1611926 Watertronics Instl-Ops-Maint Manual Rev B ECN 35765.pdf

Water Pumping Station Installation, Operation & Maintenance Manual

P/N 1611926 Rev B, ECN 35765 I Watertronics Operation & Installation Manual Introduction

Introduction Watertronics® is a registered trademark of Watertronics Inc. of Hartland Wisconsin.

This manual is intended solely for the purpose of providing a better understanding of installing, operating and maintaining the Watertronics Pumping Systems. Keep this manual accessible and in working order for all future references. Additional or replacement manuals can be prepared at a cost.

Please take the time to read this manual and understand all safety warnings before operating this equipment. Use this manual to locate the pertinent safety warning decals on this equipment.

Review all illustrations, schematics and troubleshooting guides in order to properly operate and maintain this equipment and receive optimal performance for the life of this equipment.

Review all additional OEM information for proper operation, safety and maintenance of any Watertronics vendor supplied components and equipment. OEM suppliers will have their own warranty limitation and policies. Please take the time to review these as they may not be warranted through Watertronics.

Some standard information in the manual may not pertain directly to your specific equipment. Such items may be disregarded

Watertronics Contact Information We at Watertronics welcome your comments and suggestions with regard to how we may be able to improve the information and documentation within this manual.

Contact us between the hours of 8:00 AM and 5:00 PM CST, Monday through Friday at:

Phone: 1-262-367-1000 Fax: 1-262-367-1009

Address: Watertronics, Inc. 525 East Industrial Drive, Hartland, WI., USA, 53029

Copyright Watertronics, Inc. 2017 Reproduction of this manual, in whole or part, without the written consent of Watertronics, Inc. is strictly prohibited.

P/N 1611926 Rev B, ECN 35765 Watertronics Operation & Installation Manual Table of Contents

Table of Contents Section 1– Safety Instructions.................................1-1 Section 2– Warranty .................................................2-1 Section 3– Installation ..............................................3-1 Section 4– System Operation ..................................4-1 Section 5– Maintenance ...........................................5-1 Section 6– Troubleshooting .....................................6-1 Section 7– Winterization ..........................................7-1

P/N 1611926 Rev B, ECN 35765 1-1 Section 1– Safety & Specifications

Section 1– Safety & Specifications

WARNING

Personal Safety: Throughout this manual and on all safety signs, the precautionary statements (“DANGER”, “WARNING”, “CAUTION” and “NOTICE”) can be found, followed by a hazard descrip-tion and preventative actions to be taken. These precautions are intended for the personal safety of the operator and those within the vicinity of the machinery. Please take time to read these precautions.

Hazard Severity Panels Background

Color of Panel

Contrast Color Meaning/Use Hazard Severity Panel Illustration

Red White Indicates a hazardous situation, that, if not avoided, will result in death or serious injury.

Orange Black Indicates a hazardous situation, that, if not avoided, could result in death or serious injury.

Yellow Black Indicates a hazardous situation, that, if not avoided, could result in minor or moderate injury.

Blue White Indicates information considered important, but not hazard-related (e.g. messages relating to property damage).

NOTICE

Machine Integrity: Additional precautionary statements (“ATTENTION” and “IMPORTANT”) are intended for machine integrity and are followed by specific instructions.

ATTENTION: The word “ATTENTION” is used to warn the operator of potential machine damage if a certain pro-cedure is not followed.

IMPORTANT: The word “IMPORTANT” is used to provide the reader with information necessary to prevent minor machine damage if a certain procedure is not followed.

WARNING!

Qualified Technicians Only: All maintenance and service must be performed by Watertronics or a Watertronics certified PSN service partner. Failure to comply can result in damage to property and machinery, and cause injury or death to personnel.

P/N 1611926 Rev B, ECN 35765 1-2 Section 1– Safety & Specifications

DANGER!

Lock Out/Tag Out: Disconnect all sources of energy and lock out machine before doing any maintenance or repairs to the machine. Proper Lock Out procedures will prevent the energy source from starting the machine or allowing parts to move unexpectedly as well as prevent the machin-ery from being accidentally turned on or restarted. Shut off and Lock Out all sources of potential or kinetic en-ergy. These may include, but are not limited to, electri-cal, mechanical or hydro energy sources.

Lock Out is a procedure used for placing an actual lock-ing device on the power source, preventing unexpected start up or accidental release of energy. Lock Out is the preferred method of accident prevention.

Tag Out procedure is used when the power can not be disconnected. Tag Out does not shut down the power source, Tag Out only provides a warning about the dan-ger of activating the machine.

Never try to operate machinery that is locked out or tagged out. Never attempt to remove these locks or tags on machinery. Doing so will result in injury to personnel working on the machine. Only the initiator of the Lock Out or Tag Out procedure may remove locks and tags.

Sometimes it may be necessary to energize the system to test or position equipment during maintenance or repair.

Such application must be performed only by a qualified technician and all Lock Out removal steps must be fol-lowed before power is turned on.

WARNING!

Main Disconnect: The main power disconnect is located at the main service breaker or generator. The disconnect at the panel is not the main disconnect. A fuseable service disconnect device must be placed previous to this panel with the fuses sized for the load being supplied and installed in accordance to NEC codes.

