PPS SuperNOVA Installation, Operation & Maintenance Instructions Manual
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PPS SuperNOVA Installation, Operation & Maintenance Instructions Manual

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PUMP SYSTEMS
Installation, Operations & Maintenance Instructions
0 - Warranty Information
1 - Safety Instructions
2 - Component Manual Library
3 - Flagship Pump Station Components
Precision Pumping Systems
4 - Drop Pipe Installation
5 - Custom Pump Station Components
6 - Theory of Operation
7 - Basic Operation
•
•
GoPPS.com
6515 Business Way, Boise, ID 83716
8 - Control & Monitoring
9 - Troubleshooting
10 - Maintenance & Winterization
11 - Start-Up & Winterization Checklist
•
208.323.5300

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Summary of Contents for PPS SuperNOVA

  • Page 1 PUMP SYSTEMS Installation, Operations & Maintenance Instructions 0 - Warranty Information 4 - Drop Pipe Installation 8 - Control & Monitoring 1 - Safety Instructions 5 - Custom Pump Station Components 9 - Troubleshooting 6 - Theory of Operation 10 - Maintenance & Winterization 2 - Component Manual Library 3 - Flagship Pump Station Components 7 - Basic Operation...

  • Page 2: Table Of Contents

    ............. pg. 3 1-Year Warranty .............. pg. 3 3-Year Warranty .............. pg. 4 Safety Instructions ............pg. 5 Component Manuals Library ........pg. 7 Flagship Pump Station Components ....... pg. 8 ARIEL .................. pg. 9 ATLAS ................pg. 11 SuperNOVA ..............pg. 13 NEBULA ................pg. 15 NEUTRON ..............pg. 17 NOVA ................pg. 19 ORION ................pg. 21 PHOENIX ................ pg. 23 VEGA ................pg. 25 Drop Pipe Installation ..........pg. 30...

  • Page 3: 1-Year Warranty

    Telephone technical support free-of-charge for the life of your product. Systems (PPS) provides the following LIMITED WARRANTY: Limited 1-Year Warranty PPS warrants to the original buyer that its products and systems will be free from defects in material and workmanship for a period of twelve (12) months from the date of placing the Equipment in operation or fifteen (15) months from the date of completion of manufacture of the Equipment, whichever shall occur first. When notified by Purchaser of a defect which conforms to this Warranty PPS shall, at its sole discretion, correct the defect by performing a suitable repair to the Equipment or by providing a replacement part. This warranty does not apply to equipment that has been damaged, misapplied or modified in any way. Terms and Conditions: 1. Warranty claims must be submitted directly to Precision Pumping System within the valid warranty period. No claims for warranty will be paid without prior approval by PPS. 2. The determination regarding defective status of components or products is at the sole discretion of PPS. 3. If a component or product is determined to be defective by Precision Pumping System, then PPS shall, at its sole discretion, correct the defect by performing a suitable repair to the equipment or by providing a replacement part. 4. Proper start-up and operational procedures must be followed, and the required annual preventative maintenance must be performed by authorized PPS personnel or this warranty shall be void. 5. Within the first year after start-up, PPS will cover labor and materials costs. In any subsequent years of the warranty period (if an extended warranty is purchased) only materials costs are covered by this warranty – no labor costs will be paid. Disclaimers 1. PPS shall not be liable for repairs, replacements or adjustments to the Equipment or costs of labor performed by the Purchaser without prior written consent of PPS. 2. All PPS warranty provisions require the Purchaser to operate and maintain the Equipment according to good industry practices and to comply with all recommendations by PPS regarding operation and maintenance.

