Pumping Technology
FLOWFLEX
COLD WATER BOOSTER SETS
INSTALLATION AND OPERATION MANUAL
IMPORTANT INFORMATION
These instructions must be read and understood before installing,
commissioning, operating or maintaining the equipment.
SMEDEGAARD PUMPS LTD • 10 Beech Business Park • Bristol Road • Bridgwater • Somerset • TA6 4FF
Tel: 01278 458686 • Fax: 01278 452454
Email: info@smedegaard.co.uk • www.Smedegaard.co.uk
Contents
1.
Warranty................................................................................................6
1.1
TERMS OF WARRANTY
2. Safety and environment........................................................................
6
2.1 GENERAL
2.2 USERS
2.3 SAFETY PROVISIONS
2.3.1.
Labels on the product
2.4 SAFETY PRECAUTIONS
2.4.1.
2.4.2.
During normal use
During installation, maintenance and repair
2.5 ENVIRONMENTAL ASPECTS
2
2.5.1.
2.5.2.
General
Dismantling
3.
Manual Introduction..............................................................................8
3.1
PREFACE
3.2
ICONS AND SYMBOLS
4.
Identification, service and technical support......................................8
4.1
IDENTIFICATION, SERVICE AND TECHNICAL SUPPORT
4.2
SUPPLEMENTARY DOCUMENTATION
5.
Introduction...........................................................................................9
5.1
GENERAL
5.2
INTENDED USE
5.3
WORKING RANGE
6.
Functioning............................................................................................ 9
6.1
STANDARD OPERATION
6.1.1.
6.1.2.
6.1.3.
6.1.4.
6.1.5.
6.1.6.
Settings
RS485
Water surge protection - GaardExe SPM
WSD-Sensor (option for use with base plate mounted vessels)
Temperature-sensor (option)
Dry Run Protection
Pumping Technology
7.
Transport.................................................................................................................................10
7.1
TRANSPORT
7.2
STORAGE
7.2.1.
7.2.2.
Preparations for storage
Inspection during storage
8.
Installation...............................................................................................................................10
8.1
SETTING UP THE INSTALLATION
8.2
PUMP INDICATORS
8.3
ELECTRICAL INSTALLATION
8.4
COMMISSIONING
8.4.1.
In an open or closed circuit with sufficient supply pressure
9.
Control panel..........................................................................................................................12
9.1
TYPES
9.2
DESCRIPTION - CP
9.3
DESCRIPTION - MH
9.4
SINGLE PHASE CP PANEL WIRING DIAGRAM
9.5
THREE PHASE CP PANEL WIRING DIAGRAM
9.6
SINGLE PHASE MH WIRING DIAGRAM
9.7
THREE PHASE MH WIRING DIAGRAM
9.8
PUMP WIRING
10.
FlexDrive Set-Up – Booster Sets...........................................................16
10.1
PARAMETER NAVIGATION.
10.2
SETTINGS.THOSE IN ITALIC MAY NEED TO BE CHECKED/ALTERED ON SITE.
10.3
FACTORY SETTINGS
10.4
ERROR CODES
10.5
THREE PHASE FLEXDRIVE WIRING
10.6
SINGLE PHASE FLEXDRIVE WIRING
10.7
MULTI- DRIVE CONNECTION
3
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11.
Maintenance............................................................................................................................23
11.1
INTRODUCTION
11.2
LUBRICATION
11.3
MAINTAINING THE PUMP FOR AN EXTENDED PERIOD OF NON- OPERATION
11.4
PUMP FAULT TABLE
11.5
RS-485 COMMUNICATION PROTOCOL
11.6
RS485 CONNECTIONS – 3 PHASE FLEXDRIVES ONLY.
11.7
FAILURE TABLE WSD-SENSOR(OPTION)
11.8
GAARDEXE SPM SET UP
11.9
DECLARATION OF CONFORMITY (IIA)
4
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5
Pumping Technology
1. Warranty
2. Safety and environment
1.1
2.1
TERMS OF WARRANTY
The warranty period is as shown in our general terms
and conditions of sales.
Other terms of warranty have been included in the
general terms of delivery, which are available upon
request.
))
ATTENTION - Modifications or alterations
of the product supplied are only permitted
after consultation with the manufacturer.
Original spare parts and accessories
authorised by the manufacturer
ensure safety. The use of other parts
can invalidate any liability of the
manufacturer for consequential damage.
))
ATTENTION - The warranty relating to
the operating reliability and safety of
the product supplied is only valid if
the product is used in accordance with
its designated use as described in the
following sections of this manual. The
limits stated in the data sheet must not
be exceeded under any circumstances.
The warranty becomes invalid if one or more of the
points below occur.
The buyer makes un-authorised modifications to
the equipment.
„„ The buyer carries out repairs or has these carried
out by a third party during the warranty period and
without authorisation from Smedegaard.
„„ The product has not been handled or maintained
properly.
„„ The product has un-authorised non original
Smedegaard spare parts fitted.
„„
6
Smedegaard remedies defects under warranty if the
points below are observed.
Defects are caused by flaws in the design, the
materials or the manufacture.
„„ The defect has been reported within the warranty
period.
„„
Pumping Technology
GENERAL
This Smedegaard product has been developed using
state-of-the-art technology; it is manufactured with
utmost care and subject to continuous quality control.
Smedegaard does not accept any liability for damage
and injury caused by not observing the directions and
instructions in this manual. This also applies in cases
of carelessness during the installation procedure, use
and maintenance of the product.
Non-compliance with safety instructions can
jeopardise the safety of personnel, the environment
and the product itself. Non-compliance with these
safety instructions will also lead to forfeiture of any
and all rights to claims for damages.
For example, in particular non-compliance can result
in:
Failure of important pump/system functions.
„„ Failure of prescribed maintenance and servicing
practices.