It is important to understand the differences between High Voltage On/Off switch at the equipment and the service breaker On/Off throw switch.

The power company service disconnect provides the ability to turn off or return full service to the equipment from the power company service line. This switch must be turned off and locked out when performing maintenance and repairs on the system.

The High Voltage On/Off provides the ability to turn off or return power to the equipment from the service discon-nect. This switch must be turned off and locked out in conjunction with the service disconnect switch. The High Voltage switch only disconnects the power in the control panel, as energy is still coming in from the main power line.

P/N 1611926 Rev B, ECN 35765 1-3 Section 1– Safety & Specifications

WARNING!

Proper Training: All individuals involved in the installation, operation or maintenance of this equipment must receive and understand training in the safe and proper methods of performing all duties assigned to them at the time of the initial assignment and at least annually thereafter. Safety messages and appropriate response procedures to emergencies or other situations which may arise should be fully under-stood.

WARNING!

Follow Safety Instructions: Carefully read all safety messages in this manual and safety signs on the machinery. Keep safety signs in legible condition. Replace any missing or damaged safety signs.

Learn how to operate the machine and controls properly. Do not allow anyone to operate the machinery without proper instructions.

Keep the machine in proper working condition. Only have the machine serviced by a trained service technician on a routine basis. Unauthorized modifications to the machine may void the warranty, impair machine function and/or safety and reduce the life of the machine.

CAUTION

Practice Safe Maintenance: Understand maintenance procedures before doing work.

Always follow proper Lock Out/Tag Out procedures before performing any maintenance.

Never lubricate or service machine while it is moving. Keep hands, feet and loose clothing from power-driven parts. Disengage all power and operator controls to relieve pressure. Allow all heat-generating units to cool.

Keep all parts in good condition. Remove any build up of grease, oil and debris. Ensure that all parts have been properly installed by a certified technician.

WARNING!

Electric Shock and Arc Flash: Follow these precautions to prevent serious injury or death.

DO NOT allow moisture to enter the main panel. Moisture can allow voltage to conduct across surfaces, creating a shock potential.

WARNING!

Electrical Connections: Keep all sparks and flames away from all wet cell batteries (where used), as gases given off by electrolyte are explosive. Avoid sparks by connecting the ground cable last and disconnecting it first.

WARNING!

Inspecting the System Prior to Operation: Always inspect the system before opera-tion. If the system appears impaired, do not operate the machinery and contact Watertronics.

CAUTION

Area Lighting: The owner shall provide area lighting as may be required. Improper lighting can lead to visual impairment and cause injury to personnel and damage equipment.

P/N 1611926 Rev B, ECN 35765 1-4 Section 1– Safety & Specifications

CAUTION

Use Watertronics Parts: Ensure that only Watertronics approved parts are used on the system. Using modified parts or non-approved Watertronics OEM vendor parts can result in ill-fitting components, resulting in premature part or system failure and void warranty claims.

WARNING!

Lifting Components: Extreme care is needed for lifting components during installation/ assembly. Only an approved Watertronics installation crew using the proper lifting equipment may perform this task.

Use caution when lifting heavy objects. Components weighing in excess of 50 lbs. (22.7 kg.) must be lifted with the assistance of another individual or mechanical lifting device.

Do not work or stand under system or components during assembly. Due to the weights involved, severe injury or death can result if components should fall.

WARNING!

Dismantling the System: If it is ever necessary to dismantle a Watertronics System, extreme care must be taken to prevent damaging or dropping parts. As with installation and assembly, dismantling must only be performed by an approved Watertronics installation crew.

WARNING!

Chemical Handling: Chemicals can be extremely poisonous or explosive. Improper selection or use of chemicals can injure persons, animals, plants, soils, or other property. Handle and apply chemicals with care. Follow instructions of the chemical manufacturer. Certain chemicals may be subject to state and federal emergency release notification requirements. Please consult the local or national safety authority for applicability.

CAUTION

Prepare for Emergencies: Be prepared for any emergency that may occur. Keep emergency numbers for doctors, hospital, ambulance service and fire department near your telephone.

DANGER!

Do Not Remove Guarding: Never remove guarding or barricades used to prevent the intrusion of personnel due to hazards located within. Make sure all guarding is re-installed after maintenance and before resuming normal operation. Replace any damaged or impaired guarding and barricades immediately.

CAUTION

Wear Proper PPE: Always wear appropriate Personal Protective Equipment (PPE) for the task being performed. At a MINIMUM, the following are required equipment:

Ear Protection:

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against uncomfortably loud noises.

The A-weighted emission sound pressure level at the pump station does not exceed 70 dB.

P/N 1611926 Rev B, ECN 35765 1-5 Section 1– Safety & Specifications

Eye Protection:

Sharp Objects, Debris and explosions can cause severe eye damage or blindness. Wear Safety Standard ap-proved eye protection that fully shields the eyes.

Foot Protection:

Prevent damage from falling or dropped objects on the feet by wearing steel-toe shoes/boots with metatarsal protection.

Head Protection:

Prevent damage from falling or dropped objects on the head by wearing proper head protection.

WARNING!

Observe All Safety Decals: Pay attention to all safety decals and follow any instructions listed on them to prevent injury. Never remove safety decals from the equipment and replace any safety decals that are missing or torn. Keep all safety decals clean and legible.

