hpdc o&m

1

HPDC Maintenance quick guide

Electrical.

Recommendation on checking of each motor and the control panel as below:

-Motor current operating current not exceeding full load current as rated at the motor nameplate.

Every 2 weeks

-Motor insulation within permissible operating range of 1M ohm and above. Every 3 months.

-Motor winding resistance balance reading among phases.

Every 3 months.

-Control panel operation sequence, light indicators, Thermal overload trip simulation and emergency on operation. Components and inlet air

filter should be cleaned to prevent dust accumulation that will reduce air flow through the filter and maximized components life span.

Every 6 months

* Soft vacuuming is possible.

* Please note that electrical test and checking should only be carried out by trained personel

with proper safety equipment.

** The recommended time is just a guide depending on site condition. More frequent checking is more encourage to enable system to operate smoothly.

*** Grundfos shall not bear any responsibility for the above recommendation.

2

HPDC Maintenance quick guide

Mechanical

Recommendation on checking of each pump as below:

-The pump should be check at priming plug if any air lock problem.

Every week

-The motor bearing with grease nipple required greasing.

Every month

-Y-strainer filter if any should be taken out and cleaned.

Every Month

-The pneumatic tank should be check if the precharge air is sufficient for proper operation. The system must be totally stop as the tank air precharge pressure reading at the tank is only accurate when there is no water pressure to the tank. The precharge pressure must be 70% to 90% of the setpoint (cut in) pressure.

Every 3 months.

-The pneumatic tank bladder should be taken out for inspection. The tank internal should be check for any formation of rust which might damage/puncture the bladder.

Every 12 Month

-The pneumatic tank bladder was inspected and pressure tested by the local authority Jabatan

Keselamatan

dan

Kesihatan

Pekerja

before delivery.

* Please note that electrical test and checking should only be carried out by trained personel

with proper safety equipment.

** The recommended time is just a guide depending on site condition. More frequent checking is more encourage to enable system to operate smoothly.

*** Grundfos

shall not bear any responsibility for the above recommendation.

3

HPDC Trouble shooting quick guide

General trouble shooting and possibilities of common fault.

Pump not operating when pressure low

-Panel not operating. Check power supply to panel.

-Controller not functioning. Service controller.

-Starter not functioning. Service starter.

-Thermal overload relay trip. Check motor before reset.

-Water level low at suction. Check suction level.

Pump noisy during operation.

-Pump damaged. Pump need to be serviced.

-Particles in the pump. Pump need to be serviced.

-Bearing faulty. Bearing need to be replaced.

-Pump operating at loss phase. Check power supply to pumps.

-Pump cavitations/operating out of pump curve. Throttle discharge

valve.

Thermal overload relay trip/Trip indicator at the controller.

-Motor burnt. Motor need to be service.

-Pump jammed. Pump need to be service.

-Pump operating out of pump curve. Throttle discharge valve.

-Power supply not correct. Check power supply to pumps.

Pump start/stop too frequent

-Tank precharge air low. Pre-charge the air to 70% to 90% of the setpoint pressure.

-Tank bladder burst. Replace bladder.

-Controller faulty. Service controller.

4

HYDRO PNEUMATIC DC (DIGITAL CONTROL)

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

6

GeneralThe description covers the standard unit with functions for Grundfos

Hydro Pneumatic DC Booster system, incorporating Grundfos

Hydro Control Pneumatic DC and all accessories.

Grundfos

Hydro Pneumatic Booster System is designed for pressure boosting in system supplying consumption water to dwellings, office buildings, hotels, hospitals, departmental stores, manufacturing plants and etc.

Pumps, motors and starter panelThe Grundfos

Hydro Pneumatic system is built with all Grundfos

components, except where all applicable, certain non-Grundfos

accessories are supplied. Users are not encouraged to install any equipment or connection into the system where not approved by Grundfos. The introduction of foreign equipment or connection into the system may affect the operation of the system, and may result in damage of pumps, components or the control panel. In this respect, Grundfos

shall not be liable for the damage all standard warranty will be declared null and void.

