Xylem 10 001 247 R2 User Manual

Introduction and Safety.........................................................................................................................3

Introduction..........................................................................................................................................3

Safety.....................................................................................................................................................3

Safety terminology and symbols....................................................................................................3

Environmental safety........................................................................................................................4

Recycling guidelines........................................................................................................................5

User safety............................................................................................................................................5

Precautions during work..................................................................................................................5

Wash the skin and eyes....................................................................................................................6

Product warranty.................................................................................................................................6

Transportation and Storage..................................................................................................................8

Inspect the delivery.............................................................................................................................8

Inspect the package.........................................................................................................................8

Inspect the unit..................................................................................................................................8

Transportation guidelines..................................................................................................................8

Lifting methods.................................................................................................................................8

Storage guidelines..............................................................................................................................8

Storage location................................................................................................................................8

Table of Contents

Product Description.............................................................................................................................10

General description..........................................................................................................................10

Operational limits...........................................................................................................................10

Nameplate information....................................................................................................................10

Installation.............................................................................................................................................12

Reference manuals............................................................................................................................12

Field connections..............................................................................................................................12

Earth (ground) connections.............................................................................................................12

Pump package location guidelines................................................................................................12

Foundation requirements................................................................................................................13

Level the base on a concrete foundation.......................................................................................13

Grout the baseplate..........................................................................................................................13

Piping checklist..................................................................................................................................14

Commissioning, Startup, Operation, and Shutdown......................................................................15

Preparation for startup.....................................................................................................................15

Prestartup checklist........................................................................................................................15

Final installation checks.................................................................................................................16

Final adjustments............................................................................................................................16

Pump station startup.........................................................................................................................17

Conﬁrm the job site voltage..........................................................................................................17

Field install the supply water temperature sensor (constant speed units only).....................17

Connect the storage tank..............................................................................................................17

Check for available suction water.................................................................................................17

Start the package............................................................................................................................18

Check the pump rotation..............................................................................................................18

Set the system operating pressure...............................................................................................18

Enter the setup menu.....................................................................................................................18

Test the package............................................................................................................................19

TechnoForce Package System Mechanical Installation, Operation, and Maintenance Manual 1

Table of Contents

Maintenance.........................................................................................................................................20

Precautions.........................................................................................................................................20

Monthly maintenance.......................................................................................................................20

Troubleshooting...................................................................................................................................22

Pump station troubleshooting.........................................................................................................22

The pump station does not power up.........................................................................................22

The station powers up, but the pumps do not run....................................................................22

The pumps run but do not build desired pressure....................................................................23

The pump station experiences excessive vibration...................................................................24

The pump station does not shut down and no water is used...................................................24

The pump station cycles or hunts erratically...............................................................................24

Technical Reference............................................................................................................................26

Pump station numbering system....................................................................................................26

Pump station with e-SV pumps.....................................................................................................26

Pump station with NPE pumps.....................................................................................................27

Pump station with SSH pumps......................................................................................................29

2 TechnoForce Package System Mechanical Installation, Operation, and Maintenance Manual

Introduction and Safety

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.

Introduction and Safety

Safety

WARNING:

• The operator must be aware of safety precautions to prevent physical injury.

• Any pressure-containing device can explode, rupture, or discharge its contents if it is over-pressurized. Take all necessary measures to avoid over-pressurization.

• 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.

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

• Product malfunction

TechnoForce Package System Mechanical Installation, Operation, and Maintenance Manual 3

Introduction and Safety

Hazard levels

Hazard level Indication

Hazard categories

DANGER:

WARNING:

CAUTION:

NOTICE:

Hazard categories can either fall under hazard levels or let speciﬁc symbols replace the ordinary hazard level symbols.

Electrical hazards are indicated by the following speciﬁc symbol:

A hazardous situation which, if not avoided, will result in death or serious injury

A hazardous situation which, if not avoided, could result in death or serious injury

A hazardous situation which, if not avoided, could result in minor or moderate injury

• A potential situation which, if not avoided, could result in undesirable conditions

• A practice not related to personal injury

Electrical Hazard:

These are examples of other categories that can occur. They fall under the ordinary hazard levels and may use complementing symbols:

• Crush hazard

• Cutting hazard

• Arc ﬂash hazard

Environmental safety

The work area

Always keep the station clean to avoid and/or discover emissions.

