Stuart Turner ABB V150-45-2V-1 Leitfaden

Booster Set (Vertical Twin) Installation,

Operation & Maintenance Instructions

Please leave this instruction booklet with the owner as

it contains important guarantee, maintenance and safety

information

Read this manual carefully before commencing installation.

This manual covers the following products:

ABB V150-45-2V-1

Pt. No. 46684

ABB V260-65-2V-1

Pt. No. 46687

ABB V150-60-2V-1

Pt. No. 46685

ABB V260-75-2V-1

Pt. No. 46688

ABB V150-75-2V-1

Pt. No. 46686

ABB V260-85-2V-1

Pt. No. 46689

(Subject to evidence of the required maintenance)

CE compliant product

- 2 -

PRODUCT DESCRIPTION

Twin electric motor driven centrifugal pump set complete with an automatic variable

speed duty/assist control system, incorporating pumps, VSD, transducer, pressure vessel

and electronic control.

APPLICATION

The Aquaboost Booster Set (vertical twin) range is designed for pressure boosting stored,

clean cold water into systems, where under gravity, no flow is available.

Inlet pressures to the pump and ambient temperatures must not exceed the

values given in the technical specifications.

zThis pump set must not be used for any other application without

the written consent of Stuart Turner Ltd.

zThis pump MUST NOT be connected directly to the mains water

supply.

zThis appliance can be used by children aged from 8 years and

above and persons with reduced physical, sensory or mental

capabilities or lack of experience and knowledge if they have been

given supervision or instruction concerning use of the appliance

in a safe way and understand the hazards involved. Children shall

not play with the appliance. Cleaning and user maintenance shall

not be made by children without supervision.

zChildren should be supervised to ensure that they do not play with

the appliance.

Please read installation details carefully as they are intended to ensure this

product provides long, trouble free service. Failure to install the unit in

accordance with the installation instructions will lead to invalidation of the

warranty.

STORAGE

If this product is not to be installed immediately on receipt, ensure that it is stored in a dry,

frost and vibration free location in its original packaging.

CONTENTS Page

Checklist ........................................................... 3

Important Facts - read before commencing installation ...................... 5

Location ........................................................... 7

Installation ......................................................... 9

Electrical ........................................................... 10

Control Programming ................................................. 13

Commissioning ...................................................... 20

Maintenance ........................................................ 22

Technical Specication ................................................ 23

Trouble Shooting .................................................... 25

Guarantee .......................................................... 27

- 3 -

CHECKLIST

Your product may vary slightly from the picture above.

Product Identification

Item Description Qty Item Description Qty

Booster set 1 Anti-vibration mounts 4

Pressure vessel (supplied loose) 1

IMPORTANT: With the pump removed from its packaging check for any

damage prior to installation. If any damage is found contact Stuart Turner Ltd

within 24 hours of receipt.

AB B V 150 45 2 V 1

No of pumps

Metres head (valve closed)

Flow rate (full flow, both pumps)

Variable speed

Aquaboost

Booster set

Vertical (pump orientation)

Single phase

Fig. 1

Discharge manifold

Removable cap

(ref: 2.25)

Suction manifold

Removable cap

(ref: 2.25)

Rating

plate

- 4 -

Cont ...

Product Performance

Performance curve indicates maximum performance, both pumps running.

100

0 50 100 150 200 250 300

Head (bar)

HEAD (metres)

FLOW (l/min)

Fig. 2

- 5 -

Cont ...

1 IMPORTANT FACTS: READ BEFORE COMMENCING PUMP INSTALLATION

A. Water storage capacity.

1.11 The cold water storage capacity must be sufficient to meet the flow rates

required by the pumped equipment and any other water using fittings and

appliances, which may be operated simultaneously.

1.12 Ensure the pump is primed as described in the priming section before starting,

damage to the shaft seal will result otherwise. See Section 6 - Commissioning.

B. Water temperature

This unit is designed to pump cold water only which should not exceed the following

values:

1.13 The maximum allowable water temperature is 23 oC.

1.14 The minimum allowable water temperature is 4 oC.

Note: Pump sets are available for handling greater temperatures, please contact us

for further information.

C. Pipework - General

1.15 Secure pipework: Ensure pipework to and from the booster set is

independently supported & clipped to prevent forces being transferred to inlet

and outlet branches of pump. Flexible hoses not supplied.

1.16 Flux: Solder joints must be completed and flux residues removed prior to pump

installation (flux damage will void any warranty).

1.17 Pipework design: Care should be taken in the design of pipework runs to

minimize the risk of air locks e.g. use drawn bends rather than 90obends.

1.18 DO NOT install a non-return valve, or devices which contain non-

return valves, in the suction (inlet) pipework to the pump. The pump

must be free to vent to the supply tank at all times.

1.19 DO NOT connect this pump to the mains water supply.

D. Plumbing Installation Regulations

1.20 The plumbing installation must comply with the current water and building

regulations.

1.21 The plumbing installation must be installed by a qualified person.

1.22 The electrical installation must be carried out in accordance with the current

national electrical regulations.

1.23 The electrical installation must be installed by a qualified person.

E. Pressure vessel

1.24 Ensure the pressure vessel is installed correctly before operating the unit, to

avoid damage to the pumps/controls.

Do not attempt to dismantle the pressure vessel

Pressure vessel is charged at the factory see Section 7 - Maintenance for

details.

- 6 -

Cont ...

F. Lifting/Positioning

1.25 DO NOT lift the booster set by the pipework or by the control panel, the pressure

vessel is supplied lose for transport purposes, please ensure that the booster set

has been installed and connected to the suction and discharge pipework before

installing the pressure vessel. On no account should the pressure vessel be

used to “manouvre” the booster set into place. Care should be taken when

handling this product due to it’s weight.

