Bell & Gossett S14141B User Manual
70X Multiple Pump
Pressure Booster Systems
Installation, Operation and
INSTRUCTION MANUAL
S14141B
Service Instructions
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
DESCRIPTION
A Bell & Gossett Packaged Pressure Booster System is factory
assembled, tested and shipped as a complete modular unit.
Each Pressure Booster System is tested to internal quality
standards.
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 can be found in the I.O.M.s for the specific equipment
provided.
OPERATIONAL LIMITS
See unit nameplate for pump capacity, boost, full load current
draw, and operating voltage. The pump discharge pressure
must not exceed 175 PSI unless specifically designed.
SAFETY
INSTRUCTIONS
This safety alert symbol will be used in this manual and on the
Safety Instruction decal to draw attention to safety related
instructions. When used, the safety alert symbol means
ATTENTION! BECOME ALERT! YOUR SAFETY
FAILURE TO FOLLOW THE INSTRUC
A SAFETY HAZARD!
TION MAY RESULT IN
IS INVOLVED!
UNIT IDENTIFICATION
The unit nameplate gives identification and rating information
as identified in Figure 1.
UNIT IDENTIFICATION
Records for this unit are kept by the order number (Q______)
and it must therefore be used with all correspondence and
spare parts orders.
PRESSURE BOOSTER SYSTEM
PREFACE
The 70X modular variable speed pressure booster system is
designed to maintain a constant discharge pressure while
minimizing power consumption by combining a variable
speed lead pump with one or two constant speed lag pumps.
This system creates an efficient and practical solution to a
building’s low demand water usage profile. A typical building’s
water demand varies throughout the course of a day and
often a single pump is capable of meeting the demand for
more than half of the day. The 70X controller manages pump
operation to match the wide range of pressure boosting system conditions. The pump controller uses a combination of
kW, pressure and speed to calculate the most efficient points
to stage on and off pumps for operation.
PREFACE
Power consumption is minimized by varying the speed of the
lead pump to satisfy a varying system demand. As the system
demand exceeds the capacity of the lead pump, a constant
speed lag pump is staged on. The constant speed lag pump
operates at full capacity while the lead variable speed pump
adjusts its speed to supplement the system requirement.
When speed demand decreases the lead pump slows down.
While monitoring system pressure, pump speed and power
consumption, the constant speed lag pump is staged off at an
optimal point and the variable speed pump takes over.
FIGURE 1 - Technologic 500X Control Panel Nameplate
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TABLE OF CONTENTS
70X Multiple Pump Pressure Booster Systems
Page
SECTION 1 GENERAL
Purpose of Manual ..............................................................................................................................4
Safety Requirements...........................................................................................................................4
Handling .............................................................................................................................................4
Storage................................................................................................................................................4
Ground Connections ...........................................................................................................................5
Power Wiring .......................................................................................................................................5
Field Connection Diagrams.................................................................................................................5
SECTION 2 INSTALLATION
Location...............................................................................................................................................5
Foundation .........................................................................................................................................5
Leveling ...............................................................................................................................................5
Grouting ..............................................................................................................................................5
Piping Connections .............................................................................................................................5
Misc Connections................................................................................................................................6
Lubrication ..........................................................................................................................................6
Wiring ....................................................................................................................................................
Power Wiring..................................................................................................................................6
Analog Signal Wiring .....................................................................................................................6
Pressure Transmitter Wiring ..........................................................................................................6
Differential Pressure Switch Piping and Wiring .............................................................................7
Low Suction Pressure Switch .......................................................................................................7
..........................................................................................................................................................
SECTION 3 START UP
Putting Unit into Service......................................................................................................................7
Adjustments ........................................................................................................................................7
Thermal Relief Valve .......................................................................................................................7
Pressure Reducing Valve (PRV) .....................................................................................................7
High Pressure PRV ........................................................................................................................7
Differential Pressure Switch ..........................................................................................................7
Low Suction Pressure Switch ........................................................................................................7
SECTION 4 MAINTENANCE
Maintenance (Physical)........................................................................................................................8
..........................................................................................................................................................
APPENDIX A System Piping and Unit Installation – Final Check List .......................................................................9
APPENDIX B Electrical Wiring and Control Settings – Final Check List ...................................................................9
APPENDIX C Procedure for Field Balancing Pressure Reducing Valve ..................................................................10
APPENDIX D Troubleshooting Combination Pressure Reducing and Check Valves ........................................11-12
APPENDIX E Hydropneumatic Tank Field Installation ............................................................................................12
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SECTION 1 - GENERAL
1.1 PURPOSE OF MANUAL
1.1.1 This manual is furnished to acquaint the user
with some 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. This manual
provides general instructions for installation, commissioning and operation to ensure
optimal performance and reliability.
1.1.2 Equipment cannot operate well without proper
care. To keep this unit at top efficiency, follow the recommended installation and servicing procedures outlined in this manual.
1.1.3 The control panel installed on the pressure
booster system shall have a safety instruction decal (part #S11550 shown below). If the
decal is missing or illegible contact your local
B&G representative for a replacement.
1.2 SAFETY REQUIREMENTS
1.2.1 Motor must have a properly sized starter with
properly sized overload block to provide over
load and undervoltage protection. Ground
fault protection should be sized properly.
1.2.2 Refer to the motor manufacturer’s I.O.M.
(Installation, Operation & Maintenance manual) for
specific installation information.
1.2.3 Even when the motor is stopped, it should be
considered "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.
1.2.4 Motor control equipment and electronic controls are connected to hazardous line volt
ages. 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 check
ing 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.
1.3 HANDLING
1.3.1 Care should be taken to prevent damage due
to 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.
1.3.2 The unit should be unloaded and handled by qualified 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.
1.4 STORAGE
1.4.1 For periods of storage, the unit should be
covered to prevent corrosion and contamination from dirt. It should be stored in a clean,
dry location to prevent condensation as well
as protected from freezing. After storage,
again check that it is dry before applying
power. Specific component storage instructions must be followed in accordance with
the respective equipment manufacturer’s
recommendations.
WARNING: Make sure the area surrounding the unit
is safe. Be aware of any hazardous conditions that
can exist. Always wear protective glasses and protective
shoes when working with the unit. Do not wear loose fitting
or torn clothing. Remove all jewelry when working.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN SERIOUS PERSONAL INJURY, DEATH,
AND/OR PROPERTY DAMAGE.
WARNING:
Motor can start automatically. Keep
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.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN SERIOUS PERSONAL INJURY, DEATH,
AND/OR PROPERTY DAMAGE.
DANGER: Troubleshooting live control panels exposes
personnel to hazardous voltages. Electrical trouble-
shooting must only be done by a qualified electrician.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN SERIOUS PERSONAL INJURY, DEATH,
AND/OR PROPERTY DAMAGE.
WARNING: Falling Objects Hazard. Eyebolts or lifting
lugs, if provided, are for lifting only the components
to which they are attached.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN SERIOUS PERSONAL INJURY, DEATH,
AND/OR PROPERTY DAMAGE.
CAUTION: Extreme temperatures are to be avoided.
(Below 32ºF and above 110ºF).
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN PROPERTY DAMAGE AND/OR MODERATE
PERSONAL INJURY.
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