Bell & Gossett 70M User Manual

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70E

INSTRUCTION MANUAL

S12228B

70E/70M Multiple Pump & Control Pressure Booster Systems

INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.

DESCRIPTION

Microprocessor controlled frame mounted multiple pump pressure boosting system with combination pressure reducing and non-slam check valves for maintaining system pressure. The motors are controlled by a control panel with microprocessor, starters, overload protection, virtual H-O-A switches, optional short circuit protection, and control transformer.

The microprocessor control consists of an operator interface with 2 line backlit display and membrane key pad, input/ output board with 24V power supply, and microcontrolled kW transducer.

OPERATIONAL LIMITS

See unit nameplate for pump capacity, boost, full load current draw, and operating voltage. The pump discharge pressure must not exceed 125 PSI unless special piping modifications are made.

SAFETY INSTRUCTION

This safety alert symbol will be used in this manual and on the 70E/70M Safety Instruction decal to draw attention to safety related instructions. When used, the safety alert symbol means

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD!

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70E/70M Pressure Booster INSTRUCTIONS

UNIT IDENTIFICATION

The unit nameplate gives identification and rating information as identified in Figure 1.

Permanent records for this unit are kept by the factory number and it must therefore be

used with all correspondence and spare parts orders.

Model No. Factor no. Wired for Volts Hz Ph System FL Amps Largest Motor HP System Flow GPM Suction Pressure PSIG Discharge Pressure PSIG Pump TDH Feet Date Code

FIGURE 1 - 70E/70M NAMEPLATE

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Preface

The following manual describes the 70E/70M Pressure Boosters with emphasis on the new microprocessor based Technologic Controller. This unit is in the tradition of the other members of the Technologic Control Panels as it incorporates many original, novel, and proprietary features that may only be found on B&G controllers. Some of these features require special emphasis here.

The controller is best described as a specific purpose programmable pump controller. This means that the hardware and software have been created for the control and diagnostics of pumps with consideration for their inherent characteristics. This results in an optimum pump controller without the cost of general purpose control hardware. Software is dedicated and established for the unit only after extensive testing. Changes to this software are not taken lightly and must pass rigid version control.

The controller has the unique patented analog input protection of other members of the control family. Upon inadvertent higher than normal input voltage the analog input resistor is sacrificed. An on-board spare is used to replace the plug-in resistor. Extreme hi-voltage is protected against by additional components.

Unique to this new controller are virtual selector switches. Microprocessor control coupled with discrete logic allows the pump keys to act as 3 position selector switches. The 3 positions are hand-off-auto. Virtual selector switches surpass standard selector switches in that they can be changed from auto to hand automatically upon a fault in order to maintain a process. It is novel that just as a standard selector switch can change position (by human hand) with power off, so can the virtual selector switch similarly change position.

Combined with the virtual selector switches is redundant control with discrete logic which is activated upon a microprocessor fault. This is explained in detail in Section 5.4.

In addition to this unique hardware the controller has provision for three 4-20mA analog signals and two RTD temperature inputs. Bell & Gossett is able to offer suction, system, and temperature inputs as standard. The third 4-20mA is used for an optional flow transmitter.

Bell & Gossett is thereby able to offer staging of pumps by any one of 4 methods, i.e.: watts, amps, PSI and GPM (flow). The main changes occur in the menu entries.

Staging by watts is standard. A power transducer of Bell & Gossett design is included. This transducer is factory calibrated, single conductor sensing, wide current and voltage range, and automatic adaptability to Wye or Delta systems either grounded or ungrounded. At the customer’s discretion it may be used for amp staging with the watt feature used to display total system power.

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TABLE OF CONTENTS

SECTION 1 – GENERAL

Purpose of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Safety Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Additional Safety Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Temperature and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Field Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 2 – INSTALLATION

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Unit Support and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Wiring

Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Analog Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pressure Transmitter Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Temperature Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Flow Sensor/Transmitter Wiring and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Differential Pressure Switch Piping and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Remote Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Remote Alarm Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pump On/Off Remote Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 3 – START UP

Putting Unit into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 4 – SETUP AND FEATURES

Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Setup and System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Normal Operating Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 5 – OPERATION

Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Auto Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Manual Operation (CPU OK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Manual Operation (CPU Fails) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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SECTION 6 – MAINTENANCE

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Diagnostics (Service Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Read Only – Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Read Only – Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Manual Control – Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Pre-Determined Fault and Fault Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Instruments and Their Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Field Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Serial No. and Firmware Version No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Maintenance (Physical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

APPENDIX A

System Piping and Unit Installation – Final Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

APPENDIX B

Electrical Wiring and Control Settings – Final Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

APPENDIX C

Procedure for Field Balancing 70E/70M PRV’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

APPENDIX D

Troubleshooting Combination Pressure Reducing and Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . 24

PRV Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

APPENDIX E

Service Test Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

APPENDIX F

Power Transducer Board (PTB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

NOTE:

The information contained in this manual is intended to assist operating personnel by providing information on the characteristics of the purchased equipment.

It does not relieve the user of the responsibility to adhere to local codes and ordinances and the use of accepted practices in the installation, operation and maintenance of this equipment.

Further information pertaining to the installation, operation, and maintenance of your 70E/70M Pressure Boosting System can be found in the I.O.M.s for the associated equipment provided:

A. Bell & Gossett 1510 (IOM Part #P81673) B. Bell & Gossett 1531 (IOM Part #P81567) C. Pressure Reducing Valve – CLA-VAL Co. Manual #TM90-01 D. Flow Sensor/Transmitter Manufacturers IOM

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SECTION 1 – GENERAL

1.1 PURPOSE OF MANUAL

1.1.1 This manual is furnished to acquaint you with some

1.1.2 Equipment cannot operate well without proper care.

1.1.3

1.1.4 Your Technologic 70E/70M Series Pump Controller

1.2

1.2.1 Motor must have a properly sized starter with properly

1.2.2 Refer to the motor manufacturer’s I.O.M. for specific

1.2.3 Even when the motor is stopped, it should be consid-

1.2.4 Motor control equipment and electronic controls are

of the practical ways to install, operate, and maintain this unit. Read it carefully before doing any work on your unit and keep it handy for future reference.

To keep this unit at top efficiency, follow the recommended installation and servicing procedures outlined in this manual.

SAFETY INSTRUCTION

This safety alert symbol will be used in this manual and on the unit safety instruction to draw attention to safety related instructions. When used the safety alert symbol means

YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN A SAFETY HAZARD.

should have a safety instruction decal (Part #S11550). If the decal is missing or illegible contact your local B&G representative for a replacement.

ADDITIONAL SAFETY REQUIREMENTS

sized overload block to provide overload and undervoltage protection. Ground fault protection should be sized properly.

installation information.

ered “alive” as long as its controller is energized. Keep hands away from the output shaft until the motor has completely stopped and power is disconnected from the pump controller.

WARNING: Motor can start automatically. Keeps

hands away from output shaft until motor is completely stopped and input power is removed from the motor control panel. Lockout main power switch while working near the motor shaft.

instructions could result in serious personal injury, death, and/or property damage.

connected to hazardous line voltages. When servicing electronic controls, there will be exposed components at or above line potential. Extreme care should be taken to protect against shock. Stand on an insulating pad and make it a habit to use only one hand when checking components. Always use accurate test meters when checking electrical components. Always work with another person in case of an emergency. Disconnect power when performing maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever working on electronic control or rotating equipment.

ATTENTION BECOME ALERT!

Failure to follow these

DANGER: Troubleshooting live control panels ex-

poses personnel to hazardous voltages. Electrical troubleshooting must only be done by a qualified electrician. Failure to follow these instructions could result in

serious personal injury, death, and/or property damage.

1.3

1.4

1.4.1 Care should be taken to prevent damage due to

1.4.2 The units should be unloaded and handled by quali-

1.5

1.6

1.7

STORAGE

For long periods of storage, the unit should be covered to prevent corrosion and contamination from dirt. It should be STORED in a clean, dry location between -20 and +75˚C. The relative humidity should not exceed 85%. The unit should be checked periodically to ensure that no condensation has formed. After storage, again check that it is dry before applying power.

HANDLING

dropping or jolting when moving the unit. Inspect the unit thoroughly for damage upon receipt. Transportation damage should be brought to the carrier’s attention immediately. Ensure that sensing lines are free of crimps and kinks.

fied personnel. The unit is top heavy due to the position of the motors. Use the motor eyebolts to stabilize the unit while lifting to prevent overturning. Do not use the motor eyebolts to lift.

WARNING: Falling Objects Hazard. Eyebolts or lifting lugs, if provided, are for lifting only the compo-

nents to which they are attached.

instructions could result in serious personal injury, death, and/or property damage.

TEMPERATURE AND VENTILATION

All electrical equipment is susceptible to failure if operated in ambient temperatures outside of its rating. The OPERATING temperature range for this unit is 0 to 40˚C. The relative humidity should not exceed 95% non-condensing. The unit should not be operated outside these extremes.

WARNING: Prevent electrical shocks. Disconnect the power supply before beginning installation.

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

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: 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.

could result in serious personal injury, death, and/or property damage.

POWER WIRING

Power wire types and sizes must be selected based upon conformance with the National Electrical Code and all local codes and restrictions. In addition, only copper (Cu) wire rated for 75˚C (minimum) may be used for the power connections. Refer to the input current as listed on the nameplate on the enclosure door when sizing wire.

Failure to follow these instructions

Failure to follow these

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1.8 FIELD CONNECTION DIAGRAMS

1.8.1 Refer to the pump Installation, Operation, and Maintenance Manual for specific details unique to the pump.

1.8.2 Refer to the flow sensor/transmitter Installation, Operation, and Maintenance Manual for specific details unique to the flow sensor/transmitter.

SECTION 2 – INSTALLATION

1.8.3 The following field connection diagrams should be reviewed prior to unit installation and operation.

Drawing # Description

Job Specific Print(s) Wiring Diagram(s)

Job Specific Print Dimensional Drawings

2.0 LOCATION

2.1 Locate the pumping unit for ease of inspection, maintenance and service.

DANGER: Heavy load, may drop if not lifted properly. Do not lift the entire unit by the motor eyebolts.