  • Page 4: 3-Year Warranty

    Telephone technical support free-of-charge for the life of your product. Systems (PPS) provides the following LIMITED WARRANTY: Limited 3-Year Warranty PPS warrants that its products and systems will be free from defects in material and workmanship for a period of three (3) years from the date of placing the equipment in operation or forty (40) months from the date of completion of manufacture of the equipment, whichever shall occur first. Initial start-up and preventative maintenance must be performed by an authorized PPS representative or the warranty shall be void. This warranty does not apply to equipment that has been damaged, misapplied or modified in any way. Terms and Conditions: 1. Warranty claims must be submitted directly to Precision Pumping System within the valid warranty period. No claims for warranty will be paid without prior approval by PPS. 2. The determination regarding defective status of components or products is at the sole discretion of PPS. 3. If a component or product is determined to be defective by Precision Pumping System, then PPS shall, at its sole discretion, correct the defect by performing a suitable repair to the equipment or by providing a replacement part. 4. Proper start-up and operational procedures must be followed, and the required annual preventative maintenance must be performed by authorized PPS personnel or this warranty shall be void. 5. Within the first year after start-up, PPS will cover labor and materials costs. In the second and third years of the warranty period only materials costs are covered by this warranty – no labor costs will be paid. Disclaimers 1. PPS shall not be liable for repairs, replacements or adjustments to the Equipment or costs of labor performed by the Purchaser without prior written consent of PPS. 2. All PPS warranty provisions require the Purchaser to operate and maintain the Equipment according to good industry practices and to comply with all recommendations by PPS regarding operation and maintenance.

  • Page 5: Safety Instructions

    SAFETY INSTRUCTIONS To help prevent severe injury or property damage, please carefully read through each of the following warnings: 1.1 Electrical Hazards DANGER WARNING ELECTRIC SHOCK HAZARD ARC FLASH HAZARD HAZARDOUS VOLTAGE DISCONNECT POWER BEFORE SERVICING Hazardous voltage inside this panel will cause an electrical shock or an arc flash explosion, DANGER which may result in SEVERE INJURY or DEATH.
  • Page 6 SAFETY INSTRUCTIONS To help prevent severe injury or property damage, please carefully read through each of the following warnings: 1.3 Pumped Fluid Hazards WARNING DO NOT PUMP HAZARDOUS FLUIDS This system is not designed for pumping hazardous fluids. Pumping hazardous fluids can cause fire, burns, or death. 1.4 Equipment Protection IMPORTANT RISK OF FREEZING DAMAGE...

  • Page 7: Component Manuals Library

    COMPONENT MANUAL LIBRARY FLOW METERS & FLOW SWITCHES HARMONIC FILTERS Follow this QR Code or click HERE. Follow this QR Code or click HERE. POWER MANAGEMENT HEATERS Follow this QR Code or click HERE. Follow this QR Code or click HERE. PLCs & HMIs INTERNET CONNECTIVITY Follow this QR Code or click HERE. Follow this QR Code or click HERE. PRESSURE GAUGES MOTORS Follow this QR Code or click HERE. Follow this QR Code or click HERE. PRESSURE TRANSMITTER & SENSORS AIR CONDITIONERS Follow this QR Code or click HERE. Follow this QR Code or click HERE. PUMPS AUTO DIALERS Follow this QR Code or click HERE.

  • Page 8: Flagship Pump Station Components

    FLAGSHIP PUMP STATION COMPONENTS ARIEL Series *Your station may differ slightly from this image. If you need assistance locating a component not shown, contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us. ” • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716 208.323.5300...
  • Page 9 ARIEL Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGE Your pump station includes a pressure gauge. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTER Your pump station includes a pressure transmitter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FLOW METER Your pump station may include a flow meter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FILTER Your pump station includes a filter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Can’t find the component manual you need? Contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us for assistance. •...

  • Page 10: Atlas

    ATLAS Series Flow meter (optional) Air Relief Valve Pressure Transducer Outlet Pressure Tank Bypass Suction Thermosetting epoxy powder coating provides corrosion protection (custom colors available) Run Dry Protection *Your station may differ slightly from this image. If you need assistance locating a component not shown, contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us. ” • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716 208.323.5300...
  • Page 11 ATLAS Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGE Your pump station includes a pressure gauge. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTER Your pump station includes a pressure transmitter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FLOW METER Your pump station may include a flow meter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Can’t find the component manual you need? Contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us for assistance. • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716...
  • Page 12 SuperNOVA Series *Your station may differ slightly from this image. If you need assistance locating a component not shown, contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us. ” Pressure Sensor Exhaust Fan Combo Pressure Gauge Pressure Gauge Touch Display Flow VFD Access Switch Cover Lockable Marine Vent Grade Aluminum Enclosure Exhaust Fan 1” Blow Out Pressure Tank 2” MPT...

