Xylem 19-001-200R2 User Manual
INSTRUCTION MANUAL
19-001-200R2
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
SILENT STORM
VFD Pumping System
NOTE: This product is not intended for use in potable water applications.
ii
Acknowledgements
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Flowtronex© is a registered trademark of Xylem Flowtronex.
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respective owners. The publisher and the author make no claim to these trademarks. These include
Microsoft, Windows, Windows NT, ActiveX that are either registered trademarks or trademarks of Microsoft
Corporation in the United States and/or other countries. ©2013 Microsoft Corporation. All rights reserved.
WHILE EVERY PRECAUTION HAS BEEN TAKEN IN THE PREPARATION OF THIS DOCUMENT, THE
PUBLISHER AND THE AUTHOR ASSUME NO RESPONSIBILITY FOR ERRORS OR OMISSIONS, OR
FOR DAMAGES RESULTING FROM THE USE OF INFORMATION CONTAINED IN THIS DOCUMENT OR
FROM THE USE OF PROGRAMS AND SOURCE CODE THAT MAY ACCOMPANY IT. IN NO EVENT
SHALL THE PUBLISHER AND THE AUTHOR BE LIABLE FOR ANY LOSS OF PROFIT OR ANY OTHER
COMMERCIAL DAMAGE CAUSED OR ALLEGED TO HAVE BEEN CAUSED DIRECTLY OR
INDIRECTLY BY THIS DOCUMENT.
TABLE OF CONTENTS
ACKNOWLEDGEMENTS ..................................... II
TABLE OF CONTENTS ................................
............... III
WARRANTY INFORMATION ........................................ 2
SAFETY ................................
SAFETY INSTRUCTIONS ................................................. 3
SAFETY REMINDERS ................................
Additional Safety Information ................................
......................................... 3
...................... 3
............. 4
GENERAL DESCRIPTION ............................................ 5
PRODUCT DESCRIPTION ............................................... 5
OPERATIONAL LIMITS ................................
NAMEPLATE INFORMATION ................................
STATION NUMBERING .................................................... 5
HANDLING ................................
STORAGE ......................................................................... 6
FIELD CONNECTION DIAGRAMS ................................
GROUND CONNECTIONS ................................
........................................ 6
.................... 5
........... 5
... 6
............... 7
INSTALLATION ............................................................. 8
LOCATION ........................................................................ 8
FOUNDATION ................................................................... 8
PUMP INSTALLATION ................................
Prior to Installation ................................
Installing Assembled Pump Station ............................ 8
...................... 8
...................... 8
STATION OPERATION ............................................... 11
DOOR SWITCH OPERATION ........................................ 11
System Control Switch .............................................. 11
Individual Pump Switches ......................................... 11
VFD / Bypass Switch ................................
VFD Selector Switch (Optional On Some Stations) –
P 1 / PUMP 2 / PUMP 3 .................................... 11
PUM
Low Discharge/Differential Pressure Switch ............. 11
Wye Strainer or Filter Switch .................................... 12
Lake Screen Switch ................................
Well Pump Switch ................................
Reset Push Button ................................
AUTOMATIC OPERATION ................................
Overview ................................
Line Fill Mode ................................
System Charging Mode ............................................ 13
Normal Operation ................................
................................... 13
................ 11
.................. 12
..................... 12
.................... 12
............. 13
............................ 13
...................... 14
Manual VFD Operation .............................................. 16
VFD Bypass Operation, Manual mod
VFD Bypass Operation, Auto mode ........................... 17
PLC Bypass Operation .............................................. 18
SYSTEM SAFETIES ................................
Automatic Mode of Operation .................................... 19
Manual Mode of Operation ........................................ 19
Low Discharge Pressure ................................
High Discharge Pressure ................................
Low Inlet Pressure ................................
Loss of Prime ................................
Low Level Fault .......................................................... 21
Phase Failure ............................................................. 21
INDIVIDUAL PUMP FAULTS ................................
Overload Protection ................................
High Pump Temperature (Optional) ........................... 22
VFD Fault ................................
e ...................... 16
........................ 19
............ 19
........... 19
..................... 20
............................. 20
........... 21
................... 21
................................... 22
MAINTENANCE .......................................................... 23
REGULAR MAINTENANCE = INVESTMENT .................. 23
REGULAR MONTHLY MAINTENANCE INTERVALS ..... 23
WINTERIZING PUMP STATIONS ................................... 24
Generalized Instruction
Vertical Stations ......................................................... 25
Horizontal Stations ................................
