Sunday, May 17, 2015 Pressure Booster Service

Sunday, May 17, 2015 Booster Service Basics Control Panel Components Setting a pressure switch Setting a current relay Adjusting the Easy PLC Relay Understanding and Adjusting a PRV

Sunday, May 17, 2015 Control Panel Components High Voltage: Disconnect, Starters, Overloads, Transformer Low Voltage: Current Relays, PLC, pressure switches

Sunday, May 17, 2015 Setting Overloads Factory Set Verified in the field

Sunday, May 17, 2015 Pressure Switch Basics Pressure switches have a Set Point and Re-Set Re-set value always below the Set Point Set Point and Re-Set are dependant on the purpose of the pressure switch

Sunday, May 17, 2015 Pressure Switch Adjustment Set Point Adjustment Differential Adjustment PSI Scale Reading

Sunday, May 17, 2015 Pressure Switch Adjustment Differential Setting Psig switch Differential Setting Psig switch

Sunday, May 17, 2015 Pressure Switch Applications Low suction pressure protection No-Flow shutdown pump call on Pump sequencing control High and low pressure alarms

Sunday, May 17, 2015 Low Suction Pressure Protection Purpose: Stop pump in case of low inlet pressure Set Point (Cut-In): 15 PSI - Pump Start Re-Set (Cut-Out): 5 PSI - Pump Stop differential: 10 PSI

Sunday, May 17, 2015 No-Flow Shutdown Pump Call-On Purpose: Start pump on drop in system pressure Set Point (Cut-Out): 5 PSI below system pressure - Pump Off Re-Set (Cut-In): 6 PSI - Pump On differential: 1 PSI

Sunday, May 17, 2015 Pump Sequencing Control Purpose: Start pump on drop in system pressure Set Point (Cut-Out): 5 PSI above system pressure - Pump Off Re-Set (Cut-In): 5 psi below system pressure - Pump On differential = (cut- in) - (cut - out)

Sunday, May 17, 2015 High Suction Pressure Alarm Purpose: Stop pump if inlet pressure is sufficient to supply building Set Point approx. system pressure - Pump Off Re-Set (Cut-In): approx PSI below system pressure - Pump On differential: 5-10 PSI

Sunday, May 17, 2015 Low System Pressure Cut-Out Alarm Purpose: Stop pump if outlet pressure is too low Set Point (Cut-In): approx PSI below system pressure - Pump On Re-Set (Cut-Out): 30 PSI below system pressure- Pump Off differential: PSI

Sunday, May 17, 2015 Low System Pressure Next Pump Starts Alarm Purpose: Start next pump if outlet pressure is too low. Requires manual reset Set Point (Cut-In): approx PSI below system pressure - Pump On Re-Set (Cut-Out): 30 PSI below system pressure - Pump Off differential: PSI

Sunday, May 17, 2015 High System Pressure Cut-Out Alarm Purpose: Stop pump if outlet pressure is too high Set Point (Cut-Out): 20 PSI above system pressure - Pump Off Re-Set (Cut-In): System Pressure - Pump On differential: 20 PSI

Sunday, May 17, 2015 Current Relay Adjustment

Sunday, May 17, 2015 Current Relay Adjustment On-Delay Time Scale (0-1) & (0-30)

Sunday, May 17, 2015 Current Relay Adjustment On-Delay Time Setting

Sunday, May 17, 2015 Current Relay Adjustment Threshold (Ie Value)

Sunday, May 17, 2015 Current Relay Adjustment Hysteresis - not used - set to zero

Sunday, May 17, 2015 Easy PLC Relay

Sunday, May 17, 2015 Easy PLC Relay Contains sequencing logic for pump sequencing Alarm condition activation Timer values

Sunday, May 17, 2015 Easy PLC Relay Program written in ladder logic Program changes require a programming device Does not require in-field adjustment Program access is password protected

Sunday, May 17, 2015 Setting Timer Select parameters Toggle timer value required Change timer value by pressing arrow

Sunday, May 17, 2015 Understanding and Adjusting PRV

Sunday, May 17, 2015 PRV Components Main Body Valve Piloting Assembly

Sunday, May 17, 2015 PRV Components Pressure Regulator Speed Control Check Valve Diaphragm Stem assembly Sealing Ring Valve Seat