  • Page 13: Supernova

    SuperNOVA Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGE Your pump station includes a pressure gauge. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTER Your pump station includes a pressure transmitter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FLOW METER Your pump station may include a flow meter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Can’t find the component manual you need? Contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us for assistance. • • •...
  • Page 14 NEBULA Series *Your station may differ slightly from this image. If you need assistance locating a component not shown, contact our Service Support Team at (208) 287-9361 Advanced or via email at service@gopps.us. ” Keyboard for easy control and operation Variable Frequency Drive (VFD) Controls the speed of the motor to maintain constant output pressure and varying flows Service Rated External Disconnect Single point of connection for incoming power Motor Pressure Gauge...

  • Page 15: Nebula

    NEBULA Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGE Your pump station includes a pressure gauge. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTER Your pump station includes a pressure transmitter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FLOW METER Your pump station may include a flow meter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Can’t find the component manual you need? Contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us for assistance. • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716...
  • Page 16 NEUTRON Series Control Box Pressure Gauge Flow Switch Protects the pump from running dry and helps the pump go into idle mode Pressure Transmitter Sends pressure reading to the VFD Pump and Motor *Your station may differ slightly from this image. If you need assistance locating a component not shown, contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us. ” •...

  • Page 17: Neutron

    NEUTRON Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGE Your pump station includes a pressure gauge. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTER Your pump station includes a pressure transmitter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FLOW METER Your pump station may include a flow meter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Can’t find the component manual you need? Contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us for assistance. • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716...

  • Page 18: Nova

    NOVA Series Low Ambient Temperature/ Thermosetting Epoxy Insulation and Heating Powder Coating (optional) provides corrosion protection (custom colors available) Lockable Clam-Shell Lid provides complete access to all Cooling Fan system components Automatic pump Flow meter by-pass (optional) (optional) Free of welding seams or cracks Suction &...
  • Page 19 NOVA Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGE Your pump station includes a pressure gauge. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTER Your pump station includes a pressure transmitter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FLOW METER Your pump station may include a flow meter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Can’t find the component manual you need? Contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us for assistance. • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716...

  • Page 20: Orion

    ORION Series Optional Filter Pressure Relief Valve Pressure Transmitter - High PSI Switch Flow Meter Jockey Pump Duty Pumps *Your station may differ slightly from this image. If you need assistance locating a component not shown, contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us. ” • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716 208.323.5300...
  • Page 21 ORION Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTER Your pump station includes a pressure transmitter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FILTER Your pump station includes a filter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FLOW METER Your pump station may include a flow meter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Can’t find the component manual you need? Contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us for assistance. • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716 208.323.5300...

  • Page 22: Phoenix

    PHOENIX Series *Your station may differ slightly from this image. If you need assistance locating a component not shown, contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us. ” Control Box Pressure Gauge Pressure Transmitter Sends pressure reading to the VFD Pump and Motor Industrial Grade Valves PHOENIX • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716 208.323.5300...
  • Page 23 PHOENIX Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGE Your pump station includes a pressure gauge. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTER Your pump station includes a pressure transmitter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Can’t find the component manual you need? Contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us for assistance. • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716 208.323.5300...