Spring Restart of Pumping Station ............................ 25
s for All Pump Stations ......... 24
..................... 25
TROUBLESHOOTING ................................................ 26
LOW DISCHARGE PRESSURE FAULT .......................... 26
HIGH DISCHARGE PRESSURE FAULT .........................
LOW LEVEL FAULT ................................
LOW INLET PRESSURE FAULT ..................................... 27
LOSS OF PRIME FAULT ................................
PHASE FAULT ................................
VFD FAULT ................................
MOTOR WON’T START ..................................................
......................... 27
................. 28
................................. 28
...................................... 28
27
29
GLOSSARY OF TERMS ............................................. 30
APPENDIX A —
APPENDIX B —
FINAL CHECK LIST ........................ 34
ELECTRICAL WIRING AND
CONTROL SETTINGS FINAL CHECKLIST ............... 35
NOTE: The information contained in this book is intended to assist operating personnel by providing
information about the characteristics of the purchased equipment.
It does not relieve the user of their responsibility of using accepted engineering practices in the installation,
operation, and maintenance of this equipment.
For additional questions, contact:
XYLEM FLOWTRONEX
8:00 AM to 5:00 PM Central time (800) 786-7480 x3
5:00 PM to 8:00 AM Central time
After Hours technician for emergency assistance. (214) 454-5768
support@flowtronex.com
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2
WARRANTY INFORMATION
Company warrants title to the product(s) and,
except as noted below with respect to items not
of Company’s Manufacturer, also warrants the
product(s) on date on shipment to Purchaser, to
be of the kind and quality described herein, and
free of defects in workmanship and material.
THIS WARRANTY IS EXPRESSLY IN LIEU OF
ALL OTHER WARRANTIES, INCLUDING BUT
NOT LIMITED TO IMPLIED WARRANTIES OF
MECHANTABILITY AND FITNESS, AND
CONSTITUTES THE ONLY WARRANTY OF
COMPANY WITH RESPECT TO THE
PRODUCT(S).
If within one year from date of initial operation, but
nor more than eighteen months from date of
shipment by Company of any item of product(s),
Purchaser discovers that such item was not as
warranted above and promptly notifies Company
in writing thereof, Company shall remedy such
non-conformance by, at Company affected part of
the product(s). Purchaser shall assume all
responsibility and expense for removal,
reinstallation, and freight in connection with the
foregoing remedies. The same obligations and
conditions shall extend to replacement parts
furnished by Company hereunder. Company shall
have the right of disposal of parts replaced by it.
ANY SEPARATELY LISTED ITEM OF THE
PRODUCT(S) WHICH IS NOT MANUFACTURED
BY THE COMPANY IS NOT WARRANTED BY
COMPANY and shall be covered only the express
warrant, if any, of the manufacturer thereof.
THIS STATES PURCHASER’S EXCLUSIVE
REMEDY AGAINST COMPANY AND ITS
SUPPLIERS RELATING TO THE PRODUCT(S),
WHETHER IN CONTRACT OR IN TORT OR
UNDER ANY OTHER LEGAL THEORY, AND
WHETHER ARISING OUT OF WARRANTIES,
REPRESENTATIONS, INSTRUCTIONS,
INSTALLATIONS OR DEFECTS FROM ANY
CAUSE. Company and its suppliers shall have no
obligation as to any product which has been
improperly stored and handled, or which has not
been operated or maintained according to
instructions in Company or supplier furnished
manuals.
3
SAFETY
to alert you to potential personal injury
which, if not avoided, will result in death or
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
Indicates a potentially hazardous situation,
if not avoided, may result in minor or
CAUTION
a potentially hazardous situation, which, if not
Read all safety information prior to installation
of the Silent Storm Pumping System.
SAFETY INSTRUCTIONS
SAFETY INSTRUCTION
This is a SAFETY ALERT SYMBOL. It is used
All operating instructions must be
read, understood, and followed by
the operating personnel. Flowtronex
accepts no liability for damages or
operating disorder which are the
result of non compliance with the
operating instructions.
hazards. Obey all safety messages that follow
this symbol to avoid possible injury, death!