Pneumatic vesselOne or more pneumatic vessel is supplied with the booster system. The vessel is supplied with a certain precharge air depending on the maximum operating pressure range. The pneumatic vessel forms part and parcel of the booster system operation and the system shall not be operated without a it integrally fitted into the system. The vessel shall

conform to local authority rules and regulations and where applicable, it shall be inspected annually

for defects. Users are encourage to read the accompanying manuals on the pneumatic vessel to ensure proper working and maintenance knowledge.

In general, Grundfos

supply the following sizes of standard pneumatic vessel:Type:

Actual volume

Pressure range

Max liquid tempCT300V

270 litres

100-200psi

70 deg.celsiusCT500V

527 litres

100-200psi


1000 litres

100-200psi


1526 litres

100-200psi


2017 litres

100-200psi

70 deg.celsius

Please refer to Grundfos

for optional pneumatic tank sizes and operating pressure.For optimum system operation, ensure a precharge air pressure of 70% of the setpoint.

AccessoriesDepending on system design, Grundfos

is able to supply other accessories to enhance the operation of the booster system. Users are encouraged to check with Grundfos

for more details.

DESCRIPTION

7

FEATURES

BENEFITS1.

One touch easy operation.

2.

User friendly with discharge pressure monitoring readout with indication light for the operation of the pump at the controller.

3.

Standard protection feature with front indication lights and read out at the controller.

4.

First in first out starting and stopping sequence and lead lag change over feature built in the controller.

5.

Password protected for settings of controller.

6.

Hour run meter for individual pump built in controller

7.

Clock program up to 3 start and stop setting for each day of the

week

8.

Over pressure, under pressure, sensor failure, dry run protection and excessive start/stop in the controller.

9.

Easy setting of setpoint pressure (cut in) and differential settings (cut off)

10.

Phase failure protection during operation as standard.

11.

High quality components.

Standard protection devicesGrundfos

Hydro Pneumatic Digital Controller 1. Over pressure. Protection against high pressure surges.When the pressure reaches the high pressure setting (A2-4bXX), the system will shut down and automatically reset when the pressure drop lower than the setpoint.2. Under pressure. Protection against pipe burst that will cause cavitations.When the pressure falls below 50% of the setpoint

pressure for time based on delay timer setting (A2-5rXX), the system will shut down and manual reset is required.3. Sensor failure.

Protection against continuous operation when sensor faulty.When the sensor at the discharge manifold faulty or disconnected, the controller will able to detect that the signal is less than 4mA. Then it’ll shut down the system until a new sensor is replaced and connected back. Manual reset is required.4. Dry run protection. Protection against pump operation when the suction tank is empty.When controller detected that the tank water level reached the stop point via the electrode sensors (by others) , the system will shut down and will be automatically reset when the suction tank reaches the start level.* The above protections functions in auto mode only.** Please refer to indication description of the controller.5. Excess start/stop protection. Protection against pump operating rapidly (setable

no of times) within set time. Manual Motor Starter (MMS) circuit breaker for individual pumpShort circuit protectionThermal overload protectionPhase failure protection (During operation)* Functions in all modes.

8

Auto modeDepending on the performance required the selected setpoint

will be retained via automatic start/stop of mains operation of the pumps. The pressure range in which the pump will supply are controlled by the settings of the controller as supplied in the system. The pneumatic vessel in the system acts as a pressure holding unit to prevent frequent start/stop in intermittent demand and to provide for the system pressure to be retained for a longer time before the pumps are started again. All control, operation and protection features are activated in accordance with the set parameters

To activate auto modePress the start/stop button. The pump will operate automatically

base on the setting of the controller until the start/stop button is pressed again.

SetpointThe system pressure settings is set via the controller. The setpoint

is set according to the pressure range curve of the pump used as recommended in the above diagram. This is to ensure system will operate in optimum condition and supply the pressure required according to the consumption demand. Allow for minimum pressure differential of 10 meters between the setpoint

and differential setting at the controller.Alternation of pumpsThe system is incorporated with a leadlag

feature via the controller to allow alternation of pumps in automatic mode. In the condition where more than one duty pump is required, e.g consumption exceeds one duty pump capacity and where pressure falls below the setpoint, the next pump will come into operation to supply the pressure required. Where the first pump has finished a cycle, the second pump will start.First in first out functionThe system is incorporated with first in first out function via the controller to allow the operating time of the pump to be equally shared. In the condition where more than one duty pump is required, e.g consumption exceeds one duty pump capacity and where pressure falls below the setpoint, the next pump will come into operation to supply the pressure required. When the differential setpoint

is reached, the pump that been operating the longest time will cut-off first.

