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Teral MC5 Instruction Manual

Direct-connecting booster pump unit
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Instruction Manual
Estimated Terminal Pressure
Direct-connecting booster pump unit
Constant Control of Water
Model: MC5
Supply Unit
Important Notice
Thank you very much for purchasing our direct-coupled booster pump unit.
In order to use the product appropriately, do not operate, maintain, or inspect the
direct-coupled booster pump unit until you have read and fully understood this
instruction manual.
For safety purpose, observe the cautions and warnings in this instruction manual
and those on the labels affixed on the unit.
Retain this manual where it can be consulted at any time of operation,
maintenance and inspection of the direct-coupled booster pump unit.
To whom is performing the utility work:
Please submit this manual to the customer performing the operation, maintenance
and inspection of the direct-coupled booster pump unit .
TERAL INC.

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  • Page 1 Instruction Manual Estimated Terminal Pressure Direct-connecting booster pump unit Constant Control of Water Model: MC5 Supply Unit Important Notice Thank you very much for purchasing our direct-coupled booster pump unit. In order to use the product appropriately, do not operate, maintain, or inspect the direct-coupled booster pump unit until you have read and fully understood this instruction manual.
  • Page 2 In the event of failure or breakage under proper use of the product during the warranty period, equipment supplied by TERAL INC. shall be repaired or replaced free of charge within the scope of the relevant part, provided that such failure or breakage is attributable to inadequacy of the design or workmanship of the equipment.

  • Page 3: Table Of Contents

    Contents 6.2 C ......6-3 HECKING THE AUTOMATIC OPERATION 1- - 1 1. Safety precautions 6.2.1 A ..6-3 UTOMATIC ALTERNATING OPERATION TYPE 1.1 E XPLANATION OF SAFETY INDICATIONS AND GRAPHIC SYMBOLS 7. Basic operations and display / setting7- - 1 ......................1-1 ............1-1 1.2 S 7.1 P...

  • Page 4: Safety Precautions 1

    1. Safety precautions Before using the unit, thoroughly read this “Safety precautions” to properly use the product. Information described below is vital to safe and proper use of the unit and prevention of hazard and/or damage. 1.1 Explanation of safety indications and graphic symbols This instruction manual divides safety indications into four categories according to the level of hazard (the extent of damage/losses and the urgency).
  • Page 5 TERAL INC.. If unskilled personnel carry out the work that requires special knowledge, it may lead to an accident and/or failures.
  • Page 6 Caution Properly make each setting of the control panel Do not idle the pump (operation without priming). depending on the conditions of use. Otherwise, it may cause damage to the sliding part inside the pump. Otherwise, it may hinder the normal operation. Do not touch the motor body or the cooling fins for Before operation, thoroughly clean (flush) the the control panel while the unit is running or...

  • Page 7: Before Using The Water Supply Unit

    (2) Check all fastening parts including bolts and nuts are securely tightened. (3) Check all the accessories that you ordered have been completely delivered. 2.2 Unit model description Cabinet type direct-connecting water supply booster pump MC5 Unit nominal diameter : 40mm...

  • Page 8: Configuration And Overview Of The Water Supply Unit

    Item Specification Operation mode Automatic alternate operation Unit type certification Direct-connecting booster pump unit MC5 [Certified by Japan Water Works Association] Estimated terminal pressure constant control / Discharge pressure constant control Control method by frequency control Liquid Fresh water pH5.8 8.6, Chloride ion concentration not exceeding 200 mg/L...

  • Page 9: Name And Function Of Each Part

    Unit discharge pipe (Back of the backflow preventer Fig. 3-2-1 MC5 pump unit (representative drawing) Control panel The control panel controls the pump and supplies the power to the motor. It enables to start/stop the pump, detects the operating status of the pump and automatically switches the No.
  • Page 10 Check valve pump section The buffer check valve is incorporated. By-pass pipe The buffer check valve is incorporated. When the pressure in water pipe is higher than the set value, the pump is stopped and the water is supplied through the bypass pipe. TJ valve This is a three-way valve used to discharge water inside the pressure tank when you carry out the maintenance of the pressure tank.

  • Page 11: Function Of Valve Unit

    3.2.2 Function of valve unit Be sure to set the valves for all the pumps to "Open" when the unit is in operation. Operating a pump with the valve set to "Close" may not only Caution disturb normal operation, but also increase the water temperature in the pump because of zero-discharge operation, causing a burst of steam and/or hot water from the pump.
  • Page 12 3.2.3 Name and function of operation panel BQMC5-346-0400 Fig. 3-2-3 Operation panel on the control panel Display The display is to display information about the pump unit. ( Refer to 7.2.) Power supply indicator lamp The lamp is lit when the power supply is turned on. It blinks when the pump unit is in the inspection mode.