FAILURE TO FOLLOW THE INSTRUCTIONS
MAY RESULT IN A SAFETY HAZARD.
DANGER
Indicates a potentially hazardous situation
serious injury.
WARNING
serious injury.
CAUTION
which
moderate injury.
When the Pumping System
components reach the end of life
the components should be
disposed of or recycled in
accordance with local laws.
SAFETY REMINDERS
1. This manual is intended to assist in
the installation, operation, and repair
of the system and must be kept with
the system.
2. Installation and maintenance MUST
be performed by properly trained and
qualified personnel.
3. Review all instructions and warnings
prior to performing any work on the
system.
4. Any safety decals MUST be left on
the controller and pump.
5. The system MUST be disconnected
from the main power supply before
attempting any operation or
maintenance on the electrical or
mechanical part of the system.
Failure to disconnect electrical power
before attempting any operation or
maintenance can result in electrical
shock, burns, or death.
Used without the safety alert symbol indicates
avoided, may result in property damage.
4
ADDITIONAL SAFETY INFORMATION
This pump has been designed for safe and reliable
operation. A pump is a pressure-containing device
with rotating parts that could be hazardous.
Operators and maintenance personnel must
realize this and follow necessary safety measures.
Proper safety procedures must be followed. Xylem
Flowtronex shall not be liable for damage or
delays caused by a failure to observe the
instructions in this manual.
Safety Apparel:
• Wear insulated work gloves when
handling hot bearings or using bearing
heater.
• Wear heavy work gloves when handling
parts with sharp edges, especially
impellers.
• Wear safety glasses (with side shields) for
eye protection, especially in machine shop
areas.
• Wear steel-toed shoes for foot protection
when handling parts, heavy tools, etc.
• Wear other personal protective equipment
to protect against hazardous/toxic fluids.
Coupling Guards:
• Never operate a pump without a coupling
guard properly installed.
• Never force piping to make a connection
with a pump.
• Use only fasteners of the proper size and
material.
• Ensure there are no missing fasteners.
• Beware of corroded or loose fasteners.
Operation:
• Do not operate below minimum rated flow,
or with suction/discharge valves closed.
• Do not open vent or drain valves, or
remove plugs while system is pressurized.
Maintenance Safety:
• Always lock out power.
• Ensure power is isolated from system and
pressure is relieved before disassembling
pump, removing plugs, or disconnecting
piping.
• Use proper lifting and supporting
equipment to prevent serious injury.
• Observe proper decontamination
procedures.
• Know and follow company safety
regulations.
• Never apply heat to remove impeller.
• Observe all cautions and warnings
highlighted in pump instruction manual.
5
GENERAL DESCRIPTION
PRODUCT DESCRIPTION
A Flowtronex Silent Storm Variable Speed
Pumping System is custom built to the
requirements provided by the purchaser. The
Silent Storm pumping system is a modular
variable speed system designed to maintain a
constant discharge pressure while providing a
variable flow rate to match the water demand of
the system. The system minimizes power
consumption by combining a variable speed lead
pump with constant speed lag pumps. The Silent
Storm utilizes a microprocessor-based controller
to efficiently manage pump operation to match a
wide range of pressure boosting applications.
Silent Storm Variable Speed Pumping Systems
are self-contained, pre-assembled and factorytested pumping plants. Silent Storm utilizes state
of the art technology, yet employs a simplistic and
straightforward design that makes installation,
operation, and maintenance an easy task, even for
the most inexperienced of operators.
This manual serves as a guide to understanding
the features of Silent Storm Pumping Systems and
provides a quick and clear reference for answers
to most questions pertaining to its service. Every
attempt has been made to explain all facets of
system operation and maintenance. However,
should you have specific questions not addressed
in this manual, you are encouraged to contact your
nearest Flowtronex Authorized FlowNet
representative, or the factory (800-786-7480
Ext. 3).
OPERATIONAL LIMITS
See pumping system nameplate information for
pumping system flow capacity, pressure, full load
current and electrical ratings.
Unless special provisions have been made for
your pumping systems, the system pressure rating
is as follows:
Pump system type
Max discharge pressure
End suction centrifugal
175 psi
Vertical turbine
200 psi
NAMEPLATE INFORMATION
The system nameplate gives identification and
rating information as identified in the figure below.