Emergency mode** Operate only if the Hydro Pneumatic DC controller is faulty.During emergency operation, pump operation must be monitored to prevent the pump from dry running and operating at ‘no flow’. All protection is not applicable with this mode.

Switch Off the isolator and unscrew the latch anti-clockwise to open the panel door.Switch On the isolator by turning the knob of the isolator clockwise to 900

to power “on” the starter panel.

Switch On the emergency switch by turning it clockwise to 450.The pump will run until the emergency switch is manually switched off.

* Refer to Fig 1.

OPERATION

9

1 –

Pump indicator‘On’ indicates the specific pump is running.‘Flashing’ indicates specific pump is on standby mode.‘Off’ indicates no pump or power supply not on.

2 –

Status indicator‘On’ indicates that the specific pump tripped via Manual Motor Starter(Refer MMS for protection)Status Indicator 1 flashing indicates Overpressure alarmStatus Indicator 2 flashing indicates Underpressure

alarmStatus Indicator 3 flashing indicates Pressure transmitter failure alarmStatus Indicator 4 flashing indicates Dry run protection alarm

3 –

Alpha numeric indicatorRead out of the parameter and actual monitoring pressure and parameter settings.

4 –

Start/stop buttonTo activate or shut down the system in auto mode.

5 –

Select (Enter) buttonTo enter into specific parameter, to change and enter a value of

the parameter.

6 –

Scroll right butttonTo scroll forward into the parameter or increase the value of settings.

7 –

Scroll left buttonTo scroll back into the parameter or decrease the value of settings.

8 –

Individual pump controller manual mode indicator * On indicates that the specific pump is set to operate to manual mode at n01 to n04 settings.

9 –

Clock program indicator*Flashing indicates the clock program of the controller is activated.

10 –

Auto restart (after power failure)* On indicates system will automatically operate after power resume.* Flashing indicates system will restart to previous state after

power resume.* Off indicates system will not restart after power resume. Manual activation required.

6 5

1

GRUNDFOS HYDRO PNEUMATIC DC CONTROLLER INDICATOR

7

4

3

8

910 2

10

Flow chart of the controller settings.

11

Settings description

EPS

CPS

NP

PC

PD

SP

B

TD

HL

HLT

LL

LLT

A1TY

A1LR

A1HR

AIC

ENTER A PASSWORD FOR SETTING ACCESS

CHANGE THE USER PASSWORD

TOTAL PUMPS CONTROL BY CONTROLLER

SET TO FIFO (FIXED) OTHERS NOT USED

DELAY TIME BETWEEN PUMPS WHEN START STOP (S)PREVENT ALL PUMPS TO START STOP SIMULTANEOSLY

PRESSURE SETTING (BAR) EXAMPLE: 6.5 BAR = 065

CUT OFF PRESSURE BAND (BAR)EXAMPLE: 015 = PUMP STOP AT SETPOINT + 1.5BAR

DELAY START/STOP WHEN SP1 AND B REACHED (S)

MAXIMUM PRESSURE CUT OUT SETPOINT (BAR)STOP SYSTEM WITH FAULT INDICATION WHEN PRESSURE REACHED HL SETPOINT AFTER THE HLT TIME

ALARM DELAY FOR HIGH LIMIT (S)

MINIMUM PRESSURE CUT OUT LIMIT SETPOINT (BAR)STOP SYSTEM WITH FAULT INDICATION WHEN PRESSURE REACHED LL SETPOINT AFTER THE LLT TIME

ALARM DELAY FOR LOW LIMIT (MIN)

SET TO C-CURRENT (FIXED) OTHERS NOT USED

LOWEST RANGE OF SENSOR (BAR)