Waste and emissions regulations

Observe these safety regulations regarding waste and emissions:

• Appropriately dispose of all waste.

• Handle and dispose of the processed liquid in compliance with applicable environmental regulations.

• Clean up all spills in accordance with safety and environmental procedures.

• Report all environmental emissions to the appropriate authorities.

4 TechnoForce Package System Mechanical Installation, Operation, and Maintenance Manual

Electrical installation

Recycling guidelines

User safety

General safety rules

Introduction and Safety

WARNING:

Do NOT send the product to the Xylem manufacturer if it has been contaminated by any nuclear radiation. Inform Xylem so that accurate actions can take place.

For electrical installation recycling requirements, consult your local electric utility.

Always follow local laws and regulations regarding recycling.

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

hazards.

• 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:

• 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

NOTICE:

Never operate a unit unless safety devices are installed. Also see speciﬁc information about safety devices in other chapters of this manual.

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 control.

• Beware of the starting jerk, which can be powerful.

TechnoForce Package System Mechanical Installation, Operation, and Maintenance Manual 5

Introduction and Safety

• 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.

Wash the skin and eyes

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.

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

Product warranty

Coverage

Xylem undertakes to remedy defects in products from Xylem under these conditions:

• The faults are due to defects in design, materials, or workmanship.

• The faults are reported to an local sales and service representative within the warranty period.

• The product is used only under the conditions described in this manual.

• The monitoring equipment incorporated in the product is correctly connected and in use.

• All service and repair work is done by Xylem authorized personnel.

• Genuine Xylem parts are used.

• Only Ex-approved spare parts and accessories authorized by an EX-approved Xylem representative are used in Ex-approved products.

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.

Limitations

The warranty does not cover defects caused by these situations:

• Deﬁcient maintenance

• Improper installation

• Modiﬁcations or changes to the product and installation made without consulting an

Xylem authorized representative

• Incorrectly executed repair work

• Normal wear and tear

Xylem assumes no liability for these situations:

• Bodily injuries

• Material damages

• Economic losses

6 TechnoForce Package System Mechanical Installation, Operation, and Maintenance Manual

Warranty claim

Introduction and Safety

Xylem products are high-quality products with expected reliable operation and long life. However, should the need arise for a warranty claim, then contact your local sales and service representative.

TechnoForce Package System Mechanical Installation, Operation, and Maintenance Manual 7

Transportation and Storage

Inspect the delivery

Inspect the package

1. Inspect the package for damaged or missing items upon delivery.

2. Note any damaged or missing items on the receipt and freight bill.

3. File a claim with the shipping company if anything is out of order. If the product has been picked up at a distributor, make a claim directly to the

distributor.

Inspect the unit

1. Remove packing materials from the product. Dispose of all packing materials in accordance with local regulations.

2. Inspect the product to determine if any parts have been damaged or are missing.

3. If applicable, unfasten the product by removing any screws, bolts, or straps. For your personal safety, be careful when you handle nails and straps.

4. Contact your sales representative if anything is out of order.

Transportation guidelines

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.

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.

• Do not place heavy weights on the packed product.

8 TechnoForce Package System Mechanical Installation, Operation, and Maintenance Manual

Storage between use

Long-term storage

Transportation and Storage

Observe the following for long-term storage of a pump station.

• 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.

If the unit is stored for more than 6 months, these requirements apply:

• Store in a covered and dry location.

• Store the unit free from heat, dirt, and vibrations.

• Rotate the pump shaft by hand several times at least every three months.

Treat bearings and machined surfaces so that they are well preserved. Refer to the drive unit and coupling manufacturers for their long-term storage procedures.

For questions about possible long-term storage treatment services, please contact your local sales and service representative.

TechnoForce Package System Mechanical Installation, Operation, and Maintenance Manual 9

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