Mini V 1-2 Pump Cold Water Booster
Sets TKS/GTKS Variable Speed
Operating and Maintenance Instructions
Declaration of conformity
Lowara pumps UK declare that the Mini V Booster set conforms to the requirements of the Machinery Safety
Directive 98/37/EEC.
Conforming to the UK Health & Safety Requirements S.I. 1992 No 3073 S.I. 1994 No 2063
Water supply (Water fittings) regulations 1999
Simple pressure vessel directive 87/404/EEC
Signed: Position: Engineering manager Date: 27-02-12 Revision
Clive Willmott
Introduction
This leaflet contains information to enable the safe installation and operation of the products mentioned.
The following instructions must be read and understood by all persons responsible for the installation,
operation and maintenance of this product.
Warning Symbols
Safety instructions where noncompliance would affect safety.
Safety instruction where electrical hazard is involved.
Safety instruction where noncompliance could cause damage to the equipment.
Instruction for safe us
Noise Emission
This equipment operates at a noise level lower than 70dBA.
Operating limits
This product has been designed for boosting cold water in potable water installations to the
operating conditions shown.
This product should not be installed until this leaflet has been studied carefully and understood.
Handling, transportation and installation of this equipment should only take place with the proper
use of lifting equipment. This product must be stored in a frost-free dry environment.
Fluid temperature 0°C to 40°C
Ambient temperature 0°C to 40°C
Operating pressure Max 5 Bar
Protection class Teknospeed & Electrical panel IP55
1
Installation
The cold Water booster set is despatched mounted on a wooden pallet and covered in a protective film, it is
in a ventilated, dry frost free position also ensuring adequate room for general maintenance and service. The set
should be fixed in position directly to the floor, if vibration separation is required then cork mats should be
used supplied by others.
The water tank is constructed to have a weir slot as required by the water bylaws to prevent back flow
contamination, if the inlet ball valve suffered a catastrophic failure the overflow may not be able to keep up
with the inflow in which case excess water will be ejected through the weir slot and onto the plant room
floor, if this is not acceptable then consideration should be given to fitting the booster set onto a try with
overflow to drain.
Never run pumps dry
Ensure the pumps are filled with water before switching the power on.
Electrical connections
The electrical connections must be carried out by a competent electrician in accordance with local
regulations.
on the set duty plate.
Never operate this product with isolation panels removed or the control panel door in the open
position. These Sets are fitted with variable speed drives which include large capacitors so wait at least
8 minutes after the supply has been removed before opening or removing covers.
It is essential that this equipment is earthed to the building earth system.
All metal parts must be earth bonded directly to the building earth system.
recommended that the unit be retained in the protective packaging until the product is to be
installed. The unit will arrive pre-packaged and wired ready for installation. This product has
been fully run tested at our works under simulated site conditions. The unit should be thoroughly
checked for physical damage that may have been caused during transit. If the unit is found to
have damage it must be reported immediately and should not be installed. The unit should be sited
The cable used for the incoming supply must be of adequate size to carry the motor full load
current of all pumps as they are able to operate at the same time. Motor ratings are shown on the
set duty plate. All non power cable should be limited to 1.5mm².
All connections must be made using the appropriate wiring drawings for the equipment being
installed; with particular attention being paid to the supply voltages. The supply voltage is shown
Electrical data TKS/GTKS
Note: whilst the input to the
inverter is Single phase, the
output to the motor is Three
phase.
Nominal power
(KW) 1 pump
TKS10 single phase
Absorbed current(A)
1 x 230V
GTKS20 single phase
Absorbed current(A)
1 x 230V
0.55 3.5 7
0.75 4.9 9.8
1.1 6.8 13.6
Water supply connections
Connect the incoming water supply to the break tank ball valve. The outlet of the tank will already
be connected to the booster set suction manifold. The tank will include a class AB air gap (Cate-
protect against dry running. Connect the 22mm warning pipe to a position where a discharge will cause a nuisance and be remedied. Connect the overflow pipe to drain.