Lift the unit with slings placed under the unit base rails.

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

2.2

INSTALLATION

This unit is built to give you years of service; install it properly and provide a suitable foundation. A base of concrete weighing 2

/2 times the weight of the unit is recommended. (Check the shipping ticket for the unit weight.) Tie the concrete pad in with the finished floor. Use foundation bolts and larger pipe sleeves to give room for final bolt location.

2.3

LEVELING

Place the unit on its concrete foundation, supporting it with steel wedges or shims totaling 1" in thickness. These wedges or shims should be put on both sides of each anchor-bolt to provide a means of leveling the base.

2.4

UNIT SUPPORT AND LOCATION

The Bell & Gossett Series 70E/70M Pressure Booster should be installed where there will be sufficient room for future inspection and service. If the unit is to be located near a noise sensitive area, consult a sound specialist. Special precautions should be taken to avoid sound and vibration transmission.

2.5

PIPING

2.5.1 Important. Do not install and operate Bell & Gossett 70E/70M Pressure Booster in a closed system unless the system is constructed with properly sized devices and control devices. Such devices include the use of properly sized and located pressure relief valves, compression tanks, pressure controls, temperature controls and flow controls as appropriate. If the system does not include these devices, consult the responsible engineer or architect before making pumps operational.

DANGER: The heating of water and other fluids

causes volumetric expansion. The associated forces may cause failure of system components and releases of high temperature fluids. This will by prevented by installing properly sized and located pressure relief valves and compression tanks.

Failure to follow these instructions could result in serious property damage and serious personal injury or death.

2.5.2 Make all necessay system piping connections. Be aware that connecting dissimilar metals to the headers can lead to corrosion damage due to galvanic corro-

sion. The rate of corrosion is dependant on various factors some of which are: the potential between the dissimilar metals, electrolyte conductivity, geometry and areas of the metals. Dielectric connections are recommended between dissimilar metals at the header connection. Be sure to eliminate any pipe strain on the unit. Support all pipes independently by use of pipe hangers near the unit. DO NOT ATTEMPT TO FORCE THE SUCTION OR DISCHARGE LINES INTO POSITION. Refer to assembly drawing for customer piping connections.

2.5.3 Eccentric increasers can be used in the suction lines when increasing the pipe size, with straight sides of increaser on top to eliminate air pockets.

2.5.4 As a rule, ordinary wire or band hangers are not adequate to maintain alignment. It is very important to provide a strong, rigid support for the suction line. A saddle hanger is recommended.

2.5.5 For critical installations, equipment for absorbing expansion and vibration should be installed in the inlet and outlet connections of the unit.

2.5.6 After hydrotesting, drain plugs are removed, to facilitate system drainage, placed in a cloth bag and secured to the unit. Drain plugs shall be reinstalled prior to filling the system with fluid. Inspect all unit piping connections. Joints may also become loose during transit due to vibration and shock. All joints are to be checked for tightness. Flanged joints should be checked for proper torque of all flange bolts prior to filling the system with fluid.

CAUTION: Failure to reinstall drain plugs, check all joints for tighteness and flange bolts for proper

torque could result in leaks and/or flooding. Failure to

follow these instructions could result in property damage and or moderate personal injury.

2.5.7 On an open system with a suction lift, use a foot valve of equal or greater area than the pump suction piping. Prevent clogging by using a strainer at the suction inlet next to the foot valve. The strainer should have an area three times that of the suction pipe. Provisions must be made to prime the pump suction piping on start up. Do not start the pump unless all suction piping is full of water.

2.5.8 A thermal relief valve (B&G Part #S51260) is installed on the discharge header to prevent potentially dangerous thermal buildup in the package. This valve acts as a safety device and it should never be removed or tampered with. It is factory set to open and discharge when the water temperature in the discharge header exceeds 125˚F. The

/8" NPT opening

of this valve must be piped to a floor drain.

2.6

LUBRICATION

Before starting, all pumps and motors should be checked for proper lubrication.

Page 8

DANGER: Electrical shock hazard. Inspect all elec-

trical connections prior to powering the unit. Wiring connections must be made by a qualified electrician in accordance with all applicable codes, ordinances, and good practices. Failure to follow these instructions

could result in serious personal injury, death, and/or property damage.

2.7 WIRING

2.7.1 POWER WIRING The 70E/70M Pump Control Panel can be set up to

operate across a broad range of voltages. It was factory set to operate on the voltage shown on the nameplate. Verify proper transformer primary wiring per the job-specific wiring diagram. Check power leads in accordance with wiring diagram enclosed in control cabinet. The voltage tolerance is +10%/-10%.

2.7.2

2.7.2.1

ANALOG SIGNAL WIRING

If installing the panel on an existing system, shielded cable (#22 AWG, Belden type 8762, Alpha #2411 or equal) should be installed for the DC control wiring. The shield must be terminated in the 70E/70M control panel. Do not connect the shield at the other end of the cable! Insulate the shield so that no electrical connection is made at the other end of the cable. A twisted pair of #22 AWG conductors (Belden 8442 or equal) can be used in place of shielded cable. The cable length must be limited to 3000 feet for #22 AWG wire.

PRESSURE TRANSMITTER WIRING (4-20 mA Analog Signals)

horizontal installation (see manufacturer’s IOM). See the Bell & Gossett drawing for installation instructions. The signal wiring should be terminated in the 70E/70M panel at the terminals below.

Optional Flow Sensor/Transmitter + - Shield

Terminals (J3) 9 8 10

2.7.3

2.7.3.1 DIFFERENTIAL PRESSURE SWITCH PIPING

2.7.3.2

DIGITAL SIGNAL WIRING

AND WIRING (Digital Signal) (Optional)

Differential pressure switches installed to sense the increase in pressure between the pump suction and discharge gauge taps are used to determine whether a pump is running. Each switch should be wired from the normally closed contact to the terminals below.

Pump # 1 2 3

Terminals (J4) 9, 8 10, 11 11, 12

LOW LEVEL CONTROL WIRING (Digital Signal) (Optional)

The low water level control option is utilized when drawing water from a tank. In this control circuit, two electrodes sense the water level inside of a water tank. When the water level drops below its minimum level, the pressure booster will shut down.

Pump On Pump Off

Ground Electrode Electrode

Terminals (J4) 66 67 68

Terminals (J3) + - Shield

Suction Pressure 3 2 4

System (discharge) Pressure 3 6 4

2.7.2.2 TEMPERATURE SENSOR WIRING

2.7.2.3

(Analog Resistance Input)

The 70E/70M uses resistance temperature detectors (RTDs) to sense the suction and discharge water temperatures. These devices change their resistance as the water temperature changes.

Temperature Sensor (RTD) Wiring Terminals (J3)

Low Temperature Sensor (suction) 13, 14

High Temperature Sensor (discharge) 16, 17

FLOW SENSOR/TRANSMITTER WIRING AND INSTALLATION (4-20 mA Analog Signal) (Optional)

The flow sensor should be installed at an angle no greater than 45 degrees from top dead center in a

SECTION 3 – START UP

3.0 PUTTING THE UNIT INTO SERVICE

3.1 PUMP ROTATION, 3 PHASE MOTORS ONLY

CAUTION: Seal Damage may occur. Do not run pumps dry. Fill and vent the pump volute prior to

operation. Failure to follow these instructions could re-

sult in property damage and/or moderate personal injury.

WARNING: Rotating shafts can catch loose cloth-

ing. Do not operate the pump without all guards in

place.

Failure to follow these instructions could result in

serious personal injury, death, and/or property damage.

2.7.3.3

2.7.3.4

2.7.3.5

3.2 If incorrect, turn the main disconnect off and inter-

3.3 Unit is now ready for operation (factory assembled

REMOTE START-STOP (Digital)

Install a non-powered dry contact digital input to terminals J4-1 and J4-2. With the LOCAL-REMOTEOFF switch in the REMOTE position this contact closure will provide the start signal.

REMOTE ALARM INDICATION (Digital Signal)

A digital output dry contact rated 2 Amps at 115V is supplied on terminals J5-7 and J5-8. This output closes to indicate that an alarm condition exists.

PUMP ON/OFF REMOTE SIGNAL (Digital Signal)

A digital output dry contact (one per pump) rated 2 Amps at 115V is provided for remote monitoring of pump On/Off status. This contact closes when a pump is running.

Pump On/Off Signal Pump #1 Pump #2 Pump #3

Terminals (J5) 9, 10 11, 12 13, 14

With the disconnect switch engaged to the “ON” position, momentarily the pump motor key on the key pad. See Paragraph

5.3 on page 16. Observe the pump shaft rotation.

change any two wire leads leaving the starter overload block and going to the motor.

DANGER: High Voltage 3 phase power can kill. Disconnect and lockout power prior to servicing

unit.

Failure to follow these instructions could result in

serious personal injury, death, and/or property damage.

tested units only).

start and stop each motor with

Page 9

SECTION 4 – SETUP AND FEATURES

4.1 GENERAL NOTES

4.1.1 The HELP key can be pressed at any time without

4.1.2 The key names are shown in CAPITAL LETTERS and

4.2 POWER-UP

4.2.1 Put LOCAL-REMOTE-OFF (LRO) switch in the

4.2.2 Turn main disconnect on.

disrupting system operation. The HELP key will give details on alarm conditions or if used in conjunction with any function key will give a detailed explanation of the function key application.

the operator interface responses are shown in bold

CAPITAL LETTERS.

WARNING: Electrical shock hazard. Inspect all elec-

trical connections prior to powering the unit. Wiring connections must be made by a qualified electrician in accordance with all applicable codes, ordinances, and good practices.

could result in serious personal injury, death, and/or property damage.

LOCAL position.

WARNING: Electrical shock hazard. Multiple power

sources. The off position of the LOCAL-REMOTEOFF switch does not disconnect all of the power sources in the technologic panel. All power sources must be disconnected prior to entering the control panel. Failure to

follow these instructions could result in serious personal injury, death, and/or property damage.