„„ Injury to persons by electrical or mechanical
causes.
„„
Depending on specific activities, extra safety measures
may be required. Contact Smedegaard if a potential
danger arises during use.
))
))
ATTENTION - The owner of the product
is responsible for compliance with
the local safety regulations and
internal company guidelines.
ATTENTION - Not only must the
general safety instructions laid down
in this chapter on "Safety" be complied
with, but also the safety instructions
outlined under specific headings
2.2
USERS
All personnel involved in the operation, maintenance,
inspection and installation of the product must be fully
qualified to carry out the work involved.
Personal responsibilities, competence and supervision
must be clearly defined by the operator. If the personnel
in question are not already in possession of the required
know-how, appropriate training and instruction must
be provided. If required, the operator may commission
the manufacturer / supplier to take care of such
training. In addition, the operator is responsible for
ensuring that the contents of the operating instructions
are fully understood by the responsible personnel.
2.3
SAFETY PROVISIONS
The product has been designed with the greatest
possible care. Original parts and accessories meet the
safety regulations. Modifications in the construction or
the use of non-original parts may lead to a safety risk.
))
ATTENTION - Make sure that the
product operates within its working
range. Only then is the product
performance guaranteed.
2.3.1. LABELS ON THE PRODUCT
The icons, warnings and instructions applied to the
product are part of the safety provisions. The labels
may not be removed or covered. Labels must remain
legible during the entire life of the product. Replace
damaged labels immediately.
2.4
SAFETY PRECAUTIONS
2.4.1. DURING NORMAL USE
Contact the local electricity company for questions
about the power supply.
„„ Shield parts, that can become hot in such a way,
that direct contact is impossible.
„„ When
applicable, always replace deformed
coupling protection plates to protect the coupling,
before putting the pump into use. Make sure that
the coupling protection plates are never in contact
with the running coupling.
„„ Always close the terminal box.
„„
2.4.2. DURING INSTALLATION, MAINTENANCE AND
REPAIR
Only authorised personnel may install, maintain and
inspect the product and repair electrical components.
Observe the local safety regulations.
,,
!!
!!
WARNING - Always disconnect the
electrical supply to the product first,
before installation, maintenance and
repairs. Secure this disconnection.
WARNING - Surfaces of a pump can
be hot, after continuous operation.
WARNING- Make sure that no one can
come in contact with rotating components.
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!!
!!
!!
2.5
WARNING - Handle a pump with dangerous
liquids with the utmost care. Avoid danger
for people or the environment when
repairing leakages, draining liquids and
venting. It is strongly recommended to
place a relief barge under the pump.
WARNING - Immediately following
completion of the work, all safetyrelevant and protective devices must
be re-installed and / or re-activated.
WARNING - Please observe the
commissioning instructions before
returning the product to service.
ENVIRONMENTAL ASPECTS
2.5.1. GENERAL
The products of Smedegaard are designed to function
in an environmentally friendly way during their
entire life. Therefore, when applicable, always use
biodegradable lubricants for maintenance.
!!
ENVIRONMENTAL INSTRUCTION - Always
act according to the laws, by- laws
regulations and instructions with respect
to health, safety and the environment.
2.5.2. DISMANTLING
Dismantle the product and dispose of it in an
environmentally friendly way. The owner is
responsible for this.
!!
ENVIRONMENTAL INSTRUCTION - Ask
at the local government about the reuse or the environmentally friendly
processing of discarded materials.
7
3. Manual Introduction
3.1
PREFACE
This manual contains important information for
reliable, proper and efficient operation of the booster
set. Compliance with the operating instructions is of
vital importance to ensure reliability and a long service
life of the product and to avoid any risks.
The first chapters contain information about this
manual and safety in general. The following chapters
provide information about normal use, installation,
maintenance and repairs of the product.
Read the document.
„„ Accurately follow the directions and instructions.
„„ Never change the sequence of the operations to be
carried out.
„„ Keep this manual or a copy of it together with the
logbook in a fixed place near the product which
can be accessed by all personnel.
„„
3.2
4.1
IDENTIFICATION, SERVICE AND
TECHNICAL SUPPORT
Please quote this information in all queries, repeat
orders and particularly when ordering spare parts. If
you need any additional information or instructions
exceeding the scope of this manual or in case of
damage please contact Smedegaard.
4.2
SUPPLEMENTARY DOCUMENTATION
In addition, apart from this manual, we can also supply
an O&M for the HIL pumps:
ICONS AND SYMBOLS
In this document the following icons and symbols are
used.
))
On some models, the sticker may be found inside the
control panel.
!!
,,
!!
Smedegaard Pumps Ltd
10 Beech Business Park
Bristol Road
Bridgwater Somerset
TA6 4FF
United Kingdom
Is used to indicate SAFETY
INSTRUCTIONS. Non-observance
may lead to faulty functioning
or damage to the product.
8
4. Identification, service and technical support
ENVIRONMENTAL INSTRUCTION Remarks
with respect to the environment.
WARNING - Electrical danger. Safety
sign according to IEC 417 - 5036
WARNING - Operations or procedures,
if carried out without caution, may
cause personal injury or damage
to the product. General hazard sign
according to ISO 7000 0434
Pumping Technology
The following address data are available for service
and technical support:
t +44-1278-458686
f +44-1278-452454
www.smedegaard.com
info@smedegaard.com
5. Introduction
5.1
GENERAL
As well as the booster set O&M a detailed manual the
FlexDrive is also available on request.
5.2
Any other use of the booster set is not in conformity
with its intended use. Smedegaard does not accept
any liability for any damage or injury resulting from
this. The equipment has been produced in accordance
with the current standards and guidelines. Use the
equipment should only be used while in a good state of
repair and exclusively for its deigned use. See below.
