Xylem LOWARA F 1-2 Handbuch

Operating and Maintenance Instructions

Declaration of conformity

Lowara pumps UK declare that the Mini F Booster set conforms to the requirements of the Machinery Safety

Directive 98/37/EEC.

Conforming to the UK Health & Safety Requirements S.I. 1992 No 3073 S.I. 1994 No 2063

Water supply (Water fittings) regulations 1999

Simple pressure vessel directive 87/404/EEC

Signed: Position: Engineering manager Date: 27-02-2012 Revision

Clive Willmott

Introduction

This leaflet contains information to enable the safe installation and operation of the products mentioned.

The following instructions must be read and understood by all persons responsible for the installation,

operation and maintenance of this product.

Warning Symbols

Safety instructions where noncompliance would affect safety.

Safety instruction where electrical hazard is involved.

Safety instruction where noncompliance could cause damage to the equipment.

Instruction for safe us

This product has been designed for boosting cold water in potable water installations to the

operating conditions shown.

This product should not be installed until this leaflet has been studied carefully and understood.

Handling, transportation and installation of this equipment should only take place with the proper

use of lifting equipment. This product must be stored in a frost-free dry environment.

Noise Emission

This equipment operates at a noise level lower than 70dBA.

Operating limits

Fluid temperature 0°C to 40°C

Ambient temperature 0°C to 40°C

Operating pressure Max 5Bar.

Protection class. Motor & Electrical panel IP55

Mini F 1-2 Pump Cold Water

Booster Sets Fixed Speed

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Installation

The cold Water booster set is despatched mounted on a wooden pallet and covered in a protective film, it is

recommended that the unit be retained in the protective packaging until the product is to be

installed. The unit will arrive pre-packaged and wired ready for installation. This product has

been fully run tested at our works under simulated site conditions. The unit should be thoroughly

checked for physical damage that may have been caused during transit. If the unit is found to

have damage it must be reported immediately and should not be installed. The unit should be

sited in a ventilated, dry frost free position also ensuring adequate room for general maintenance and

service. The set should be fixed in position directly to the floor, if vibration separation is required then cork

mats should be used supplied by others.

The water tank is constructed to have a weir slot as required by the water bylaws to prevent back flow

contamination, if the inlet ball valve suffered a catastrophic failure the overflow may not be able to keep up

with the inflow in which case excess water will be ejected through the weir slot and onto the plant room floor,

if this is not acceptable then consideration should be given to fitting the booster set onto a try with overflow

to drain.

Never run pumps dry

Ensure the pumps are filled with water before switching the power on.

Electrical connections

The electrical connections must be carried out by a competent electrician in accordance with local

regulations.

The cable used for the incoming supply must be of adequate size to carry the motor full load

current of all pumps as they are able to operate at the same time. Motor ratings are shown on

the set duty plate. All non power cable should be limited to 1.5mm².

All connections must be made using the appropriate wiring drawings for the equipment being

installed; with particular attention being paid to the supply voltages. The supply voltage is shown

on the set duty plate.

Never operate this product with isolation panels removed or the control panel door in the open position.

It is essential that this equipment is earthed to the building earth system.

All metal parts must be earth bonded directly to the building earth system.

Electrical data HM sets

Water supply connections

Connect the incoming water supply to the break tank ball valve. The outlet of the tank will already be connected

to the booster set suction manifold. The tank will include a class AB air gap (Category 5 protection)

the tank will also include a low level float switch connected to the booster set to protect against dry

running. Connect the 22mm warning pipe to a position where a discharge will cause a nuisance

and be remedied. Connect the overflow pipe to drain. When the tank has been filled check the

water level and adjust ball valve as necessary.

Ensure the tank is thoroughly flushed through before the set is put on line.

It is the responsibility of the installer to ensure that the overflow is able to keep up with the incoming water

volume, if this is not the case then a pressure reducing valve should be fitted to reduce the incoming mains

water volume.

Nominal power

(KW) 1 pump

GMS10 single phase

Absorbed current(A)

1 x 230V

GMS20 single phase

Absorbed current(A)

1 x 230V

0.45 2.77 5.54

0.55 3.76 7.52

0.75 5.74 11.48

0.9 6.49 13.0

mini f booster set o and m instructions:Layout 1 09/05/2012 15:37 Page 2

Discharge pipe work

On two pump sets the discharge pipe work can be connected to either end of the booster set, ensure the

blanking cap is fitted to the end not used. A flexible connector fitted between the booster discharge manifold

and the system connection pipe will help prevent the transmission of noise/vibration. On single pump units

connect to the port provided. An isolation valve should be provided between the booster discharge line and

the system to aid maintenance. The discharge pipe work should be sized to achieve a maximum velocity of

approximately 2.5m/s.

Pressure vessels

The booster set is fitted with 1 or 2 x 24lt vessels which is the minimum that should be used with fixed speed

pump sets. Larger vessel can be added if required. If stand alone vessels are added they should have an

isolation valve and drain cock fitted to allow the vessel to be isolated from the system and drained to check

the pre-charge pressure.

The vessel pre-charge should be set to approximately 0.2 bar below the pump stating pressure.

Pressure switch setting details

The booster set will be fitted with 1 pressure switch for each pump.

Pump operation is controlled by pressure switches, one for each pump. The unit will normally be

supplied with the pressure switches set to match the pumps fitted.

If pressure switch settings need altering they should be adjusted as follows. Read in conjunction

with fig A

P1s = pump 1 stop pressure which is normally set to 0.5

bar below Pmax (pump closed valve head).

P2s = pump 2 stop pressure which is normally set to 1

bar below Pmax when fitted.

P1 = pump 1 differential pressure which is normally set

at 1 bar, this will start pump one, 1 bar below P1s.