WARNING!

Multiple Power Sources: Hazardous voltage. Multiple power sources may be present.

Disconnect all electric power including remote disconnects before servicing. Failure to do so may cause personal injury, property damage or death.

Use proper Lock out/ Tag out procedures before servicing.

Interfacing control signals sources by other equipment are wired with ORANGE wire. Verify source has been dis-connected before working on orange circuits.

WARNING!

Slippery Surfaces: During normal operation of the equipment; do not walk, stand or climb on apparatus. Water, condensation, debris or other contaminants will result in a slippery surface.

WARNING!

Pinch Point: During operation of the equipment, the manual override actuator can inadvertently grasp clothing. All maintenance shall be performed by trained/qualified personnel. Obey all established Lock out / Tag out procedures when working on the equipment.

WARNING!

Hot Surfaces: During abnormal conditions, motors or other surface have the potential to over-heat and become HOT to the touch. Exhibit caution during abnormal conditions and do not touch any surface without the appropriate protective equipment.

P/N 1611926 Rev B, ECN 35765 1-6 Section 1– Safety & Specifications

WARNING!

Pressurized System: System contents are under pressure. Leaking may occur during abnor-mal weather conditions resulting in high pressure water or air escaping from the equipment. Always wear appropriate PPE to protect from high pressure injection hazards. Leaks occurring within the range of live electrical equipment pose a possible electrocution hazard. Disconnect power to the equipment.

Freezing of pipes could damage the system. Always follow proper winterization procedures and operate the equip-ment only within the given temperature ranges.

DANGER!

Current Leakage: This electrical equipment has earth leakage current greater than 10mA AC.

Earth ground connection is essential before connecting the supply power.

WARNING!

Phase Sensitivity: This equipment is dependent on phase sequence. Refer to the Initial Start- Up Procedure in Section 3 for more detailed instructions.

IMPORTANT: Electrical equipment shall be capable of operating correctly at altitudes up to 1000 meters above mean sea-level.

IMPORTANT: Pump Station installation must comply with all local and national codes. Consult local authori-ties in the installation area for requirements.

P/N 1611926 Rev B, ECN 35765 1-7 Section 1– Safety & Specifications

MAINTENANCE &

the

Additional System Specific Safety Warnings The following are safety warning decal that can be found all around the pump station. It is important to familiarize yourself with these warnings then locate them on your system.

P/N 1611926 Rev B, ECN 35765 1-8 Section 1– Safety & Specifications

NOTICE

This door is electrically interlocked.

To release interlock, turn off electrical power to this enclosure.

WARNING

Shut off and lock out main disconnect and any other sources of power to this equipment prior to performing inspection/service

P/N 1611926 Rev B, ECN 35765 1-9 Section 1– Safety & Specifications

Watertronics OEM Vendor Safety: Review the OEM Vendor information that is supplied along with this manual for safety instructions and warnings that pertain specifically to OEM equipment provided on the Watertronics system.

AC Supply Specifications Requirements for various AC voltages that can be supplied to the pump station.

Supply Voltage Phase Type Min Max Hertz

208 3 WYE 200 220 60

240 1 - 220 250 60 240 3 Closed Delta 220 250 60 380 3 - 375 400 50 400 3 - 375 415 50 415 3 - 390 420 50 480 1 -1 455 495 60 480 3 WYE/Delta 455 495 60 575 3 - 560 590 60

*Open delta, phase converter or other forms of unbalanced power are not acceptable.

Frequency For 50 Hertz systems, frequency must be maintained between 48.5Hz and 50.5Hz.

For 60 Hertz systems, frequency must be maintained between 58.5Hz and 60.5Hz.

Harmonics Harmonic distortion not exceeding 10% of the total RMS voltage between live conductors for the sum of the sec-ond through to the fifth harmonic. An additional 2% of the total RMS voltage between live conductors for the sum of the fifth through to the thirtieth harmonic is permissible.

Voltage Unbalance Neither the voltage of the negative sequence component nor the voltage of the zero sequence component in three-phase supplies exceeding 2% of the positive sequence component.

Voltage Interruption Supply interrupted or at zero voltage for not more than 3 milliseconds at any random time in the supply cycle with more than one second between successive interruptions.

Voltage Dips Voltage dips not exceeding 10% of the peak voltage of the supply for more than one cycle with more than one second between successive dips.

Temperature Equipment to be operated within the range of 0°C to 40°C.

P/N 1611926 Rev B, ECN 35765 2-1 Watertronics Operation & Installation Manual Section 2– Warranty

Section 2– Warranty The following pages are the Warranty Policies and Terms of Field Service and Conditions for this Watertronics System. Read these terms carefully to prevent voiding your warranty.

P/N 1611926 Rev B, ECN 35765 2-2 Watertronics Operation & Installation Manual

Standard Limited Warranty Watertronics warrants its golf and landscape pump station products to be free of defects in materials and workmanship for a period of two (2) years from the date of startup, but not later than 27 (27) months from the date of invoice, unless modified by customer with the selection of the extended warranty option. Stations deemed delivery complete and invoiced accordingly, at Watertronics’ factory and stored there, shall have the warranty period commence as of the invoice date. Should the system require storage before startup after leaving the Watertronics’ facility, the system must be stored in a secured, climate controlled environment that will not allow for degradation of the system due to moisture, extreme temperature variations, or human negligence.

