protection. The pump is

overvoltage-protected.

9. Supply voltage:

1 x 208-230V Single Phase.

Cable: 0.5 – 1.5mm2 / 14-12 AWG.

See nameplate.

Recommended fuse size:

Motor sizes from 0.37 to 1.1 kW: Max. 10 A.

Standard as well as quick-blow or slow-blow fuses may be used

Warning: If the supply cable is damaged, it

must be replaced by the

manufacturer, the manufacturer’s

service partner or similarly qualified

persons in order to avoid a hazard.

10. The number of starts and stops by way of the

mains voltage must not

exceed 4 times per hour.

When the pump is switched on by way of the mains, it will start after

approx. 5 seconds.

When the pump is started/stopped by way of an external on/off switch, it

will start immediately.

Note: These steps have been already completed at assembly for

this product. For your information:

The connection terminals inside the pump terminal box for

the pressure sensor and blade or service disconnect cord

are shown in the figure below with installation directions

listed.

Warning: Never make any connections in the pump terminal box

unless the electricity supply has been switched off for at

least 5 minutes.

Pressure Sensor Installation: With the protective cover off, bring the wire

from the pressure sensor into the motor through the strain relief in the middle.

Connect the yellow-green wire to terminal 6, the blue wire to terminal 7 and the

brown wire to terminal 8. Clip the remaining wires as they are not used. Make

sure remaining wires are isolated from ground. Replace the access cover after

all connections have been made.

Blade or Service Disconnect Cord Installation: With the protective cover off,

bring the line cord through the strain relief furthest from the pump inlet.

Terminate the white wire into the connection marked N, the green wire to

ground terminal and the black wire to L. Replace the grey protective cover after

all connections have been made.

SYSTEM DESIGN DRAWING

START-UP

Warning: At high temperatures, the pump may be extremely hot. Do not

touch it.

Priming:

Before startup, or if the pump has been drained, the pump must be filled with

liquid and vented.

Proceed as follows:

Close the discharge isolating valve and bypass valve.

(See System Design drawing)

Remove the priming plug in the pump sleeve. (See Plug drawing).

Slowly open the suction valve (See System Design drawing), in the inlet

pipe until a steady stream of liquid runs out of the priming port.

Warning: The escaping liquid may be very hot. Therefore, care must be

taken to ensure that the liquid does not cause personal injury or

damage to other components.

Replace priming plug and tighten securely.

Start the pump and slowly open the discharge valve until it is fully open.

Completely open the suction valve in the inlet pipe.

Plug Drawing

MAINTENANCE

The pump and motor are maintenance free.

PRELIMINARY CHECKS: MEASURING VOLTAGE & CURRENT

When measuring voltage, use a volt meter,(set to the proper scale) to measure

the voltage at the pump terminal box or starter.

Measure between power leads L1 and L2 or L1 and N for 115 volt units.

When the motor is under load, the voltage should be within +6% to +10% of the

Nameplate voltage. Larger voltage variation may cause winding damage.

Large variations in the voltage indicate a poor electrical supply and the pump

should not be operated until these variations have been corrected. If the voltage

constantly remains high or low, the motor should be changed.

When measuring current, use an ammeter (set on the proper scale) to measure

the current on each power lead at the terminal box or starter. See the motor

nameplate for amp draw information.

Current should be measured when the pump is operating at a constant discharge

pressure.

TROUBLE SHOOTING THE PUMP

Before removing the terminal box cover, make sure that the electricity supply has

been switched off.

Warning: The pumped liquid may be scalding hot and under high pressure.

Before any removal or dismantling of the pump, the system must

be drained or the suction & discharge valves must be closed.

Fault Cause ___________________

Pump capacity not constant. a) Pump inlet pressure is too low.

b) Inlet pipe partly blocked by

impurities

c) Pump takes in air.

___________________________________________________________

Pump runs but gives no water. a) Inlet pipe partly blocked by

impurities

b) Suction valve blocked in closed

position.

c) Leakage in inlet pipe.

d) Air in inlet pipe or pump.

___________________________________________________________

Pump runs backwards when a) Leakage in inlet pipe.

switched off. b) Suction valve defective.

c) Suction valve blocked in open

or partly open position.

___________________________________________________________

Valves

Do not run the pump without the suction or discharge valve completely open

during normal operation. The bypass valve should be closed at this time.

INDICATOR LIGHTS

The operating condition of the pump is indicated by the green and red indicator

lights on the pump control panel.

Indicator lights

________________________________________________________________

Indicator lights___________________________________________________

Fault Operation Description

(red)____ (green)___________________________________________

Off Off The electricity supply has been switched off.

________________________________________________________________

Off Permanently The pump is operating.

________________________________________________________________

Permanently Off The pump has stopped because of a fault.

on Restarting will be attempted (it may be

necessary to restart the pump by resetting

the fault indication).

Possible causes:

* Too high motor temperatures

* Undervoltage

* Overvoltage

* Too many restarts (after faults)

* Overload

________________________________________________________________

Permanently Permanently The pump is operating, but it has been

on on stopped because of a fault.

Reset the fault indication or switch off

the electricity supply.

________________________________________________________________

Note: See Setting By Means Of Control Panel on page 10-12, for information

on resetting the fault indication and stopping/starting the pump.

SETTING BY MEANS OF CONTROL PANEL

Warning: The motor can develop surface temperatures up to 115 degrees F.

Touching the motor for any length of time may cause burns. Only

the buttons should be touched to avoid injury.

The pump control panel, incorporates the following

buttons and indicator lights:

CONTROL PANEL

The desired setpoint is set by pressing the up or down button.

The light fields on the control panel will indicate the setpoint set.

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