waterpak pro series - · pdf fileall waterpak pro series systems are warranted against defects...

7/11/2012

WaterPak Pro Series

Model WP3

Installation and Operation

Manual

l

M O D E L W P 3 I N S T A L L A T I O N A N D O P E R A T I O N M A N U A L

M O D E L W P 3 I N S T A L L A T I O N A N D O P E R A T I O N M A N U A L i

Table of Contents

This manual is intended solely for the purpose of providing a better understanding of the Watertronics® Pumping System. Watertronics assumes no responsibility or liability for injury or damage due to the use or misuse of this manual. Reproduction of the contents of this publication, in whole or part, without written permission of Watertronics, LLC is strictly prohibited.

1 General Information

Receiving ............................................................................................... 1 Warranty ................................................................................................ 2 Introduction ............................................................................................ 2 Important Safety Considerations ........................................................... 3

2 Product Overview

Specifications ........................................................................................ 5 Key Features ......................................................................................... 5 Component Locations – Interior ........................................................... 6 Component Locations – Exterior ........................................................... 8

3 Installation

Mechanical Installation .......................................................................... 14 Electrical Installation ............................................................................. 15

4 System Start-up

System Start-up ..................................................................................... 21

5 Customizing the Pump Station

Keypad Overview ................................................................................... 27 Access the Pump Control Menu ........................................................... 28 Changing the Pump Control Parameters ............................................. 29

6 Winterization

Winterization ........................................................................................... 33

7 Troubleshooting

Troubleshooting .................................................................................... 37

8 Appendix

Replacement Parts ................................................................................ 39 Pump Specification Sheet Parts Diagram Variable Frequency Drive Programming Manual VFD MONITORING Screen Detail

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M O D E L W P 3 I N S T A L L A T I O N A N D O P E R A T I O N M A N U A L

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M O D E L W P 3 I N S T A L L A T I O N A N D O P E R A T I O N M A N U A L 1

General Information

Receiving While in most instances you will be picking up your WaterPak pump station directly from a Select Distributor, sometimes units will be shipped directly to a job site. In these cases, please follow these simple instructions listed below.

When you receive your WaterPak pump station, please carefully check for damaged or missing items. Note any missing or damaged items. While we makes every effort to ensure that all items are in good condition before shipping, occasionally products do get lost or damaged in shipping. If you notice damaged or missing items, please contact your Select Distributor immediately.

Watertronics® recommends the following:

• Provide a safe and secure means to off-load the product.

• Unpack and inspect the pump station for concealed damage prior to accepting shipment. Note all damages or missing components.

• Exercise caution when unpacking the pump station to prevent scratching or damaging external parts.

• Store the pump station in a secure location to prevent vandalism or weather damage.

We want all of our customers to be satisfied and promise to make every effort for your complete satisfaction with your new WaterPak pump station.

1.

G E N E R A L I N F O R M A T I O N


Warranty All Waterpak devices and systems are manufactured according to the most recent technical standards and subjected to a comprehensive quality assurance system.

All WaterPak Pro Series systems are warranted against defects in material and workmanship for a period of one (1) year from the date of purchase from a select distributor. This warranty is limited to replacing or repairing any defective component and does not apply to equipment that has been damaged, misapplied or has been modified in any way.

Regular scheduled maintenance is required to keep the WaterPak Pro Series systems running in top condition.

This warranty does not cover damages under the following conditions:

• Lightning strikes, misapplied or inappropriate in-coming power, improper grounding, vandalism, or any incidental, consequential, or acts of God

• Repairs or replacements made without pre-authorization

• Exposure to destructive gaseous, water, or chemical solutions

• Operation of the system outside of the recommended design and operating specifications

• Pumping polluted water, such as gray or black water, without proper chemicals

Introduct ion Here are a few tips on how to get the most out of this manual:

• Take a few minutes to review the Product Overview section. This will help you understand your pump station and may answer many of your questions. The troubleshooting section contains answers to solving the most common issues. Quite often, you will be able to find answers or solutions on your own, without having to call your select distributor. In addition, there are numerous “how to” videos covering the most frequently asked questions including installation and winterization of your system at www.watertronics.com .

• This owner’s manual can be an invaluable reference tool. Keep it in a safe, assessable location for everyone who may benefit from it.

• Review the illustrations (figure drawings) included in this manual. This will help you identify, and become familiar with the pump station components described throughout this manual. The more knowledgeable you are about your pump station, the easier it will be to use and maintain.