The intended use as laid down in EN 12100-1 is
the use for which the product is intended according
to the specifications of the manufacturer. The use
of the product has been described in the available
documentation and information. Always observe the
instructions as given in the installation and operating
instructions. When in doubt the product must be used
as becomes evident from its construction, version and
function.
WORKING RANGE
Working conditions for the FlowFlex range of booster
sets:
Table 1. Specification of the working range
Type
Maximum ambient
temperature [˚C]
Liquid temperature [˚C]
Maximum working
pressure [Bar]
Minimum suction
pressure
Type
FlowFlex
Application
(Drinking water) supply
systems.
6. Functioning
INTENDED USE
The FlowFlex range of booster sets is designed for
boosting the pressure of cold potable water within the
working range of the set.
5.3
Table 2. Specific application
FlowFlex
40
-15 to 40
10
Unless indicated
otherwise
Not cavitating, suction
pressure plus pump
pressure, must never
be higher than the
maximum working
pressure.
6.1
STANDARD OPERATION
The FlexDrive is a wall or pump mounted inverter that,
if it is to be pump mounted should only be done so
with purpose made parts. The inverter is self cooling
either by natural convection/radiation or via the built in
fan(s). Each inverter utilizes the signal from a ‘master’
pressure transducer installed on the pump outlet (or
from another source) to vary the speed of the pump
motor. Should the master transducer fail electrically
then (if fitted) another transducer will take over. The
FlexDrive inverters can be interconnected with each
other, up to 6 pumps can be controlled in this way. On
multiple pump booster sets the lead pump is alternated
based on the run time of each pump. If a single pump is
not capable of meeting the duty then further pumps, as
available, will be bought into operation. Whether sized
for duty/assist or duty/standby, the sets are always
configured to run duty/assist.
6.1.1. SETTINGS
The inverters are programmed and tested prior to
dispatch. It should only be necessary to check/alter the
set pressure. The alteration to the set pressure in one
drive will be transmitted to any other interconnected
drives.
6.1.2. RS485
When fitted, RS485 communication is available (3
phase drives only). The communication protocol is
listed on page 25 of this document.
6.1.3. WATER SURGE PROTECTION
An optional water surge protection module (SPM) is
available. This module protects the system, on initial
start-up and in the event of a power failure, from the
effects of water hammer caused by the pumps operating
at full speed due to the low pressure caused by the
system not being full. The full set-up is described on
page 27 of this document.
For booster sets fitted with the GaardExe module,
for the warranty to be validated, the set must be
commissioned by Smedegaard.
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6.1.4.
WSD-SENSOR
This device can be fitted to monitor the flow of water
in and out of the pressure vessel. The WSD control
module can be used to send an alarm signal based on:
Insufficient water refreshment in the vessel.
Damaged diaphragm.
„„ Loss of vessel air charge.
„„
„„
6.1.5. TEMPERATURE-SENSOR (OPTION)
This is an option for use with the WSD device and
is used to monitor the temperature of the vessel. This
is especially important in areas with a high ambient
temperature.
Further information can be found on page 26.
6.1.6. DRY RUN PROTECTION
The FlexDrives incorporate electronic dry run
protection based on the system pressure. However,
the booster set control panels are fitted with terminals
to allow for the fitting of a low water level sensor in
the suction manifold or break tank. As electronic dry
run protection is not suitable for all systems then float
switch protection is the advised option.
7.2
STORAGE
7.2.1. PREPARATIONS FOR STORAGE
Drain the set if there is a danger of frost.
Store the installation in a frost-free environment.
„„ Protect from the weather.
„„ Protect from dust and other debris
„„ Protect from physical damage.
„„
„„
7.2.2. INSPECTION DURING STORAGE
Turn the motor shaft(s) every three months. This
protects the seals from seizure.
„„ After a storage period of six months or longer,
inspect the installation before using it again.
„„
8. Installation
8.1
SETTING UP THE INSTALLATION
7. Transport
7.1
TRANSPORT
!!
!!
10
WARNING Only lift using suitable
equipment such as a fork lift
truck and taking care to protect
the base of the booster set.
WARNING - Only qualified people
should be involved with the lifting/
transportation of this equipment.
DO NOT USE THE MANIFOLDS TO LIFT
BOOSTER SET.
Transport the booster set on a pallet.
„„ Make sure that the booster set is stable.
„„ Protect from the weather.
„„
Room – Should be clean, dry, dust free, frost free and
properly lit.
The FlowFlexx range of cold water booster sets is
designed for installation into a suitable plant room,
outbuilding or similar.
The set should be so positioned as to enable maintenance
access from all sides and from overhead.
There should be proper provision for drainage in the
event of spillage during maintenance or in case of a
leak.
Foundation – Should be smooth, level and large
enough to entirely support the base of the booster set.
Pumping Technology
Connect the water supply to the booster set suction
(indicated with sticker). The suction head should
be sufficient to enable the priming of the pump
and to prevent the ingress of air due to vortexing
during normal operation. It should be ensured that
the supply is capable of meeting the demands of
the system.
„„ Connect the booster set discharge (indicated with a
sticker) to the cold water demand pipe work
„„
In order to reduce the sound level to a minimum,
proceed as follows:
Position the booster set on anti-vibration (AV)
mounts.
„„ Make sure the supply and discharge lines are
correctly installed and bracketted.
„„ Fit flexible pipe connectors to the booster set inlet
and discharge manifolds (option).
„„ Insert a filter in the water supply line in case of
pollution/debrie.
„„ Manifolds must be connected free of tension.
„„ Diameter of the supply lines of sufficient size.
„„
))
ATTENTION Use dry run protection.
Fit an isolating valve on the
suction and discharge.
8.2
PUMP ROTATION AND FLOW
INDICATORS
See diagram below:
Vent Plug
Direction
of Rotation
Drain Plug
8.3
ELECTRICAL INSTALLATION
!!