Failure to follow these instructions

4.2.3 The operator interface will display the ITT Bell &

4.2.4 The operator interface will perform a lamp test and

4.2.5 Press CLEAR to stop the test.

4.2.6 The START-STOP led will be red.

4.2.7 If the START-STOP led is not illuminated as des-

4.2.8 The Auto-Hand led should be green for auto opera-

4.2.9 Press the PUMP 1 ON/OFF key to obtain a flashing

4.3

4.3.1 Press the SETUP key. Enter the serial number of the

4.3.2 Confirm the system setup values per the following

Gossett corporation signature.

display test.

cribed above, press the START-STOP button once to obtain the red LED.

tion. If not green, press the AUTO-HAND key to obtain green led.

green light. On two pump systems, press the PUMP 2 ON/OFF key to obtain a flashing green LED and press PUMP 3 ON/OFF key, for 3 pump systems, to obtain a flashing green LED. Refer to Section 5 for operation.

SETUP & SYSTEM CONFIGURATION

assembly by pressing the appropriate numeric keys. Press the ENTER key. The serial number may always be found by reading the 4th message after power up and the word “booting” disappears.

table. Use the UP or DOWN ARROW keys to move through the menu. To change values, press ENTER, modify the value using the numeric key pad or UP and DOWN ARROW keys, press ENTER to accept the modification.

Default Allowable Field

Line # DISPLAY ➀ Value Range Values

1 Number of Pumps 1

Number of Pumps on the System (1-2-3)

2 Alternation Sequence None

Use up/down keys to select: None, Duplex, Triplex - all, None As Listed Triplex - 132A

3 Auto Alt. Period 0

O = Manual only, for Auto Enter 0 0 - 6553 Alternation period in hours

4 Reset Pump 1 Time No

Yes = arrow key to reset

5 Reset Pump 2 Time No

Yes = arrow key to reset

6 Reset Pump 3 Time No

Yes = arrow key to reset

7 Staging Type Watts

Use up/down keys to select the primary method of Watts As Listed pump staging: Watts, AMPs, PSI, GPM, TEMP

8 Pump #1 HP 0

Enter Motor #1 nameplate horsepower

9 Pump #2 HP 0

Enter Motor #2 nameplate horsepower

10 Pump #3 HP 0

Enter Motor #3 nameplate horsepower

11 Pump 1 AMPs 0

Enter Motor #1 nameplate FLA

1 1 - 3

No Y/N

0 0 - 99.9

0 0 - 175

Page 10

Default Allowable Field

Line # DISPLAY ➀ Value Range Values

12 Pump 2 AMPs 0

Enter Motor #2 nameplate FLA

13 Pump 3 AMPs 0

Enter Motor #3 nameplate FLA

14 Pump #1 GPM 0

Enter Staging GPM of Pump #1

15 Pump #2 GPM 0

Enter Staging GPM of Pump #2

16 Pump #3 GPM 0

Enter Staging GPM of Pump #3

0 0 - 175

0 0 - 30,000

17 1 - 2 Stage % 80

Enter percent of NPHP, NPFLA, or GPM to stage 2nd pump in sequence

80 0 - 100

18 2 - 3 Stage % 80

Enter percent of NPHP, NPFLA or GPM to stage 3rd pump in sequence

80 0 - 100

19 Destage % 90

Enter percent of stage percent for destaging with HP, AMPs, or GPM only

90 0 - 99

20 Staging PSI 0

Enter pressure to stage in PSI mode after entering system 0 0 - System Span pressure span (see Line 38)

21 Destaging PSI

Enter pressure to destage in PSI mode after entering system 0 0 - System Span pressure span (see Line 38)

22 Forced Destg Tmr. 60

Enter in minutes (0 - 99) value of a timer after which the 60 0 - 99 pump will be forced to de-stage; ‘0’ disables this function

23 GPM Xmiter Span

Enter value equal to GPM transmitter calibration

24 2nd Stage Proof 2

2nd pump stage proof time in seconds

25 3rd Stage Proof 2

3rd pump stage proof time in seconds

26 Display Watts YES

Use up/down keys to enter yes or no

0 0 - 30,000

5 1 - 180

Yes Y/N

27 Three phase Watts YES

Use up/down keys to enter yes or no, YES = three phase, Yes Y/N NO = single phase

28 Display AMPs YES

Use up/down keys to enter yes or no

29 Display GPM No

Use up/down keys to enter yes or no

30 Suction Press. Span 100

Enter value equal to suction pressure span

Yes Y/N

No Y/N

100 0 - 999

31 High Suct. Press. 0

Enter value of the high suction pressure above which an 0 0 - 100 alarm will be set

32 High Suct. Pr. TMR. 0

Enter in seconds (0 - 999) value of high suction cutout 0 0 - 999 proof timer, ‘0’ disables this function

33 High Suct. Reset 0

Enter value of the high suction reset pressure

0 0 - 100

34 Low Suct. Press. 5

Enter value of the low suction pressure below which an 5 0 - 100 alarm will be set

35 Low Suct. Pr. TMR. 20

Enter in seconds (0 - 999) value of low suction proof timer; 20 0 - 999 ‘0’ disables this function

36 Low Suct. Reset 10

Enter value of the low suction reset pressure

10 0 - 100

Page 11

37 Low Suct. Auto RST Yes

To change the Low Suction reset, use UP/DOWN key Yes Y/N to enter yes or no

38 System Press. Span 300

Enter value equal to system pressure span

300 0 - 999

39 High Sys. Press. 125

Enter value of the high system pressure above 125 0 - SPAN which an alarm will be set

40 High Sys. PR. TMR. 20

Enter in seconds (0 - 60) value of proof timer, 20 0 - 60 ‘0’ disables this function

41 Audible Alarm 0

Enter 1 for low suction only, 2 for high system only, 3 for 0 0 - 3 low suction and high system, 0 to disable audible alarm

42 Low Sys. Press. 0

Enter value of low system pressure below 0 0 - Span which an alarm will be set

43 Low Sys. Pr. Tmr. 0

Enter in seconds (0 - 60) value of proof timer, 0 0 - 60 ‘0’ disables this function

44 High Temp Cut Out 125

Enter value of the high temp cut-out in deg. F above 125 0 - 200 which an alarm will be set

45 High Temp PR. TMR. 20

Enter in seconds (0 - 60) value of proof timer, 20 0 - 60 ‘0’ disables this function

46 High Temp. Reset 100

Enter value of the high temp. Reset in deg. F

100 0 - 199

47 FS NFSD PR TMR

Enter in seconds (5 - 60) value of the 0 5-60 no flow condition proof timer, ‘0’ disables the function

48 NFSD Temp. Cut Out 0

Enter NFSD temp differential, ‘0’ disables this function

5 0-10

49 NFSD Min. Run TMR. 10

Time period (minutes) to ignore no flow sequence 10 0 - 999 after restart from no flow shut down

50 NFSD Restart PSI 0

Enter value of system pressure to restart

0 0 - SPAN

51 NFSD Test Pr. TMR. 0

Enter in seconds (0 - 999), value of the no flow condition 0 0 - 999 proof timer ‘0’ disables this function

52 DP 1 Start Time 30

Time period in seconds to allow pump 1 to start prior 30 15-60 to detecting pump failure

53 DP2 Start Time 30

Time period in seconds to allow pump 2 to start prior 30 15-60 to detecting pump failure

54 DP3 Start Time 30

Time period in seconds to allow pump 3 to start prior to 30 15-60 detecting pump failure

55 DP 1 Proof Time 3

Pump #1 failure proof time in seconds

56 DP 2 Proof Time 3

Pump #2 failure proof time in seconds

57 DP 3 Proof Time 3

Pump #3 failure proof time in seconds

58 Minimum Run Timer 5

Minimum time a pump will run after auto start in minutes

3 0-30

5 0-25

59 Backup Staging WATTS, AMPS,

Select method of backup staging in the event WATTS PSI, GPM, the primary method fails TEMP

Page 12

60 TEMP Xmitr Span

Enter value equal to remote temperate transmitter span. Note this input is used for temperature staging requiring

0 999

a 4-20mA temperature transmitter.

61 Stage TEMP Rise

Select yes to stage pumps on temperature rise Yes Y/N based on setpoint.

62 Temp Staging H

Enter the high temperature for staging/destaging.

63 Temp Staging L

Enter the low temperature for staging/destaging.

75 999

50 999

64 Standby

When yes is selected disables the staging of the N Y/N last pump in sequence.

65 DI SUC ALARM

0 = Low Level 0 0-1 1 = Low Pressure

66 DI SA PT (DI ALARM TMR)

Enter in seconds proof timer for alarm. 1 0-99 “0” disables this function.

67 Default All ? N

Set all parameters to factory default

N Y/N

4.3.3 Press the CLEAR key. You will return to the standard operating display.

NOTES:

The top line of each display is stationary while the changeable value, if any, is flashing. The bottom line scrolls from right to left continuously. To scroll from

➀

display to display continuously press either arrows. At any display the data may be changed by pressing enter, pressing the key or keys to change data, and pressing ENTER again. If a value to be entered is out of range the following is displayed:

Top Line - value out of range Bottom Line - X1 < = Value < = X2 With X1 being the minimum value and X2 the maximum value of the range

Note: For software version 3.28 or greater.

➁

4.4 KEY FUNCTIONS

HELP MESSAGES. PRESS HELP AFTER

CLEARING ANY ALARMS

LINE KEY MESSAGE

➀ 1 Start/Stop Used to start and stop pumps. ➁ 2 Auto/Hand Used to select auto or manual operation.

3 Pump 1 Used to start/stop pump 1; green = run, flashing green = enable,

Enable flashing red = failure.

4 Pump 2 Used to start/stop Pump 2; green = run, flashing green = enable,

Enable flashing red = failure.

5 Pump 3 Used to start/stop Pump 3; green = run, flashing green = enable,

Enable flashing red = failure.

➂ 6 Alternation Used to alternate pump sequence.

7 Service Test Used to perform service test. 8 Reset/Silence Used to reset alarm after its correction and to silence audible alarm.