When the tank has been filled check the water level and adjust ball valve as necessary.
Ensure the tank is thoroughly flushed through before the set is put on line.
It is the responsibility of the installer to ensure that the overflow is able to keep up with the incoming
water volume; if this is not the case then a pressure reducing valve should be fitted to reduce the incoming
mains water volume.
gory 5 protection) the tank will also include a low level float switch connected to the booster set to
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Discharge pipe work
fitted to the end not used. A flexible connector fitted between the booster discharge manifold and the system
connection pipe will help prevent the transmission of noise/vibration. An isolation valve should be provided
between the booster discharge line and the system to aid maintenance. The discharge pipe work should be
sized to achieve a maximum velocity of approximately 2.5m/s.
Pressure vessels
Variable speed booster sets can operate with relatively small pressure vessels; each set is supplied with 1 x 8
or 24lt vessel for each pump depending on pump type which is more than adequate for the set to function
correctly. Larger vessel can be added if required. If stand alone vessels are added they should have an
isolation valve and drain cock fitted to allow the vessel to be isolated from the system and drained to check
the pre-charge pressure.
The vessel pre-charge should be set to approximately 0.2 bar below the pump stating pressure.
Teknospeed basic setting details
The Teknospeed has only one adjustable parameter which is the system set point, to adjust see item 14
below under commissioning.
Commissioning
With the main power isolated check:
1. The break tank feeding the set is filled with water and the ball valve is set to the correct height.
2. The set/system vessels have been charged with Nitrogen to the correct pressure (set point -0.2 bar).
3. Open suction line isolation valve.
9. Open discharge valve.
10. Ensure all vessel valves are open.
11. Switch the main power supply on.
12. allow water to flow and clear air through the system
13. close discharge valve and check pressure reading on pressure gauge
14. To raise or lower the system set point use the screwdriver provided and turn the adjusting screw in the
inverter housing clockwise to increase pressure, anti-clockwise to decrease pressure. When
decreasing pressure it may be necessary to open a discharge outlet to release pressure after adjusting,
close discharge and pump should stop after approximately 60 seconds. Do not set the system set point
higher than the pump can produce as the pump will not stop. See Fig. 1 below for adjusting screw
position.
4. Open suction and discharge pump isolation valves.
5. Close main discharge isolation valve.
6. Open the pump vents at the top of each pump.
7. Allow all air to escape until water flows freely.
8. Close pump vent valves.
See Teknospeed O&M for more in depth pump details.
3
Operation
The booster set is designed to maintain a constant system pressure with varying flows.
Each inverter head has its own 4-20ma transducer which monitors the system pressure at all times.
If one inverter or transducer fails the next inverter will continue to function independently. All inverters
talk to each other through a RS485 serial coms link. Each inverter head is fitted with an adjusting screw
to adjust the set point. See figure 1 below
When a demand is placed on the system, water will be supplied from any vessels that are fitted to the
system, once this supply is depleted the system pressure will start to fall, when the pressure falls to the
system set point the first Teknospeed pump will start to ramp up to maintain the set point, if demand
increases and the first Teknospeed reaches maximum speed and again the system pressure continues to
fall the second Teknospeed (When fitted) will be called in to ramp up and assist the first pump.
When demand reduces the last Teknospeed to be called in will start to ramp down and eventually stop, if
demand continues to decrease the next Teknospeed will start to ramp down and stop. The next time the
pressure falls the pumps will have been rotated so the opposite pump will be the first to operate.
If a low level in the break tank occurs all pumps will be stopped until the water supply has been
reinstated, the pumps will then be automatically released to resume normal operation.
The remote inhibit if fitted will operate in the same way and stop all pumps if inhibited.
Volt Free Contacts
Volt free N/O (Closes for fault) alarm contact is available from each Teknospeed head. See electrical
drawing for connection details.