WARNING Only a qualified person
should be allowed to make the
electrical connections.
Pumping Technology
Electrical connections
„„ Ensure the electrical supply is suitable for the motor
rating. Check the electrical diagrams to confirm the
wiring of the motors.
„„ Connect the set using an interruptible supply.
„„ After completion of the wiring, close the control
panel.
8.4
COMMISSIONING
!!
WARNING - The pumps
should never be run dry.
Before commissioning the system:
„„ Rinse the booster set and the rest of the pipework
thoroughly prior to use.
8.4.1. IN AN OPEN OR CLOSED CIRCUIT WITH SUFFICIENT SUPPLY PRESSURE
1. Close the suction shut-off valve and the outlet shut-off valve.
2. Remove the vent plug.
3. Gradually open the suction shut-off valve until the liquid flows from the fill plug opening.
4. Close the plug opening.
5. Fully open the suction shut-off valve.
6. Check the rotational direction of the pump.
7. Slowly open the outlet valve to allow the system to stabilise.
))
ATTENTION - Seen from the suction end,
the pump should rotate anti-clockwise.
In case of a 3-phase motor the rotation
direction can be changed by exchanging
two of the three supply cables.
!!
WARNING - Always check the
direction of rotation. This can be
checked by watching the fan.
11
8.4.2. VESSEL PRESSURE
For a correct functioning of the installation the supply
pressure in the pressure vessel should be 20-50 kPa
lower than the pump cut-in pressure. Proceed as
follows to determine the supply pressure:
9. Control panel
9.1
The control panel is either an IP66 enclosure (suffix
CP) or an IP55 MCB housing (suffix MH)
9.2
A
1. Measure the pressure (A) in the vessel when there is no pressure on the waterside (B).
2. Fill the vessel with nitrogen or air. Use preferably nitrogen.
WARNING - Before using the
installation, first put the pressure
vessel under pressure.
ON COMPLETE PACKAGED BOOSTER
SETS THE PRESSURE WILL NORMALLY
BE FACTORY SET IN ACCORD WITH THE
INFORMATION PROVIDED AT ORDER
STAGE. THE PRESSURE SHOULD ONLY
REQUIRE CHANGING IF THE SITE REQUIRED
BOOSTER SET OPERATING PRESSURE
IS DIFFERENT FROM FACTORY SETTING.
THE VESSEL PRESSURE SHOULD BE
REGULARLY CHECKED.
12
Pumping Technology
DESCRIPTION - CP RANGE
The panels fitted to the FlowFlex range of booster
sets contain a panel MCB, pump MCB’s, low water
terminals, power in – power out terminals and
either common fault terminals or, if fitted, RS485
connections. Common fault terminals and RS485 are
only available on 3 Phase sets.The panel door is fitted
with a door interlocked isolator and power on/low
water lamps.
B
!!
TYPES
The inverter/booster set status displays are on each
inverter and the setting up of the booster set is carried
out via the inverters.
9.3
DESCRIPTION - MH
The MCB housing fitted to the FlowFlex Range
of Booster Sets contains the pump MCB's Power
Isolating MCB, Power In - Power Out Terminals, Low
Water Contacts.
The inverter/booster set status displays are on each
inverter and the setting up of the booster set is carried
out via the inverters.
9.4
SINGLE PHASE CP PANEL WIRING
DIAGRAM
9.5
THREE PHASE CP PANEL WIRING
DIAGRAM
NOTE: THE ABOVE WIRING DIAGRAM IS
FOR A TWIN PUMP BOOSTER SET, FOR
EACH ADDITIONAL PUMP THE TERMINALS
4/5/6 WILL BE DUPLICATED AND NUMBERED
7/8/9 FOR A TRIPLE PUMP SET.
TERMINALS 10 TO 20 THEN BEING
NUMBERED 13 TO 23.
13
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9.6
SINGLE PHASE MH WIRING DIAGRAM
14
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9.7
THREE PHASE MH WIRING DIAGRAM
15
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9.8
PUMP WIRING
Each drive is connected to the pump terminals U, V
and W. The direction of rotation should be checked, if
it is not correct then either, switch any two of the wires
to the pump terminals U V W or, reverse the direction
of rotation using menu option Dr-20 in the FlexDrive.
10. FlexDrive Set-Up Booster Sets
If fitted, an SPM Module may slow the setting of the
drives. To prevent this it should be disabled during the
set-up then re-enabled for normal use.
Refer to page 27.
If the drives have been supplied as part of a booster
set then they will have been configured for that use.
In which case it may only be necessary to refer to
section 8.3 and to check the pressure setting, refer to
section 10.3.
The Factory set-up instructions are provided for
information only but, may be required in the event of
the replacement of a drive.
10.1 PARAMETER NAVIGATION.
When the power is first applied, the drive will normally
be in the ‘St’ menu. To change the menu, press and
hold the up/down keys, together, for approx. 3
seconds. The menu will change to ‘Pr’, release the
buttons. Repeat to get to ‘Dr’ and repeat to get back
to ‘St’.
Use either the up or down key to navigate to the
required parameter.
Press the set/reset key to select the parameter, this
will cause the parameter to flash.
Use the up or down key to alter the parameter then
press set/reset to save the change.
16
When the settings have been altered, navigate to and
leave in ‘St’.
‘Dr’ – Drive related settings.
‘St’ – Status display.
‘Pr’ – Pump related settings.
Pumping Technology
10.2 SETTINGS.THOSE IN ITALIC MAY NEED
TO BE CHECKED/ALTERED ON SITE.