• We welcome your comments and suggestions with regard to how we may be able to improve the information and documentation in this owner’s manual.

http://www.watertronics.com/



Important Safety Considerat ions

Throughout this manual , and identify practices or circumstances that can lead to, property damage or economic loss, personnel injury or death.

WARNING! Main disconnect switch’s upper lugs ARE NOT de-energized even when the disconnect switch is off. Turn off power feeding the pump station. If unable to do so, exercise extreme caution when working near this area.

CAUTION! Before servicing any part of this pump station make sure all power sources are locked off and pressure has been relieved from the system.

CAUTION! The control enclosure may contain voltage from external sources NOT routed through the main disconnect switch. If so, determine the location of source and lock it in the OFF position.

CAUTION! Variable Frequency Drives (VFDs) have charged capacitors that hold high voltages even after power has been removed. Before working on or around the VFD, wait a minimum of 10 minutes after the main power has been removed for these voltages to dissipate.

CAUTION! The pump station and associated piping is under high pressure. Close the gate valve to isolate the station from the irrigation system and drain the water from the station before adjusting or removing any plumbing, fittings, etc. Failure to de-pressurize the system may result in injury.



Safety and Warning Label Locat ions See pages 6 and 8 for component locations.

30 amp disconnect Variable Frequency Drive

30 amp disconnect Motor/pump assembly


Product Overview

Specif icat ions • 3HP, 230 volt, single phase

• 30 GPM @ 70PSI

PSI 90 85 80 75 70 65 60 55 50 45 40 35

10 15 20 25 30 35 Flow

Figure 1. - Waterpak Pro GPM/PSI graph

• Variable Frequency Drive (VFD) Control

• Suction lift or booster applications

• See the pump specification sheet for performance and other technical data.

Key Features • NEMA 3R service rated fused

disconnect

• Lighting surge protection

• Non-corrosive UV-resistant composite enclosure

• TEFC (Totally Enclosed Fan Cooled) motor

• Thermally protected motor

• Priming port

• Liquid filled gauges

• Dual brass impellers

• Alarms

• High and low pressure shutdowns

• Dry running protection

• Multi-line operator interface

• Pressure transducer

• High pump temperature shutdown

• Performance run tested prior to shipment

2.


P R O D U C T O V E R V I E W


Component Locat ions – Inter ior

Figure 2. - Interior component locations

1. Station gate valve 2. Pressure gauge 3. Pressure transducer 4. Variable frequency drive (VFD) 5. User interface keypad

6. VFD controller card 7. Priming port 8. Pressure/vacuum gauge 9. Selco temperature switch

10. Air release petcock 11. Drain 12. Motor pump assembly 13. Air vents

1

2

3

4

5

6

7

8

9

10

11

12 13

13

13



Inter ior Component Detai l 1 Station gate valve 4 Variable frequency drive 7 Priming port

2 Pressure gauge 5 User interface keypad 8 Pressure/vacuum gauge

3 Pressure transducer 6 VFD controller card 9 Selco temperature switch



Inter ior Component Locations (Cont inued) 10 Air release petcock 11 Drain 12 Motor pump assembly



Component Locat ions – Exter ior

Figure 3. - Exterior component locations

1. WaterPak composite enclosure 2. 30 Amp disconnect 3. Disconnect blade

4. 30 Amp fuses 5. Citel surge arrestor

2

3

4

5

1



Exterior Component Detai l 2 30 Amp disconnect 4 30 Amp fuses

3 Disconnect blade 5 Citel surge arrestor



VFD Keypad Overview

CAUTION! Pressing buttons may result in a sudden pump start or stop causing personal injury or equipment damage.

Note: Depending on your system configuration some of the keys may be disabled so no action will take place when pressed.