  • Page 13: Configuration Of The Control Panel

    3.2.4 Configuration of the control panel While the power is on, high voltage is applied inside the control panel, which is very dangerous. Any person other than the one authorized to Warning do so must not open cover of the control panel. if not followed, it may cause an electric shock.

  • Page 14: Control Board

    3.2.5 Control board The following are the details of the control board. Do not remove the protective cover on the control board or the cover Warning of the I/O terminal block when the power is turned on. Otherwise, it may lead to an electric shock. CN20 CN19 CN18 CN12...

  • Page 15: Control Panel Specification

    3.3 Control panel specification Table 3-3 Control panel specification Item Specification 1 Specification 2 Control panel type BQMC5C Operation mode Automatic alternate operation Casing material High corrosion resistant hot-dip galvanized steel sheet Single phase 200V(50/60Hz) 0.75 1.1kW Output range 3-phase 200V(50/60Hz) 0.75 7.5kW Ground fault interrupter Individual pump system...

  • Page 16: Specification List

    (unit) range sealing pressure rate Sucti Disch capacity dB(A) flow rate MPa(kgf/cm /min arge /min MC5-2020-0.4S2D 0.22(2.2) 0.015 0.04 10 33 MC5-2020-0.75S2D 0.75 0.04 0.33(3.4) 0.015 0.04 33 54 MC5-2020-1.1S2D 0.44(4.5) 0.015 0.04 48 75 MC5-2525-0.4S2D 0.17(1.7) 0.04 0.10...
  • Page 17 Note 1) The maximum operating pressure (maximum value of water supply total head) is 0.75 MPa (7.6 kgf/cm ). Select the devices that satisfy the condition: "Maximum operating pressure Boost pressure + Total head (unit) - Pressure loss of backflow preventer". Note 2) The model of the unit depends on the type, mounting position and others of the backflow preventer.

  • Page 18: Installation 4

    4. Installation 4.1 Cautions on installation Check the weight of the unit, referring to the catalog, assembly drawing, etc. Warning before lifting, and then lift the unit appropriately within the rated lifting load of the lifting sling. Otherwise, drop, injury and/or physical damage may occur. Lifting with a lifting sling hooked on a wooden frame may damage the Warning wooden frame.

  • Page 19: Backflow Preventer

    4.1.2 Backflow preventer (1) It is necessary to provide the reduced pressure backflow preventer with open piping to receive the drain from the relief valve. The drain piping shall be inclined so that water can be discharged by gravity flow, being equipped with a specified space at the discharge port. For the examples of the drain piping installation, refer to "4.2.2 Drain piping of backflow preventer".

  • Page 20: Cautions On Piping Work

    4.2 Cautions on piping work Do not use any piping material that forms rust. It may cause the Caution failure of the direct-couples booster pump unit. Do not apply hydraulic-test pressure on the piping side to the direct- Caution connecting booster pump unit. It may damage the equipment. Provide a pipe support which is strong enough to prevent the piping Caution load from being applied to the direct-connecting booster pump unit.
  • Page 21 200mm or more 200mm Test piping 200mm or more 200mm 200mm 200mm or more Side Side 200mm or more 200mm 200mm or more 200mm Side Side Vibration Vibration Plain view isolation joint isolation joint Gate valve Gate valve Discharge Suction pipe pipe Pipe support Pipe support...

  • Page 22: Drain Piping Of Backflow Preventer

    4.2.2 Drain piping of backflow preventer This section describes some examples of drain piping installation of the backflow preventer when this direct-connecting booster pump unit has a built-in vibration-proof joint. Be careful to prevent the flanges from interfering with the drain receiver of the backflow preventer at the time of piping installation.
  • Page 23 (2) In case of installing the backflow preventer on the discharge side Discharge flange Base opening Discharge flange Base opening Suction flange Suction flange Eccentric Hopper hopper 50×30 100×50 Base Base height height Unit bore 20/25A Unit bore 32A Base opening Discharge flange Suction flange Pump...