This warranty is limited to replacing or repairing any defective component supplied by Watertronics at Watertronics’ sole discretion and does not apply to equipment that has been damaged, misapplied or has been modified in any way.

Any work performed on the pump station must be provided by a Watertronics recognized PSN (Pump Service Network) service provider and documentation of all work performed within the warranty period must be on file at the factory. Any maintenance or repairs done without the pre-authorization of Watertronics, or its recognized service providers shall void this warranty.

This warranty does not cover damages under the following conditions, unless otherwise specified in writing:

(1) Misapplied or inappropriate incoming power, improper grounding, vandalism, or any incidental damage, consequential damage, or act of God, (2) repairs or replacements made without the pre-authorization of Watertronics, or its recognized service providers, (3) exposure to destructive gaseous or chemical solutions, (4) exposure to water pH levels of less than 6.0 which is typically the result of SO2 burner or sulfuric acid injection,

(5) water salinity levels greater than 2000 parts per million, (6) water from a reverse osmosis process plant, (7) unusually high dirt load or abrasives in the water, or (8) pumping water not suitable for turf irrigation.

Watertronics will not accept liability for any costs associated with the removal or replacement of equipment in difficult to access locations. This includes, but is not limited to, the use of cranes larger than 15 tons, scuba divers, barges, helicopters, or other unusual means. These extraordinary costs shall be borne by the owner, regardless of the reason necessitating removal of the product from service.

THIS WARRANTY IS ABSOLUTELY IN LIEU OF ANY OTHER EXPRESS OR IMPLIED WARRANTIES. THIS INCLUDES ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY OTHER OBLIGATION ON THE PART OF WATERTRONICS.

NO AGENT, EMPLOYEE OR REPRESENTATIVE OF WATERTRONICS HAS ANY AUTHORITY TO BIND

WATERTRONICS TO AN AFFIRMATION, REPRESENTATION OR WARRANTY CONCERNING THE PRODUCT

SOLD UNDER THIS WARRANTY. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE

DESCRIPTION ON THE FACE HEREOF.

525 E. Industrial Drive, Hartland, WI 53029, USA ● Phone - +1 262-367-1000 ● Fax +1 262-367-1009

P/N 1611926 Rev B, ECN 35765 2-3 Watertronics Operation & Installation Manual

Engine Driven Generator Power Warranty Policy & Operation Guidelines

Pump stations operating under engine driven generator power encounter problems with performance and component failure more frequently that those placed on permanent utility power. For this reason, Watertronics discourages the use of generators as a temporary power source. If connecting the pump station to a generator power is a necessity, the station will be covered by Watertronics’ standard warranty against defects only if the following requirements are satisfied:

• Generator must be internally voltage/frequency regulated. Externally regulated generators are not acceptable. Minimum generator capac-ity is stated in Table 1 below.

• Proper grounding must be in place. Pump station control box ground and generator ground must be bonded. Bonded ground must be connected to earth ground and megged to confirm a resistance reading not to exceed 12 Ohms.

• A Watertronics technician must be present at initial startup to confirm generator conformity and to perform commissioning of the pump station.

• A Watertronics technician must be present after the pump station is connected to permanent utility to confirm phasing and to re-commis-sion the pump station. Charges likely to apply for this return visit, depending on location.

• When pump station is not in use, prior to powering down the generator, place each pump HOA switch in the OFF position and the main service disconnect in the OFF position. Upon startup, allow the generator to warm up a minimum of 10 minutes prior to placing the pump station into service.

If any electrical or rotating mechanical component on the pump station fails and it is determined that the cause of the failure was the result of the generated power, or the pump station was not placed into service per the above requirements, labor and material charges will apply for the repair per Watertronics Field Service Terms and Conditions.

Table 1 Engine Driven Generator Internally Regulated only

Total pump Station HP

Minimum Rating of Generator

KW KVA

1 3 3.8

1.5 4 5

2 5 6.25

3 7.5 9.4

5 10 12.5

7.5 15 18.75

10 20 25

15 25 31

20 30 37.5

25 40 50

30 50 62.5

40 60 75

50 75 94

Table 1 Engine Driven Generator Internally Regulated only

Total pump Station HP

Minimum Rating of Generator

KW KVA

75 150 188

100 175 219

125 200 250

150 250 313

175 275 344

200 300 375

250 375 468

300 425 530

350 475 593

400 550 688

450 600 750

500 650 812

NOTE: If any single motor on the pump station is X HP or larger, choose the next generator size large than that indicated.

Generator Maintenance Note:

The primary cause of pump station component failure while on generator power is related to operation and maintenance of the generator.

Therefore, it is strongly recommended that a maintenance schedule for the generator be established and strictly adhered to. All preventative maintenance details stated in the generator’s Operation and Maintenance manual must be observed. Engine fuel filter, air filter, oil level, fuel level and generator output voltage/frequency must be monitored regularly.

