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Related Manuals for ITT Flowtronex SIlent Storm
Summary of Contents for ITT Flowtronex SIlent Storm
- Page 1 Flowtronex Instruction Manual 19-001-200 Rev 0110 SILENT STORM VFD Pumping System Installation, Operation, Maintenance INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’ S USE. NOTE: This product is not intended for use in potable water applications...
- Page 2 Acknowledgements All materials ©2009 by ITT Flowtronex, an ITT Corporation company. Flowtronex© is a registered trademark of ITT Flowtronex. All rights reserved. No parts of this work may be reproduced in any form or by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of the publisher.
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Page 3: Table Of Contents
It does not relieve the user of their responsibility of using accepted engineering practices in the installation, operation, and maintenance of this equipment. For additional questions, contact: ITT FLOWTRONEX (800) 786-7480 x1 www.flowtronex.net/ service@flowtronex.com... -
Page 4: Warranty Information
WARRANTY INFORMATION Company warrants title to the product(s) and, conditions shall extend to replacement parts except as noted below with respect to items not of furnished by Company hereunder. Company shall Company’ s Manufacturer, also warrants the have the right of disposal of parts replaced by it. product(s) on date on shipment to Purchaser, to be of the kind and quality described herein, and ANY SEPARATELY LISTED ITEM OF THE... -
Page 5: Safety
SAFETY Read all safety information prior to installation of the Silent Storm Pumping System. All operating instructions must be read, understood, and followed by SAFETY INSTRUCTIONS operating personnel. Flowtronex accepts no liability for SAFETY INSTRUCTION damages or operating disorder which result compliance with... -
Page 6: Additional Safety Information
Operators and maintenance personnel must realize this and follow necessary safety measures. • Use proper lifting and supporting Proper safety procedures must be followed. ITT equipment to prevent serious injury. Flowtronex shall not be liable for damage or • Observe proper decontamination delays caused by a failure to observe the procedures. -
Page 7: General Description
GENERAL DESCRIPTION PRODUCT DESCRIPTION NAMEPLATE INFORMATION A Flowtronex Silent Storm Variable Speed The system nameplate gives identification and Pumping System custom built rating information as identified in the figure below. requirements provided by the purchaser. The Silent Storm pumping system is a modular variable speed system designed to maintain a constant discharge pressure while providing a variable flow rate to match the water demand of... -
Page 8: Handling
S = Submerged Sled pump assembly The unit is top heavy due to the position of the equipment. Do not use component eyebolts to lift M = Floating pump assembly the pump station. 3. Pump Type: WARNING: Falling Objects Hazard C = Horizontal Eyebolts, if provided, are designed to lift only the S = Submersible... -
Page 9: Ground Connections
GROUND CONNECTIONS A grounding terminal is provided for a dedicated ground wire connection. All provisions of the National Electrical Code and local codes must be followed. WARNING: Electrical Shock Hazard Conduit grounds are not adequate. A separate ground wire must be attached to the ground lug provided in the enclosure to avoid potential safety hazards. -
Page 10: Installation
INSTALLATION After the pumping system has been leveled, install LOCATION the correct number of anchor bolts and tighten to secure the system. Locate the pumping system in a clean, well ventilated, and properly drained location. It is recommended that the location selected facilitates PUMP INSTALLATION ease of inspection, maintenance, and service. - Page 11 Figure 3: Lifting Pump 2. After the cable-sling is attached to the lifting lugs (lifting eyes) on the pump head, raise the pump to a vertical position. While in this position, install the strainer basket with bolts and clips. Position the pump over its access hole on the skid.
- Page 12 6. Line up the spool with the pump isolation valve on the manifold-discharge pipe and set the pump on the skid. Start threading the base bolts on the pump head. Slide the Victaulic clamp gasket so that the clamp rides in the gloves on both the isolation valve and the spool.
