Municipal Boost System K-A-MCB Series · 1020 Industrial Driv e, Orlinda, TN 37141 615-654-4441 [email protected] 615-654-4449 fax. Operation Manual Municipal Boost System

1020 Industrial Drive, Orlinda, TN 37141

615-654-4441 [email protected] 615-654-4449 fax

Operation Manual

Municipal Boost System

K-A-MCB Series



TABLE OF CONTENTS

Section 1 GENERAL

1.2 Warnings and Cautions ..................................................... 1

1.2 Theory of Operation ........................................................ 2

1.3 System Illustration ......................................................... 3

1.4 System Components ....................................................... 4

1.5 Modes of Operation ........................................................ 7

Section 2 SPECIFICATIONS

2.1 Water and Electrical Requirements ...................................... 8

2.2 Dimensions & Weight ....................................................... 9

Section 3 INSTALLATION

3.1 Inlet Plumbing ............................................................... 10

3.2 Outlet Plumbing ............................................................. 11

3.3 Pressure Sensor Installation ............................................... 12

Section 4 ROUTINE MAINTENANCE

4.1 Routine Maintenance ....................................................... 13

4.2 Pressure Setting Change ................................................... 14

4.3 Reboot Procedure .......................................................... 15

Operation Manual Specialty Water Technologies, Inc. Municipal Boost


615-654-4441 [email protected] 615-654-4449 fax 1

Section 1.1 WARNINGS AND CAUTIONS

WARNINGS

• Read this manual in its entirety before operating the Municipal Boost System.

• The “OFF” position does not disconnect power from the control box this must be done at the circuit breaker.

• The Hand / Manual Mode turns the boost pump on regardless of a “Run” signal from the RO or the state of the “Flow Switch”. Pump or plumbing failure will occur if left in this position for an extended time.

• Misuse, improper operation, and/or improper monitoring of this system could result in serious injury, death, or other serious reactions to the end users of the equipment.

• Routine maintenance of the system is required to protect the system from over-pressurizing and over-temperature which could result in damage to the facility, injury to staff, or the end users of the equipment.

CAUTIONS

• When used as a medical device, Federal law restricts this device to sale by or on the authority of a physician. Per CFR 801.109 (b)(1).

• All local, state, and federal regulations regarding the installation and operation of this system must be observed.




Section 1.2 THEORY OF OPERATION

The Variable Frequency Drive (VFD) Municipal Water Booster System was designed to be the next step forward in Municipal Water Booster Systems. This serves as a reliable alternative to the existing bladder tank pressurization systems. The VFD Municipal Booster System utilizes a Variable Frequency Drive motor controller in lieu of a contactor and thermal overload. The system is also equipped with a pressure transducer which senses the pressure on the outlet/discharge side of the pump which will maintain the pressure programed into the controller. Once the system is set-up at the final site, it must be calibrated before use. This procedure is included with each system. Once installed and calibrated, the system will adjust and maintain the preset pressure required for adequately running the RO system and the regeneration cycles of the media tanks. The pressure sensor continuously transmits an electronic signal to the VFD motor controller, which then accelerates or decelerates the pump in an attempt to maintain the preset pressure. This speed adjustment is accomplished by varying the frequency of the power going to the motor on the pump, which in turn controls the speed (RPM revolutions per minute) at which the motor, and therefore the pump, turns. The motor/pump RPM controls the amount of pressure and flow the pump produces.

This allows the pump to operate when the R.O. turns on, or when a pre-treatment component (such as a media tank) goes into backwash and/or regeneration. This tight control all but eliminates pressure spikes when the R.O. turns off, and also prolongs the life of the Municipal Boost pump and motor. The VFD Municipal Boost system is designed to convert single phase 220 volts into three phase, using one third of the energy required by the existing pump systems. This moves the SWT Municipal Boost System forward into the next generation of pretreatment equipment.




Section 1.3 SYSTEM ILLUSTRATION

Control Box

Inlet Pressure Gauge

Pump Bypass Valve

Pump

Inlet Service Valve

Emergency Water Connection

Fiberglass Mount

Temperature Monitor

VFD Pump Controller

Hose Bibb

Outlet Service Valve

Flow Meter 4-40 GPM

Flow Switch

HDPE Stand

Temperature Sensor




Section 1.4 SYSTEM COMPONENTS

See illustration on previous page Flow Switch:

Monitors if water is flowing through pump or not. An electrical signal is generated if flow is present. In “Automatic” mode the state of flow switch (flow or no flow) is monitored continuously. If a run signal is present and flow is sensed, pump will turn on; no flow sensed, pump will turn off. Flow switch has no effect in “Hand/Manual” mode.