  • Page 24: Vega

    VEGA Series Thermosetting Epoxy Powder Coating UL rated control provides corrosion protection cabinet for VFD (custom colors available) Pressure Transmitter Pressure Gauge Pressure tank Check Valve Inlet Pressure Transmitter Flow Meter and Gauge *Your station may differ slightly from this image. If you need assistance locating a component not shown, contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us. ” •...
  • Page 25 VEGA Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGE Your pump station includes a pressure gauge. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTER Your pump station includes a pressure transmitter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FLOW METER Your pump station may include a flow meter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Can’t find the component manual you need? Contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us for assistance. • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716...
  • Page 26 NEPTUNE Series 3.10 COMING SOON • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716 208.323.5300...
  • Page 27 NEPTUNE Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGE Your pump station includes a pressure gauge. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTER Your pump station includes a pressure transmitter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FLOW METER Your pump station may include a flow meter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Can’t find the component manual you need? Contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us for assistance. • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716...
  • Page 28 VIRGO Series 3.11 COMING SOON • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716 208.323.5300...
  • Page 29 VIRGO Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGE Your pump station includes a pressure gauge. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTER Your pump station includes a pressure transmitter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FLOW METER Your pump station may include a flow meter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Can’t find the component manual you need? Contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us for assistance. • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716...
  • Page 30 HDPE Drop Pipe Installation Guide FIGURE 1 FIGURE 2 FIGURE 3 STEP #1: Connect elbow (shipped loose) to pipe coming from pump staton. Place gasket all the way onto the pipe from the pump station, then butt the elbow up against the pump station pipe (figure 1). Slide gasket so that it is covering both ends of the pipe and elbow (figure 2). Then place clamp into the grooved area on the pipe and the elbow, tighten bolts (figure 3). FIGURE 4 FIGURE 5 FIGURE 6 STEP #2: Connect HDPE drop pipe to grooved elbow from step one with groove x HDPE clamp (figure 4). Remove bolts from groove x HDPE clamp as shown (figure 5). Install gasket all the way over the HDPE drop pipe as shown (figure 6). Install grooved x HDPE clamp over HDPE drop pipe and grooved elbow (figure 7). Completed assembly will be as shown (figure 8). NOTE* HDPE drop pipe can be cut to length for desired pipe depth.

  • Page 31: Custom Pump Station Components

    CUSTOM PUMP STATION COMPONENTS Canned Turbine Station *Your station may differ slightly from this image. If you need assistance locating a component not shown, contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us. ” UL Listed Touch Variable Speed Screen Control System Storage User Tanks Interface Multi-stage Canned Vertical Turbine Pumps Air Relief Pressure Gauges High Pressure Relief Valve Automatic Actuated Butterfly Valve Powder Coated...
  • Page 32 Canned Turbine Station Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGE Your pump station includes a pressure gauge. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Can’t find the component manual you need? Contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us for assistance. • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716 208.323.5300...

  • Page 33: End Suction Centrifugal Booster

    End Suction Centrifugal Booster Control Panel Vents UL Listed Variable Speed Control System Pressure Gauges Touch Screen User Interface High Pressure Switches Main Disconnect Switch Pressure Transducers Butterfly VMS Pony Pump Valves Air Relief Check Valves *Your station may differ slightly from this image. If you need assistance locating a component not shown, contact our Service End Suction Centrifugal Support Team at (208) 287-9361 Booster Pumps or via email at service@gopps.us.
  • Page 34 End Suction Centrifugal Booster Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGE Your pump station includes a pressure gauge. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTER Your pump station includes a pressure transmitter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FLOW METER & FLOW Your pump station may include a flow meter and flow switch. Locate the brand and model number in your pump station and locate the correct SWITCH manual by following this QR Code or clicking HERE.

  • Page 35: Submersible Pump Station

    Submersible Pump Station Filter Flush Sun Shade High Flow Automatic Self Cleaning Filtration UL Listed Variable Speed Control System Utility Heater Air Conditioning Harmonics High Pressure Relief Valve High Pressure Switches Air Relief Jockey Pumps High Flow Submersible Duty Pumps Wet Well Access Hatch Powder Coated...
  • Page 36 Submersible Pump Station Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. HARMONIC FILTERS Your pump station includes harmonic filters. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FILTERS Your pump station includes a filter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. CONDITIONERS Your pump station may include an air conditioner. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FLOW METERS & FLOW Your pump station may include flow meters and flow switches. Locate the brand and model number in your pump station and locate the SWITCHES correct manual by following this QR Code or clicking HERE.