P2 = pump 2 differential pressure which is normally set

at1 bar, this will start pump two 1 bar below P2s when

fitted.

Commissioning

With the main power isolated check:

1. The break tank feeding the set is filled with water and the ball valve is set to the correct height.

2. The set/system vessels have been charged with Nitrogen to the correct pressure (set point -0.2 bar).

3. Open suction line isolation valve.

4. Open suction and discharge pump isolation valves.

5. Close main discharge isolation valve.

6. Open the pump vents at the top of each pump.

7. Allow all air to escape until water flows freely.

8. Close pump vent valves.

9. Open discharge valve.

10. Ensure all vessel valves are open.

11. Switch the main power supply on.

12. allow water to flow and clear air through the system

13. close discharge valve and check pressure reading on pressure gauge

14. The system set point should already be set but to change refer to fig A above.

See GXS O&M for more in depth pump details.

Pump 1

Pump

Fig A

mini f booster set o and m instructions:Layout 1 09/05/2012 15:38 Page 3

Fig 2

Operation

The booster set is designed to boost the system pressure and maintain sufficient pressure to overcome the

static height and friction losses in the pipe work and provide each outlet with sufficient flow at the required

pressure.

When a demand is placed on the system, water will be supplied from any vessels that are fitted to the

system, once this supply is depleted the system pressure will start to fall, when the pressure falls to the

system set point the first pump will start and raise the pressure to maintain the set point, if demand

increases and the first pump is not able to cope the pressure will continue to fall to the second pump cut in

pressure (if fitted) The second pump will start and assist the first pump.

When demand decreases the last pump to be called in will be stopped, if demand continues to decrease

the next pump will be stopped. On two pump sets minimum run timers are fitted so once a pump has been

signalled to start it will run for a minimum of 90 seconds (default setting) even if the demand has cessed.

The next time the pressure falls the pumps will have been rotated so the opposite pump will be the first to

operate.

If a low level in the break tank occurs all pumps will be stopped until the water supply has been reinstated,

the pumps will then be automatically released to resume normal operation.

Because the pumps can run on through the timer circuit it is possible that the system pressure can sit at the

closed valve pressure of the pump.

Volt Free Contacts

Volt free contacts are not available on single pump units or on twin GXS sets.

Remote inhibit

Remote inhibit facilities are not available.

Alarm indicators

LEDs are provided to indicate:

Single pump sets. Pump run, pump tripped and low water level Fig 3

Twin pump sets. Pump run each pump, Power on and low water level Fig 1 & 2.

Panel

Fig 2. Gives details of indications and switches for the GXS20 twin pump control panel.

Fig 3

Single pump

Pump

running

fault

LOWARA

Low

level

`Hand Auto

Off

mini f booster set o and m instructions:Layout 1 09/05/2012 15:38 Page 4

Caution

This booster set is an automatic machine; the pumps may start up automatically without

prior warning.

The set contains pressurised water; reduce the pressure to zero before servicing.

Maintenance

Routine check (6 monthly intervals)

1. Check all pumps produce the correct pressure.

2. Check that the pump operates without undue noise or vibration.

3. Check the break tank is clean and that the correct water level has been maintained.

4. Check that all screws are tight on electrical components.

5. Check that the earth connections are tight and making good contact.

6. Check that the gas pre charge is at the correct pressure, this should be done by isolating the vessel

from the system and draining water out of the vessel via the isolation valve drain point.

Once the water has been discharged, a tyre gauge can be connected to the pre charge valve to display the

vessel pre charge pressure. Recharge as necessary with Nitrogen or dry air.

Any other expansion vessels connected to the system can be checked in the same manner.

Clean any filters that may be connected to suction/discharge lines and ensure the mesh is in good condition.

General fault finding guide

Fault Possible Cause Remedy

Pump fails to start

Power supply failure

Control panel fuse blown

MCB tripped

Low water level

Reinstate incoming power supply

Replace power supply fuse

Reset MCB

Reinstate water supply

Pump fails to stop

Set point set too high

System pressure low due to

large leak

Lower set point

Switch unit off until leak is repaired

Pump switches on and off

quickly

Air in system

Vessel pre-charge incorrect

Purge air from pumps and pipework

Check vessel pre-charge and Charge as

necessary with Nitrogen or dry air

Pump runs but will not make

pressure

Pump air locked

Non-return valve jammed

Passing too much water

Open pump bleed screw and vent pump

Clean/replace valve

Check system for leaks

Pump overheating Pump partially seized Remove pump and check for foreign

objects

Pump set frequently

starting. (pressure falls to

cut in point)

Newly installed system with

large amount of air in pipe work

Leaks in system pipe work

Vessel pre-charge incorrect

Bleed system to remove air

Repair leaks

Isolate vessel and pre-charge with

Nitrogen as appropriate

Break tank overflowing Leaking ball valve

Non-return valve letting by

Replace ball valve seal

Replace/clean non-return valve

Pump leaks water

Defective mechanical seal

Undue mechanical stress on

pump

Replace seal

Support the pipe work

mini f booster set o and m instructions:Layout 1 09/05/2012 15:38 Page 5

Disposal

Disposal of this product should be carried out in accordance of local codes and regulation pertaining to the

disposal of waste, including packaging materials.

Booster set details

Lowara UK Limited

Millwey Rise Industrial Estate, Axminster, Devon EX13 5HU - UK

Tel: 01297 630230 Fax: 01297 630270

e-mail: [email protected]

http://www.lowara.co.uk http://completewatersystems.com

Lowara reserve the right to make modifications without prior notice.

cod. UKLIT0088 P05/12

Model type

Order Code

Pump type

Serial number

Installation date

System set point

Booster set notes

mini f booster set o and m instructions:Layout 1 09/05/2012 15:38 Page 6

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