Flow Meter:

Monitors the amount of flow in gallons per minute (GPM). When pump is on, a visual flow reading can be done by aligning the top of the stainless steel cylinder to the gallon engravings on side of the flow meter.

Hose Bib:

Convenient water faucet for multiple applications.

Pressure Sensor:

The Pressure Sensor maintains the pressure setting programed into the drive’s control, and should be placed downstream as close to the RO as possible.

Example: Pressure Sensor Installation

PRE- August 2015 August 2015 - Present





System Components cont. Leak Detector with Auto Shut Off: (Optional Feature) The Leak Detector is used to monitor for leaks in the water treatment room and will automatically turn off the municipal boost system and close the inlet water valve when a leak is detected. When this feature is added the leak detector is placed on the floor. It should be placed at the lowest level of the floor where water will naturally travel. When liquid is detected the water inlet valve closes and the pump will power off. When the system is in “Auto” or “Manual” modes of operation, the system will power on if no leak is detected. To clear leak detection, clean up water spill. Gently shake the sensor to remove water.

Leak Detector Inlet Water Valve

Depending on the state of the valve, the valve knob

will point to open or closed





Water Temperature Monitor:

Monitors the water temperature post blend valve, coming into the boost pump.

User settable.

Factory default to alarm at 90 degrees Fahrenheit.

User may change alarm parameters by pressing the up or down arrow to the desired temperature.

Press the SET button to set temperature.




Section 1.5 MODES OF OPERATION

Auto “Automatic” Mode:

Constantly monitors the RO for a “Run Signal”. A run signal is generated in one of two ways;

(1) When RO is turned “ON”. (2) By a backwash cycle of any media tank that is connected to the interlock circuit. (Red knob must be pushed in to run in “auto” mode)

When a run signal is generated the pump turns on and remains on until the “Flow Override Timer” turns off (factory 40 seconds). When the timer is “Off” if flow is present at “Flow Switch”, the pump will remain on; if flow is not present pump will turn off. Pump turns off automatically when RO turns off or in a “no flow” state.

“Override” Mode:

Turns pump on immediately. Pressure is monitored and maintained in “Override”. The state of “Flow Switch” is not monitored in “Override” therefore no run dry protection in enabled. A “Run Signal” has no effect in “Override Mode.” To activate this mode, turn Power to “ON” and Turn Key to override system. (Red knob will be in outward position)

WARNING: Do not run system in “Override Mode” unattended. If system is running in “Override” mode and no flow is going through system the pump and piping will overheat. “Override” mode should only be used when priming pre-treatment system or in emergency situations. “Override” mode switch should be locked out when not in a maintenance or emergency situation.




Section 2.1 SPECIFICATIONS

ELECTRICAL AND WATER REQUIREMENTS:

Inlet Water Connection: Inlet water piping capable of delivering 20 GPM (Gallons per Minute), and 30-40 PSI (Pounds per Square Inch) pressure.

Feed Water Connection: The connection from the water feed side of the Municipal Boost to the trunk line is normally 1 ½” sch. 80 PVC. (Occasionally 1” piping is used)

Electrical Requirements: 2HP Pump:

208-230 volt, single phase 20 AMP dedicated circuit w/twist N lock receptacle.

3HP Pump:

208-230 volt, single phase 30 AMP dedicated circuit w/twist N lock receptacle.




Section 2.2 SPECIFICATIONS

DIMENSIONS & WEIGHT:

Size: 54.375”H X 31”W X 19”D

Weight: 185 LB. Dry

31.00 19.00

54.3

75




Section 3.1 INSTALLATION – INLET PLUMBING

Remove the existing equipment taking notice of existing electrical connections and configurations. Observe all local codes and facility safety procedures when removing existing electrical equipment.

Illustrated is a typical installation with the recommended 1 ½” piping. Modifications can be done to convert to 1”plumbing. The SWT Municipal Boost System will compensate for trunk size difference.