9 Used for selection in a menu. 10 Set Up Used to define system parameters - security. 11 Clear Clears latest entry (operation and data). 12 Help User assistance; press: Help + Key/Item. 13 Enter Used to accept data and operation input.

In every case above the message scrolls right to left twice and blanks out. Press CLEAR twice to exit.

NOTE: Keys from Line 2 through Line 12 (except clear) also have numbers for numerical entry within a menu.

NOTES:

➀ ➁ ➂

➔

One pump must be enabled to obtain start function. Has green - run and red - stop LED.

To change selection the START-STOP key must be in stop. Green LED-AUTO, red LED-HAND.

The alternation sequence will be according to the user menu selection and will be displayed according to the message of 4.5 below

to match that selection.

Page 13

4.5 NORMAL OPERATING MESSAGES

4.5.1

NORMAL SCROLL AUTO OR HAND

LOCAL OR REMOTE ➀➁

MESSAGE CONDITION

Alternation

Elapsed Time P1 Hours XXX Elapsed Time P2 Hours XXX If 2 pumps selected Elapsed Time P3 Hours XXX If 3 pumps selected High suction cutout No flow shut down Suction Pressure PSI XX If span is entered System Pressure PSI XX If span is entered Suction Temperature XX F˚ If high temperature cut-out is entered System Temperature XX F˚ If high temperature cut-out is entered Total AMPS XXX If selected in menu Total KW XXXX If selected in menu Flow = XXXXX ➃GPM If span entered * Alarm (flashing) When an alarm occurs Startup — Standby Bottom Line Only Alternation Engaged Standby Bottom Line Only Pump Not Available Bottom Line Only Please Enable a Pump Bottom Line Only Not Allowed Bottom Line Only User Setup Lost Top Line Call Factory For Assistance Bottom Line Only

NOTES:

Press ENTER and ARROW keys for scroll lock.

➀

Display is blank if CPU fails.

➁

Not scrolled in hand operation.

➂

XXXX reverts to ??? if span is entered and signal is less than 4mA.

➃

* See 4.5.2 for alarm messages.

➂

“None” According to menu entry for simplex,

or duplex or triplex.

“1-2, 2-1”

or “1-2-3 2-3-1”

3-1-2

or “1-2-3 1-3-2”

Bottom Line Only Bottom Line Only

Page 14

4.5.2 ALARMS

ALARMS

CONDITION HELP MESSAGE

Overload X Failure Check AMP draw, use manual reset if OK High Suction PSI High suction pressure – check suction

Low Suction PSI Low suction detected – check suction

High System PSI High pressure detected in the system –

Low System PSI Low pressure detected in the system –

Water Level Low Check water level in holding tank Water Temp High Check water temperature Pump X Off Need pump in system – if OK enable pump Suction Trans Fail Check wiring, piping, polarity, and continuity System Trans Fail Check wiring, piping, polarity, and continuity Flow Trans Fail Check wiring, piping, polarity, and continuity Suction RTD1 Fail Check wiring, continuity System RTD2 Fail Check wiring, continuity Power Fail Check cable connections and plug insertions Pump X Failure Check DP switch, impeller, coupler, motor Remote Contact Open 7 Day Timer Off

NOTES:

Bottom line only. No help message.

➀

pressure and trip point

check trip point

check PRV and set point

Page 15

SECTION 5 – OPERATION

5.1 POWER UP

5.1.1 Initial – turn selector switch to local or remote with

5.1.2 Message Scroll

5.1.3 Set Up and System Configuration. User Menu.

5.2

5.2.1 Local

5.2.2 Auto/Hand

5.2.3 Enable/Pump/s

5.2.4 Start/Stop

5.2.5 Pump Start

5.2.6 Alternation

5.2.7 Staging – According to the method of staging selected

power on.

A. “Booting” B. “Bell & Gossett”

“Pressure Booster”

C. “Technologic 70E”

“Pump Controller”

“Fluid Handling Division”

E. “FW Release VX.XX”

“Serial # XXXXX”

F. Normal Scroll per 4.5 commences

A. Press the SETUP key. Enter the serial number fol-

lowed by the ENTER key.

B. Press the UP or DOWN arrow key to step through

user menu of paragraph 4.3.2. To change any value press ENTER, modify the default value using the numeric key pad, and then press ENTER to load. Press CLEAR to exit menu.

AUTO OPERATION

(turn selector switch to local or remote).

– select Auto.

by pressing 1, 2, or 3 PUMP ENABLE keys according to number of pumps in menu. Green LED’s flash.

– Press START/STOP key momentarily. Green LED is on. Note: Only if selector switch is turned to local or remote and at least 1 pump is enabled. Message: Top Line – see below. Bottom Line – “start up standby”.

– The first pump in the alternation sequence starts and LED turns to solid green. Only 1 pump is on.

– If the alternation key is pressed the next pump in sequence starts and both pumps then run for 5 seconds at which time the first pump stops. During alternation: Top Line – normal scroll. Bottom Line – “Alt. Engaged standby”.

If Alternation Timer picks up the action is the same as above provided an entry other than 0 is made in the user menu.

in the user menu, i.e., HP, AMPs, PSI, GPM the 2nd pump in the alternation sequence will turn on when:

1. HP matches % stage value or 2. AMP value matches % stage value or 3. GPM value matches % stage value or 4. Pressure matches PSI stage value

The third pump in the alternation sequence turns on similarly.

Staging will not occur if:

1. No flow condition is on.

2. High suction is on.

3. Low suction is on.

4. High temperature is on.

5. High system in on.

6. Timed de-stage is on.

7. Starter feedback is not on.

The 3rd pump stages in the same manner as the second pump according to the menu entry for that pump.

5.2.8 Destaging

1. HP last pump staged, plus the cumulative value of all other running pumps, reaches the destage percent value entered in the user menu, and a proof timer and the minimum run timer time out.

2. GPM in the menu. The pump stops after a proof timer and then a minimum run timer.

3. PSI is reached. The destage PSI is higher than stage PSI and a proof timer and the minimum run timer time out.

All of these methods of destaging are exclusive and may not be mixed.

5.2.9 Pump Shut Down

5.2.9.1 High Suction Pressure “High Suction Pressure” of the menu is reached and the “High Suction Pressure Timer” of the menu expires. All pumps stop. Alarm message is set. Pumps start when “High Suction Reset” is reached.

5.2.9.2 Low Suction Suction Pressure” in the menu and “Low Suction Pressure Timer” in menu times out. All pumps stop. Alarm message is set. Audio visual alarm is set. Pumps restart when “Low Suction Reset” setting in the menu is reached. Auto reset.

5.2.9.3 High System Pressure “High System Pressure” of the menu is reached and “High System Pressure Timer” of menu setting expires. All pumps stop. Alarm message is set. A-V alarm turns on. Manual reset to start pumps.

5.2.9.4 Low System Pressure “Low System Pressure” and after “Low System Pressure Timer” menu setting times out the alarm message is set. Does not stop pumps. Auto reset.

5.2.9.5 High Temperature analog reaches “High Temperature Cut Out” value of the menu. The “High Temperature Pressure Timer” times out. Alarm message set. Pump/s stop. Auto reset occurs when “High Temperature Reset” of the menu is reached. NOTE: A value must be entered for temperature display.

5.2.9.6 Low Level accessible proof timer of 5 seconds the pumps stop. Alarm message is set. When level returns to normal and another non-accessible proof timer of 5 seconds times out the pumps start. Auto reset.

occurs when:

or AMPs (selected method of stating) of the

decreased to the value of the destage GPM

setting of the destage PSI value in the menu

occurs when:

analog signal triggers when

analog signal reaches the level of “Low

analog signal triggers when

analog reaches menu setting

probes detect low level. After non-

Page 16

5.2.9.7 NFSD analog RTD inputs reach a temperature within “NFSD Cut Out” in the menu and after “NFSD Test Pressure Timer” the pump stops. Pump will start when “NFSD Restart Pressure” analog input reaches this point in the menu setting. Auto reset. NFSD cannot occur again until “NFSD Minimum Run Timer” setting in the menu elapses. NOTE: NFSD will only occur while one pump is running.

5.2.9.8 O.L.X. Failure

from digital inputs from starters 1M, 2M and 3M from pumps 1, 2 and 3, respectively trip and shut down the associated pump. The next pump in the sequence will start. “Alarm” message flashes. Manual reset. Upon manually resetting the tripped starter and pushing the reset key the previously tripped starter starts it pump and the pumps run together for 5 seconds and then return to normal operation.

5.2.9.9 Pump X Failure

from digital inputs from DP switches 1 through 3, respectively trip and shut down the associated pump 1, 2, or 3 respectively. The next pump in sequence then starts. Pump fail message set. Manual reset. Shut off pump now restarts with 2 seconds delay.

5.2.9.10 (B) Alarms

– are listed in Table 4.5.2. Most alarms are

discussed with the balance self-explanatory.

5.2.9.11 Normal Stop

– with power on press start/stop key. Enabled pumps have flashing green LEDs. All faults are in memory and do not reset. Status of the 3 pump keys is written to memory.

5.2.9.12 Stop – with power failure, alarms are reset but status of start-stop key and 3 pump keys is held in memory.

5.3 MANUAL OPERATION (Watchdog LED Off)

5.3.1 Choose local or remote operation.

5.3.2 AUTO/HAND Key

5.3.3 Enable Pumps

5.3.4 Start/Stop

5.3.5 Pump Start

– select HAND.

by pressing 1, 2 or 3 PUMP keys.

as 5.2.4 above.

as 5.2.5 above.

5.3.6 Alternation

5.3.7 Staging

5.3.8 De-staging

5.3.9 Pump Shut Down

– none.

– none. However, all alarms of Table 4 are active but do not shut the pumps down. Some items are not in normal scroll. See foot note of Table 3. Note that motors are still protected with O.L. relays as part of the respective starter.

5.4 MANUAL OPERATION

(CPU Fails, Watchdog LED On)

The 70E/70M has a redundant feature allowing critical operation even though the microprocessor and its support I.C.’s may have failed. Although this is a rare occurrence, B&G has planned for this possibility.