P/N 1611926 Rev B, ECN 35765 3-1 Watertronics Operation & Installation Manual Section 3– Pump Station Installation

Section 3– Pump Station Installation Unloading Procedures Observe the pump station items and those of any accessories, before off loading. Compare the items against the bill of lading for missing or damaged components. Note damages or discrepancies on the trucking companies bill of lading and contact Watertronics immediately. If possible, provide pictures of any damaged items. Obtain a copy of the bill of lading and submit these items to Watertronics.

Lay out pipes and structural items in an order of assembly for easier handling and assembling of parts.

Keep all hardware in the original containers and within close proximity to their designated assembly.

Only remove protective coverings or open bags at the moment of actual assembly. Reseal bags and coverings properly if assembly is interrupted and delayed.

Pre-Installation Storage Procedures IMPORTANT, Storage Temperatures: Equipment must be stored in an environment that does not exceed -20 to 60 degrees Celsius.

Store any uncrated operator panels in a vertical upright position to prevent moisture from accumulating inside the panel. Never store a panel on its side or back.

Cover all panels and electrical components to keep animals and moisture damage from occurring. Do not cover electrical components with plastic, as plastic can allow moisture to condensate within the covering.

P/N 1611926 Rev B, ECN 35765 3-2 Watertronics Operation & Installation Manual

Recommended Tools The following are recommended equipment and tools needed for installation of the Pump Station.

1. A boom truck or crane with a 15’ high, 6000 Lb. lift capacity with 8’ clearance from the truck bed to cable verti-cal is required for assembly.

2. A tractor or loader can also be used for quick unloading and easier pipe and truss assembly.

3. Multiple chains and/or lift straps with a minimum 3 ton lift capacity rating.

4. Impact wrenches: 1/2” drive for air power or 3/4” drive for electric.

• 6 inch impact extension

• 1/2”, 9/16”, 3/4”, 15/16”, 1” and 1-1/8” impact sockets

• 80-100 feet minimum of 3/8” diameter extension cord

• 1 piece of 4 x 4 lumber, 36” long

• 2 tubes of water resistant grease

5. Hand Tools.

• 7/16”, 1/2”, 9/16”, 3/4”, 15/16”, 1-18” and 1-1/2” combination wrenches

• 1/2” drive ratchet (long handle)

• Adjustable (Crescent) wrenches 12” and 15”

• Hammers

• Punches (for alignment)

• Vice-grips

• Set of screwdrivers

• Diagonal pliers

• Wire stripper

• Cable stripper (available from Watertronics)

• Long nose pliers

• Two- 18” pipe wrenches

• Adjustable pliers and 10” and/or 12” channel-lock

• One cable ratchet

• One crowbar

• One wire brush

• One 12” flat file

• Two chisels

• One 1/4” x 28 tap

• One 3/8” NPT tap

• One 3/4” NPT tap

6. Small trailer (or truck bed) for carrying bolts, motors, control boxes, couplers and various small items.

7. Air compressor: 10 CFM at 90 PSI or generator: 120V with 1000 to 1500 watt capacity, for running impact wrenches.

P/N 1611926 Rev B, ECN 35765 3-3 Watertronics Operation & Installation Manual

Site Preparation Ensure the concrete pad is formed as level as possible. Set the anchors in concrete as shown below.

If shims are required, shims and shim kits can be purchased from Watertronics to aid in leveling equipment bases (as shown below).

P/N 1611926 Rev B, ECN 35765 3-4 Watertronics Operation & Installation Manual

Installation Assemble and wire the pump station according to the electrical schematics and assembly drawings provided separately.

Upon completion, review the following for completeness:

• All pipe connections are properly connected and bolts are torqued to specifications.

• All electrical connections are secure.

• Pumps, motors and meters are installed in the correct direction (direction of flow).

• All valves can actuate manually, if applicable.

• With electrical power on, the motors, panels, VFD’s and other accessories power up.

• With power to the system. The main disconnect functions properly.

Commissioning Check List Review the following items after installation and before initial start up. Obtain customer’s approval that all items below have been satisfactorily met.

• All parts were received and installed properly.

• Suction screens are properly installed.

• Suction piping and foot valve are properly installed.

• All fasteners connections are tight and to torque specifications, if applicable.

• Pump skid is level (plumb) and secured properly.

• Motors are level and secure.

• Motors are properly lubricated with oil and/or grease.

• Valve orientation is correct.

• Filters are properly installed.

• Service power to the pump station is approved, if necessary, by local authorities. Installation was performed by a certified electrician.

• All power connections are made (to the panel and to the motor).

• Inlet water level and pressure is per specifications.

Before the initial start-up perform the following steps:

1. Review the following system start-up procedure.

2. Set the Main Disconnect to OFF.

3. Set any hand/Off/Auto (HOA) selector switches to the OFF position.

4. Verify all drain valves are closed.

5. Verify PRV (Pressure Relief Valve) isolation valve is open.

6. Verify the station discharge isolation valve is closed.

Initial Start-up Procedure Upon completing the system commissioning, the station is ready for initial start up.

1. Turn the main disconnect to ON.

2. Turn the panel power selector switch to ON.

3. The display should power up and display the Select screen.

NOTE: If the display screen does on power up, the power may have been cut due to loss of phase or phase imbalance. If the green pilot light on the phase monitor is not illuminated, contact Watertronics Service (262- 367-5000).

