Xylem 19-001-251R3 User Manual

INSTRUCTION MANUAL

19-001-251R3

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

Floboy

™

VFD Pumping System

NOTE: This product is not intended for use in potable water applications.

Acknowledgements

Flowtronex® is a registered trademark of Xylem Flowtronex.

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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 ·········································· I

TABLE OF FIGURES ············································· II

WARRANTY INFORMATION ··································· 2

SAFETY ······························································· 3

Safety instructions .................................................... 3

Safety Reminders ..................................................... 3

Additional Safety Information ................................... 4

Safety Apparel .......................................................... 4

Coupling Guards ...................................................... 4

Operation .................................................................. 4

Maintenance Safety .................................................. 4

GENERAL DESCRIPTION ······································ 5

Product Description .................................................. 5

Operational Limits .................................................... 5

Nameplate Information ............................................. 5

Station Numbering: ................................................... 6

Example: FBSNV4BF10D46R3ABD ........................ 6

handling .................................................................... 7

Storage ..................................................................... 7

Field Connection Diagrams ...................................... 7

Ground Connections ................................................ 7

RECEIVING ·························································· 8

Preparing to Receive the Pump Station ................... 8

Inspecting the Shipment ........................................... 8

Unpacking and Storing This Equipment ................... 8

INSTALLATION ···················································· 8

Location .................................................................... 8

Foundation ............................................................... 9

Anchoring the Station ............................................... 9

Suction Piping .......................................................... 9

Discharge Piping .................................................... 12

Electrical Connections ............................................ 12

START-UP AND ADJUSTMENTS ···························· 13

Power Check .......................................................... 13

Voltage Variance .................................................... 13

Voltage Imbalance .................................................. 13

Pump Priming ......................................................... 13

Pump Rotation ........................................................ 14

System Pressurization ............................................ 15

Priming Line Adjustment ........................................ 15

Overload Trip Adjustment ....................................... 15

STATION OPERATION ·········································· 16

DOOR SWITCH OPERATION ............................... 16

Individual Pump Switches .............................. 16

OPERATIONAL SETTINGS IN THE HMI .............. 16

Auto-Manual Select ........................................ 16

LDP Override ................................................. 16

Reset Control (F5) .......................................... 16

Resetting Faults ............................................. 16

AUTOMATIC OPERATION .................................... 17

Overview ........................................................ 17

System Charging Mode .................................. 17

NORMAL OPERATION .......................................... 17

MANUAL VFD OPERATION .................................. 18

CONTROLLER BYPASS OPERATION ................. 19

Overview ........................................................ 19

SYSTEM SAFETIES .............................................. 19

Fault Reset ..................................................... 19

Low Discharge Pressure ................................ 19

High Discharge Pressure ............................... 19

Low Inlet Pressure ......................................... 20

Loss of Prime ................................................. 20

INDIVIDUAL PUMP FAULTS ......................... 21

Overload Protection ....................................... 21

High Pump Temperature (Optional) ............... 21

VFD Fault ....................................................... 21

NAVIGATING THE CONTROLS ······························· 21

Overview ................................................................ 21

Pump Status Indicators .......................................... 22

Pressure Setpoint Adjustment ................................ 22

Trends and Alarms ................................................. 23

Totals ..................................................................... 24

Pump Control ......................................................... 24

Start settings .......................................................... 24

Stop Settings .......................................................... 24

Speed Test ............................................................. 25

Safety ..................................................................... 25

Panel Config ........................................................... 25

Sys Config .............................................................. 25

PID Parameters ...................................................... 25

Other Settings ........................................................ 25

MAINTENANCE ···················································· 26

REGULAR MONTHLY MAINTENANCE INTERVALS

............................................................................... 26