When the Watchdog LED is “on” a separate section of LOGIC is used to bypass the problem area. This LOGIC has its own memory which is held with power off by a small clock battery (B1). This memory must be pre-set for operation as desired upon CPU failure. To set this memory perform the following (assuming unit is running in auto):

1. Press STOP Key – Red stop LED is on.

2. Press AUTO/HAND Key – Red HAND LED is on.

3. Press PUMP ENABLE Keys in any order for pumps

to run upon a CPU failure. Associated green LED’s will flash.

4. Press AUTO/HAND Key – green AUTO LED is on.

5. ENABLE PUMPS as required and press

START/STOP key – green LED on.

The unit is now running in auto. If the CPU fails the system reverts to the manual operation that was preset in steps above. Pumps do not stop except for overload trip. Press the PUMP ENABLE key to stop a specific pump or press START/STOP key to stop all pumps.

Press PUMP ENABLE key to re-start a pump. Only the hand and pump LED’s are active. All other LED’s and the display are off.

Page 17

SECTION 6 – MAINTENANCE

6.0 Preface: The following is a description of the hard-

6.1 TECHNICAL OVERVIEW

6.2

6.3 DIGITAL OUTPUTS

6.4 ANALOG INPUTS

ware, diagnostics, and corrective action to maintain a process being controlled by the Technologic 70E/70M.

NOTE: The following should not be interpreted as the maximum configuration of this controller, rather this describes its application as a technologic 70E/70M only.

The Technologic 70E/70M is a micro-processor based dedicated pump controller unique to and exclusively manufactured by Bell & Gossett. All aspects of this unit are strictly proprietary to Bell & Gossett.

It consists of 3 electronic assemblies. The first assembly consists of 3 circuit boards, i.e., display, keyboard, and central processor unit (CPU) and is referred to as the operator interface panel (OIP).

This operator interface is connected (with ribbon cable) to a large board assembly known as the input/ output (I/O) board. This board contains a 24 volt DC power supply to power the unit, all I/O, and a limited number of sensors. It also has the terminals to connect to external devices. All hard wire interface to the outside world resides on this board and is protected from the external environment.

The third electronic assembly is the power board which connects to the OIP with a special cable. This board senses amps, voltage, and calculates the total power for staging and display on the OIP.

DIGITAL INPUTS

The controller has provision for digital inputs with a voltage operating range of 22 to 26.4 VDC. This signal voltage must be obtained from the on-board 24 VDC power supply. Eighteen terminals are provided with 6 of these terminals used to connect to the 24 VDC power supply.

It is not recommended that other power sources be used without factory approval.

The terminal will accommodate (2) No. 18 AWG wires.

The controller has provision for relay outputs to control 120V 50/60 HZ devices.

Sixteen terminals are provided. All terminals will accept up to (2) No. 14 AWG wires.

The relays are not removable. If defective the I/O board must be returned to the factory for repair.

All relays operate as single pole single throw. Components are provided to reduce contact arc and extend electrical life.

Analog inputs are provided on the I/O board for process variables and for flow readout. All analog inputs operate at 4-20mA. They may be powered from 24 VDC on board or self powered, in any mix, without isolators.

Each analog input has 4 terminals associated with it, i.e., 2 for signal input, 1 for 24 VDC, and 1 for shield chassis ground.

Each analog input terminal will accommodate (2) No. 18 AWG conductors.

6.5

6.5.1 The EPROM is the only removable chip. However, it

6.5.2 The EEPROM holds all data entered by the operator.

6.5.3 The RAM chip is not replaceable and requires no

6.6 CPU

6.7 POWER SUPPLY

6.8 DIAGNOSTICS (Service Test)

6.9 READ ONLY – Digital Inputs

6.9.1 To Enter – press CLEAR key twice and then press

6.9.2 Display – numbers 1 through 12 (implied) on the top

MEMORY

is not recommended that it be changed by other than the factory.

The EPROM is programmed by Bell & Gossett and its code is copyrighted. On power up the software version is displayed as FW RELEASE VX.XX on the top line and unit assembly serial No. on the bottom line.

It is not removable. Old data is erased with new. All data may be erased by the factory at which time all data reverts back to default values published elsewhere in this manual.

maintenance.

The CPU does not require any maintenance, and cannot be replaced as a field repair.

The power supply provides 24 VDC for all digital and analog signals. It is specifically rated only for the controller and other loads should not be applied without factory approval.

The power supply also supplies 5 VDC for all TTL devices.

The power supply is protected with Fuse F1 located near the 120 VAC line terminals.

The Technologic 70E/70M has built in I/O diagnostic capabilities activated with a SERVICE TEST key while in normal message scroll. It consists of 2 menus, i.e., read only and read/write. Read/write overrides the program and requires a security code.

NOTE: Service test cannot be used if any of the following occur:

1. Power is off.

2. Display and or the start/stop LED is off (red or

green).

3. Watch dog LED (CR6) on the I/O board on.

SERVICE TEST key once while in normal scroll.

line and status on the second line. Status is displayed as a “1” for signal on and “0” for signal off.

Page 18

6.9.3 Interpretation – compare the status shown to the following terminals and the wiring diagram. For example, starter 1M “on” signal at J4 4 and 8 is display No. 3 and should be a “1” if the 1M starter is energized.

Input J4 Input No.

Signal Terminals On Display

Local ** 1 to 2 1

Remote 3 to 2 2

1M 4 to 5 3 2M 6 to 5 4

3M 7 to 8 5 * DP1 9 to 8 6 * DP2 10 to 11 7 * DP3 12 to 11 8 * Low Level 18 to 17 12 * 7 Day Timer 19 to 20 13

* Optional ** This input is also used for remote start when the selector switch is in the REMOTE position. NOTE: Terminal No.’s on the right, e.g., 2, 5, 8, etc. are all in common.

6.9.4 Corrective Action – compare the inputs on to the device/s connected to the digital inputs and trigger same. If a “1” is not received check the associated wiring or the particular device and correct or replace the cause of the fault.

6.9.5 Controller Operation – the keyboard (except the CLEAR key) and all LED’s cannot change state. The display is dedicated to the digital input display. The program is otherwise active.

6.9.6 Exit – press CLEAR twice and then press ENTER twice.

6.10 READ ONLY ANALOG INPUTS

6.10.1 To enter (from normal scroll) – press CLEAR key twice and press SERVICE TEST key once. Then press CLEAR key once.

6.10.2 Display – ANALOG INPUT TEST on top line and input type and measurement on bottom line. Press key 1, 2, 3 or 4 to read channels 1, 2, 3 or 4 in % with 4mA @ 20% and 20mA at 100%. Six other items may be accessed with the up arrow key. These items are: RTD 1(˚F), RTD 2(˚F), Dc supply (DCV), and power board readings. “Power Board Readings” is now displayed on top line. These readings are: voltage in volts, current in amps, and power in watts.

6.10.3 Interruption – read channel values from connected devices with channel 1 as suction pressure, channel 2 as system pressure, channel 3 as flow input (optional) and channel 4 is unused at this time.

If there is a problem replace the analog source with a known source such as a 20mA signal generator. Connections to terminal block J3 are as follows:

Source 2 Wire

*Step Signal Input Terms Terms

1 Suction 1 1-, 2+ 2-, 3+ 2 System 2 5-, 6+ 6-, 3+ 3 Flow 3 7-, 8+ 8-, 9+

Polarity shown is that of the signal analyzer and not the markings on the I/O board.

4 not used 4 — — 5 RTD1 RTD in 1 — 13, 14 6 RTD2 RTD in 2 — 16, 17

A substitute 100 OHM resistor @ terms. 13 & 14, or 16 & 17 will result in a temperature reading of 32˚F.

7 DC Supply = 24.00 VDC ± 10% satisfactory. 8 Display top line changes to: Power Board

Readings.

8 Voltage = XXX VAC equal to system line

voltage.

9 Current = XXX amps equal to actual load.

10 Power = XXX watts actual power.

* Step = each momentary step of up arrow key.

WARNING: Prevent electrical shocks. Disconnect the power supply before beginning installation.

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

6.10.4 Corrective Action – correct the wiring or a faulty device. If a signal is good with a signal generator then the inter-connection wires are good and the sensor is bad. In the case of RTD’s a substitute 100 OHM resistor will isolate a problem to the sensor.

Power board readings may be confirmed by a separate clamp-on line current readings, line voltage reading, and calculations for watts.

DANGER: Troubleshooting live control panels ex-

poses personnel to hazardous voltages. Electrical troubleshooting must only be done by a qualified electrician.

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

6.10.5 Controller Operation – keyboard (except arrows, clear, 1, 2, 3, 4) and all LED’s cannot change state. The display is dedicated to the analog input display. The program is otherwise active.

6.10.6 Exit – press CLEAR once and then press ENTER twice.

6.11

MANUAL CONTROL – OUTPUTS

To enter this section a user code (serial no.) is required. Since the program is being overridden caution must be exercised.

IF NOT SURE CALL THE FACTORY. IF “USER CODE” IS DISPLAYED PRESS THE ENTER KEY TWICE TO RETURN TO NORMAL SCROLL.

DO NOT LEAVE UNIT IN SERVICE TEST.

6.12 DIGITAL OUTPUTS

6.12.1 To enter: A. Normal scroll on display B. Press CLEAR twice C. Press SERVICE TEST D. Press CLEAR twice E. Enter user code (serial no.) F. Press ENTER key

Page 19

6.12.2 Display = output #1 through 8 on top line and state, either 0 or 1, on bottom line. A “1” = output “on” (relay coil energized) and a “0” = off. Toggle output with a numerical key to match the output #.

6.12.3 Interpretation – this is an output forcing operation to allow checking of wiring and the connected device. Since some outputs are normally closed the following must be observed.