ENSURE THE SET HAS BEEN CORRECTLY
INSTALLED AND THAT THE NECESSARY
WATER
CONNECTIONS
HAVE
BEEN
COMPLETED BEFORE TURNING ON THE
INVERTERS. ALSO ENSURE THE SET HAS
BEEN VENTED AND PRIMED.
Settings can only be altered with the
FlexDrives in ‘STOP’ mode, see section 10.1.
Only the pressure setting will be communicated to
other attached drives. All other settings need to be
programmed into each drive.
If multiple drives are provided then select a ‘Master’
drive. Under the cover of each drive (ensure the power
is off before removing the cover) there are 2 switches.’
PNP/NPN’, leave on NPN. ‘Open-Short’, for the
master (or only) drive, set this to ‘Short’. For the other
‘slave’ drives, set this to ‘Open’.
Replace the covers and switch on the set.
Ensure there is power to the drive(s).
It/they should be in St mode, if not then navigate it/
them to St mode.
LONG PERIODS WITHOUT POWER, SUCH
AS STORAGE, MAY LEAD TO A LOSS OF THE
SETTINGS
10.3 FACTORY SETTINGS
When in St mode the system pressure P will be
displayed on all the drives and will show the static
pressure. On the master drive hold set/reset for
approx. 2 seconds, display will change to d and the
parameter will flash. Use the up/down keys to alter
the setting to the required pressure (in Bar). Set/reset
to save. This setting should be transmitted to any slave
drives.
The following settings are required to be checked/
altered on both master and slave drives.
Pr-50 Single drive (default) 0. Multiple drives set to 1.
Pr-51 In each drive set a different ’address’. 1,2 etc.
Pr-01 Set the motor kW as found on the motor label.
Pr-02 Default 1.
label. (Repeat of Pr-01)
Dr-11 2 pole (2900rpm) motor set to 1, 4 pole (1450rpm) motor set to 2.
Dr-12 From the motor label, set the 3phase amps. 1 phase supply – use 3x230V amps, 3 phase supply – use 3x400V amps.
Dr-13 From the motor label, set the speed. ie 2850rpm.
Pr-03 Transducer range, default 16 bar, Smedegaard normal setting 10 bar.
Dr-14 Motor voltage. For 3 phase drives then will typically be 400 volts and for 1 phase drives will typically be 230V (230 3 phase).
Pr-04 Used to cailibrate the transducers against (ie) a pressure gauge. Set +/- tenths of a bar.
Dr-17 Motor supply Hz, default 1 (60Hz), change to 0 for 50Hz.
Pr-12 Default 0.3. Allowed pressure drop (bar) before the pump starts. Can effect the vessel charge pressure.
Dr-20 To reverse motor direction of rotation. 1 or 0.
Pr-54 Default 12, set to 1.
Dr-23 Default 6 seconds.
Pr-70 Default setting 2 bar (above the set pressure). High pressure alarm.
Dr-30 Default 1.
Pr-71 Assuming the use of a float switch in the break tank, set to 0. 1 if a float switch is not being used.
Dr-43 Default 60, normally set to 50Hz.
Pr-74 Time for low water level to react, factory set to 30 seconds.
Pr-75 Low pressure trip setting. Factory set to 0.3 bar.
Pr-76 Default 0 for low pressure sensing, set to 1 for level switch low water sensing.
Pr-77 Default 2 seconds.
Pr-81/85
Last 5 error codes, most recent in 81.
Pr-86 Default 0, set to 1 to clear error log. Automatically resets to 0.
Pr-90 Factory reset of Pr memory.
Dr-01 Default 0 for operation control from the drive, 1 for remote operation command.
Dr-02 Default 0
Dr-10 Set the motor kW as found on the motor Pumping Technology
Dr-22 Default 3 seconds.
Dr-32 Overload trip time set to 5
Dr-90 Factory reset of Dr menu.
Navigate back to St mode.
ENSURE THE SET HAS BEEN CORRECTLY
INSTALLED AND THAT THE NECESSARY
WATER
CONNECTIONS
HAVE
BEEN
COMPLETED BEFORE TURNING ON THE
INVERTERS. ALSO ENSURE THE SET HAS
BEEN VENTED AND PRIMED.
The system pressure P will be displayed on all the
drives and will show the static pressure. On the master
drive hold set/reset for approx. 2 seconds, display
will change to d and the parameter will
flash. Use the up/down keys to alter the setting to
the required pressure (in Bar). Set/reset to save. This
setting should be transmitted to any slave drives.
17
10.4 ERROR CODES
Display
Content
Er-01
Er-02
Er-03
Er-04
Er-05
Er-06
tSF
tOP
tLP
tUL
tASH
tOC
Er-07
Er-08
Er-09
Er-10
Er-11
Er-12
Er-13
Er-14
Er-15
SOC
tMOH
tOH
tLv
tOv
tOL
tdOL
tGF
tldE
Er-16
Er-17
Er-18
Er-20
Er-21
tCE
tIO
tOO
tES
tLt
Description
Pressure sensor error
High pressure alarm
Low pressure alarm
Low level alarm
Drive arm short trip
Drive H/W over current trip
Drive H/W over current
restriction trip
Motor overheat (TMOH)
Drive overheat trip
DC-Link low voltage trip
DC-Link high voltage trip
Overload operation trip
Drive overload operation trip
Ground trip
Communication IC duplication
trip
Communication error
Input error
Output error
External fault input
Allowable time elapsed
Restarting
O
O
O
O
X
O
O
O
O
O
O
O
O
X
X
X
X
X
X
X
Remarks
7-2
7-3
7-4
7-5
7-5/6
7-6/7
7-8
7-7
7-8
O - Auto Reset
X - Does not Auto Reset
7-2
7-3
7-4
18
7-5
7-5/6
7-6/7
7-8
To reset Manually, if in PR press Set/Reset twice or once if in ST. If fault still exists the alarm will
again trigger.