  • Page 37: Vertical Multi-Stage Booster

    Vertical Multi-Stage Booster Vertical Multi-Stage Booster Pumps UL Listed Variable Speed Control System Air Relief Pressure Gauges Galvanized Piping High Pressure Switch Pressure Transducers Butterfly Valves Powder Check Valves Coated Station Skid *Your station may differ slightly from this image. If you need assistance locating a component not shown, contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us. ” • •...
  • Page 38 Vertical Multi-Stage Booster Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGE Your pump station includes a pressure gauge. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTERS & SENSORS Your pump station includes pressure transmitters and sensors. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Can’t find the component manual you need? Contact our Service Support Team at (208) 287-9361 or via email at service@gopps.us for assistance. • • • Precision Pumping Systems GoPPS.com 6515 Business Way, Boise, ID 83716 208.323.5300...

  • Page 39: Vertical Turbine-Submersible

    Vertical Turbine Submersible Touch Screen User Interface Main Disconnect Switch Self Cleaning Filter Submersible Turbine Pump Flow Meter High Pressure Switches Pressure Transducers Butterfly Valves UL Listed Variable Speed Check Valves Control System Pressure Powder Coated Station Skid Gauges (Steel or Stainless) Jockey Pump *Your station may differ slightly from this image. If you need assistance locating a...
  • Page 40 Vertical Turbine Submersible Component Manuals PLC & HMI Your pump station includes a physical or digital PLC and HMI. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. Your pump station includes a variable frequency drive. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PUMP Your pump station includes an end-suction centrifugal pump. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. MOTOR Your pump station includes a motor. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FILTERS Your pump station includes a filter. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE GAUGES Your pump station includes pressure gauges. Locate the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. PRESSURE TRANSMITTERS Your pump station includes pressure transmitters and sensors. Locate & SENSORS the brand and model number in your pump station and locate the correct manual by following this QR Code or clicking HERE. FLOW METERS &...

  • Page 41: Theory Of Operation

    THEORY OF OPERATION 6.2 Theory of Operation — MULTI PUMP 6.1 Theory of Operation — SINGLE PUMP The system is designed to maintain the discharge Pressure The system is designed to maintain the discharge Pressure Setpoint. Setpoint. A pump is turned on when the system pressure drops to the W ake- A pump is turned on when the system pressure drops to the Wake- Up Setpoint (Wake PSI), a specific amount of pressure below the Up Setpoint (Wake PSI), a specific amount of pressure below the pressure setpoint. pressure setpoint. A variable frequency drive (VFD) will operate the pump so that the A variable frequency drive (VFD) will operate the pump so that the pressure setpoint is constantly maintained—slowing it down and pressure setpoint is constantly maintained—slowing it down and speeding it up as needed to meet fluctuating demands. speeding it up as needed to meet fluctuating demands. The pump will stop (enter sleep mode) when the system pressure The pump will stop (enter sleep mode) when the system pressure setpoint is reached and demand stops. Demand is measured by setpoint is reached and demand stops. Demand is measured by using either the flow rate or the pump speed (indicated by VFD using either the flow rate or the pump speed (indicated by VFD frequency).

  • Page 42: Start-Up

    6.2.1b Lead-Lag Alternation These systems can also automatically send faults and warnings via To wear evenly, the duty pumps alternate between lead and lag email or text message. designations. The PLC counts down the total time (Alternation 6.3 Start-Up Delay Time) that a pump operates as the lead pump. Once the alternation delay time reaches zero, the system stops 1. Visually inspect the pump station for any apparent abnormali- all pumps. Then, it switches the lead pump designation to a ties such as loose wires, loose fittings, and for any damage. different pump; the former lead pump becomes a lag pump. NOTE: Notify Precision Pumping Systems immediately if KEY TERMS anything abnormal is found. System Pressure Setpoint: The system pressure that the 2. Turn the HOA (“Hand”, “Off”, “Auto”) switches on front of the station is set to maintain. panel to the “OFF” position. Jockey (Pony) Pump: Designed for pressure maintenance and low demands, it is the first pump to operate when pressure drops below the setpoint. Lead Pump: The lead pump turns on if demand exceeds the capacity of the jockey pump. It varies its speed to meet fluctuating demand. If it can’t meet demand, then the lag...