1.26 This equipment must not be pressurised beyond maximum working pressure

(refer to technical specifications).

- 7 -

Cont ...

2 LOCATION - GENERAL

2.11 Access: For emergencies and maintenance the booster set must be

easily accessible.

2.12 Protection: The booster set must be located in a dry position, frost

free and protected from freezing. Avoid environments which have a

high ambient temperature, high humidity or excessive condensation.

Avoid dust, corrosive gas, explosive gas, inflammable gas, grinding-

fluid mist and salt damage, etc.

2.13 Ventilation: Ensure an adequate air flow to cool the pump. Separate

the pump from other appliances that generate heat.

2.14 Safety: The motor casing can become very hot under normal

operating conditions. Care must be taken to ensure it cannot be

touched during operation.

2.15 Water retention: Site the pump in a location where in the unlikely

event of a water leak, any spillage is contained or routed to avoid

electrics or areas sensitive to water damage.

2.16 Static inlet pressure: Care must be taken to ensure the booster set has

flooded suction from the cold water storage tank. Before deciding where to

locate the unit check to ensure the static inlet head between pump and the

bottom of the tank (Fig. 3) is at least 1 metre and does not exceed the max inlet

head of 10 metres. Inlet pressures in excess of 3 metres should be taken into

account when selecting the working pressure of the booster set, i.e. take the

static inlet pressure away from the required working pressure.

2.17 Booster set position: The unit must be mounted as close to the water source

as possible on a level surface, and if the plant-room has a chance of flooding it is

recommended that the unit is installed on a suitable plinth capable of taking total

working weight. If the optional anti-vibration bolt down mounts have been

purchased then fix these to the floor/plinth then fix the booster set to the anti-

vibration mounts.

2.18 Ensure that location of the unit allows adequate space to give reasonable access

to all parts to accommodate all service/commissioning, must be a minimum of

250 mm and easily see/operate the readout/controls.

2.19 Ambient temperature: The pump must be sited in a location where the

maximum ambient temperature does not exceed 40 oC.

2.20 Pipework: For optimum performance:

V150 models have 1.1/2 “ BSP suction and discharge manifolds.

V260 models have 2 “ BSP suction and discharge manifolds.

All isolation valves should be full bore, non-restrictive type.

Flexible hoses are available separately, please contact us for further information.

Discharge pipework should only be reduced when entering the terminal fittings.

Note: Inlet pipework must always be greater than or equal to the outlet

pipework diameter.

2.21 Static outlet pressure: The static outlet head (Fig. 3) must also be within the

maximum requirement of 13 metres. The booster set should have been

selected to provide the required operating pressure at the highest outlet after

allowing for the static height of the highest fitting and the frictional losses in the

pipework. The minimum requirement at the highest outlet is usually 1 bar but

can be up to 3 bar depending on the type of fittings used.

- 8 -

Cont ...

2.22 Direction of flow: See Fig. 1 to identify the suction and discharge connections.

2.23 Isolating valves: Separate system isolating valves (non restrictive) must be

fitted to the suction and discharge of the pump set on the system side of the

flexible hoses.

- 9 -

Cont ...

3.11 The cold water supply: Must be a DEDICATED AIR FREE supply via a tank

connector and must be able to self vent. Flexible hoses are supplied with the

pump set and must be fitted between both suction and delivery manifolds and

the installation pipework.

Do not connect to the mains.

3.12 The suction and discharge caps can be installed on either end of the manifold to

facilitate ease of installation, please ensure these are water tight before switching

the unit on (see Fig. 1).

3.13 Pressure vessel: The pressure vessel is supplied loose, this must be fitted to

the connection on the discharge pipework. The connection is sealed with two

‘O’-rings within the end of the connection, ensure the ‘O’-rings are not damaged

during assembly. To fit the vessel tighten the running nut and open the isolation

valve.

3.14 DO NOT install the booster set where the control panel can be exposed to direct

sunlight or near sources of heat.

3.15 Non-return valves must not be fitted to suction or delivery as this may cause

incorrect operation and damage to the unit.

3 INSTALLATION

Fig. 3

Outlet to the

system

Static inlet pressure

Min. 1m

Max. 10 m

Static outlet pressure

Max. 13 m

Fig. 4

Running nut

Turn lever to isolate

pressure vessel

Drain valve

Press button

- 10 -

Cont ...

4 ELECTRICAL

4.11 Regulations: The electrical installation must be carried out in

accordance with the current national electrical regulations and

installed by a qualified person.

4.12 Safety: In the interests of electrical safety a 30 mA residual current

device (R.C.D. not supplied) should be installed in the supply circuit.

Any RCD fitted must be suitable for operation with inverter drives,

i.e. Type A suitable for pulsation DC leakage current. This may be part

of a consumer unit or a separate unit.

4.13 Before starting work on the electrical supply ensure power supply is

isolated.

4.14 Install an emergency stop key separately from the isolator.

4.15 Earthing: This appliance must be permanently earthed via the supply cord,

which must be correctly connected to the earth point located in the terminal box.

The inverter should be protected separately against ground fault.

4.16 Additional earthing: Certain installations may require additional earthing

arrangements such as equipotential bonding. Reference should be made to the

relevant regulations concerning this subject to ensure compliance.

4.17 Connections: The pump set must be permanently connected to the mains

supply using a suitable sized cable using the double pole isolator fitted to the

pump set.

4.18 Wiring of connection unit:

WARNING: This appliance must be earthed.

Do not remove any cover of electrical components for at least 5 minutes to

allow total discharge of components after supply has been disconnected. When

making the electrical connections ensure all appropriate anti-static procedures

are taken.

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