P/N 1611926 Rev B, ECN 35765 3-5 Watertronics Operation & Installation Manual

4. Upon power up, the display will show a “Phase/Voltage” alarm. Clear this by pressing the red Reset button.

5. Press the Return to the Select Screen button to access the Select screen. Press “Main” on the Select screen.

6. Check for proper pump/motor rotation. If the pump is rotating in the wrong direction, turn off the main discon-nect and reverse the motor leads, then recheck for roper rotation.

Pump line shafts on VT models should NOT be connected to the motor for this procedure, as damage may occur to the pump if rotated backward. Monitoring discharge pressure will confirm submersible pump rotation.

If pressure is low, turn off the main disconnect and reverse the motor power leads and recheck for proper rota-tion.

7. Slowly open the pump station discharge isolation valve allowing water to flow into the system, ensuring no damage is done to downstream piping, valves and fittings. It is recommended upon initial start up that an air release or discharge to a daylight drain opened to allow air to escape from the system.

CAUTION! If the system pressure is low, or there is a flow demand, the pump station may start automatically.

8. After the piping has filled, turn all pumps to the off position using the HOA (Hand/Off/Auto) selector switches and fully open the pump station discharge isolation valve.

9. Turn the HOA selector switches to the automatic position.

10. The pump(s) should now sequence on and off, depending on system demand.

P/N 1611926 Rev B, ECN 35765 4-1 Watertronics Operation & Installation Manual Section 4– System Operation

Section 4– System Operation Altivar VFD Accudrive Operation Instructions (for Water-max Series Pump Stations Only) The follow is an overview of the VFD panel controls. Note that some of the screens shown here may differ from your specific programmed VFD, depending on the system configuration.

NOTE: Depending upon your system configuration, some keys may be disabled, so no action will take place when they are pressed.

NOTICE: Sudden system start ups and stops may occur when pressing buttons on the key pad.

Graphic Display

Function Keys

Pump Stop/Reset Button

Pump Run (Auto Enable) Button Rotary Dial and Enter Button (when pressed)

Forward/Reverse Button (not enabled for pumps)

Escape (cancel the current command or returns to the last menu)

P/N 1611926 Rev B, ECN 35765 4-2 Watertronics Operation & Installation Manual

Start Up Screens

When power is applied to the unit, the display will toggle through a sequence of screens.

NOTICE: If the unit’s Auto-Enable is set to “On” when power is applied to the unit, the pump may start.

If for any reason you are attempting to power the unit without pump start, press and hold the Stop/Reset button on the display until the monitoring screen appears and shows the Auto Enable is set to “Off”.

RDY APP PSI=0 GPM=0

DRIVE MENU

1.1 Simply Start

1.2 Monitoring

1.3 Settings

1.4 Motor Control

1.5 Inputs/Outputs

Code << >> TK Then 10 seconds later...

RDY APP PSI=0 GPM=0

MONITORING

Auto Enable Total Flow Run Time Output Frequency Consumption

: OFF

: 133 xK : 455 h : 0.0 Hz : 12 Wh

TK

P/N 1611926 Rev B, ECN 35765 4-3 Watertronics Operation & Installation Manual

Monitor Screens in APP Mode

RDY APP PSI=0 GPM=0

MONITORING

Auto Enable Total Flow Run Time Output Frequency Consumption

: OFF

: 133 xK : 455 h : 0.0 Hz : 12 Wh

TK

Drive State Code:

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: Under-voltage alarm

Auto Enable:

OFF: The pump will not run. Equivalent to the Off position of a common HOA switch.

ON: The pump will run if the field conditions require the pump to run and no faults are present. Equivalent to the AUTO position of a common HOA switch.

RUN: The green Run button will switch the Auto Enable to ON.

CAUTION! Whenever the Auto Enable is ON, the pump can start at any time.

STOP/RESET: The red Stop/Reset button will put the Auto Enable to OFF.

CAUTION! Whenever servicing any part of the pump station, perform proper Lock-Out/ Tag-Out procedures to the pump station.

DO not rely on the Auto Enable in the OFF position to prevent the pump from starting.

Drive Mode:

APP: Displays when the automatic functionality of the VFD will be active, allowing the pump to start, stop and maintain system pressure.

HMI: Displays when the TK button is pressed for putting the system into manual control. This maintains a fixed pump speed and bypasses all alarm conditions.

Fixed Displays:

Depending on the system configuration, 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 display with the current level is used to stop the pump.

Hz: Motor speed in Hertz. Typically speeds are from 0 to 60 Hz. Same as Output Frequency displayed below.

P/N 1611926 Rev B, ECN 35765 4-4 Watertronics Operation & Installation Manual

More APP Mode Monitor Screens

MONITORING

Auto Enable Total Flow Run Time

Consumption

: OFF

: 133 xK : 455 h

: 12 Wh

TK

Total Flow:

Displays the total gallons (per 1000) pumped through the system, when a flow meter is present. The value will roll back to 0 when it exceeds 65535.

This can be manually reset by pressing the Reset button then press the Enter button.

If a flow meter is not present, the Output Current to the motor will display instead.

Run Time:

Displays the elapsed run time for the pump motor. This value cannot be reset.

When blank, This field will display the motor speed in Hertz.