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Page 13: Station Operation
STATION OPERATION mode depending on the position of the This section covers the sequence of operation for system switch. VFD is the normal position your station including: Door Switch Operation, of the switch. Automatic Operation, and System Safeties. BYPASS This switch position, places the pump station in either "Automatic VFD DOOR SWITCH OPERATION Bypass"... -
Page 14: Wye Strainer Or Filter Switch
Well Pump Switch automatic operation prevent overloading the pump motors and avoid If present on the station, this switch allows the damaging erosion in the event of a major operator to control the operation of a well pipe break. pump. In most cases, the operation of this pump is completely independent of the DIFFERENTIAL PRESSURE OVERRIDE operation of the pump station. -
Page 15: Automatic Operation
AUTOMATIC OPERATION Combo 1. The values of 30 PSI and 90 Overview seconds were intentionally selected since they The primary benefit of Variable Speed are out of range and will never be used. Pumping (VSP) Systems is to ensure surge- There are three (3) main types of auto free starts and stops while maintaining a operation –... -
Page 16: Normal Operation
leakage, or other small demands. A PM pump System control switch: AUTO is provided to address this issue. Most Pump 1 switch: ON stations, but not all, include a PM pump. Door switches are set as follows (from end of line fill Pump 2 switch: ON mode): Pump 3 switch: ON... - Page 17 PSI. If the VFD speed falls below a If the demand for water is still greater than the capacity of these two pumps, then Combo 4 predetermined value pressure starts. As occurred in the previous Combo, the remains above the reduced setpoint for 15 inverter (VFD) speed immediately ramps down seconds, the VSP turns OFF, and the setpoint to the “...
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Page 18: Manual Vfd Operation
mode, return the system switch to AUTO and Manual VFD Operation turn ON all pump switches. Overview VFD Bypass Operation, Manual mode Manual operation is selected by the system control switch. In manual operation, all pump activity is controlled by the individual pump Overview switches. -
Page 19: Vfd Bypass Operation, Auto Mode
NOTE: When done, turn OFF all pump Delay time to start Combo 1 0 SEC switches and place system control switch in 5 PSI Pressure above setpoint to stop OFF. Return Override/Active switch Combo 1 ACTIVE. Delay time to stop Combo 1 5 SEC VFD Bypass Operation, Auto mode 12 PSI... -
Page 20: Plc Bypass Operation
Override/Active switch: LDP Override PLC Bypass Operation (Low Discharge Pressure fault disabled). If Overview initial system pressure is high enough, place in Active. This is an abnormal operating mode and would be used if the PLC was not operable VFD Bypass switch: Bypass and there is need to irrigate. -
Page 21: System Safeties
Manual Mode of Operation All faults are cleared by pressing the Reset SYSTEM SAFETIES button, or by re-arming individual pump faults. Overview Low Discharge Pressure The program in the PLC protects the system The pressure transducer located in your by shutting down in either of the “ Auto” or station discharge line communicates the “... -
Page 22: Low Inlet Pressure
down. Once the high pressure condition Turn clockwise to increase the pressure clears, the station automatically resets, and setpoint, counter-clockwise to decrease. automatic operation resumes. The PLC allows three (3) automatic restarts in a one-hour period. At the fourth occurrence in a one-hour CAUTION: Delta Pressure Setting Hazard period, the station shuts down (hard fault). -
Page 23: Low Level Fault
fault). The red station fault light on the control panel door comes on, and the display WARNING: Equipment Damage Hazard indicates an "Alarm Shutdown Alert." Go to "Alarms," and the display should show that a Do not attempt to bypass this safety, as pump "Phase Failure fault"... -
Page 24: High Pump Temperature (Optional)
VFD Fault Resetting the overload is accomplished by The VFD sends a fault signal (120 VAC) pushing in the blue Differential Overloads directly to the PLC. The display shows, button on the right front face of the device, "Inverter Fault." This is normally a VFD fault. and rotating it approximately an eighth of a To determine the nature of the problem, you turn clockwise. -
Page 25: Maintenance