Figure 4. - VFD keypad

1. Graphical display 2. Function keys 3. Pump stop and reset 4. Pump run (Auto enable)

5. Rotary dial/ENTER 6. Escape to last menu 7. Forward/Reverse (NOT USED)

1

2

3

4

5 7

6



Figure 5. - MONITOR screen overview

(A) Drive State Codes

(B) Drive Mode

(C) Fixed Displays

-ACC: Acceleration -CLI: Current limit -CTL: Controlled stop on input phase loss -DCB: DC injection braking in progress -DEC: Deceleration -FLU: Motor fluxing in progress -FRF: Drive at fallback speed -FST: Fast stop -NLP: No line power on L1, L2, L3 -NST: Freewheel stop -OBR: Auto-adapted deceleration -PRA: Power Removal function active -RDY: Drive ready-RUN: Drive running -SOC: Controlled output cut in progress -TUN: Auto-tuning in progress -USA: Undervoltage alarm

APP: displayed when the automatic functionality of the VFD will be active allowing the pump to start, stop and maintain system pressure. HMI: displayed when the TK button is pressed to put the system in manual control to maintain a fixed pump speed and bypass alarm conditions

Depending on the system setup this display will show different system conditions. PSI: Pressure in the system (Pounds per Square Inch) GPM: Flow read by the flow meter (Gallons per Minute) A: Current (Amps) going to the motor. This unit will be displayed when the current level is used to stop the pump. Hz: Motor speed in Hertz. Typical speeds are from 0-60Hz.

For more detail about the keypad see VFD Programming Manual in the appendix.

(A) (B) (C)



Installation

Figure 6. - Proper Installation

Purpose Follow the installation procedures on the following pages to install a new pump station or re-install a pump station following extended inactivity.

Before You Begin □ Review the Important Safety Considerations detailed on page 3.

□ Read the VFD Keypad Overview on page 11. Unexpected pump conditions may occur that will require you to use the keypad to resolve.

□ Read procedures in full before attempting installation.

Site Select ion □ Choose a location site that receives indirect sunlight and is free from erosion dangers.

Choosing a site with indirect sunlight will reduce the temperature fluctuations in the enclosure and minimize temperature related issues.

□ The pump station must sit on either a prefabricated air conditioner pad or a level, graded bed of crushed rock, tamped down solid.

3.

I N S T A L L A T I O N


Mechanical Instal lat ion

DANGER! This equipment contains LIFE THREATENING VOLTAGES. Exercise EXTREME CAUTION when working inside the control panel. Never open the electrical control panel until you have TURNED OFF all power.

DANGER! This equipment can create LIFE THREATENING WATER PRESSURE. Exercise EXTREME CAUTION when working with piping and valves. Never loosen fittings under pressure.

1. Place the pump station on the air conditioner pad or level gravel bed.

2. Check the pump station to make sure the gate valve is closed.

CAUTION! Open valves and leaks will expose electrical components to water and cause damage to the system.

3. Connect the suction line from the water source to the pump station.

Important! To reduce the chance of start-up problems ensure suction line assembly to the pump station is free from leaks and has a working check valve assembly at the. An inability to prime or maintain prime is generally due to problems with the suction side of the assembly. Always verify functionality of the intake screen, foot valve assembly and integrity of the suction line itself. Please see the WaterPak Optional Equipment section on page Error! Bookmark not defined., the WaterPak Instructional Videos list on page Error! Bookmark not defined., or consult your Select Distributor on approved suction line assembly equipment.

4. Connect the discharge piping (1″ male NPT thread) of your WaterPak Station to your irrigation system. Ensure that the connections are Teflon® taped and leak proof.



Electrical Instal lat ion

Important! All electrical connections must be made in accordance with the national electrical code and/or local city or state codes, please consult a professional.

Important: The pump station electrical control enclosure and/or mounting skid must be electrically connected to an earth ground.

Important: All wiring must be free of kinks, and charred or missing insulation. If there is evidence of short circuit, over current, or water damage, the pump station must not be placed into service until the cause is identified and corrected.

Important: Check mounting & termination of all electrical equipment. Studs, screws and nuts should all be in place. Wire terminals can vibrate loose during transit to the job site as well as over prolonged periods of operation. Re-torque as needed during initial setup on the job site and periodically thereafter (spring and fall).

1. Ensure there is no power to the station by turning off the 30 Amp breaker (If wired from a residence or fuse box) and pull the disconnect blade located in the 30 Amp disconnect. See page 9 for component locations.

Figure 7. - 30 amp disconnect and disconnect blade



2. Bring power to the pump station The pump station requires 230V single phase 30 Amps. Land incoming power as shown below.

Figure 8. - Incoming power

L1 L2

Ground



3. Inspect the VFD wiring Ensure that all wires at the bottom of the VFD are connected as shown below. From left to right , the first three wires are the main 220 volt single phase power from the 30 Amp disconnect box, black (L1), white (L2), green (ground) that are feeding power to the VFD. The next series of 4 wires are the converted power that is running the motor. These are green (ground), black (U1), white (V1), and red (W1). These 4 leads will need to match the corresponding locations on the motor. If they do not the motor may run in the reverse direction.