Escape:

ESC: The escape button allows the user to return to the previous screen, cancel the current input without saving or allows the user to enter the drive parameters.

Consumption:

Displays the total power used by the motor being driven. This value cannot be reset.

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RDY APP PSI=0 GPM=0

MONITORING

Auto Enable Total Flow Run Time Output Frequency Consumption

: OFF

: 133 xK : 455 h : 0.0 Hz : 12 Wh

TK

More APP Mode Monitor Screens

Terminal/Keypad:

TK: The Terminal/Keypad function is assigned to the F4 button. This allows the user to toggle between the following modes:

Automatic Pump Program Mode: The sta-tion’s control system responds to demand for water by the field control’s that automatically use the array of sensors wired to the drive. It also enables protective faults inherent in the VFD controls. When operating in this mode, the display bar will indicate APP.

Keypad Mode: The station is allowed to run, stop, and change motor speed based on user input through the keypad. This mode is similar to the Hand position of a HOA switch.

Faults such as temperature, low pressure, high pressure, and water level are disables. Also, the pump will not stop until the Stop button is pressed.

Use this mode only for troublehshooting and pump station maintenance. When in this mode the above display bar will indicate HMI.

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Monitor Screens in HMI Mode When placed in HMI mode, by using the T/K (F4) button on the display, the pump will run at the fixed speed set by using the rotary dial. Faults and alarms such as temperature, low pressure, high pressure and water level are disabled. Also, the pump will not stop until the Stop button on the display unit is pressed. Use HMI mode only for troubleshooting and pump stations maintenance.

RDY HMI PSI=0 GPM=0

HMI Frequency Ref.

0.0 Hz

Min= 1000.0 Max= 1000.0

<< >> TK

HMI:

Displays the Human Machine Interface (Keypad) has control of the drive/motor functions.

Speed Reference:

The motor speed is displayed here. The user can change the motor speed by turning the rotary dial. Follow the arrows printed above the dial for increase (+) and decrease (-) direction of motor speed. The display will allow the user to exceed the limits set in the motor profile, but the motor will not respond to entries outside the profile. A typical profile will be 35 to 90 Hz.

Stop/Reset Button:

Used to stop the pump and reset any VFD protection faults that become active.

Run Button:

Used to start the pump. The pump will continue to run, at the speed set using the rotary dial, until the Stop button is pressed or a VFD protection fault becomes active.

P/N 1611926 Rev B, ECN 35765 4-7 Watertronics Operation & Installation Manual

Alarms As a precautionary measure, the pump station is designed to protect itself from potential damage by stopping the pump if the control system detects an undesirable condition.

Such conditions will be indicated by an alarm message on the display. Should this situation occur, take the nec-essary steps to correct the indicated alarm condition (refer to the Troubleshooting Section of this manual for an explanation of alarms). To reset alarms, press the Stop/Reset button or cycle the pump station power.

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Altivar® 61 Quick Reference Guide

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P/N 1611926 Rev B, ECN 35765 4-10 Watertronics Operation & Installation Manual

Pump Control Parameters for ATV 61’s

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Virtual Vision III Panel Operation (for Stations Equipped with Sigma PLC’s) Home Screens Navigation Flow Chart The Select Menu is the Home menu-screen from which all other menus are centrally accessed from.

Select Menu (Home)

See the next two pages for Options and Set up menus, respectively

System Menu Overview Menu

Flow Menu

Logging

Graph Calendar

Alarm Menu

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Options Screens Navigation Flow Chart The options will change according to the equipment selected for this pump system.

The Enhanced button will be visible only if custom software has been included on your application.

Water Level

Discharge Strainer

Water Level Control Settings

Discharge Filtration

Chemical Injection BAS Intake Menu

Inlet Strainer

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Setup Screens Navigation Flow Chart Set up menus are password protected and entered using the numerical keypad. Once the correct password is entered, the Set Up Main menu will display.

Set Up Main Menu

Numerical Key PadPulse Scale Configuration Regulate Settings

I/O Monitoring

Change a Register

Touch Screens

Analog Scale Config.

Program Config.

Pump Config.

VFD Speed Control

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Select Menu

Home Button: From any other screen, press this button to return to the last menu screen that was accessed.

This also displays common system information such as pressure, flow and water level

Overview: Press to access the Overview Menu

System: Press to access the System Menu

Logging: Press to access the Log Menu

Alarm: Press to access the Alarm Menu

Flow: Press to access the Flow Menu

Alarm is Present

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Options Menu Note: Options may note be present on all pumping systems.

Time of Use: Press to use Time of Use controls

Water Level: Press to use Water Level controls

Inlet Strainer: Press to use Inlet Strainer controls

Discharge Strainer: Press to use Discharge Strainer controls

Discharge Filtration: Press to use Discharge Filtration controls

Chemical Injection: Press to use Chemical Injection controls

BAS Intake: Press to use BAS Intake controls

Water Feature: Press to use Water Feature controls

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Overview Screens

Press the individual pump images to see the elapsed motor run-time hours and pump capacities

Representation of a Vertical Turbine style station

Representation of a Horizontal Centrifugal style Station

Pump Status - Running/OFF

The Enable/Disable box displays the pump status. If the pump is “Enabled”, the pump can be run automatically by the system to supply water for the current demand. If the pump is “Disabled”, the pump is not in automatic mode via the HOA switch.