Remote inhibit
A remote inhibit can be achieved by utilising the low water terminals, a N/C external Stop/Start circuit can
be connected in series with the low water terminals. (open to inhibit) See electrical drawing for connection
details.
Alarm indicators
LEDs are provided to indicate:
Power-Run-Alarm2
The number of times a Red LED flashes indicates
The type of alarm (see Figure 2)
An attempt is made to reset the alarm every 20
seconds after 3 unsuccessful attempts the inverter stops
f at least 10 minutes elapse after an alarm without any
further faults occurring the reset attempts counter is reset.
Fig 1.
Fig 2.
LED No OF
FLASHES
2 Converter overcurrent
3 Converter overtemperature
4 Motor overtemperature
5 No water (LOW1/LOW2)
6 No signal from pressure transmitter
7 Undervoltage
8 Serial interrupted (timeout)
TYPE OF ALARM
4
Caution
This booster set is an automatic machine; the pumps may start up automatically without
prior warning.
The set contains pressurised water; reduce the pressure to zero before servicing.
Maintenance
5. Check that the earth connections are tight and making good contact.
6. Check that the gas pre charge is at the correct pressure, this should be done by isolating the vessel from
the system and draining water out of the vessel via the isolation valve drain point.
Once the water has been discharged, a tyre gauge can be connected to the pre charge valve to display the
vessel pre charge pressure. Recharge as necessary with Nitrogen or dry air.
Any other expansion vessels connected to the system can be checked in the same manner.
Clean any filters that may be connected to suction/discharge lines and ensure the mesh is in good condition.
General fault finding guide
Routine check (6 monthly intervals)
1. Check all pumps produces the correct pressure.
2. Check that the pump operates without undue noise or vibration.
3. Check the break tank/s are clean and that the correct water level has been maintained.
4. Check that all screws are tight on electrical components.
Fault Possible Cause Remedy
Power supply failure
Control panel fuse blown,
Pump fails to start
Pump fails to stop
Pump switches on and off
quickly
Pump runs but will not make
pressure
Pump overheating Pump partially seized
Pump set frequently
starting. (pressure falls to
cut in point)
Break tank overflowing
Pump leaks water
MCB tripped
Remote inhibit active
Low water level
Set point set too high
System pressure low due to
large leak
Air in system
Vessel pre-charge incorrect
Pump air locked
Non-return valve jammed
Passing too much water
Newly installed system with
large amount of air in pipe work
Leaks in system pipe work
Vessel pre-charge incorrect
Leaking ball valve
Non-return valve letting by
Defective mechanical seal
Undue mechanical stress on
pump
Reinstate incoming power supply
Replace power supply fuse
Reset MCB
Turn remote inhibit off
Reinstate water supply
Lower set point
Switch unit off until leak is repaired
Purge air from pumps and pipework
Check vessel pre-charge and Charge as
necessary with Nitrogen or dry air
Open pump bleed screw and vent pump
Clean/replace valve
Check system for leaks
Remove pump and check for foreign
objects
Bleed system to remove air
Repair leaks
Isolate vessel and pre-charge with
Nitrogenas appropriate
Replace ball valve seal
Replace/clean non-return valve
Replace seal
Support the pipe work
5
Disposal
Disposal of this product should be carried out in accordance of local codes and regulation pertaining to the
disposal of waste, including packaging materials.
Booster set details
Model type
Order Code
Pump type
Serial number
Installation date
System set point
Booster set notes
Lowara UK Limited
Millwey Rise Industrial Estate, Axminster, Devon EX13 5HU - UK
Tel: 01297 630230 Fax: 01297 630270
e-mail: lowaraukenquiries@xyleminc.com
http://www.lowara.co.uk http://completewatersystems.com
Lowara is a trademark of Xylem Inc. or one of its subsidiaries. © 2011 Xylem, Inc.
Lowara reserve the right to make modifications without prior notice.
cod. UKLIT0089 P05/12
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