Er-01 is a sensor error indication but may also be caused by a faulty drive.
Er-05 can be caused by entering a too short acceleration/deceleration time into Dr-22 but, can also
be caused by damage to the motor windings. Er-06 is similar but usually occurs during the free
running of the motor.
Er-07 may be caused by Er-05 Er-08 may be caused by an under-rated drive or motor.
Er-09, problem with the motor cooling fan or high ambient temperatures.
Er-10 is an indication of a low supply voltage.
Er-11 is an indication of a high supply voltage or, the motor deceleration time (Dr-23) is to short
for the pump/motor rating.
Er-12 trips when the motor over-load is exceeded for more than a pre-set time. Check motor plate
for current rating, check Dr-10 for current setting, Dr-12 for motor rating, Dr-30 for trip time Dr31 for trip level, Dr-32 for trip time.
Er-13. Load is greater than the drive capacity.
Er-14 Drive out-put cable or motor winding short circuit.
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7-7
7-8
Er-15. See Pr-51, occurs when multiple drives have the same ID.
Er-16. Fault CAN communication. May be faulty connection or faulty drive.
Er-17. Output wiring fault, usually terminals
Er-18. Output wiring fault, usually terminals.
Er-20. External signal error.
Er-21. Time elapsed contact Smedegaard.
19
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10.5 THREE PHASE FLEXDRIVE WIRING
MCCB
R
U
S
V
T
W
MOTOR
FG
Control Circuit
24V
S1P
P1
S1N
CG
PNP
NPN
S2P
ESTOP
NPN
CONNECTION
Input frequency
S2N
CG
LV1
V1
LV2
0-10V
VGND
4-20mA
CANH
I1
OPEN
SHORT
CG
CAN
Communication Terminal
CANL
Run condition
Output
Output
AT
CT
RUN
BT
RS 485 (Optional)
485_TX
AT
CT
BT
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CG
FAULT
485_RX
RS 485
Communication Terminal
(Optional)
10.6 SINGLE PHASE FLEXDRIVE WIRING





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10.7 MULTI- DRIVE CONNECTION
22
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11. Maintenance
11.1 INTRODUCTION
,,
WARNING: Observe the general
safety precautions for installation,
maintenance and repair.
Regular maintenance is necessary for the correct
operation of the installation. For maintenance of
the installation, please contact your supplier. A draft
maintenance contract is available upon request.
11.2 LUBRICATION
Sealed for life bearings, no lubrication required.
11.3 MAINTAINING THE PUMP FOR
AN EXTENDED PERIOD OF
NON-OPERATION
Turn the shaft every three months. This protects the
seals from seizure.
To protect the pump if there is a risk of frost. Proceed
as follows:
1. Close all pump valves.
2. Drain each pump and/or the system.
3. Remove all plugs from the pump.
4. Open the shut-off and fill/air vent plug, if present.
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11.4 PUMP FAULT TABLE
,,
WARNING - Observe the general
safety precautions for installation,
maintenance and repair.
Problem
Leakage along the shaft.
Pump is vibrating and
makes a lot of noise.
Possible cause
Shaft seal worn.
Pump has been operated
without water.
There is no water in the
pump.
No water supply.
Bearings of pump and/or
motor defective.
Installation / pump does
not start.
Hydraulic assembly
defective.
Pump rotates in the
wrong direction.
No voltage on the
connecting clamps.
Thermal motor safety
switch triggered.
Run-dry protection
triggered.
Pressure set point
incorrect.
Drive error.
24
Installation / pump sup- There is air in the pump.
plies insufficient capacity Pump rotates in the
and/or pressure.
wrong direction.
Capacity of water meter
in the supply line is too
small.
System filter.
Pumps continuously start
and stop.
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Outlet and/or inlet shutoff valve is closed.
Membrane switch
vessel(s) leaky or
incorrect pressure.
Possible solution
Replace the shaft seal.
Replace the shaft seal.
Checkpoints
Check the pump for dirt.
Fill and de-aerate the
pump.
Restore the water supply. Check if the supply pipes
are not clogged.
Have the bearings
replaced by a certified
company.
Replace the hydraulic
assembly.
Switch two phase wires.
Check the power supply. Check there is water in the
supply tank and the supply
to the booster set is not
blocked.
Reset the thermal motor
safety. Contact the supplier, if this problem
occurs more often.
Restore the water supply.
Reset the installation.
Adjust the pressure setpoint.
Reset drive and note the
error code.
Vent the pump.
Change two phase wires
on the main switch.
Increase the capacity of
the water meter.
Clean filter or check
filter flow capability and
change if necessary.
Open both shut-off
valves.
Have your supplier
check the installation.
11.5 RS-485 COMMUNICATION PROTOCOL
Address
(Decimal)
4096
Addrress
4097
0x1001
The State of Sytem
Operation
4098
4099
0x1002
0x1003
4100
0x1004
Setting Pressure
Discharge Pressure
(Differential Pressure)
Stop state Inverter
4101
0x1005
Ready state Inverter
R
4102
0x1006
Run State Inverter
R
4103
0x1007
System Fault Content
4104
0x1008
Inverter Fault
4111
4112
4113
4114
4115
4116
0x100F
0x1010
0x1011
0x1012
0x1013
0x1014
Inverter
Inverter
Inverter
Inverter
Inverter
Inverter
0x1000
Parameter
program version
1 Output
2 Output
3 Output
4 Output
5 Output
6 Output
Scale
0.01
Unit
R
0.01
0.01
bar
bar
R/W
R
R
R
0.1
0.1
0.1
0.1
0.1
0.1
%
%
%
%
%
%
11.6 RS485 CONNECTIONS – 3 PHASE FLEXDRIVES ONLY.
The RS485 connections are via:
AUX1 (TX)
AUX2 (RX)
CG - Common
Connections should be made using 3 core screened cable.