Relay

Contact

Output Relay with a Output

# Function # State of 1" Terminals

1 1M control K5 Closed J5 1-2 2 2M control K6 Closed J5 3-4 3 3M control K7 Closed J5 5-6 4 Alarm K8 Open J5 7-8 5 Pump 1 on K1 Closed J5 9-10 6 Pump 2 on K2 Closed J5 11-12 7 Pump 3 on K3 Closed J5 13-14 8 not used K4 Closed J5 15-16

Correlate output terminals to the wiring diagram for actual practice.

NOTE: It is important to view status on the display before any state is changed. This shows the actual output state of the program as it was presently running.

CAUTION: Do not trigger outputs unless the resultant action is known. Do not trigger all outputs on at

one time or trigger at random.

Failure to follow these instructions could result in property damage and/or personal injury.

6.12.4 Corrective Action – if a fault is suspected trigger the associated output to confirm that either connections to the connected device is the problem.

6.12.5 Controller Operation – all outputs are static and controlled by the numerical keys. The program is static. Confine operation to numerical keys. LEDs are static.

6.12.6 Exit – press CLEAR and ENTER. All forced outputs are cleared.

6.13 PRE-DETERMINED FAULT AND FAULT CONTROL

6.13.1 Pre-determined Fault – a software timer known as a watch dog times out upon a software or CPU failure and shuts down in a predicable manner. LED CR6 on the I/O board turns on and all outputs are turned off.

OIP board components are now used to determine the state of all relays according to LOGIC installed by the factory.

6.13.2 Fault Control – operates as follows:

A. Press START-STOP key for stop. B. Press AUTO-HAND key for HAND. C. Enable pump/s as desired. (Press PUMP keys) to

run upon control failure.

D. Press AUTO-HAND key for auto.

Press START-STOP key to start.

E. Upon a CPU or software fault the unit will revert to

pumps selected in C above.

If power is momentarily interrupted the unit will return to the same “hand” operation as before provided pump keys were not pressed while the power was off.

6.14 PROTECTION

6.14.1 Analog inputs – the analog inputs provided on the Technologic 70E/70M must be wired according to the wiring diagram that shipped with the unit.

6.14.2 Protection – all analog inputs are protected from high voltage, crossed wiring, etc. A 1 AMP fuse (F1) fast acting 3AG located just above relays K6, K7 and K8 protects all analog inputs up to 600V (in error only). A sustained fault may blow this fuse and burn out the input resistors. They are located just below terminals J3 and are numbered R3, R4, R1 and R2 for channels, 1, 2, 3 and 4 respectively.

6.14.3 Field Repair – resistors R1, R2, R3 and R4 plug in and are easily replaced.

WARNING: Electrical shock hazard. Multiple power

sources. The off position of the HAND-OFF-AUTO switch does not disconnect all of the power sources in the Technologic panel. All power sources must be disconnected prior to entering the control panel.

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

Unplug a bad resistor by pulling it from the socket and replace with a 124 OHM,

/4 watt, 1%, metal film (no substitute). Cut leads and bend to fit sockets. Resistors are also available from the factory.

NOTE: It is not always clear that a resistor is bad by observation. It may be brown or black. The best way to check is unplug the resistor and check with an ohm-meter. DO NOT check resistors on board. It may cause other problems and will not give a true reading.

6.14.4 Digital Inputs – as long as input power is derived from the integral 24VDC power supply they are protected.

6.14.5 Digital Outputs – each output shall not exceed 1 AMP @ 115 VAC (6 AMP inrush).

6.14.6 Power Supply – the power supply has inherent short circuit protection, thermal overload shutdown, transient protection, and line noise filtering. To reset the power supply cycle input power off and on.

6.14.7 Protection – fuse F1 located near terminal J4 (power in) protects the power supply. It is rated 1 AMP fast acting #3 AG.

6.14.8 Operator Interface – it is protected by the I/O board.

6.15

FAULT ISOLATION

Certain messages, common sense, observation, and diagnostics allow fault isolation of an on-board fault.

6.15.1 CONDITION: RAM Error on the display and auto/hand red LED on. Watch dog LED CR6 is on.

Corrective Action: Pumps will run in manual operation according to paragraph 5.4 above. Replace the operator interface.

6.15.2 CONDITION: Comm Error in the display and pump 1 red LED is on. Watch dog LED CR6 is on.

Corrective Action: Pumps will run in manual operation according to paragraph 5.4 above. Replace the operator interface.

Page 20

6.15.3 CONDITION: I/O Error on the display and pump 2 red LED is on. Watch dog LED CR6 is on.

Corrective Action: Pumps will run in manual operation according to paragraph 5.4 above. Replace the operator interface and the I/O board.

6.15.4 CONDITION: E2 Bad. System Halted. Call factory for assistance. Watch dog LED CR6 is on.

Corrective Action: Pumps will run in manual operation according to paragraph 5.4 above. Replace the operator interface.

6.15.5 CONDITION: No Program Found on the display and pump 3 red LED is on. Watch dog LED CR6 is on.

Corrective Action: Pumps will run in manual operation according to paragraph 5.4 above. Replace the operator interface.

6.15.6 CONDITION: E2 Defaults Set on the display. Watch dog LED CR6 is not on.

Corrective Action: Remove EPROM. Watch dog LED CR6 will turn on. Pumps will run in manual operation to paragraph 5.4 above. Replace the operator interface.

6.15.7 Display Blank

A. Watch dog LED CR6 is off.

Corrective Action: Confirm power to OIP with at least 1 LED on or measure 120 volt. A. C. at J6 L1 and N. If power present reboot and if display stays off, replace OIP.

DANGER: Troubleshooting live control panels ex-

poses personnel to hazardous voltages. Electrical troubleshooting must only be done by a qualified electrician. Failure to follow these instructions could result in

serious personal injury, death, and/or property damage.

B. Watch dog LED CR6 is on.

Corrective Action: None. No display. This condition except back light is on. Unit will run in manual per paragraph 5.4.

6.15.8 Key Board Inoperative

A. Watch dog LED CR6 is off.

Corrective Action: Be sure power is on by checking or observing display or at least one LED. Press RESET and HELP keys. If condition prevails replace OIP.

B. Watch dog LED CR6 is on.

Corrective Action: Only 4 keys are active: START/STOP, PUMP 1, PUMP 2, and PUMP 3. If these keys are inoperative replace the OIP. Unit will run in manual per paragraph 5.4.

6.15.9 LEDs Malfunction

A. Observe that all LEDs turn on during the booting

process. Watch dog LED CR6 is off.

Corrective Action: If any fail to operate replace the OIP.

B. Watch dog LED CR6 is on. Only the red HAND

LED and the 3 green LEDs with one for each pump key will turn on, or off. Unit will run in manual per paragraph 5.4.

Corrective Action: Replace OIP.

C. Watch dog LED CR6 is off but all LEDs or some

LEDs are off.

Corrective Action:

1. Check that the ribbon cable is plugged in.

2. Check for ribbon cable damage.

3. If all LEDs off check incoming power and fuse F1.

4. Reboot.

5. Replace OIP unit.

WARNING: Electrical shock hazard. Multiple power

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

6.15.10 Selector Switch Malfunctions

Press SERVICE TEST –

A. In local, input 1 should be “1” (J4). B. In remote, input 1 = 0 with remote contact open

and input 2 = “1” (J4).

Corrective Action: A and B are not present; correct wiring or replace the switch. See wiring diagram for correct wiring. A new switch may be obtained from the factory.

6.15.11 Suction Transducer Fault

A. Alarm per 4.5.2 indicates this fault. B. Confirm with analog input test of CHNL 1 per 6.10.3.

Corrective Action:

1. Disable transducer by entering user menu per

4.3 and changing suction pressure span (item

11) to “0”. Alarm message turns off. Low and high suction is disabled.

2. Replace this transducer.

6.15.12 System Transducer Fault

A. Alarm per 4.5.2 indicates this fault. B. Confirm with analog input test of CHNL 2 per 6.10.3.

Corrective Action:

1. Disable transducer by entering user menu per

4.3 and changing system pressure span (item

37) to “0”. Alarm message will turn off. Low and high system PSI and PSI staging is inoperative.

2. Replace this transducer.

Page 21

6.15.13 Flow Transducer Fault

A. Alarm per 4.5.2 indicates this fault. B. Scroll of GPM shows flow as: ??? C. Confirm with analog input test of CHNL 2 per 6.10.3.

Corrective Action:

1. Disable transducer by entering user menu per

4.3 and changing GPM xmitter span (item 23) to “0”. Alarm message will turn off. GPM staging is inactive.

2. Replace flow transducer.

6.15.14 RTD1 or RTD2 Fault

A. Alarm per 4.5.2 indicates this fault. B. Confirm with analog input test of RTD channels

(steps 5 or 6) per 6.10.3.

Corrective Action:

1. Disable RTD1 and RTD2 by removing respective connections at J3 13 & 14, and 16 & 17 and replacing each with a 100 OHM resistor. Both RTD’s must have this substitute resistor even though only one is defective.

2. Ignore 32˚F temperature display.

3. High temperature cut out and no flow shut down are both inoperative.

4. Replace defective RTD. Observe and perform any calibration procedure that may accompany the RTD.

WARNING: Prevent electrical shocks. Disconnect the power supply before beginning installation.

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

6.16

INSTRUMENTS AND THEIR USE

With the diagnostics described herein extensive instruments are not required. However, the instruments used should be quality units to meet the following at a minimum.

Under no circumstances shall any instrument be used to test any on board components. Especially risky is an ohmmeter with battery voltage higher than TTL logic or applied with incorrect polarity.

6.16.1 AC/DC Voltmeter –

– Input impedance shall not be less than

10 MEGOHM.

– Accuracy - AC ± 2% of F.S.

- DC ± 3% of F.S.

– Rated circuit to ground voltage = 1000V.

Note F.S. = Full Scale.

6.16.2 OHMMETER

– Accuracy ± 2 – Max open circuit voltage =

/2%

/2 volt

6.16.3 Millimeter

– Accuracy ± 2% of F.S.

6.16.4 Signal Generator (analyzer) - recommended

A. Beta calibrator Model 434 20mA signal analyzer. B. Altec calibrator Model 334 4-20mA loop analyzer.

Either instrument may be purchased from your Local Process Control Distributor.