Sunday, May 17, 2015 PRV Control Logic Outlet pressure of the valve is controlled by the pilot mounted PRV Spring setting in PRV pilot determines outlet pressure of the main PRV Turning PRV nut clockwise (down) will cause outlet pressure of main valve to increase

Sunday, May 17, 2015 PRV Control Logic Small Area Large Area

Sunday, May 17, 2015 PRV Control Logic Opening the pilot relieves pressure on top of the diaphragm opening the main valve. CHECK CLOSED

Sunday, May 17, 2015 PRV Control Logic Closing the pilot increases pressure on top of the diaphragm closing the main valve. CHECK CLOSED CHECK OPEN

Sunday, May 17, 2015 PRV Control Logic Check Valves in piloting circuit ensure valve closes and stays closed when pumps stop and the pressure reverses CHECK CLOSED CHECK OPEN

Sunday, May 17, 2015 PRV START UP Bleed air off Main Cover & Controls Start system with pilot valve adjusted to lower than required value Adjust to higher pressure as system stabilizes Make all adjustments slowly, allowing for the control valve and system to balance the change

Sunday, May 17, 2015 PRV TROUBLESHOOTING Irritants to PRV operation –Dirt, Sand, obstructions of any kind –Air entrapment or entrainment into valve body –Damaged or worn parts –Humans

Sunday, May 17, 2015 Types of Problems PRV’s will not regulate PRV’s will not hold pressure Non operating pump spins when off Pilot valve leaks

Sunday, May 17, 2015 PRV TROUBLESHOOTING conditions Valve will not regulate –Air in control Pilot –Closing speed control not adjusted properly –Clogged strainer or Pilot Valve –Faulty Pilot –Valve stem is jammed in cover bearing –Diaphragm failure

Sunday, May 17, 2015 PRV TROUBLE SHOOTING conditions Valve will not hold pressure Because of: –Strainer is clogged –Check valve not sealing –Faulty pilot –Insufficient Supply Pressure

Sunday, May 17, 2015 Types of Problems Non operating pump spins when off –PRV check valves not sealing properly –PRV diaphragm broken –Check valves not sealing

Sunday, May 17, 2015 Types of Problems Pilot valve leaks –Pilot diaphragm broken

Sunday, May 17, 2015 Types of Problems Power on - pumps don’t come on Pumps on - don’t shut off Pumps come on too soon Pumps do not stay off for a long time on No-flow shut down Pumps short cycle

Sunday, May 17, 2015 Types of Problems Power on but pumps don’t come on –Motor overloads tripped –Check inlet pressure and low suction pressure switch, high suction pressure switch –Check no-flow pressure switch –Check discharge pressure and low discharge pressure switch

Sunday, May 17, 2015 Types of Problems Pumps on - don’t shut off –Verify current relay settings –Verify alarm conditions (high Suction pressure, low system pressure, etc..) –Verify No-Flow shutdown - Aquastat and pressure switch setting

Sunday, May 17, 2015 Types of Problems Pumps come on too soon –Verify motor current against factory test data –Verify current relay settings

Sunday, May 17, 2015 Types of Problems Pumps do not stay off for a long time on No-flow shut down –Verify tank pre-charge –Adjust Aquastat setting –Adjust call on pressure setting lower –Verify tank bladder is not broken

Sunday, May 17, 2015 Types of Problems Pumps short cycle –Check timer settings –Verify that the Aquastat setting is correct –Adjust pressure switch –Adjust current relay setting –Verify alarm pressure switch settings

Sunday, May 17, 2015 Booster Application Knowledge 2 pump system recommended for flows up to 300 GPM 5 step sequencing recommended for systems over 500 GPM Do Not install No-flow shutdown units on continuous demand systems

Sunday, May 17, 2015 Booster Application Knowledge Booster systems are designed to have a positive supply pressure PRV’s are not required when drawing from a tank using single stage pumps Tank pre-charge should be set at 5 PSI less than the call on pressure switch setting

Sunday, May 17, 2015 Questions & Answers

Sunday, May 17, 2015 Thank You