Figure 9. - Correct VFD wiring

4. Inspect the transducer, temperature switch, and jumper connections Open the access door below the keypad of the VFD. Verify the connections have not come loose.

Figure 10. - Remove VFD access door to inspect connections

Access door

Jumper

Temperature switch

Transducer



5. Inspect the pressure transducer wiring The pressure transducer has two wires that feed the signal (4-20 mA) to the VFD. The brown wire is landed at the PWR location within the VFD. The blue wire is landed on the AI2 location within the VFD.

Note: The metal tab is a jumper that is sharing power (+ 24) between the two locations.

Figure 11. - Pressure transducer connections

6. Inspect the jumper connection The jumper feeds power to the internal VFD controller card by taking power from the PWR location and routing to the 24V location on the VFD Controller Card.

Figure 12. - Jumper connection

Al2

PWR

24V

PWR



7. Test the white temperature switch connection Gently tug at the white temperature wire where it enters the behind the VFD keypad. If the connection does not seem solid, inspect the connection.

Figure 13. - Test the temperature switch connection

8. Inspect the temperature switch connections To inspect the temperature switch connections, remove the VFD keypad and face plate.

9. To remove the VFD keypad, press the side tabs inward and pull the keypad straight toward you.

Figure 14. - Removing the VFD keypad

Temperature switch wire



11. To remove the VFD faceplate, press the tabs and gently pull the faceplate straight toward you. The faceplate will pivot on the bottom of the VFD.

Figure 15. - Removing the VFD faceplate

12. Verify the connection of the temperature switch The black temperature switch wire is located on the +24. The white temperature switch wire is landed to the LI56 location.

Figure 16. - Verify connection of temperature switch wiring

LI56

+24V


System Start-up

Before You Begin □ Check the pump station to make sure the gate valve is closed.

CAUTION! Make sure all valves are closed. Open valves and leaks will expose electrical components to water and cause damage to the system.

1. The pump station ships filled with environmentally safe antifreeze. Drain if desired, and ensure that the drain plug is re-installed prior to startup.

Figure 17. - Drain plug

2. Remove the cap from the priming port and fill with water until full.


4.

Drain plug

Priming port cap

S Y S T E M S T A R T - U P


3. Loosen the air release petcock on the volute case to bleed off air during the priming process.

Figure 19. - Air release petcock

4. To avoid loss of prime during start-up of the pump station close the petcock once water begins to flow.

5. Once the air has been bled and the priming port is full replace the priming port cap.

6. You are ready to start your pump station.

WARNING! Pump station is in an auto run mode and will commence with an automated sequence once power is applied. Dangerous pressures and/or improperly installed connections can spray water at the installer or VFD causing possible electrocution or death.

WARNING! If the unit’s Auto Enable=ON when power is applied to the unit the pump may start. If powering the unit and the pump must not start for any reason press and hold the red STOP button on the display until the MONITORING screen shows the Auto Enable=OFF. IF the Auto Enable is OFF, press the green RUN button on the keypad to start the pump station when ready.

7. Turn on power to the station by re-installing the disconnect blade and turning on the 30 Amp breaker.

Air release petcock

Auto-Enable



8. Once the VFD is receiving power, the keypad will turn on.

Figure 20. - Start-up screen

9. After power-up is complete the keypad will display the DRIVE MENU.

Figure 21. - DRIVE MENU screen

10. After 10 seconds the keypad will switch to the MONITORING screen. If after 10 seconds you do not see this screen, press and hold the ESC key until the MONITORING screen appears. For more detailed information about the MONITORING screen, seethe VFD Keypad Overview on page 11 or the VFD MONITORING Screen Detail in the appendix.

Note: Drive State Code “NST” indicates the

VFD is in Free Wheel Stop.

Figure 22. - MONITORING screen

Figure 23. - MONITOR screen overview

Fixed Displays

Drive Mode

Drive State Codes





11. Ensure that the gate valve is closed, and that there is a demand to allow water to begin filling the irrigation system once the valve is opened. Begin to slowly throttle the gate valve open to start filling your irrigation main line. Once the main line is full, the gate valve can be completely opened to allow the water to flow freely.

Figure 24. - Close the gate valve.