HIGHEST RANGE OF SENSOR (BAR)

0 (FIXED) OTHERS NOT USED

ENTER PASSWORD

CHANGE PASSWORD

NUMBERS OF PUMP

PUMP CONTROL

START/STOP TIME GAB

SETPOINT

PRESSURE DIFFERENTIAL

TIME DELAY

HIGH LIMIT

HIGH LIMIT DELAY

LOW LIMIT

LOW LIMIT DELAY

ANALOGUE INPUT

AITY LOWEST RANGE

AITY HIGHEST RANGE

AITY COMPENSATION

12

Settings description (cont)

RT1

RT2

RT3

RT4

RSTT

MO1

MO2

MO3

MO4

AR

RT

SDAY

SCLK

ETS

NPE

NPT

PUMP1 HOUR RUN DISPLAY (READ ONLY)




RESET ALL PUMPS HOUR RUN TIME






DELAY TIME TO RESTART THE SYSTEM AFTER POWER FAILURE WHEN AR SET TO 10. (SEC)1 –

7 MONDAY TO SUNDAY

0000 -

2359

0 = DISABLE. 1= ENABLE, SYSTEM OPERATE AS T11S TO T73E SETTINGS0 –

255 NUMBER OF START LIMIT

0 –

255 MINUTES OF MEASUREMENT PERIOD.

P1 RUN TIME

P2 RUN TIME

P3 RUN TIME

P4 RUN TIME

RESET HOUR RUN

PUMP1 MODE

PUMP2 MODE

PUMP3 MODE

PUMP4 MODE

SYSTEM RESET MODE

SYSTEM RESET DELAY

CURRENT DATE

CURRENT CLOCK

CLOCK PROGRAM FUNCTION

PERMISSIBLE TOTAL START LIMITPERMISSIBLE TIME PERIOD

T11S TO T73E IS THE CLOCK PROGRAM FUNCTION FOR SYSTEM OPERATION AT SPECIFIC TIME AND DAY. PLEASE REFER TO GRUNDFOS FOR FURTHER INFORMATION.

* THE DATE, CLOCK SETTINGS AND CLOCK PROGRAM FUNCTION ARE RESET UPON POWER ON/OFF.

13

Operators are advised to check regularly whether the system has been fully adjusted to existing operating conditions.

Control panelAll electrical components should be inspected and where necessary, contactors and overload protections shall be cleaned and tested periodically to ensure its worthiness. Mains voltage and current should be checked regularly to ensure operating within acceptable limits.

PumpsPump bearings are water lubricated and maintenance free. Priming

can be done to ensure no airlock in the pumps due to other reasons.

MotorsMotors which are not fitted with grease nipples are maintenance free.Motors fitted with grease nipples should be lubricated with a high temperature lithium based grease, see the instructions on the fan cover of Grundfos

motors. Operating current measurement is recommended to ensure both pump and motor operate within acceptable range.In the case of seasonal operation (motor is idle for more than 6

months of the year), it is recommended to grease the motor when the pump is taken out of operation.Motor should be checked on the insulations and resistance according to specifications annually.Please refer to Grundfos

for the specifications.

Pneumatic tankIt is critical that the pneumatic tank pre charge air to be checked regularly recommended not longer than every 3 months to ensure the pre charge air pressure

is 70-80% of the setpoint

pressure to ensure optimum and proper operation. The system must be shut down to have the discharge pressure drop

lower than the precharge

air pressure or second option is to have the tank inlet/outlet closed and drain off the water from the tank. Pre charge pressure can be measure with a pressure gauge install above the tank when discharge water pressure lower than pre charge. However the most

accurate is to have tank water drain out completely.Should the system operate with the pneumatic tank pre charge out

of the recommended range, there is high chances of damaging the bladder in the tank which will damage other components in the system later.Please note that all pre-charge tank is recommended to be tested and checked every 15 months with the approval of JKKP (Jabatan Keselamatan dan Kesihatan Pekerja)

Maintenance of the Hydro Pneumatic DC system.