  • Page 24: Example Of Drain Piping Installation With Water Leak Detector

    4.2.2.2 Example of drain piping installation with water leak detector Please also refer to “10.2 Specification with leak detector” for the specification with water leak detector. (1) In case of installing the backflow preventer on the suction side Discharge flange Discharge flange Base opening Base opening...
  • Page 25 (2) In case of installing the backflow preventer on the discharge side Discharge flange Base opening Discharge flange Base opening Suction flange Suction flange Water leak detector Water leak detector Eccentric hopper Eccentric hopper 100×50 100×50 Base Base height height Unit bore 32A Unit bore 20/25A Base opening...

  • Page 26: Installation Of Direct Hydrant For Common Use

    4.3 Installation of direct hydrant for common use Install a hydrant for common use which can be used by the users of the direct-connecting booster pump unit in case of the restriction on water supply, failure, and power interruption. For the installation procedure, refer to the work standards of each Note water supply business unit.

  • Page 27: Cautions On Wiring Work

    4.5 Cautions on wiring work Wiring work shall be performed according to the Technical Standard for Electric Facilities and Interior Wiring Code using the wiring equipment which matches the conditions of use. Be sure to perform Warning wiring work by qualified persons, such as licensed electricians. Unqualified persons are prohibited by the law to conduct the wiring work.

  • Page 28: Instrumentation

    4.5.2 Instrumentation Carry out wiring work for instrumentation according to the following procedure. Connect all the wirings for instrumentation to the input/output terminal block on the control board. Attach grommets ( 22) to the wire inlet ports to protect the wires, or Caution use conduit tubes.

  • Page 29: Preparation For Operation

    5. Preparation for operation 5.1 Item to be checked before the test operation 5.1.1 Checking the electric system Before carrying out work such as changing the wiring, be sure to shut off the main power of the panel board and check that the power lamp Warning is tuned off.
  • Page 30 (6) Fully close the sluice valve installed between the water distribution pipe and pump unit, or fully close the ball valve on the suction side in the pump unit; and then remove the strainer cap to take out the strainer. When water is passed for the first time, the strainer may be clogged with some foreign material left at the time of piping installation, thus preventing the direct-connecting booster pump unit from running normally.

  • Page 31: Power Supply

    5.2 Power supply After the power is turned on, do not touch any parts other than those Danger used for the operation described below. It may cause an electric shock. Do not operate the control panel by wet hands. It may cause an Warning electric shock and/or short circuit.

  • Page 32: Test Operation

    6. Test operation 6.1 Check items related to manual operation Note Check the following items related to manual operation for all the pumps. No.1 selected Pump No. No.2 selected P1 P2 P1 P2 900rpm 900rpm Rotation speed Pump status Selecting pump No. P1 P2 P1 P2 900rpm...
  • Page 33 Do not run the pump continuously for over one minute while the sluice valve on the discharge line is shut (zero-discharge operation). Warning Otherwise, the temperature and pressure will increase inside the pump, which may damage the pump and/or cause steam to blow off.

  • Page 34: Checking The Automatic Operation

    6.2 Checking the automatic operation Press and select "Automatic operation mode" to start automatic operation. Carefully read the following to understand the operation in advance, and then check that the unit runs normally using the piping for test. While checking the operation, also check each pump for any abnormal pressure, noise, or vibration.

  • Page 35: Basic Operations And Display / Setting7

    7. Basic operations and display / setting This section describes detailed information about operation, display and setting for the unit. 7.1 Pump operation 7.1.1 Selecting operation mode Press on the operation panel and select the operation mode. Table 7-1-1 Operation mode selection “Manual operation mode”...

  • Page 36: Indications On The Screens

    7.2 Indications on the screens The screens are divided into the home screen, menu screen, and each item screen. The home screen displays emergency information, such as the pump operating state and error. The menu screen displays each menu. Each item screen displays the contents according to each item, such as pump information and error log.

  • Page 37: Indication Of Active Errors

    If multiple events occur, the system displays the event with the highest priority. Press to switch between the display items. Press , or to display the condition of each pump. If no operations are made for a long time, the display returns to the event of the highest priority. Table 7-3 List of display items on the home screen Refer to Display item...

  • Page 38: Indication On The Menu Screen

    7.4 Indication on the Menu screen The menu screen displays each menu item. Press to switch the display. Press while each item is displayed to switch each item screen. Table 7-4 List of display items on the menu screen Refer to Display item Description section...

  • Page 39: Basic Display Menu

    7.4.1 Basic display menu It displays the information of each item in Table 7-4-1. Press to switch the information. Table 7-4-1 List of display items on the basic display menu Display item Description Suction pressure It displays the pressure in the suction piping. Unit: Meter [m] Number of starts on the It displays the number of starts of the unit on the...