  • Page 43: Basic Operation

    • Monitor the pump station operations to ensure the pump NOTE: If any FAULTS appear on the screen, turn the HOA switches station is operating correctly. back to the OFF position and contact Precision Pumping Systems • If the pump station gets to the Pressure Setpoint, then the immediately. pump station is operating correctly. BASIC OPERATIONS 7.1 OVERVIEW: Manual vs. Automatic Modes 7.3 Start a Pump in Auto Mode MANUAL MODE AUTOMATIC MODE CAUTION! If the pumping system has been shut-down for a...
  • Page 44 CONTROL AND MONITORING GUIDE Overview The controller interface is comprised of four main menus. Below are example screens: MAIN Controls • Water Level (Requires level Monitoring transmitter) • Emergency Stop • System Status (Normal, • Access to Pump System faulted, standby) • Pump Status Settings • Discharge Pressure • Motor Frequency & Amperage • Flow Rate (Requires flow meter) FAULT LOG TREND LOG View and Diagnose View System System Faults Operational Data: • Discharge Pressure • Flow • Pump Frequency • Level (Requires Level transmitter) MENU System Settings...
  • Page 45 CONTENTS 8.7 Controller Settings ..............36 8.0 Controlling & Monitoring Guide ............ 36 Enable/Disable Remote Mode ............ 36 Load/Save Controller Settings 8.1 Pressure Settings ..............30 ..................36 Set Password Adjust the Discharge Pressure Setpoint ......... 30 ............37 Set the System Data & Time Intake PID Mode ................30 ........37 Control Panel Temperature Settings Adjust Discharge Pressure Fault Settings ....... 30 8.8 Additional Automation Functions ....... 37 Adjust Intake Pressure Fault Settings ........30 ............. 37 Custom Controls Settings Calibrate a Pressure Transmitter ..........31 8.9 Control &...

  • Page 46: Pressure Settings

    8.1 Pressure Settings Adjust the Discharge Pressure Setpoint Adjust the Discharge Pressure Fault Setpoint Navigation: Navigation: MAIN PRESSURE MAIN PRESSURE About Pressure Fault Settings: To prevent damage to the system, the controller will shut-down the station if the pressure is too high, or too low.

  • Page 47: Calibrate A Pressure Transmitter

    Calibrate a Pressure Transmitter Calibrate the Flow Meter Navigation: Navigation: MAIN FLOW MAIN INTAKE OR DISCHARGE About Flow Meter PRESSURE Calibration: When replacing a flow meter or About Pressure Transmitter sensor, it’s necessary for Calibration: When replacing the controller to know the the pressure transmitter, it’s sensor’s max scale value.

  • Page 48: Level Settings

    8.3 Level Settings Level PID Mode Settings Navigation: Adjust Level Fault Settings MAIN LEVEL Navigation: LEVEL PID MODE MAIN LEVEL About Level PID Mode About Level Fault Settings NOTE: Requires Level NOTE: Requires Level Transmitter Transmitter With this mode enabled, the controller automatically reduces the To prevent damage to the PSI Setpoint (and therefore pump speed) to prevent the source pump caused by low water,...

  • Page 49: Pump Settings

    8.4 Pump Settings Lag Pump Settings Pump Sleep Settings Navigation: Navigation: MAIN PUMP 1 MAIN PUMP 1, 2, or PUMP 2 or PONY PUMP LAG SETTINGS SLEEP SETTINGS About Lag Settings About Pump Sleep Mode The controller starts and The main (Lead) pump and stops Lag pumps based on Pony (Jockey) pumps enter demand.

  • Page 50: Lead-Lag Alternation Mode

    View / Reset Total Pump Run Hours Pony Pump Start / Stop Settings Navigation: Navigation: MAIN PUMP 1, MAIN PONY PUMP 2, or PONY PUMP FLOW CUT-OUT MODE About Pony Pump Start/Stop Settings SETTING DEFINITION Also called a Jockey or Pressure Indicates total pump operation hours TOTAL HOURS, Maintenance Pump, the Pony pump is used for low demands.