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R/W
R
R
R
R
R
R
R
Content
0~65535
0 : STOP,
1 : READY(inverter EN and
output zero),
2 : RUN(inverter EN and
output non-zero),
3 : Fault(system fault)
0~10000
0~10000
Content for each bit(1:stop /
0: none) Bit 0: INV 1
Bit 1: Inv 2 Bit 2: Inv 3 Bit 3:
Inv 4 Bit 4: Inv 5 Bit 5: Inv 6
Content for each bit(1:ready /
0: none) Bit 0: INV 1
Bit 1: Inv 2 Bit 2: Inv 3 Bit 3:
Inv 4 Bit 4: Inv 5 Bit 5: Inv 6
Content for each bit(1:Run /
0: none) Bit 0: INV 1
Bit 1: Inv 2 Bit 2: Inv 3 Bit 3:
Inv 4 Bit 4: Inv 5 Bit 5: Inv 6
Content for each bit
Trip content
Bit 0: Sensor Fault
Bit 1: High Pressure Fault
Bit 2: Low Pressure Fault
Content for each bit
Bit 0: Inv 1 Bit 1: Inv 2 Bit 2:
Inv 3 Bit 3: Inv 4 Bit 4: Inv 5
Bit 5: Inv 6
0~1000
0~1000
0~1000
0~1000
0~1000
0~1000
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11.7 FAILURE TABLE WSD-SENSOR(OPTION)
,,
WARNING - Observe the general
safety precautions for installation,
maintenance and repair.
Problem
There is no input signal
when a pump is started.
Input signal remains
active.
Nothing responds
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Possible cause
Shut-off valve to the
WSD Sensor is closed.
Pump is operating against
the maximum pressure
of the unit and does not
deliver.
Possible solution
Open the shut-off valve.
Adjust the switch-on
pressure of the pump to
at least 80 kPa below the
maximum pressure of the
unit.
Pressure in the membrane Adjust the air pressure
switch vessel(s) is too
in the membrane switch
high.
vessel to the correct
values.
Pressure in the membrane Adjust the air pressure
switch vessel(s) is
in the membrane switch
too low, or there is no
vessel to the correct
pressure at all.
values.
Reed contact on the WSD Replace the reed contact.
Sensor defective.
Magnet in the WS
Replace / clean the
Sensor is stuck.
interior
of the WSD-Sensor.
Magnet in the WSD
Replace / clean the
Sensor is stuck.
interior
of the WSD-Sensor.
Short circuit on the input
signal.
Reed contact defective.
Replace the reed contact.
There is no voltage on the Fuse defective.
booster set.
Checkpoints
Shut-off valve should
always be opened.
Adjust the pressure set
point.
Make sure maintenance is
performed regularly.
Check if the membrane
switch vessel is not
leaking, if so, replace the
membrane switch vessel.
Adjust the reed contact.
Deposits / dirt.
Deposits / dirt.
Check the wiring.
Check the correct voltage.
11.8 SMEDEGAARD - GAARDEXE -SURGE PROTECTION MODULE.
NORMAL Operation Control Buttons
When operating normally, if you press and hold any of the Buttons, the Controller will respond as
follows…
DOWN Button.
Pressing the left most (DOWN) Button will cause the Controller to jump into its HISTORY LOG.
The last 32 ERROR EVENTS are stored here along with a TIME and DATE STAMP. If multiple
errors occurred simultaneously (eng WATER LOW and PRESSURE LOW, then they will scroll in
sequence so you can see what the state of the Controller was at any point in time. Using the UP and
DOWN Buttons, you can scroll through the logged 32 events. The latest event is numbered 1 and
the oldest is number 32. Pressing the SET Button will exit the HISTORY LOG back into normal
operation (as will no activity from the operator whilst continuously displaying the log for about 50
Seconds).
UP Button.
Pressing the centre (UP) Button will cause the Controller to MUTE the ALARM audible BEEPER.
If the Alarm BEEPER is running continuously and giving folks a headache, press this Button to
toggle the BEEPER ON or OFF.
SET Button
The SET Button has a dual function. Press and release within a Second or so will cause the
Controller to prompt ‘ENTER PIN:’ in order to access the SETUPs. Press and hold this Button for
FIVE SECONDS or so, and the Controller will switch OFF and display ‘STANDBY MODE’ (see
‘Initial POWER-ON section).
For booster sets fitted with the GaardExe module, for the warranty to be validated, the set must be
commissioned by Smedegaard.
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SETUP Options - USER SETUP (Entered through pressing the Return Key)
Standby Mode : If set to NO (Factory Default) will allow the Controller to start operating as soon
as Power is applied. If set to YES, will cause a ‘STANDBY MODE’ message to appear on the LCD
and the unit will remain in this mode until manually switched ON by a User (think of it as an ON/
OFF Button on your VCR). Press and hold the SET Button for at least FIVE SECONDS to switch
ON. Similarly, to
switch INTO Standby Mode, press and hold the SET Button for at least FIVE SECONDS (pressing
for less than this time will cause the ‘Enter PIN’ message - for entry into the SET-UP Menu to
appear).
Caution: In STANDBY MODE the equipment remains LIVE - Don’t try to change the
Control Panel or any Pumps without completely isolating the equipment at the wall.
Set Pressure : This is the Operational Pressure the equipment is intended to run at.
Integral Pressure : This is the Pressure setting (in Bar) up to which the ACTUAL Pressure needs
to rise before direct control is transferred to the Pumps. (Factory Default is 0.2 Bar below the Set
Pressure).
Integral Time : This is a slope pre-set by the Commissioning Engineer to allow the system to drop
from the Operational Pressure (Set Pressure) to Zero. It is adjustable in MINUTES from 0 to 240
(Factory Default is 30)
Integral Sequence : The time interval to elapse before a further Pump would be sequenced in.