12. If the pressure is at 0 PSI and the motor is running at full speed (60Hz), loss of prime may have occurred. Repeat steps if needed. If there is a re-occurring loss of prime at start up, continue to close gate valve before restarting the station and then open slowly after re-applying power. Also verify condition of suction line.

13. Allow water to fill the zone.

14. Check the MONITORING screen to verify that the station is performing at 70 PSI. If system is supplying the irrigation zone, but is not achieving the desired set point (pressure setting), verify the current zone is at 30 GPM or less and that there are not any major leaks in the main line. (System Parameters – 30gpm @ 70psi)

Figure 25. - Pressure gauge showing system performing at 70PSI.

15. Once the station is regulating to 70 PSI close the irrigation zone. The pump station will go into a sleep mode until a demand is required. If the station does not shut off or the pump is cycling ON/OFF in less than a 30 minute timeframe check for irrigation system leaks.

Tip: An optional pressure tank can be used if the irrigation system is small or if minor leaks have developed over time causing the pump station to cycle in less than the 30 minute timeframe. The pressure tank creates a buffer allowing the irrigation system to maintain pressure for a longer duration of time. See the Optional Equipment section on page Error! Bookmark not defined. or consult your Select Distributor for more details.



16. Once the station is up and running, check the vacuum/pressure gauge and record the readings. With a clean intake screen assembly, it should be around 10 inHg. This means the pump station is pulling a vacuum of 10 inches of Mercury. If the reading is significantly higher it could indicate the intake screen is dirty or clogged. When the station is at pressure and is shut off, both gauges will read a similar pressure (PSI).

Figure 26. - Check the pressure gauge

17. Congratulations! You have completed the install of your WaterPak Pro Series 3 station. Once the station has filled the irrigation system and there is no longer a demand for water, the pump station will enter a sleep mode until a demand is present. The VFD will display the MONITORING screen. In the example below the system is in an Auto Enable: ON mode, it has 70 PSI in the irrigation system, and is currently not running. Once the pressure of the irrigation system drops below 50 PSI, the pump will turn back on and regulate at 70 PSI unit the demand is terminated. Take note of the information on this screen for your system.

Figure 27. - MONITORING screen



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Customizing the Pump Station

Sometimes it is necessary to alter the factory set parameters to enhance the performance of the pump station for specific site conditions. Some of these conditions may be due to very small drip zones verses larger rotary zone, or variation in how the water is being supplied to your station. Water can be supplied from a lake or an in ground tank (Suction Lift), it can be supplied from an above ground tank or reservoir (Flooded Suction), or can be from a well or city source (Booster). Due to these varying conditions you may need to modify the default settings to maximize the performance of the pump station.

By accessing the DRIVE MENU→1.14 PUMP CONTROL menu on the VFD keypad you can alter various parameters to control the functionality of your pump station.

Before You Begin □ Familiarize yourself with how the pump station works and how to use the VFD keypad. A

sound understanding of the system and the VFD keypad are critical to customizing the system.

Keypad Overview

CAUTION! Pressing buttons may result in a sudden pump start or stop causing personal injury or equipment damage.

Note: Depending on your system configuration some of the keys may be disabled so no action will take place when pressed.

Figure 28. - VFD keypad

1. Graphical display 2. Function keys 3. Pump stop and reset 4. Pump run (Auto enable)

5. Rotary dial/ENTER 6. Escape to last menu 7. Forward/Reverse (NOT USED)

5.

1

2

3

4

5 7

6

C U S T O M I Z I N G T H E P U M P S T A T I O N


Access the Pump Control Menu 1. On the keypad, press and release the ESC button until you see the MAIN MENU on the display. Rotate the

dial to highlight the DRIVE MENU. Press the rotary dial/ENTER button to select the DRIVE MENU.

Figure 29. - Select the DRIVE MENU

2. Rotate the dial to highlight 1.14 PUMP CONTROL. Press the rotary dial/ENTER button to select PUMP CONTROL.

Figure 30. - Select the PUMP CONTROL Menu



Changing the Pump Control Parameters PSI Set Point (Sys. Reg. S.P.) Once you enter 1.14 PUMP CONTROL, you will see numerous parameters. Sys. Reg. S.P. stands for system regulate set point. This is the PSI to which VFD is going to regulate the system pressure during the irrigation cycle. At the factory this is set to 70PSI, which will produce up to 30GPM to the irrigation system depending upon the required demand. This can be altered up or down and can drastically affect the output of the pump station. Therefore, verify the desired performance characteristic per the pump curves found in the Pump Specifications section of the Appendix.