  • Page 51: Vfd Bypass Mode

    VFD Bypass Mode Underload Settings Navigation: Navigation: MAIN PUMP 1 MAIN PUMP (or PUMP 2) UNDERLOAD SETTINGS VFD BYPASS MODE About Underload Settings DANGER: Improperly bypassing a VFD can cause The underload function is an serious equipment damage, severe injury or death. automatic pump protection Call Precision Pumping Systems for assistance: feature used for run-dry...

  • Page 52: Using The Trend Log

    8.5 Using the Trend Log 8.7 Controller Settings Enable/Disable Remote Mode Navigation: MAIN REMOTE SETTINGS About Remote Mode Remote mode enables the system to be started and stopped remotely via 24VAC relay signal from an irrigation controller. SETTING DEFINITION The Trend Log records and graphically displays system operational data, such as: REMOTE ENABLED: The pump will only start when it...

  • Page 53: Set The System Data & Time

    8.8 Additional Automation Functions Set the System Data & Time Navigation: Line Fill Mode MENU SET CLOCK Navigation: MENU LINE FILL MODE 1. Press in a white box to change values. About Line Fill Mode Format: When pumping into an empty or non-pressurized pipe network, MONTH/DAY/YEAR | MINUTE: SECOND it’s important to fill it slowly—otherwise, pumping at full speed 2. A keypad will appear—use it to input the new password: can cause pressure surges or water hammer, which can severely...
  • Page 54 TROUBLESHOOTING TROUBLESHOOTING SYSTEM FAULTS CAUTION WARNING AUTHORIZED VFD TECHNICIAN ONLY This station uses a variable frequency drive (VFD). HAZARDOUS VOLTAGE VFD servicing or troubleshooting to be performed Hazardous voltage inside this panel will cause by an authorized VFD Technician ONLY. an electrical shock or an arc flash explosion, which can cause SEVERE INJURY or DEATH.
  • Page 55 Defective sensor wiring Repair or replace sensor wiring. Defective pressure trasmitter Compare pressure transmitter data (via HMI) with the discharge pressure gauge. A significant difference between readings indicates either an incorrectly scaled, or failed pressure transmitter. The replacement pressure transmitter must have an appropriately scaled 4-20mA output signal. VFD Failure Determine if the motors are running correctly at full capacity. Contact VFD manufacturer, or PPS for support. 9.3 High Flow POSSIBLE CAUSE POSSIBLE SOLUTIONS Break/leak in the discharge network Inspect piping network for leaks/breaks. Repair leaks or breakage in the piping network. Incorrect fault settings Use the Trend Log to determine if the fault occurs while the system is operating at design flow & pressure. Inspect and correct the High Flow Fault setting. Defective sensor wiring Repair or replace sensor wiring.
  • Page 56 9.4 Low Flow POSSIBLE CAUSE POSSIBLE SOLUTIONS Incorrect sleep settings Increase the Sleep Flow setting and/or reduce the Sleep Delay time. Incorrect motor/pump rotation Inspect/correct direction of motor rotation. 1. View the motor rotation by quickly turning the motor On & Off. 2. Viewing from the motor end, the shaft must rotate clockwise. 3. Interchange any two motor output leads to reverse rotation. Incorrect fault settings Use the Trend Log to determine if the fault occurs while the system is operating at design flow & pressure. Inspect and correct the Low Flow Fault setting. Defective sensor wiring Repair or replace sensor wiring. Defective flow sensor/meter Replace with flow sensor/meter with appropriately scaled Pulse output signal. Incorrect sleep settings Decrease the Sleep Flow setting and/or increase the Sleep Delay time. 9.5 Low Level Fault POSSIBLE CAUSE POSSIBLE SOLUTIONS The pump station supply water is...