  • Page 40: Pump Information Menu

    7.4.2 Pump information menu It displays the information of each item in Table 7-4-2. Press to switch the information. Press to switch the machine unit for the same display item. Table 7-4-2 List of display items on the pump information menu Display item Description Operation rotation speed...

  • Page 41: Parameter Menu

    7.4.3 Parameter menu Various functions of water supply unit can be set / adjusted with various parameters. The parameter settings are stored even while the power is off. 7.4.3.1 Parameter list Table 7-4-3-1 Parameter list Parameter Class Symbol Initial value Adjustable range (Display) Total head...

  • Page 42: Parameter Setting Procedure

    7.4.3.2 Parameter setting procedure Follow the procedure - to change the parameter. Changing to the menu screen Press while the home screen is displayed to change the screen to menu screen, is displayed. Changing to parameter menu Press either to display and then press In the parameter menu, the selection screen for basic parameters will be displayed first, and then...
  • Page 43 To exit the parameter menu Press to return to the menu screen. Press again to return to the home screen from the menu screen. The screen will automatically return to the home screen after 60 seconds of inactivity while the menu screen and the parameter menu is displayed.

  • Page 44: Basic Parameters

    7.4.3.3 Basic parameters The following are basic parameters for using the water supply unit. (1) Total pump head Total pump head This function sets the total pump head in automatic operation. Function Refer to “3.4 Specification list” and set the set value for total pump head within the specified range.
  • Page 45 (6) Operation permission setting Setting for permission for No. 1 run Setting for permission for No. 2 run This function is to permit or inhibit the operation of each pump. Function The pump which is set to inhibition cannot be operated either manually or automatically.

  • Page 46: Optional Parameters

    7.4.3.4 Optional parameters The optional parameters are to set/adjust the various functions of the direct-connecting booster pump unit. The optional parameters can be changed only when the operation mode is set Note to “Stop mode.” Therefore, set the parameters before starting the operation of the direct-connecting booster pump unit.
  • Page 47 (2) Interlock signal setting Interlock signal setting This function is to select the type of signal used for interlocks that forcibly stop the water supply unit. Function Usable signals are no-voltage a-contact or no-voltage b-contact. In case that the interlock is disabled, select “a .”...
  • Page 48 (4) High temperature error detection setting High temperature error detection setting Function This function is to select whether or not to detect high temperature errors. Detect Adjustable range Not detect Detect Initial value (If value was specified with order, the specified value is already set as the initial value.) Select “OFF”...

  • Page 49: Error Log Menu

    7.4.4 Error log menu It displays the error log. Using keys, you can view 5 previous errors. The error occurrence date can also be displayed by pressing . The clock setting is required to display the exact time of error occurrence (refer to "7.4.5 Clock menu"). When there is no error log, it displays 1 E201 1 2010/02/18...

  • Page 50: Clock Menu

    7.4.5 Clock menu It displays the current date. When the date and time is displayed, press to enter the clock setting screen. If the clock setting notice is displayed on the home screen, press to enter the clock setting screen. Press to select an item to change (year, month, day, hour and minute).

  • Page 51: Maintenance And Inspection

    8. Maintenance and inspection 8.1 Cautions on maintenance and inspection Conduct the maintenance and inspection of the direct-connecting booster pump unit in accordance with “8.3 Maintenance checklist”. Be sure to perform daily and periodical inspections based on the Caution maintenance checklist. Failure to conduct inspection may cause a failure, resulting in an accident.
  • Page 52 ( 3.2.1 ) TJ valve (Fig. 3.2.1(11)) Connect to the pressure gauge and fill the air through the metal fixture for pumping (used for car tires) Normal handle Remove the cap position Air valve Procedure for checking the sealing pressure in the pressure tank] Stop operation.

  • Page 53: Inspection Mode

    8.2 Inspection mode The mode can be changed to “Inspection mode” to notify others that maintenance is in progress. (1) Changing to and canceling the inspection mode To change to the inspection mode of the basic parameter to “ON.” To cancel the inspection mode of the basic parameter to “OFF.”...