1. Press the rotary dial/ENTER button to select the Sys. Reg. S.P. menu.

Figure 31. - System Regulate Set Point menu

2. Press the rotary dial/ENTER button again to highlight parameter.

Figure 32. - Select the parameter

3. Rotate the dial to change the PSI to which you want the system to regulate to during the irrigation cycles.

Figure 33. - Select the PSI

4. Press the rotary dial/Enter to confirm the setting.

5. Press ESC to return to the PUMP CONTROL screen.




Change the “Wake Up” Point (Start Below) The Start Below parameter alters how your pump station reacts to the irrigation system. This parameter works in conjunction with the Sys. Reg. S.P in that it controls the wake up mode of the pump station. When the irrigation system is done irrigating and there is no longer a demand for water, the pump station goes into a sleep mode. The Start Below parameter tells the VFD to turn the pump station back on (wake up mode) when the pressure in the irrigation system reaches the Sys. Reg. S.P parameter minus the Start Below parameter to equal the wake up PSI.

For example: If the Sys. Reg. S.P is 70 PSI and the Start Below parameter is 20 PSI, then 70 PSI minus 20PSI establishes the wake up point at 50PSI. When the irrigation system bleeds off pressure to 50 PSI or less, the pump station will turn the pump and motor back on to coincide with the irrigation demand. These set points can be used to control how often the pump station turns on and off.

Leaks in the irrigation system or pressure decay can also cause the pump station to cycle on and off in less than the 30 minute window. If the pump stations is turning on and off in less than a 30 minute timeframe, a pressure tank may need to be added to the system or verify that significant leaks have not occurred in the irrigation system itself.

1. Access the Start Below menu from the DRIVE MENU →PUMP CONTROL menu.

2. Press the rotary dial/ENTER button to select the Start Below parameter.

Figure 34. - Start Below Menu

3. Press the rotary dial/ENTER button again to highlight parameter.

4. Rotate the dial to change the PSI value the system will use to calculate the PSI at which the system will start - System Regulating PSI minus the value you select.


6. Press ESC to return to the PUMP CONTROL screen



Change the “Sleep” Point (Stop Below) The Stop Below parameter controls when the pump station enters a sleep mode after there is no longer a demand from the irrigation system. The stop below parameter monitors the amount of AMPS being drawn by the motor at any given time.

The factory setting is 4.7amps. That means as long as the draw stays above 4.7 Amps, the pump station will not turn off.

Certain situations, such as a very small drip irrigation zone, may require you to adjust the default setting. This can be evaluated by running the smallest zone in the irrigation sequence and monitoring the AMP draw during this cycle. If, for example, during the test the draw is only 4.6 amps, the Stop Below parameter should be adjusted to 4.5 Amps or .1 Amp lower than the smallest zone.

1. Access the Stop Below parameter from the DRIVE MENU →PUMP CONTROL menu.

Figure 35. - Stop Below Menu

2. Press the rotary dial/ENTER button to select the Stop Below parameter.

3. Rotate the dial to change the value.


5. After adjusting the parameter, always turn off the irrigation zone to verify the pump station will enter sleep mode as intended.

6. If the pump station is sleep mode and the display is in MONITORING mode, the screen will look like Figure 35. -

Figure 36. - Monitoring screen

For more information about the MONITORING screen, see the Monitoring Screen Detail section in the Appendix of this manual.



Winterization Perform this winter shut down procedure at the same time as the irrigation system is blown out. To prevent damage the pump station and its components must be properly winterized. See page 9 for locations of components in this procedure.

Before You Begin 1. Turn off the main disconnect power to the pump station.

Figure 37. - Main disconnect

2. If applicable, turn off 30 Amp breaker in the fuse box.

3. Remove the disconnect blade in the 30 Amp disconnect box.

Figure 38. - Disconnect blade

4. After power has been terminated wait 10 minutes to ensure that capacitors in the VFD have had sufficient time to dissipate their charge.

6.

W I N T E R I Z A T I O N


Winter Shutdown 1. Completely drain all manifolds and supply lines of water. When the system is drained, close the gate valve

to eliminate any remote source from feeding water into the pump system.

2. Remove the pressure transducer wire by removing the M12 connector located below the liquid-filled gauge on the discharge manifold.