NOTE: If some other instrument is used it must float above ground, preferably battery powered.

6.17 FIELD REPAIR

6.17.1 General – field repair, except replacing fuses, replacing analog input resistors, and assuring connections, such as ribbon cable, are correct and secure, is not recommended.

6.17.2 EPROM Changing – normally EPROMS are not changed in the field. In an emergency this is the procedure to be performed when authorized by the factory.

A. Record all data from the OIP. B. Turn off all power to the panel. C. Ground your body. Touch earth ground to dis-

charge static electricity.

WARNING: Electrical shock hazard. Multiple power

follow these instructions could result in serious personal injury, death, and/or property damage.

D. With one hand only gently pry EPROM (chip U1)

up from its socket alternating from each end in small increments. Use a small screwdriver. Do not place free hand on OIP components. Ground free hand if possible.

E. Insert new EPROM with all pins in the socket and

the notch oriented as chip U2 notch (adjacent

chip). F. If done carefully, the EPROM will not be corrupted. G. Turn on power. Enter user menu per 5.1.3 and

check special data for the job at hand.

6.18

SERIAL NO. AND FIRMWARE VERSION NO.

6.18.1 Both of these numbers may be found as the 4th message after booting. If the factory is called for information or service on this unit the serial No. and firmware version No. may be requested. They are important to B&G in order to track the unit.

6.19 MAINTENANCE (Physical)

6.19.1 Electrical – no maintenance is required for the electrical panel except to keep the boards free of dirt and dust that might hold moisture. Cabinet door should be kept closed, and the components kept dry.

6.19.2 Mechanical – A Series 1531 pump was lubricated at the factory. Future lubrication should be according to the motor manufacturer’s instructions.

A Series 1510 pump requires regreasing after every 2500 hours of operation or every six months whichever occurs first. Lubricate motor per motor manufacturer’s instructions.

If there is a danger of freezing, drain the pump. Inspect pump and system piping regularly.

For leaky seals or gaskets and loose or damaged components, replace or repair as required.

For more information on the B&G pumps see the following manuals:

1510 (IOM Part #P81673) 1531 (IOM Part #P81567)

Page 22

APPENDIX A

APPENDIX B

SYSTEM PIPING AND UNIT

INSTALLATION – FINAL CHECK LIST

____ 1. Is the unit base properly leveled, grouted and

____ 2. Are all lubrication points properly lubricated?

____ 3. Is the outlet side of the high temperature regulating

____ 4. Are the shut-off valves to the suction and discharge

____ 5. Is the shut-off valve to the pump suction open?

____ 6. Is the shut-off valve on the discharge line open?

____ 7. Is the bypass valve, if used, closed? This valve may

____ 8. Are the stop cocks for the check feature on the PRV

____ 9. Is the piping properly supported so as to prevent

____ 10. Is the system, including the pumps and PRV’s,

____ 11. Are the bleed valves at the high temperature valve

secured?

valve connected to the drain with tubing or pipe size

/8" or greater?

transmitters open?

be left open if a check valve is installed in series with it.

open? They must normal operation. Throttle cock if check slamming is noted.

strains on unit?

purged of debris and air?

CAUTION: Seal damage may occur. Do not run pumps dry. Fill and vent the pump volute prior to

operation. Failure to follow these instructions could

result in property damage and/or moderate personal injury.

header open?

never be completely closed during

ELECTRICAL WIRING AND CONTROL

SETTINGS – FINAL CHECK LIST

____ 1. Does the feeder line voltage correspond to the unit

____ 2. Are the feeder wires correctly sized for the load?

____ 3. Are the fuses correctly sized? They must not exceed

____ 4. Is the unit properly grounded?

____ 5. Have all the power terminals in the control panel

voltage? Check the unit nameplate or motor terminal connection.

WARNING: Electrical shock hazard. Inspect all elec-

trical connections prior to powering the unit. Wiring connections must be made by a qualified electrician in accordance with all applicable codes, ordinances, and good practices.

could result in serious personal injury, death, and/or property damage.

1.75 times the full load current of the motor. Usual sizing is 1.15 to 1.5 times the full load current.

WARNING: 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. Failure to follow these instructions

could result in serious personal injury, death, and/or property damage.

been checked for tightness? This is imperative since stranded wires tend to “flow” and become loose after initial installation.

DANGER: High voltage 3 phase power can kill. Disconnect and lockout power prior to servicing

unit.

Failure to follow these instructions could result in

serious personal injury, death, and/or property damage.

Failure to follow these instructions

____ 12. Are the pump and motor shafts properly aligned?

____ 13. Is the pump rotation correct?

Page 23

APPENDIX C

PROCEDURE FOR FIELD BALANCING 70E/70M PRV’S

1.0 Pressure Reducing Valve (PRV) Adjustment

1.1 The pressure reducing valves are “factory set” on

1.2 Any deviation from the above conditions will prevent

1.3 To adjust the PRV place the pump in manual opera-

70E and 70M systems, therefore, change of setting may be required. If needed, the following items should be checked first before any attempt is made to change the setting:

a) Does the desired system pressure correspond to

the pressure indicated on the nameplate?

b) Is the suction pressure equal to or higher than the

pressure indicated on the nameplate?

c) Is the demand (GPM) within the capacity indicated

on the nameplate?

d) Has the PRV been properly vented?

the unit from operating at the factory (nameplate) settings.

tion per paragraph 5.3. With the pump now running, slowly close the main gate valve downstream of the discharge header allowing a through it. Read the system pressure on the display. It should read 3 or 4 psi higher than the desired system pressure. If not, remove the protective cap on the pilot control valve and loosen the jam nut on the adjusting stem of the PRV. Slowly turn the stem clockwise to increase the delivery pressure and counter clockwise to decrease pressure. (Note that a pilot valve furnished for a 20 to 300 psi range will change the main valve setting approximately 28 psi for each full turn of the adjusting screw.) Set the screw so the system display reads 3 to 4 psi than the desired system pressure.

trickle of water to flow

higher

1.4 Open the gate valve fully. If feasible, draw between 50 to 80% of the designed pump capacity to recheck valve setting. The display should now read the desired system pressure. Tighten jam nut and replace cap.

1.5 Repeat the above procedure for all pump and valve combinations as required.

1.6 The CV Flow Control Valve (opening speed control) may require field adjustment if pressure hunting occurs. Normal setting of the valve is from 4 to 7 turns open. Never open more than 8 turns.

Page 24

APPENDIX D

TROUBLESHOOTING COMBINATION – PRESSURE REDUCING AND CHECK VALVES

1.0 System Pressure Higher than Desired Set Point

1.1 Primary Causes

a) Insufficient pressure on top side of diaphragm. b) Leakage through main valve seat c) Pressure build-up due to thermal expansion, such

as caused by volumetric expansion of the water in a heater connected to the system side of the PRV.

d) Inaccurate system pressure signal.

1.2 Tests and Remedies (see Figure 1 for item numbers)

a) Install gauge, install on CRD (Item 6), if necessary. b) Vent air from air vent (Item 9) and from other high

points of PRV trim. Valve cover bolts may have to be loosened on some units with PRV mounted

horizontally. c) Check CRD set point adjustment. d) Close stop cock (Item 7) in check line. If PRV now

operates properly, clean or replace adjacent check

valve (Item 8). e) Inspect CRD (Item 5) disc and seat for proper

seating. f) Inspect strainer (Item 1) that the screen is clean. g) Inspect orifice (Item 3) that it is not clogged. h) Plug outlet side of CRD. If main valve closed tight,

the problem most likely is in the CRD. Replace

same. If the main valve does not close tight, disas-

semble it for inspection. Check for scored seat.

2.0

2.1 Primary Causes

2.2 Tests and Remedies (see Figure 1 for item numbers)

System Pressure Lower than Desired Set Point

a) Excessive pressure on top side of diaphragm. b) Suction pressure below design conditions (check

nameplate on panel door for design conditions). c) Desired system pressure is higher than design

condition (check panel nameplate). d) Flow Rate is greater than design condition. e) Inaccurate system pressure signal.

a) Install gauge, install on CRD (Item 6), if necessary. b) Vent air from air vent and all high points. c) CRD disc guide or yoke binding. d) Check motor amps. If greater than full load amps

(motor nameplate), flow rate may be greater than

design.

DANGER: Troubleshooting live control panels ex-

poses personnel to hazardous voltages. Electrical troubleshooting must only be done by a qualified electrician.

Failure to follow these instructions could result in

serious personal injury, death, and/or property damage.

e) Leak into upper diaphragm chamber. Close stop

cock (Item 7) and remove a connection between the flow control valve (Item 4) and the PRV valve cover. Plug the flow control side. Open pump suction valve and start pump. If water emits from the valve cover plate, there is a leak passing the diaphragm into the upper chamber.

f) Remove valve cover plate for inspection. Remove

“cancerous” buildups which may prevent diaphragm from lifting fully. Check for binding of valve stem assembly.

g) Opening speed control valve (Item 4) clogged in

restricted flow mode (out of PRV valve cover).

h) Orifice (Item 3) missing. The orifice fitting identical

in appearance to a flare to MPT adapter, therefore may have been inadvertently replaced or misplaced during valve service.

i) Check pump discharge pressure. Does it corre-

spond to the TDH curve?

3.0

3.1 Primary Causes

3.2 Remedies (see Figure 1 for item numbers)

4.0 System Pressure Overshoots Greatly

4.1 Primary Causes

4.2 Remedies (see Figure 1 for item numbers)

System Pressure Slow to Recover from Under Pressure to Set Point

a) Pressure above the diaphragm is not being re-

moved quickly enough.

b) Mechanical binding in main PRV or CRD pilot

valve.

c) Excessive suction supply line pressure drop.

a) Any of the items of 2.2 may be a contributing factor. b) Readjust flow control valve (Item 4) to less restric-

tive setting, turn counter clockwise.