Heat exchanger: ............................................. 26

Control panel: ................................................. 26

Motor lubrication: ............................................ 26

Pumps - horizontal: ........................................ 26

Sound and visual checks of whole station: .... 26

Station skid: .................................................... 26

WINTERIZING the PUMP STATION ..................... 27

Winterizing ..................................................... 27

Spring Restart ................................................ 27

TROUBLESHOOTING ············································ 28

LOW DISCHARGE PRESSURE FAULT ............... 28

HIGH DISCHARGE PRESSURE FAULT ............... 29

LOW LEVEL FAULT .............................................. 29

LOW INLET PRESSURE FAULT ........................... 29

LOSS OF PRIME FAULT ....................................... 30

VFD FAULT ............................................................ 30

MOTOR WON’T START ........................................ 31

GLOSSARY OF TERMS ········································· 32

APPENDIX A — FINAL CHECK LIST ························ 35

APPENDIX B — ELECTRICAL WIRING AND CONTROL SETTINGS FINAL CHECKLIST ················ 36

TABLE OF FIGURES

Figure 1: Typical Floboy suction and discharge piping, Boost applications ....................................................... 5

Figure 2: Typical Floboy suction and discharge piping, Lift applications ........................................................... 5

Figure 3: Sample Nameplate ............................................................................................................................. 6

Figure 4: Typical Floboy installation on slab. ..................................................................................................... 9

Figure 5: Anchoring the station to the concrete slab. ......................................................................................... 9

Figure 6: Proper suction lift principles .............................................................................................................. 11

Figure 7: Improper suction lift application ........................................................................................................ 11

Figure 8: Proper installation of pump ............................................................................................................... 12

Figure 9: Confirm rotation by making sure motor is operating in the direction of the motor tag ...................... 15

Figure 10: Floboy controller. ............................................................................................................................ 22

Figure 11: Main Screen .................................................................................................................................... 22

Figure 12: Pump Status Indicators ................................................................................................................... 22

Figure 13: Perssure Setpoint ........................................................................................................................... 22

Figure 14: Setpoint Password Entry Screen .................................................................................................... 22

Figure 15: Entering the password for the setpoint screen ............................................................................... 23

Figure 16: Changing the setpoint ..................................................................................................................... 23

Figure 17: Performance Graph ........................................................................................................................ 23

Figure 18: Alarms Screen ................................................................................................................................ 23

Figure 19: Alarm Description ........................................................................................................................... 23

Figure 20: Menu ............................................................................................................................................... 24

Figure 21: Totals .............................................................................................................................................. 24

Figure 22: Pump Control .................................................................................................................................. 24

Figure 23: Stop Settings .................................................................................................................................. 24

Figure 24: Pump Control, Combo Selection .................................................................................................... 24

Figure 25: Speed Test ..................................................................................................................................... 25

Figure 26: Safety .............................................................................................................................................. 25

Figure 27: Safety, Others ................................................................................................................................. 25

Figure 28: Panel Configuration ........................................................................................................................ 25

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

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.

SAFETY

Read all safety information prior to installation of your pumping system.

SAFETY INSTRUCTIONS

SAFETY INSTRUCTION

This is a SAFETY ALERT SYMBOL. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death!

FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD.

DANGER

Indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation, which if not avoided, may result in minor or moderate injury.

CAUTION

Used without the safety alert symbol indicates a potentially hazardous situation, which, if not avoided, may result in property damage.

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.

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.

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.

GENERAL DESCRIPTION

PRODUCT DESCRIPTION

Floboy Pumping Systems are self-contained, pre-assembled and factory-tested pumping systems. Floboy utilizes state of the art technology, yet employs a simplistic and straight forward design that makes installation, operation and maintenance an easy task, even for the most inexperienced of operators.

This manual will serve as a guide to understanding the features of Floboy Pumping Systems and provide 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 for a variety of applications. However, should you have specific questions not explained or illustrated in this manual you are encouraged to contact your nearest Floboy Pumping Systems distributor, representative or the factory.

Floboy utilizes a single main pump (with or without a pressure maintenance pump) to supply water to a turf irrigation system or other nonpotable application requiring water at a constant pressure. Because Floboy is a totally automatic system, the pump is energized whenever a demand for water is sensed (pressure start). Conversely, the pump is de-energized when the demand no longer exists (pressure stop or flow stop). In this manner, pressure is maintained in any system at all times, thereby reducing piping fatigue and minimizing the introduction of air into the piping network.

For those customers who wish to start and stop a pump based on a remote signal, as with an irrigation controller, this function is available as a selectable option on all models of Floboy. The system can be controlled using 24V AC/DC signal outputs from an irrigation controller or other control devices (relay start).

Figure 1: Typical Floboy suction and discharge

piping, Boost applications

Figure 2: Typical Floboy suction and discharge

piping, Lift applications

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 175 psi for end suction centrifugal.

NAMEPLATE INFORMATION

The system nameplate gives identification and rating information as shown below.

Figure 3: Sample Nameplate

Field

Explanation

Voltage

Required input voltage

SCCR

Short circuit current rating

Phase

Number of motor phases

FLA

Full load amps

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: FBSNV4BF10D46R3ABD

08FB=Floboy II

1. Size Code

a. S=Small (52”l x 40”w x 45”h)

b. M=Mid (64”l x 53” w x 55” h’)

2. Lift or Boost

3. Control Type: V = VFD

4. Pump model

5. Horsepower

6. Impeller Code. Specific to type of pump used.

7. Voltage (46=460, 23=230, 20=208)

8. Start/Stop Control. R=Relay, F=Flow, P=Pressure. Floboy 2009 models are field configurable between models, unlike the previous Floboy systems.

9. Phase: 3=3 Phase, 1=single phase. 3Phase power is generally more efficient and less expensive per KWH, but may not be available.

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. Typical wiring diagrams are included in Appendix D.

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.

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 or death, or property damage.

RECEIVING

PREPARING TO RECEIVE THE PUMP STATION

Each Floboy Pumping System is shipped on a wooden pallet and is enclosed in either a cardboard box or shrink wrap. It will probably arrive in an enclosed van or semi-trailer which will require specialized equipment, such as a fork lift, to off-load. Please remember, it is your responsibility to provide a safe and secure means to remove this equipment from the carrier's vehicle. Once you take possession of the pump station, the freight carrier is no longer responsible for damage due to mishandling.

CAUTION

Caution: This equipment is heavy. Do not attempt to pick it up or move it manually. Bodily injury may result.

INSPECTING THE SHIPMENT

Inspect the pump station for damaged goods

prior to accepting shipment. Note all damages or missing components on the "Bill of Lading".

Note: When the pump station arrives, it is your responsibility to inspect this equipment for damage or lost goods prior to signing the carrier's freight bill.

Should you notice shorted or damaged goods, you must make a notation to that effect on the face of the "freight bill" and keep a copy so a claim can be processed with the freight company. If you give

the freight company a clear receipt for goods that have been damaged or lost in transit you do so at your own risk and expense.

If you receive the pump station and subsequently discover damaged equipment or lost goods that were concealed by the packaging you must contact the freight company immediately. Do not proceed with the system's installation until the freight company has inspected this equipment. A "Concealed Damage Report" must be made within 15 days of receiving the equipment or any claim of loss will not be honored.

The factory will assist you in every possible manner to collect a claim for loss or damage but be advised that the laws of interstate commerce make it your responsibility to file, process and collect all claims directly from the freight company or its agent.

UNPACKING AND STORING THIS EQUIPMENT

When cutting the packaging with a knife or razor, take care not to scratch the paint on the metal enclosure. If the pump station is to be stored for any period of time, make certain it is left in a secure location, preferably one which is free of excessive moisture and freezing conditions.

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.

The factory recommends positioning the Floboy Pumping System on a concrete slab that provides a permanent and supportive base. The system should be positioned as close to the intended source of water as possible. For systems lifting water from a lake or pond, the pump station elevation should be close to the water surface elevation. In most cases the pump site should never be more than five feet above the minimum water elevation as long as this elevation is above the normal flood plane.

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