14

FAULT FINDING AND REMEDIES

Controller does not operate when start/stop button is pressed (All indicator light does not activate)Step A1 Check incoming power supply Power supply down Rectify the source

Power supply on Go to step A2

Step A2 Check emergency switch position ON position Switch to OFF positionOFF position Go to step A3

Step A3 Check control MCB OFF position Switch to ON positionON position Call Grundfos for assistance

Status indicator light for specific pump on (specific pump trip)Step B1 Check the MMS Trip position Check pump and motor outgoing cable

Reset the MMS once onlyIf fault repeat, call Grundfos for assistance

Normal position Reset. If fault repeat, call Grundfos.

Status indicator 1 light flashing (overpressure) Controller read out "PHL"Step C1 Check the high pressure setting at the controller Pressure reading is higher than HL limit Reset. If fault repeat, call Grundfos.

Pressure reading is lower than HL limit Go to step C2

Step C2 Check the Pneumatic tank Tank is faulty Call Grundfos for assistanceTank is functional Reset. If fault repeat, call Grundfos.

Status indicator 2 light flashing (under pressure) Controller read out "PLL"Step D1 Check the pressure reading on pressure gauge Pressure reading is higher than LL limit Reset. If fault repeat, call Grundfos.

Pressure reading is lower than LL limit Go to step D2

Step D2 Check the discharge pipe for major leakage Leakage detected Rectify the leakageNo leakage detected Reset. If fault repeat, call Grundfos.

Status indicator 3 light flashing (pressure transmitter faulty) Controller read out "SEnF"Step E1 Check the pressure reading on pressure gauge Pressure reading is same as at controller Reset. If fault repeat, call Grundfos.

Pressure reading is at 0 at the controller Go to step E2

Step E2 Check the connection to the pressure transmitter Disconnected Rectify the connectionConnection correct Reset. If fault repeat, call Grundfos.

Status indicator 4 light flashing (dry run protection) Controller read out "LSS"Step F1 Check the suction tank water level Water below electrode start level Auto reset when reach start level

Water above electrode start level Go to step F2

Step F2 Check the connection of the electrode Disconnected Rectify the connectionConnection correct Reset. If fault repeat, call Grundfos.

Pump does not run when the pressure is lower than the setpoint in Auto ModeStep G1 Check the pressure reading on controller Pressure reading is lower than setpoint Go to step B2

Pressure reading is higher than setpoint Go to step G2

Step G2 Check the indicators at controller Status indicator light on/flashing Refer to light description and reset faultStatus indicator light not activated Go to step G3

Step G3 Check the settings at controller Settings incorrect Reset the settings at the controllerSettings correct Reset. If fault repeat, call Grundfos.

Pump does not run when emergency switch is activatedStep H1 Check incoming power supply Power supply down Rectify the source

Power supply on Go to step H2

Step H2 Check control MCB OFF position Switch to ON positionON position Go to step H3

Step H3 Check the MMS OFF position Switch to ON positionON position Go to step H4

Step H4 Check the MMS OFF position Switch to ON positionON position Go to step H5

Step H5 Check the contactor Activated Check outgoing motor cableNot activated Reset. If fault repeat, call Grundfos.

Pump start/stop too frequent or ESSF indicate at displayStep I1 Check controller settings Settings incorrect Reset all settings

Settings correct Go to step I2

Step I2 Check tank precharge air Precharge air less than 70% of setpoint Check for leakage, and chrage air to 70%of setpoint

(system off without pressure) Precharge air at 70 to 80% of setpoint Reset. If fault repeat, call Grundfos.

15

Ambient temperature: +5 to 45 deg.Celsius.

Operating voltage: 3 X 380-440 V

Operating frequency: 50-60 HZ

Operating current: Depends on model

Enclosure class: IP50 (Optional IP54 for weather proof upon requested)

Motor starting:Direct on lin

starting: 0.37 kW to 2.2kWStar/Delta starting: 3kW to 7.5kWAutotrans starting: 11kW and above.Please refer to Grundfos

for optional forms of starting e.g soft staring, variable speed

starting and etc.

Material of panel: 1.5 mm Mild steel

Colour

of panel: Epoxy coat light grey as per Grundfos

standard

STANDARD SPECIFICATIONS

hpdc o&m

Documents