NOTE: Forcing the stem too far CCW will shear the stem snap ring and cause the stem to blow out. Recommend that the stem be initially turned CW, noting the number of turns required to seat the stem, then backing it out CCW a few more turns than the original setting. The maximum CCW setting is about 9 turns.

and Slow to Recover to Set Point

a) Pressure above the diaphragm is not being ap-

plied soon enough.

b) Mechanical binding in main PRV or CRD pilot

valve. c) Leaky seat in main PRV or CRD valves. d) Excessive suction supply line pressure drop. e) System side surge (water hammer) due to sudden

closure of a quick opening valve. f) Strainer (Item 1) clogged.

a) Any of the items of 1.2 may be contributing factors. b) Install larger orifice (Item 3).

Page 25

APPENDIX D (continued)

5.0 PRV Does Not Close (Check) on Pump Shut Down

5.1 Primary Causes

a) Insufficient pressure on top of diaphragm. b) Leak through main valve seat or diaphragm

assembly.

5.2 Remedies (see Figure 1 for item numbers) a) Stop cock (Item 7) closed preventing pressure

from reaching valve cover. b) Leaking check valve (Item 2). c) To determine whether leak is in main valve seat or

diaphragm assembly:

1. Disconnect line between flow control valve (Item 4) and valve cover.

2. Plug flow control side.

3. Install pressure gauge in valve cover.

4. Remove vent plug in pump volute to drain inlet side of PRV.

5. Apply pressure to top side of diaphragm by opening shutoff valve on outlet side of PRV.

6. Read gauge pressure.

7. Close stop cock (Item 7).

If gauge pressure fails, there is a leak in the diaphragm assembly. This test, however, does not indicate whether the seat is also leaking.

6.0

PRV Slams Shut on Pump Shut Down

6.1 Primary Causes

a) Too rapid buildup of pressure on top of diaphragm. b) Main valve assembly binding. c) Check valve (Item 2) sticking open momentarily.

6.2 Remedies (see Figure 1 for item numbers)

a) Throttle stop cock (Item 7).

NOTE: Closing this stop cock will completely prevent PRV from functioning as a check valve.

b) Vent air from PRV (see 1.2b).

7.0 PRV Setting

7.1 Preparation in the Field

If one or more pumps must be kept running at all times, install gauge (Item 6) or a Schraeder fitting in each CRD. CRD has a

/8" NPT tapping.

7.2 Low Flow Setting

Since the design flow rate through each PRV is difficult to obtain, the valves should be set a very low flow rate. Barely crack open the shutoff valve on the outlet side of the PRV and set the CRD so the pressure gauge reads 3-4 psi above the desired system pressure.

7.3 Balancing the Settings

a) Between two or more equal pumps:

1. Check the motor amps of each pump quickly (to reduce the possibility of load changes during reading) with both or all equal size pumps running simultaneously – controller in “hand” if necessary to stabilize pump operation.

DANGER: Troubleshooting live control panels ex-

poses personnel to hazardous voltages. Electrical troubleshooting must only be done by a qualified electrician.

Failure to follow these instructions could result in

serious personal injury, death, and/or property damage.

2. Select the lower reading of two equal pumps and balance the amperage of the other pump to that reading by lowering the CRD setting (turn CCW) very slightly, but not more than

3. Select the middle reading of three equal pumps and balance the other two pumps to that reading as in Step 2 above.

4. Secure the CRD adjustment stem with the locknut.

b) Between the fixed (usually smaller) lead pump and

other pump(s):

1. Check the motor amps through pump #1 without any other pumps running.

DANGER: Troubleshooting live control panels ex-

poses personnel to hazardous voltages. Electrical troubleshooting must only be done by a qualified electrician.

Failure to follow these instructions could result in

serious personal injury, death, and/or property damage.

2. While observing the ampere reading of the lead pump #1, start pump #2 in the “hand” position. If pump #1 does not show a decrease in amperage of at least one amp for a motor under 5 HP or two amps for large motors, increase CRD #2 setting (turn CW) very slightly, usually not more than

/8 turn, to lower the amperage of pump #1. This adjustment will assure that pump #1 will trip out when the water demand decreases. On three pump units, calibrate pumps #1 and #3 as #1 and #2 above.

3. Secure the CRD adjustment stem with the locknut.

/8 turn.

Page 26

COMBINATION PRESSURE REDUCING AND CHECK VALVE

Item Name Primary Function

1 Strainer Prevents orifice from clogging. 2 Check Valve Prevents backflow from top of diaphragm when pump stops. 3 Orifice Provides metered water flow to top-side of diaphragm. 4 Opening Speed Flow Control Dampens pressure fluctuations (slow opening). 5 CRD Pilot PRV. 6 Gauge Optional location for system pressure gauge. 7 Cock Adjustment for rate of closure (non-slam). 8 Check Valve Prevents backflow from top of diaphragm during normal operation. 9 Vent Bleeds air from top of diaphragm.

10 Diaphragm Divides inlet and outlet pressures.

PRV REPAIR KITS

Table I: Complete Valve CLA-VAL Model 90-01A - 125#, epoxy coated, bronze trim valves

with 30-300# pilot (CRD) spring range.

Size Angle Style (for 70M) Globe Style (for 70E)

/2 NPT S11230 S11882

2 Flanged S11231 S11883

/2 Flanged S11232 S11884 3 Flanged S11233 S11885 4 Flanged S77535 N/A

B&G Part No.

Table II: PRV Repair Kits

PRV Size 11/2"2"2

Cla-Val Repair Kit No. 8155001E 8155002C 8155003A 8155004J 8155005F B&G Part No. 185251 185252 185253 185254 185255

Above Kits consist of the following parts and Cla-Val Part No.:

Strainer C2891E C2891E C3084F C084F C3085C Diaphragm, Main Valve 83239E 80522G 83240C 83241A C8184J Disc, Main Valve V5562D V5564G V1637H V1734C V5467F Spencer Washers (3) V5180E V5332D V0631B V0631B V0634F Diaphragm, Pilot C6936D C6936D C6936D C6936D C6936D Gasket, Pilot 40174F 40174F 40174F 40174F 40174F Disc Retainer, Pilot C4256H C4256H C4256H C4256H C4256H

/2"3" 4"

Page 27

APPENDIX E

SERVICE TEST OVERVIEW

Service Test is explained under paragraph 6.8; Diagnostics. The following may be used in conjunction with paragraph 6.8 as an additional aid to its utilization.

SERVICE TEST

DISPLAY STATUS

Digital Input Test

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 0’s and 1’s

x x x x x x x x x x x x x x x x

Analog Input Test

➁

Input X = XX%

Digital Output Test

Output # 1 2 3 4 5 6 7 8 0’s and 1’s State x x x x x x x x

NOTES:

Press SERVICE TEST key at any time. To exit press CLEAR key.

➀

Press CLEAR key for this. X = 1, 2, 3, 4, 5, 6, 7 and 8 for analog channels from suction transmitter, system transmitter, flow transmitter, low temperature

➁

transmitter, high temperature transmitter, D.C. supply line, line voltage, line current, and power in watts, respectively.

➀

% (CHANNELS 1 - 4)

APPENDIX F

POWER TRANSDUCER BOARD (PTB)

1.0 GENERAL DESCRIPTION

The PTB is a B&G proprietary board designed to measure total RMS load current and line voltage for either single or 3 phase systems. This data is entered into a microcontroller to calculate true power. True power, amps, and volts are transmitted continuously to the 70E/70M OIP microprocessor. These values are then used for staging and/or display.

1.1 SAFETY

The PTB is an electronic board with high voltage. It carries 3 phase voltage up to 600 volts. Do not touch it. There are no manual adjustments on board. If it should become defective, as described elsewhere in this manual, replace it. Field repair is absolutely not authorized under any circumstances.

DANGER: Troubleshooting live control panels ex-

poses personnel to hazardous voltages. Electrical troubleshooting must only be done by a qualified electrician.

Turn power off prior to opening control panel door.

Turn power off and confirm it is off with a voltmeter. Lock-out disconnect/s.

DO NOT:

– Touch PTB with power on. – Move jumpers with power on. – Wire with power on. – Even think about modifications. – Even think about repair.

Failure to follow these instructions will result in serious personal injury, death, and/or property damage.

Page 28

1.2 CURRENT SENSING

This is accomplished by inserting one common power conductor through a linear output Hall effect doughnut.

1.3 VOLTAGE SENSING

This is accomplished with a resistor network and a potential transformer. Maximum voltage level is 600V RMS.

1.4 CALIBRATION

Calibration is performed at the factory for all ranges of current and voltage. This resides in the EEPROM on board the PTB.

1.5 APPLICATION

The following is performed by the factory. However, if a PTB is being replaced in the field the following must be observed:

A. One common (to load) conductor must be run

through the doughnut.

NOTE: This conductor must not rest on the PTB components except for the current transformer. Arc the wire, in order to bias it away from the PTB, before inserting it in the current transformer. Secure in place with wire ties.

B. Insert this conductor into the hole on the flat side

of the doughnut with the load side of the conductor coming out of the opposite side of the hole.

C. 3 Phase – connect all 3 phases to terminals of J1

marked AØ, BØ, and CØ. Do not use com. AØ must also be the same phase as that inserted into the doughnut. Which is AØ, BØ or CØ is arbitrary but must be established to follow these rules. Single Phase – connect the “hot” line to AØ only and neutral to com. Again AØ phase must be the same phase as inserted into the doughnut.

D. Move voltage jumpers J3 and J6 to a voltage as

close to actual as possible. Jumpers on J3 and J6 must match each other.

E. Move jumper J2 to next highest amp terminal above

total motor load in amps. that may run at one time.

1.6 PHASE CONSIDERATIONS

The PTB will perform well with delta or wye systems, grounded or ungrounded. However, on 3 phase grounded systems do not ground the com. terminal of J1.

1.7 MENU CONSIDERATIONS

A menu entry must be made as to whether this unit will be used in a 3 phase or 1 phase system.

AUTHORIZED REPRESENTATIVE

Xylem Inc.

10661 Newkirk Street Dallas, TX 75220 Phone: (469) 221-1200 Fax: (214) 357-5861 www.xyleminc.com/brands/bellgossett

Bell & Gossett 70M User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual