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TECHNOForce e-HV
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Bell & Gossett TECHNOForce e-HV Mechanical Installation, Operation, And Maintenance Manual

Mechanical Installation, Operation,
and Maintenance Manual
10-001-287 Rev 4
TECHNOForce e-HV
Table of Contents
1 Introduction and Safety..............................................................................................................3
1.1 Introduction.......................................................................................................................... 3
1.2 Safety..................................................................................................................................... 3
1.2.1 Safety terminology and symbols.................................................................................3
1.2.2 Protecting the environment.........................................................................................4
1.3 User safety.............................................................................................................................4
1.3.1 Wash the skin and eyes................................................................................................5
2 Transportation and Storage...................................................................................................... 7
2.1 Examine the delivery........................................................................................................... 7
2.1.1 Examine the package................................................................................................... 7
2.1.2 Examine the unit............................................................................................................7
2.2 Transportation guidelines...................................................................................................7
2.2.1 Lifting methods............................................................................................................. 7
2.3 Storage guidelines...............................................................................................................7
2.3.1 Long term storage........................................................................................................ 8
Table of Contents
3 Product Description................................................................................................................. 10
3.1 General description...........................................................................................................10
3.1.1 Operational limits....................................................................................................... 10
3.2 Nameplate information.....................................................................................................10
4 Installation................................................................................................................................. 12
4.1 Reference manuals............................................................................................................ 12
4.2 Field connections...............................................................................................................12
4.3 ground (earth) connections..............................................................................................12
4.4 Pump package location guidelines................................................................................. 12
4.5 Foundation requirements.................................................................................................13
4.6 Level the base on a concrete foundation ...................................................................... 13
4.7 Grout the baseplate...........................................................................................................14
4.8 Piping checklist.................................................................................................................. 14
5 Commissioning, Startup, Operation, and Shutdown.......................................................... 15
5.1 Preparation for startup...................................................................................................... 15
5.1.1 Prestartup checklist.................................................................................................... 15
5.1.2 Final installation checks............................................................................................. 16
5.1.3 Final adjustments........................................................................................................16
5.2 Pump station startup......................................................................................................... 16
5.2.2 Connect the storage tank.......................................................................................... 17
5.2.3 Optional water level control relay............................................................................ 17
5.2.4 Check for available suction water.............................................................................19
5.2.5 Start the package........................................................................................................19
5.2.6 Check the pump rotation...........................................................................................19
5.2.7 Set the system operating pressure...........................................................................19
5.2.8 Enter the setup menu.................................................................................................19
5.2.9 Test the package.........................................................................................................20
6 Maintenance..............................................................................................................................21
6.1 Precautions......................................................................................................................... 21
TECHNOForce e-HV Mechanical Installation, Operation, and Maintenance Manual 1
Table of Contents
6.2 Monthly maintenance........................................................................................................21
7 Troubleshooting....................................................................................................................... 23
7.1 Pump station troubleshooting......................................................................................... 23
7.1.1 The pump station does not power up..................................................................... 23
7.1.2 The station powers up, but the pumps do not run.................................................23
7.1.3 The pumps run but do not build desired pressure................................................ 24
7.1.4 The pump station experiences excessive vibration............................................... 24
7.1.5 The pump station does not shut down and no water is used...............................25
7.1.6 The pump station cycles or hunts erratically...........................................................25
8 Technical Reference.................................................................................................................26
8.1 Pump station numbering system..................................................................................... 26
8.1.1 Pump station with e-SV pumps................................................................................. 26
9 Appendix................................................................................................................................... 28
9.1 Installation drawings..........................................................................................................28
10 Product warranty.................................................................................................................... 36
2 TECHNOForce e-HV Mechanical Installation, Operation, and Maintenance Manual

1 Introduction and Safety

1.1 Introduction

Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
1 Introduction and Safety

1.2 Safety

WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual could cause death, serious personal injury, or damage to the equipment. This includes any modification to the equipment or use of parts not provided by Xylem. If there is a question regarding the intended use of the equipment, please contact a Xylem representative before proceeding.
• Do not change the service application without the approval of an authorized Xylem representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in physical injury, damage, or delays.

1.2.1 Safety terminology and symbols

About safety messages
It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards:
• Personal accidents and health problems
• Damage to the product and its surroundings
• Product malfunction
Hazard levels
Hazard level Indication
DANGER:
TECHNOForce e-HV Mechanical Installation, Operation, and Maintenance Manual 3
A hazardous situation which, if not avoided, will result in death or serious injury
1 Introduction and Safety
Hazard level Indication
WARNING:
A hazardous situation which, if not avoided, could result in death or serious injury
CAUTION:
NOTICE:
Special symbols
Some hazard categories have specific symbols, as shown in the following table.
Electrical hazard Magnetic fields hazard
Electrical Hazard:

1.2.2 Protecting the environment

Emissions and waste disposal
Observe the local regulations and codes regarding:
• Reporting of emissions to the appropriate authorities
• Sorting, recycling and disposal of solid or liquid waste
• Clean-up of spills
A hazardous situation which, if not avoided, could result in minor or moderate injury
Notices are used when there is a risk of equipment damage or decreased performance, but not personal injury.
CAUTION:
Exceptional sites
CAUTION: Radiation Hazard
Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless Xylem has been informed and appropriate actions have been agreed upon.
Recycling guidelines
Always follow local laws and regulations regarding recycling.

1.3 User safety

General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within the work area:
hazards.
4 TECHNOForce e-HV Mechanical Installation, Operation, and Maintenance Manual
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections dealing specifically with electrical connections.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the product:
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
• Do not exceed the maximum working pressure of the pump.
• Do not open any vent or drain valve or remove any plugs while the system is
• Never operate a pump without a properly installed coupling guard.
1 Introduction and Safety
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information about safety devices in other chapters of this manual.
control.
pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping.

1.3.1 Wash the skin and eyes

Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin:
Condition Action
Chemicals or hazardous fluids in eyes
Chemicals or hazardous fluids on skin
Lockout/Tagout provisions
DANGER:
Electrical hazard sufficient to kill. Always disconnect and lock out the power before you service the unit.
TECHNOForce e-HV Mechanical Installation, Operation, and Maintenance Manual 5
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
1 Introduction and Safety
WARNING:
• Always disconnect and lock out power to the driver before you perform any installation
The main station panel is equipped with a main station disconnect for completely powering down the system. This panel also provides individual circuit breaker service disconnects for each pump. These disconnects are accessible without disengaging the main station disconnect to ensure that operation of the system is not interrupted during individual pump service. In both situations (complete station or individual pump power down), provisions for lockout / tagout capability have been provided.
The main station disconnect has a door interlocking feature that utilizes a handle that allows for padlocking.
or maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical injury.
The individual circuit breaker disconnects are accessible through an inspection/service window that has an integrated locking tab feature. The use of a lockout scissor clamp is highly recommended to properly lockout any of these individual disconnects.
6 TECHNOForce e-HV Mechanical Installation, Operation, and Maintenance Manual

2 Transportation and Storage

2 Transportation and Storage

2.1 Examine the delivery

2.1.1 Examine the package

1. Examine the package for damaged or missing items upon delivery.
2. Record any damaged or missing items on the receipt and freight bill.
3. If anything is out of order, then file a claim with the shipping company. If the product has been picked up at a distributor, make a claim directly to the
distributor.

2.1.2 Examine the unit

1. Remove packing materials from the product. Dispose of all packing materials in accordance with local regulations.
2. To determine whether any parts have been damaged or are missing, examine the product.
3. If applicable, unfasten the product by removing any screws, bolts, or straps. Use care around nails and straps.
4. If there is any issue, then contact a sales representative.

2.2 Transportation guidelines

2.2.1 Lifting methods

WARNING:
• Assembled units and their components are heavy. Failure to properly lift and support this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steel-toed shoes at all times.
• Tip over hazard. Do not use component eyebolts to lift the pump station. The eyebolts are only designed to lift the components to which they are attached.
• Do not attach sling ropes to the panel stand.

2.3 Storage guidelines

Storage location
The product must be stored in a covered and dry location free from heat, dirt, and vibrations.
NOTICE:
Protect the product against humidity, heat sources, and mechanical damage.
NOTICE:
Do not place heavy weights on the packed product.

2.3.1 Storage between use

Observe the following for long-term storage of a pump station.
TECHNOForce e-HV Mechanical Installation, Operation, and Maintenance Manual 7
2 Transportation and Storage
• Insure system is drained of any water.
• Remove transducers to ensure that they do not freeze.
• System may be top-heavy, brace to keep from tipping.

2.3.1 Long term storage

The following procedure applies to Boosters and HVAC Packages.
1. Customer furnished equipment and accessories that are not offered as standard or optional by the factory must be handled in accordance with the respective manufacturer's recommendations.
2. Storage longer than one month Is considered long term storage.
3. Pumps should be prepared for storage using the following procedure.
SAFETY
• Select a storage location that will prevent potential hazards to persons allowed access to the storage area.
• Appropriate precautions should be taken to ensure safe on-site receipt and transit.
• Potential energy risk should be minimized. Keep product at ground level and prevent stacking or other unsafe positioning that could result in falling, dropping, and/or tipping.
LOCATION AND TREATMENT
• Indoor Storage
– Little extra preparation is needed if indoor storage area is dry and clean. – Care should be taken to prevent extremes In temperature (below 32°F and above
110°F). Also, keep the pump out of direct sunlight and covered to protect it from dust and dirt.
– Care should be taken to prevent moisture build-up around the pump, either by
allowing proper ventilation or tightly sealing the pump in the cover with a suitable amount of desiccant to ensure dryness.
– If indoor storage area is humid or dirty, such as an unfinished building, treat the
pump as if it were to be stored outdoors.
– If exposure to condensation is expected, un-painted external steel or cast-iron
surfaces should be coated with rust-inhibiting oil such as Cortec’s VCI-329.
– Storage location should also provide minimal exposure to vibration and other
damage potentially transmitted from adjacent operating equipment.
– Product supplied in factory cartons, pallets or similar Xylem packaging should be
kept in ‘as-shipped’ condition where possible.
– Inspect suction and discharge manifold flange covers.
• Outdoor Storage
– Pump should be covered to protect it from weather and direct sunlight. – All coverings should be property secured to withstand high wind. – Care must be exercised in covering pumps to prevent moisture build-up under the
cover. This can be done either by allowing proper ventilation or tight sealing cover with suitable amount of desiccant to ensure dryness.
– Extreme heat and cold are to be avoided, as rubber parts and seals could age
prematurely (below 32°F and above 110°F).
– Storage area should be inspected weekly, and after storms for damage to
protective covers.
– Inspect suction and discharge manifold flange covers.
• Installed But Not in Service
8 TECHNOForce e-HV Mechanical Installation, Operation, and Maintenance Manual
2 Transportation and Storage
– Preparation for storage under these conditions is the same as for indoor and
outdoor, except the suction and discharge piping will serve as flange covers.
– The suction and discharge valves must be tightly closed and all water removed
from the pump and attached piping. The interior of the pump and piping must be thoroughly dried.
– Inspect un-painted external steel or cast-iron surfaces once a month for moisture
and replace volatile corrosion inhibitor at that time (see section 1.B.a.v)
EQUIPMENT PROTECTION
• Pumps
– Every 30 days, the pump and motor shaft should be rotated by hand (10-15 turns)
to prevent bearing damage and potential for binding. Be sure shaft comes to rest in different positions.
– Close-coupled pumps may have minimal access to exposed shaft areas. In those
cases, care must be taken to avoid damage to the shaft though use of channel-lock pliers or similar tools.
– If removal of the coupling guard is required for hand-rotation of the pump and
motor shafts, this guarding must be reinstalled prior to removal of lock-out tag-out and start-up.
• Control Panels, VFDs, and Electronics
– For storing electrical control panels, drives and other electrical items for more than
3 months, insertion of moisture absorbing packets within the enclosure by be necessary. Periodically replace as required. Remove packets prior to equipment start-up.
• Package Enclosures
– Housing vents and/or openings will be sealed with plastic wrap and waterproof
tape.
– Condensation protection shall be provided in accordance to instructions previously
noted.
PREPARATION FOR OPERATION
• Remove all rust inhibitor from exposed machined surfaces using the method described by the supplier.
• Remove all corrosion protection devices or material from package.
• Remove flange covers, tape, and all unnecessary pipe plugs.
TECHNOForce e-HV Mechanical Installation, Operation, and Maintenance Manual 9