Figure 1: Sample Nameplate
Field
Explanation
Voltage
Required input voltage
SCCR
Short circuit current rating
Phase
Number of motor phases
FLA
Full load amps
Hz
Required frequency (hertz)
Max. HP
Maximum horsepower
Permanent records for this system are referenced
by the serial number. Include the serial number
with all correspondence and spare parts orders.
STATION NUMBERING
Example: V W T P - 900 - 3 - 120
1. Control Type:
V = VFD
2. Water Source Type:
W = Wet Well
V = Vessel
C = Can
F = Flooded
L = Lift
B = Boost
D = Deep Well
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S = Submerged Sled pump assembly
M = Floating pump assembly
3. Pump Type:
C = Horizontal
S = Submersible
T = Vertical Turbine
M = Multi-stage Horizontal (ex. Goulds
SSV)
E = Submersible Trash Pump (ex. Ebara)
4. System Type:
P = Pump Station
T = Transfer
X = Control Package
5. System Gallons per Minute: If a multi-zone
system, show all zones with a slash ( / )
between each. If it is a control package,
show the total number of pumps to be
controlled.
6. Quantity of Pumps: Include pressure
maintenance pump and current pumps do not include future pumps in model
number.
7. System Pounds per Square Inch: If multizone system, show all zones with a slash
( / ) between each zone. Design must
assume that all zones run at the same
time. Describe in no-uncertain terms the
performance of each zone. If the station
has spacing for future pumps, always
create a model number showing the
current conditions service. Make notes in
your documentation describing the
"current" versus "future" conditions of
service. On boosted systems, model
number should reflect the differential
pressure with notes describing the
incoming pressure.
HANDLING
Qualified personnel should unload and handle the
unit. Prevent damage due to dropping or jolting
when moving the unit. Thoroughly inspect the unit
for damage upon receipt. Immediately notify the
carrier of transportation damage. Ensure that
sensing lines are free of crimps and kinks.
The unit is top heavy due to the position of the
equipment. Do not use component eyebolts to lift
the pump station.
WARNING: Falling Objects Hazard
Eyebolts, if provided, are designed to lift only the
components to which they are attached.
Failure to follow these instructions could result in
serious personal injury, death, and/or property
damage.
STORAGE
During periods of storage, the unit should be
covered to prevent corrosion and contamination
from dirt. Store the unit in a clean, dry location to
prevent condensation and freezing. After storage,
check that it is dry before applying power. Specific
component storage instructions must be followed
in accordance with the respective equipment
manufacturer's recommendations.
CAUTION: Extreme Temperature Hazard
Extreme temperatures are to be avoided. (Below
32ºF and above 110ºF.)
Failure to follow these instructions could result in
serious property damage and/or moderate
personal injury.
FIELD CONNECTION DIAGRAMS
Actual equipment manufacturers/models installed
are system specific. Refer to specific
manufacturers’ Installation, Operation &
Maintenance Manuals for details unique to each
component. The pump instruction manual is
supplied with the system (if applicable).
Review the wiring diagrams and dimensional
drawings prior to unit installation and operation.
NOTE: Electrical supply must match the control
panel nameplate specification. Incorrect voltage
can cause fire, damaging electrical components
and void the warranty.
NOTE: Electrical supply must be installed by a
qualified electrician in accordance with all
applicable codes, ordinances, and good practice.
7
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: Electrical Shock Hazard
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, or property
damage.
8
INSTALLATION
LOCATION
Locate the pumping system in a clean, well
ventilated, and properly drained location. It is
recommended that the location selected facilitates
ease of inspection, maintenance, and service.
Outside installation requires protection from
freezing.
WARNING: Falling Objects Hazard - Heavy
Load, May Drop If Not Lifted Properly.
Do not lift the entire unit by component eyebolts.
Eyebolts on components are used for factory
assembly only and are not intended to lift the
complete package.
Failure to follow these instructions could result in
serious personal injury, death, or property
damage.
FOUNDATION
With proper installation and a suitable foundation,
this unit is built to supply years of service.