  • Page 57 9.7 Voltage Fault POSSIBLE CAUSE POSSIBLE SOLUTIONS Defective supply power Wait for the system to attempt an auto restart. If the system does not restart or shuts down again, call a certified electrician for further diagnosis. Inspect incoming power for missing or out of balance. Contact Power Company if incoming power is the issue. 9.8 Overload POSSIBLE CAUSE POSSIBLE SOLUTIONS Excessive demand exceeds Use the Trend Log to determine if the fault occurs while the system is operating at design flow & pressure. Make sure demand does not motor/pump capacity exceed the motor/pump design capacity. 9.9 Underload POSSIBLE CAUSE POSSIBLE SOLUTIONS Prime Loss (Pump is running dry) See Section 6.6 Prime Loss, above.
  • Page 58 MAINTENANCE & WINTERIZATION NOTE: This section is a summary of recommended maintenance tasks for the supplied equipment. Refer to equipment manufacturer manuals for detailed maintenance and safety instructions. DANGER: DANGER: Disconnect/lockout power before HAZARDOUS PRESSURE: Working on a pressurized system can cause an explosion attempting any maintenance.
  • Page 59 PART MAINTENANCE TASK MAINTENANCE INTERVAL VALVES Piping, Visually inspect system for leaks. Look at all couplings, flanges, and valves. 1 YEAR Valves & Fittings Inspect for leaks and repair as needed. Isolation 1 YEAR Valves See equipment manufacturer manual for detailed disassembly & repair instructions. Exercise valves. 1 YEAR 1. Shut down the pump. 2. Repeatedly close & open each valve. 3. To clean out sediment, open and close the valves while operating the pump in manual mode set to 20 Hz. CAUTION: Do not operate the pump with closed isolation valves for extended periods of time. Check Inspect for leaks and repair as needed. 1 YEAR Valves See equipment manufacturer manual for detailed repair instructions. Air Release Inspect for leaks and repair as needed. 2-3 MONTHS, or whenever Valves visually inspecting the system See equipment manufacturer manual for detailed repair instructions. Backflow 1 YEAR, or as required per Inspect for leaks and proper operation and repair as needed. Preventer local requirements and system See equipment manufacturer manual for detailed repair instructions.
  • Page 60 PART MAINTENANCE TASK MAINTENANCE INTERVAL MOTOR CONTROLS Control Inspect filters. Replace when dirty or if airflow is restricted. Replace filter at 2-3 MONTHS Panel least once per year. Filter Fans How to Replace a Filter: WARNING: Risk of injury from rotating fan blades. Remove all power to the fans before opening the fan grill. 1. Remove all power to the control panel. 2. Pull the filter grate outward from the place marked “PULL. ” 3. Inspect the filter. 4. Replace if needed. 5. Press grill back into place and restore power to the control panel. VFDs CAUTION: Authorized Personnel Only. Maintenance by certified technicians only. ANNUALLY DANGER: Disconnect/lockout power before attempting any maintenance. Failure to disconnect power can lead to severe injury or death. CAUTION: See manufacturer manual for detailed safety instructions. 1. Check quality of supply voltage. 2. Visually inspect spare parts. 3. DC circuit capacitor reforming, spare modules and spare capacitors. 4. Visually inspect tightness of terminals.
  • Page 61 START-UP & WINTERIZATION 11.1 System Start-Up Checklist Job Name: Technician: Date: Check Incoming Voltage and Record Test Amiad Filter Operation Inspect Incoming Power Connections Check AMP Draw - All Pumps Make / Inspect Motor Lead Connections Test All Butterfly Valves Check Overloads Connections and Settings Check VFD Parameters;...
  • Page 62 11.2 Winterization Checklist NOTES: Check Sumps for Sediment Accumulation — Notify Owner if Excessive Inspect and Clean Enclosures (Interior & Exterior) Inspect and Clean Component Filters Close Pump Station Isolation Valve and Relieve Pressure Remove Pressure Transducer, Blow Water Out and Leave Transducer in Electrical Panel Remove Pressure Switch, Blow Water Out and Leave Switch in Electrical Panel...

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