INLET WATER CONNECTION (Typical 1 1/2”Piping)

1 ½” Female Adapter, Copper, S X T

1 ½” Male Adaptor SCH 80

One 1 ½” Union Old Style SCH 80

One 1 ½” Treaded Nipple

Two or Four 1 ½” Elbow S SCH 80

One 1 ½” Elbow Street Spig X S SCH 80

Roughly four feet of 1 ½” SCH 80 PVC Pipe

MAP Gas Soldering Torch and Flux core solder

Plumber’s sandpaper 250grit

Pipe Joint Compound

Clean the fitting and pipe. Both should be completely free of any dirt or grime. After cleaning all sharp edges and dirt away, solder the copper female adapter onto the copper water line. The male adapter can then be threaded into the copper fitting using Teflon tape and a small amount of pipe joint compound. At this point a short 1 ½” SCH 80 PVC nipple will be glued into the male fitting and then into the 1 ½” SCH 80 union. Use the 1 ½” elbow as needed to intersect into the inlet water side of the Municipal Boost. The union is used to tighten any leak point that may occur at the copper fitting.




Section 3.2 INSTALLATION – OUTLET PLUMBING

OUTLET SIDE CONNECTION

One 1 ½” Union SCH 80 Old Style

Two 1 ½” Elbows S SCH 80

One 1 ½” Elbow Street Spig SCH 80

Roughly Four Feet of SCH 80 PVC Pipe

One piece of 6” strut

One 1 ½” PCR (Plastic Clamp)

The Municipal Boost is equipped with a union connection on both sides at the stand for quick connect/disconnect. Illustrated is the outlet side of the Municipal Boost. At this point a piece of 1 ½” PVC SCH 80 pipe will be used to connect the 1 ½” SCH 80 elbow towards the wall (stay 1 ½” from the wall for mounting the strut). At this point transition upward from a 1 ½” SCH 80 elbow with the 1 ½” PVC SCH 80 pipe to the next 1 ½” SCH 80 elbow intersecting with the height of the existing trunk line that feeds the existing media tanks.




Section 3.4 INSTALLATION – PRESSURE SENSOR

Objective: Remove existing pressure gauge and install the pressure sensor assembly that controls the variable frequency drive that auto tunes the Municipal Boost System to pre-set pressure.

1. Verify water is turned OFF and system is de-pressurized.

2. Locate Pressure sensor cable on Municipal Boost System and route to pressure gauge nearest to the RO system water inlet as pressure sensor cable length will allow.

3. Remove pressure gauge.

4. Apply Teflon tape to the threads of the following components:

Pressure sensor

1/4” nipple (both ends) and

5. Thread the above components together.

6. Connect pressure sensor cable to pressure sensor.

7. Use zip ties (not provided) to secure the pressure sensor cable to the existing piping.

8. Complete.




Section 4.1 ROUTINE MAINTENANCE

Routine inspection of the system is recommended. Follow all facility procedures regarding regular inspection of electrical equipment.

Quarterly system should be inspected as follows:

♦ Unplug from wall outlet and inspect plug for signs of electrical burn. Inspect plug for frayed wires. Repair and replace as needed.

♦ Inspect and clean fan vents on left side and bottom of control box. Ensure adequate ventilation.

♦ Wipe exterior and inspect pump for dust and debris accumulation on top of fan shroud. Keep fan shroud clean.

♦ Inspect and clean glass on flowmeter for visual clarity.

♦ Over the course of time, the variation of temperatures, pressure and vibration may cause some threaded fittings to loosen. Tighten only enough to stop the leak. Overtightening may cause damage to the fitting.

♦ Check hand-tightened fittings (valve couplings) for leaks. Hand tighten only enough to stop leak. Overtightening may cause damage to the valve union.

♦ Inspect the flange mounts on each side of the pump for leaks. Tighten clamp bolts to 22 ft/lbs or just enough to stop the leak.




Section 4.2 PRESSURE SETTING CHANGE

To change the pressure setting on the VFD Drive:

1. Press ENT. Current pressure is displayed.

2. Adjust pressure up or down with arrows.

3. Press ENT to set new pressure.

Enter

Adjust up or down




Section 4.3 REBOOT PROCEDURE

Reboot Procedure – This may be used to reboot the boost system if one of the following fault detection codes is present on the VFD drive display.

CrF1 InF3 ---- OCF SCF4

InF1 InF4 InFb SCF1 SOF

InF2 InF9 InFE SCF3 tnF

1. Open the control box.

2. Flip the Main breaker to the “OFF” position.

3. Wait 45 seconds. (Indicator light on VFD Drive must be completely out)

4. Flip the Main breaker to the “ON” position.

Error code should now be reset and system should resume normal operation

Main Breaker

Indicator Light VFD Display



Municipal Boost Manual K Series Rev. 12_2017

Manual P/N: OM-K-A-MCB-X

Documents

Municipal Boost System K-A-MCB Series · 1020 Industrial Driv e, Orlinda, TN 37141 615-654-4441 [email protected] 615-654-4449 fax. Operation Manual Municipal Boost System