  • Page 54: Maintenance Check List

    Caution inspection that requires disassembly of the unit, be sure to contact a specialized vendor or the service center specified by TERAL. Incorrect work may cause accidents or failure. Do not perform an insulation resistance test on the control panel. When...
  • Page 55 Table 8-3(b) Maintenance check list Consumables Frequency Inspection point Inspection item Method Criterion Replacement Consumable Qty. cycle Visual Head As per the specifications check Electric current value Measure As per the specifications Operating conditions Listen Noise, vibration No abnormal condition Touch Visual Each motor rotates in the correct...
  • Page 56 In the event of an alarm or abnormal condition that cannot be resolved, immediately stop the operation and contact TERAL or its service representative. Otherwise, it may lead to an accident. Caution Before the contact, check the status of abnormal condition and the alarm code No., as well as information shown on the nameplate, and...

  • Page 57: Troubleshooting

    9. Troubleshooting 9.1 When an error occurs 9.1.1 Checking the error description When an error occurs, the buzzer will sound, the error indicator lamp on the operation panel Failure Display will flash, and error No. will be displayed on the indicator section display.

  • Page 58: Causes Of Troubles And Countermeasures

    The diaphragm of the pressure tank is Requires checking/replacement damaged, and the pressure cannot be pressure tank. Contact TERAL or service maintained when the pump stops, increasing representative. the number of times the pump starts. Abnormal Check and maintain the piping.
  • Page 59 If disassembly is required for checking, E202 Discharge disconnection of the power line, etc. contact TERAL or the service representative. pressure The suction piping, pump or strainer is clogged abnormal drop of with foreign substances and the flow passage is Requires disassembly of the pump.
  • Page 60 No.1 Requires disassembly of the cooling fan. Inverter overheat The cooling fan is faulty. E217 Contact TERAL or service representative. for pump No.2 Communication The earth leakage breaker has been error of pump turned off due to a cause other than the Turn on the earth leakage breaker.

  • Page 61: Special Specifications

    10. Special specifications 10.1 Elevated water tank system The elevated water tank system is of a type which automatically runs the pump while it detects the water level in an elevated water tank. 10.1.1 Operation The operation cycles of the elevated water tank system are as follows. Note that the following cycles are the case where the solenoid valve operation option is set to "AUTO"...

  • Page 62: Wiring Connection

    10.1.2 Wiring connection For the elevated water tank system, connect the relevant electrode and solenoid valve for control. For the symbols on the input/output terminal block and their intended use, refer to "3.2.5 Control board". Connect the electrode rods and solenoid valve for the elevated water tank as follows. Table 10-1-2 Elevated water tank wiring pattern Elevated water tank system Unit...

  • Page 63: Display And Setting

    10.1.3 Display and setting The condition of solenoid valve is added to the basic display menu (refer to "7.4.1 Basic display menu"). Table 10-1-3 (a) Condition of solenoid valve on display Display item Description It displays whether the solenoid valve is Solenoid valve state opened/closed.
  • Page 64 (3) Liquid level error reset setting : Liquid level error reset setting Select whether to reset the level error (full level or low level of the elevated Function water tank) manually by pressing and holding or automatically by level recovery. Manual reset Option Automatic reset...

  • Page 65: Error Contents

    10.1.4 Error contents The following errors are added or deleted to/from the standard specifications. Table 10-1-4 (a) Errors to be added/deleted to/from the standard specifications of elevated water tank system Error to be added Error to be deleted Elevated water tank full level Flow switch error E001 E005...

  • Page 66: Specifications Of The Unit With Leak Detector

    10.2 Specifications of the unit with leak detector The leak detector is used to detect any abnormal water leak in the space at the discharge port of the backflow preventer. 10.2.1 Detection condition A water leak error is detected when "Water leak Water leak reference value x Water leak detection time".

  • Page 67: Indications And Settings

    " appears in the message field). Table 10-2-5 Causes and solutions of water leak Error Description Possible cause Solution number Requires overhauling the backflow Water is leaking from the backflow E008 Water leak preventer. Contact TERAL or service preventer. representative. 10-7...

  • Page 68: Freeze-Proof Specifications

    10.3 Freeze-proof specifications For freeze-proof specifications, a cement heater and harness (with thermostat) are added to the standard specifications. When the ambient temperature drops to 3°C, the thermostat of the harness is turned on and the cement heater is turned on. When the ambient temperature reaches 7°C, the thermostat of the harness is turned off.
  • Page 70 Head Office 230, Moriwake, Miyuki-cho, Fukuyama-city, Hiroshima, 720-0003, Japan Tel.+81-84-955-1111 Fax.+81-84-955-5777 www.teral.net 2019 12 E‑IMN‑00396‑000‑A...

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