Establish a base of concrete weighing a minimum
of 2-1/2 times the weight of the unit. (Check the
shipping tickets or the pumping system drawing for
unit weight.) Tie the concrete pad in with the
finished floor. Use the appropriate anchor bolts to
secure the pumping system to the foundation.
Pump packages with electrical conduit below
surface may require corrosion protection approved
for this condition.
WARNING: Electrical Shock Hazard
Electrical conduit installed below the surface may
require a corrosion resistant protective coating to
prevent conduit corrosion and electrical shock.
Failure to follow these instructions could result in
serious personal injury, death, or property
damage.
Place the unit on its concrete foundation,
supporting it with steel wedges or shims. These
wedges or shims should be put on both sides of
each anchor-bolt and midway between the bolts,
to provide a means of leveling the base.
After the pumping system has been leveled, install
the correct number of anchor bolts and tighten to
secure the system.
PUMP INSTALLATION
In most cases, if the pumps have an overall length
of less than twenty (20) feet, they are shipped
assembled. Only the motor, head shaft, strainer
basket, and discharge connection are shipped
separately. The following instructions describe
installation for assembled pump stations.
Prior to Installation
1. Measure each pump and document on the
set/start report.
2. Confirm wet well probe measurements.
Measure the distance from the bottom of
the wet well to the top of the skid to
ensure that pumps were ordered with the
correct length. Preferred length is 12
inches above the bottom of the wet well.
3. Tighten all bolts and couplings on the
pump before proceeding.
4. Install each pump according to the last
digit on the pump identification tag.
Figure 2: Location of Serial Number and
Skid Position
Installing Assembled Pump Station
1. To set pump, use a crane or other
adequate lifting device and a cable sling of
adequate length. Attach the cable to the
lifting lugs (lifting eyes) on either side of
the pump.
9
Figure 3: Lifting Pump
2. After the cable-sling is attached to the
lifting lugs (lifting eyes) on the pump head,
raise the pump to a vertical position. While
in this position, install the strainer basket
with bolts and clips. Position the pump
over its access hole on the skid.
WARNING: Falling Objects Hazard
DO NOT work under heavy suspended object
unless there is positive support and safeguards
should a hoist or sling fail.
Failure to follow these instructions could result in
serious personal injury, death, or property
damage.
3. Very slowly, lower the pump through its
access, keeping one hand on the pump to
detect any bumping by the pump against
the edge of its hole or the wall of the wet
well. When the pump is properly installed,
it should not touch the side of the wet well.
Premature bearing failure or destruction of
the bowl assembly can result from
improper installation.
Figure 4: Position Head Over Access
Hole on Skid
WARNING: Equipment Damage Hazard
Be prepared to stop lowering the pump
IMMEDIATELY if any bump is felt.
It is possible that the pump bowl could catch on
the edge of the skid and become unhooked from
the cable or other lifting device. Possible serious
bodily injury or damage to the pump could result.
Verify and ensure that the safety latch on the hook
works properly.
Failure to follow these instructions could result in
serious personal injury, death, or property
damage.
4. Push the pump slightly off-center when it
is being lowered in the wet well to avoid
hitting the manifold discharge pipe.
5. Stop lowering the pump when the base of
the head is approximately 1/8 to 1/4 inch
above the platform.
10
6. Line up the spool with the pump isolation
valve on the manifold-discharge pipe and
set the pump on the skid. Start threading
the base bolts on the pump head. Slide
the Victaulic clamp gasket so that the
clamp rides in the gloves on both the
isolation valve and the spool. Tighten the
Victaulic clamp. Tighten the base bolts.
7. If the pumps are shipped unassembled,
refer to the Gould Pumps, Model VIT
Installation, Operation, & Maintenance
Instructions.
8. Install the vertical hollow shaft motor to
the top of the pump’s disconnected head.
Refer to the Gould Pumps, Model VIT
Installation, Operation, & Maintenance
Instructions.
WARNING: Falling Objects Hazard
DO NOT work under heavy suspended object
unless there is positive support and safeguards
should a hoist or sling fail.
Failure to follow these instructions could result in
serious personal injury, death, or property
damage.
CAUTION: Motor Rotation Hazard
DO NOT install motor shaft, Gib key, or adjusting
nut until motor rotation has been verified.
Failure to follow these instructions indicates a
potentially hazardous situation, which, if not
avoided, may result in property damage.
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