MAINTENANCE REGULAR MAINTENANCE = INVESTMENT Maintenance is an investment that will pay 3. Motor lubrication: dividends in the form of improved reliability and a. If your motor has an oil bath thrust durability. Site maintenance checks are a matter of bearing, you need to ensure that it is day to day, week to week care that is important to filled to the recommended fill line on... -
Page 26: Winterizing Pump Stations
even electrical arcing or that something DANGER: Personal Injury Hazard is in a bind? This can indicate a serious problem. Pump station maintenance must be performed by b. There is going to be some harmonic properly trained and qualified personnel. Hazards vibration with the pumps and motor. -
Page 27: Vertical Stations
3. Check that the drain plugs are installed in both valves. pumps and piping. 3. Carefully remove all tubing from pressure NOTE: Contact ITT Flowtronex PSI, if you switches and transducers. Make certain have further questions on winterizing your that the station piping is completely pump station. -
Page 28: Troubleshooting
TROUBLESHOOTING 1. If a troubleshooting step needs to be performed by a qualified person, it is labeled “ To be performed by a qualified person only.” 2. Steps that can be performed by unqualified persons are not labeled. 3. Qualified persons are those who have been trained in avoiding the electrical hazards of working on or near exposed energized parts. -
Page 29: High Discharge Pressure Fault
HIGH DISCHARGE PRESSURE FAULT Cause Cure High system pressure setting too low. Press F1, F8, F11 and verify n70:0 is set to 60 seconds. System pressure transducer reading high. Compare display readout to the pressure gauge. Calibrate if possible, and replace transducer if necessary (FlowNet). -
Page 30: Loss Of Prime Fault
and verify that the supply valve is open. If equipped with a suction manifold strainer, clean as required. Ensure the supply piping not clogged or restricted. Pressure is actually low – dynamic. Ensure that the flow rate is less than the supply capacity. -
Page 31: Motor Won' T Start
(located at wire terminal strip). If the power is good, replace the fan. There is no water flow through heat exchanger. Make sure both ball valves are open. Water is leaking at the heat exchanger. Repair or replace the coil. Fault code 2 –... -
Page 32: Glossary Of Terms
GLOSSARY OF TERMS Alternating Current. The voltage, and therefore current, constantly oscillates positive and negative. For North America, the line frequency is 60 Hz. Some other areas of the world use 50 Hz. Across-the-line (XL) Applying 100% of line voltage to a motor during startup and run. A simple large relay with a contact for each power phase (for 3 phase) is used to control the motor OFF/ON. - Page 33 equipment if allowed to continue. Direct Current. Such as a battery. The voltage is stable, and does not oscillate (at least intentionally). Digital A simple ON/OFF condition. For example, the presence or lack of a 120VAC signal on a wire is a digital condition. Downstream Relief Valve is used to limit the maximum allowable downstream pressure.
- Page 34 run-time. Lift This refers to how high water must be "lifted" to reach the pump suction. Lift stations have even harsher NPSHR than Flooded Suction systems. Loss of prime safety is an excellent choice for these systems. Auto-re-prime systems are available to help maintain a full suction line (CRD reprime, vacuum pumps).
- Page 35 storage or temporary storage during mathematical calculations. Relay This is a normally open or normally closed device that changes output state when it is energized or de-energized, and sends or removes a 120VAC signal to the PLC. SCADA Supervisory Control And Data Acquisition. Sequential alternation One of several methods of selecting which pump to use first.
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Page 36: Appendix A - Final Check List
APPENDIX A — FINAL CHECK LIST £ Is the base unit properly leveled and secured? £ Are all lubrication points properly lubricated? £ Is the shut-off valve on to the pump suction open? £ Is the shut-off valve on the discharge line open? £... -
Page 37: Appendix B - Electrical Wiring And Control Settings Final Checklist
APPENDIX B — ELECTRICAL WIRING AND CONTROL SETTINGS FINAL CHECKLIST £ Does the feeder line voltage correspond to the unit voltage? Check the unit nameplate or motor terminal connection. WARNING: Electrical Shock Hazard Inspect all electrical connections prior to powering the unit. - Page 38 ITT Flowtronex © COPYRIGHT 2009 Phone: (800) 786-7480 x1 BY ITT CORPORATION PRINTED IN U.S.A. service@flowtronex.com www.flowtronex.net THE ITT ENGINEERED BLOCKS SYMBOL AND ENGINEERED FOR LIFE ARE REGISTERED TRADEMARKS OF ITT CORPORATION...
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