(Factory Default = 0 - All Pumps Enabled).
Number of Pumps : The Number of Pumps in the installation.
Cross-Over Action : The action to be taken once the Actual Pressure and the Integral Pressure is
equal. If TRANSFER is the selected option, the actual Transducer is connected to the lead (Master)
Pump. Only WATER-LOW continues to be monitored. If SIMULATE is the selected transfer
option, then the unit will continue to provide a Simulated Pressure Signal reflecting the ACTUAL
Transducer Input, and PRESSURE-LOW, PRESSURE-HIGH and WATER-LOW will continue to
be monitored
28
Pressure-Low Alarm ON : The value at which the Pressure LOW Alarm activates. Zero is
Disabled. (Factory Default = 0)
Pressure-Low Alarm OFF : The value at which the Pressure LOW Alarm deactivates. (Factory
Default = 0)
Pressure-High Alarm ON : The value at which the Pressure HIGH Alarm activates. (Factory
Default = 2 Bar above the Set Pressure)
Pressure-High Alarm OFF : The value at which the Pressure HIGH Alarm deactivates. (Factory
Default = 1 Bar above the Set Pressure)
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Stop on Pressure High : A YES/NO option that will shut-down the Pumps if a Pressure High
Alarm is activated. (Factory Default = YES)
Water Low Mode : Enables setting of Alarm on Make or Alarm on Break type connections. These
should be volt free type. If no Switch/Sensor is to be fitted, then select Alarm on Make and leave
the Water Low terminals unconnected or set to Disabled. (Factory Default – Alarm on Break).
Water Low Reset : Starts a Timer (0-60 minutes) to prevent Pumps from immediately restarting
following reset from a Water-Low Alarm. Allows the Water Tank time to refill in order to prevent
continually switching the Pumps whilst emptying small amounts of water from the bottom of a
tank. (Factory Default - 0).
Leak Alarm : Flags an Alarm if pumps have run for equal to or more than the total cumulative
preset time (in MINUTES) during the initial GAARD INTEGRAL MODE. (Factory Default - 0/
Disabled).
Stop on LEAK : A YES/NO option that will shut-down the Pumps if a Leak Alarm is activated.
(Factory Default - No)
VOLT-FREE Relay : Sets all the conditions that will enable the VOLT-FREE Relay. By default
the User will ‘Skip Sub-Menu’ if SET is simply pressed, however by using the UP and DOWN
Buttons to change this to ‘Configure’ and then pressing SET, the User can then enable or disable
all the multiple options that will trip this Relay. The FAILSAFE option reverses the operation of
the STOP Relay (ie so it is normally ON and drops out on Alarm, rather than normally OFF and
switching ON for Alarm ). Failsafe allows for the provision of signaling an Alarm on PowerFailure. Naturally the NC/NO contacts as marked on the PCB operate in reverse if the Failsafe
setting option is used.
Factory Defaults :
Pressure Low - ON
Pressure High - ON
Water Low - ON
Water Leak - OFF
Service Due - OFF
System Fault - ON
Failsafe - OFF
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BEEPER : This option sets all the conditions that will enable the BEEPER.
Factory Defaults :
Pressure Low - ON
Pressure High - ON
Water Low - ON
Water Leak - ON
Service Due - ON
System Fault - ON
Key Press - ON
ALARM LED : This option sets all the conditions that will cause the Status LED to blink RED.
Factory Defaults :
Pressure Low - ON
Pressure High - ON
Water Low - ON
Water Leak - ON
Service Due - ON
System Fault - ON
Key Press - ON
Erase History : Allows the History/Event Log to be Erased.
Set Contrast : Changes the LCD (Display) Contrast Ratio for User comfort.
Set Date & Time : Allows setting of the System Date and Time which is only used for History/
Event Logging.
User PIN : Allows entry/setting of the User PIN code.
*Please note that any or all settings may be changed from Default at
Commissioning.
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11.9 DECLARATION OF CONFORMITY (IIA)
Factory declaration (2.1) according to EN 10204
Undersigned:
Smedegaard Pumps Ltd
10 Beech Business Park
Bristol Road
Bridgwater
Somerset
UK
Tel. +44 (0)1278 458 686
Fax +44 (0)1278 452 454
Declares as manufacturer entirely on his own responsibility, that the products:
Product: Flex Booster Sets
Type: ExeFlex/FlowFlex/FalFlex
to which this declaration refers, is in accordance with the following standard:
EN-809, EN-ISO-12100-1
EN-IEC-61000-6-1/3, EN-IEC-61000-3-2
EN 1010, EN-IEC-60204-1
according to the provisions of (when applicable):
Machine directive 98/37/EC
EMC directive 89/336/EEC
Low voltage directive 73/23/EEC
If the installation is used as a stand-alone product, it is subject to this declaration of conformity.
If the installation is built in an appliance or is assembled together with other equipment in certain installations,
then it should not be put into operation until a declaration has been given with respect to the appliance
concerned that it complies with the directives listed above.
Bridgwater Somerset,
18-01-2011
55
Responsible person:
C.K.Barrett, UK Director
It is Smedegaard’s policy to continually improve and develop its product range. We reserve the right to change specifications without prior notice. Whilst every care has
been taken to ensure the data is correct, no responsibility can be taken for inaccuracies or misprints.
Pumping Technology
Smedegaard Pumps Ltd
United Kingdom
Tel. +44 (0)1278 458 686
Fax +44 (0)1278 452 454
info@smedegaard.co.uk
www.smedegaard.co.uk
T. Smedegaard A/S
Denmark
Tel. +45 43 96 10 28
Fax +45 43 63 17 66
info@smedegaard.dk
www.smedegaard.dk
FR 18/01/2011