Figure 39. - M12 connector

3. Remove the pressure transducer unit by unthreading it from the T-fitting. Store it in a location where it will not be subjected to freezing temperatures. Damage will occur if the sensor is exposed to temperatures below 32 degrees F.

4. Seal all ports with a plug with a ¼” NPT thread to prevent foreign materials from entering the system.

5. Remove both the gauges from the station. The gauges are filled with a Glycerin solution, but they may freeze in extreme environments. Seal the ports with a plug with a ¼” NPT thread to prevent foreign materials from entering the system.

Figure 40. - Remove the gauges



6. Open the drain at the bottom of the volute case to drain the remaining water. Replace the drain plug.


7. Fill the volute case with environmentally safe antifreeze just to the start of the intake piping, approximately 8 oz. This will prevent the cast iron volute case from rusting and minimize sticking of the impellers on start up in the spring.

8. Open the drain valve at the bottom of the pressure tank (if applicable), and the ensure tank is completely drained.

9. Disconnect any piping, including suction lines, which will remain in standing water over the winter months.

10. Securely fasten the pump station cover with a padlock or zip-tie lock to prevent wind damage over the winter months.

Drain plug


Troubleshooting

WARNING! Life threatening voltages and water pressure can occur.

Troubleshooting Table Symptom Probable Cause Corrective Action

Pressure remains at one reading on display

The Pressure sensor in not connected at the terminal strips in the VFD or is unplugged.

Check for loose or unplugged wires and repair.

The pressure transducer has frozen and failed. Replace pressure transducer.

Pump will not start in Auto mode even though system pressure is low

Alarm condition exists. Check for cause(s) of the alarm and correct.

The station may require other condition to start such as irrigation controller input.

Check the wiring diagram and specifications.

The pressure reading on the display is not accurate.

Calibrate the pressure display to match pressure gauge.

Pump station display is not on and pump station will not run

No power to the pump station. Turn ON power to the station.

If breaker is on, but there is no power to the station check fuses. Replace fuses if needed.

Pump station runs in Auto mode, but does not Shut-off and/or continuously cycles on and off

Irrigation system is demanding water. Check for open sprinkler heads or broken pipes in the irrigation system.

Pump station runs in Auto mode, but alarms Alarm condition is present.

Correct and clear alarms. See Alarm Conditions in the Variable Frequency Driving Programming Manual in the Appendix of this manual.

The pump losses prime

A significant leak exists in the suction line. Repair the leak in the system.

The suction line foot valve is leaking. Repair, or replace the foot valve.

A petcock on the volute case may be open. Close the petcock.

There may be a defective mechanical seal in the pump. Repair/Replace defective seal.

Alarm message on VFD display

The pump station is designed to protect itself from potential damage by stopping the pump if the control system detects an undesirable condition. The VFD display will show the fault code. See the Faults, Causes and Remedies section of the Variable Frequency Driving Programming Manual in the Appendix of this manual. To reset alarms, press the STOP/RESET button or cycle power to the pump station.

7.

http://www.watertronics.com/edit/f8web/?uf=/waterpakmanual/ATV61_Fault_codes.pdf

http://www.watertronics.com/edit/f8web/?uf=/waterpakmanual/ATV61_Fault_codes.pdf


T R O U B L E S H O O T I N G




Appendix

Replacement Parts See Component Locations – Interior on page 6 and Interior Component Detail on 7 for photos that show component location and detail.

Interior Components

1 System Gate Valve 41-15-3010 2 Pressure Gauge (0-200PSI) 14-25-3020 3 Pressure Transducer 69-20-0223 Photoelectric Transducer Connector 09-11-2412 4 Variable Frequency Drive (VFD) 70-11-1004 5 User Interface (Keypad) 6 Altivar VFD Controller Card 70-11-3501 7 Priming Port 38-20-3150 8 Pressure/Vacuum Gauge (-30”Hg To 150PSI) 14-25-3000 9 Selco Temperature Switch 15-03-3120 10 Air Release Petcock 11 Drain 12 Motor/Pump Assembly 47-16-2516

Exterior Components

1 Waterpak Composite Enclosure 16-50-3024 2 30 Amp Disconnect 15-17-6322 3 Disconnect Blade 4 30 Amp Fuses 21-10-0030 5 Citel Surge Arrestor 77-05-2410

8.

A P P E N D I X



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