3 Product Description

3 Product Description

3.1 General description

Description
A pump station is a pre-engineered and fabricated line of packaged booster systems that provides:
• Energy efficiency
• System protection
• Hydraulic capability up to 780 GPM
• Boost pressures up to 270 PSI
Intended applications
WARNING:
This product can expose you to chemicals including Lead, which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to: www.P65Warnings.ca.gov.
The pump station is intended for these applications:
• High rise buildings
• Industrial plants
• Municipal and rural water districts
• Agriculture / irrigation
• General water pressure boosting

3.1.1 Operational limits

Pressure
This table describes the pressure ratings for a pump station using the pump model shown
Pump system type Max. discharge pressure
e-SV Pumps 270 PSI

3.2 Nameplate information

Important information for ordering
Every pump station has a nameplate that provides information about the pump station. The pump station nameplate is located on the inside of the control enclosure door.
When ordering spare parts, be prepared to identify the nameplate information when contacting the factory.
• Model
• Size
• Serial number
• Item numbers of the required parts.
10 TECHNOForce e-HV Mechanical Installation, Operation, and Maintenance Manual
Date Code
Pump Boost
Station Flow
Largest Motor HP
SCCR
System FLA
Station Voltage
Serial Number
Model Number
Applied Water Solutions Dallas, Texas, U.S.A Customer Service 1.800.786.7480
3 Product Description
Nameplate field Explanation
Model number The manufacturer's number to indicate the particular type of product which has been
acquired.
Serial number A set of characters that uniquely identifies a single unit and can be used for traceability
and warranty purposes.
Station voltage The rated voltage at which the station has been designed for. Should match the
application site supply voltage.
System FLA The full-load-amperage at which the station can operate.
SCCR “Short-Circuit Current rating”. Represents the maximum level of short-circuit current
that a component or assembly can withstand.
Largest motor HP The rated HP for the largest pump in the system.
Station flow The designed duty point, in GPM, LPH, etc.
Pump boost The difference between the input side of the pump station and the output side of the
pump station.
Date code Marking of products to indicate their date of manufacture.
TECHNOForce e-HV Mechanical Installation, Operation, and Maintenance Manual 11

4 Installation

4 Installation

4.1 Reference manuals

Additional installation information
For information on installing controllers, use the following IOM:
• Hydrovar - Instruction Manual
• Hydrovar - Overview Software Parameters

4.2 Field connections

Diagrams
Actual equipment manufacturers/models installed are system specific. Refer to specific manufacturer Installation, Operation, and Maintenance manuals for details unique to each component. The pump instruction manual is supplied with the system.
Review the wiring diagrams and dimensional drawings provided with the station before you install and operate the unit.
Electrical precautions
WARNING:
Electrical shock hazard. The electrical supply must match the control panel nameplate specification. Incorrect voltage can cause a fire, which damages the electrical components and voids the warranty. Failure to follow these instructions could result in serious personal injury or death, or property damage.
NOTICE:
Electrical connections must be made by certified electricians in compliance with all international, national, state, and local rules.

4.3 ground (earth) connections

WARNING:
Electrical shock hazard. Conduit grounds are not adequate. You must attach a separate ground (earth) wire to the ground (earth) lug provided in the enclosure in order to avoid potential safety hazards. Failure to follow these instructions can result in serious personal injury, death, or property damage.
A grounding terminal is provided for a dedicated ground (earth) wire connection. You must follow all provisions of the National Electrical Code and local codes.

4.4 Pump package location guidelines

WARNING:
Assembled units and their components are heavy. Failure to properly lift and support this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.
Guideline Explanation/comment
Make sure that the space around the pump package is
sufficient.
12 TECHNOForce e-HV Mechanical Installation, Operation, and Maintenance Manual
This facilitates ventilation, inspection, maintenance, and service.
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