Nor is the pump alarmed or locked out by a remote signal

Pump/Motor Control indicates the position of the electronic butterfly valve and/or the speed of the VFD. IF the control type is not used, the display will not be present

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System Screens

User Password- Key In 546 and press Enter

Current Regulate: This display is real-time, displaying the pressure the pump system is trying to maintain, independent of outgoing flow. As the system is pressurizing, this value is less the user entered regulate set point

Restarts Remaining: Displays the number of times the pump station will attempt to reset current alarms before final shutdown. When the display reads 0, the pump station will shutdown until the user presses the red reset button located on the control panel

System Status OK: Displays when the system has reached the final regulate set point. If “Pressurizing System” is displayed, then the current regulate is less than the final regulate

Press to display the Options menu

Regulate Setting: This display is real-time, displaying the entered regulate set point

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Settings Menu

The Settings menu will display screens used by service technicians to calibrate the pumping system. Changing any parameters in the following screens may have a negative effect on the pump system. Only a qualified service technician should access these screens.

Please see service documents for the following:

• Pump Number Configuration

• Program Configuration

• Change a Register

• Analog Configuration

• Pulse Configuration

Pop-Up screen for individual pump configuration

Press to monitor the PLC’s I/O

Press to adjust Pressure Regulate Settings

Press to set the Time and Date or configure screen settings

Used to manually run the VFD at a fixed speed. SERVICE USE ONLY!

CAUTION! If in manual mode, the pump station will not regulate system pressure with changing flow demands

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Regulate Settings

Two modes are available, Single Set Point Regulation and Flow based Regulation.

Single Set Point Regulation mode provides constant pressure to the irrigation system regardless of flow.

Flow Based Pressure Regulation provides a means to ramp up the pump station discharge pressure as the flow increases to overcome increasing friction losses. Supplying only the required sprinkler design pressure saves energy.

Flow Based Pressure Regulation Settings (Please see Data Entry, later in this section, for use of the Data Keypad)

Note: Pressure regulate difference between consecutive set points should not exceed 3 PSI

Single Set Point Regulation Setting.

(Please see Data Entry, later in this section, for use of the Data Keypad)

The Single Set Point/ Flow Based Pressure Regulation button toggles between the regulate modes

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Screen Settings

Changes made at this level can have a negative effect on the pump system. Do NOT make changes to any set-tings other than those described below.

Time and Date

Adjust Screen Colors

Return to Virtual Vision

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I/O Screen

The I/O screen allows the user to monitor which PLC inputs and outputs are activated during pump station opera-tion. Active I/O is indicated by a green light and inactive I/O are gray.

Monitoring PLC Inputs

Monitoring PLC Outputs

Press to toggle between Inputs and Outputs

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Time of Use Lockout

Changes made at this level can have a negative effect on the pump system. Only a qualified service technician make adjustment on this screen.

Allows the user to set the lock and unlock times and days of the week to disable selected devices. Active days are highlighted in green

Disables and enables the selected lock-out group. If disabled, the lock-out times will be ignored

The Exit Button will return you to the Settings Menu

Up to three different lock-out configurations can be set up. Use this button to toggle between groups

Allow the user to select the devices to disable for the configured times and days.

Note: All devices may not be listed for each pump station.

Active devices are highlighted in green

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Flow Screen

Total Gallons x 1000 is the amount of flow produced by the system since installation

Total Gallons x 1000 User #1 is the amount of flow produced since the last time it was reset

Total Gallons x 1000 User #2 is the amount of flow produced since the last time it was reset

Reset Gallons User #1 will reset the User #1 display to Zero. The date and time for the last reset will be displayed.

Reset Gallons User #2 will reset the User #2 display to Zero. The date and time for the last reset will be displayed.

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One Hour Graph

Press to access the Graph Tools

Graph Area:

The red line represents the pressure in PSI The blue line represents flow in GPM

Press to show Pen descriptions

Puts the graph into Historic mode

Puts the graph into Real-time mode

Return to the Main menu

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Alarm Screen

Active Alarms: These indicators will be visible when there are active alarms present. To reset active alarms, press the red reset button located on the control panel.

At the time an alarm becomes active, it will appear in this list in red. When the alarm is reset, the alarm will change to green.

Used to navigate through the alarm pages

Will clear the alarm log but does not reset active alarms

Will acknowledge logged alarms but does not reset active alarms or clear them from the log

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Water Level Screen Note: Some options may not be present on your specific pumping system.

Water Level is displayed in a numerical format in real-time

If the Water Level falls below the Low Level Pump Cutout setting, the pump station will initiate an alarm in the status bar and retire any configured pumps

Many fields on these screens use the keypad for configuring settings. Refer to the Data Entry Keypad later in this section.

Water Level where the Low Level Cutout will reset

The Water Level Control Settings button is present when the system is configured to transfer water from one location to another.

Press to access the Fill Config. screen

Running indicator for the selected transfer pump

The transfer operation can be disabled/en-abled with this button

The User can force the trans-fer with this button regardless of the level. CAUTION! The pond fill pump will remain ON, independent of water level, until the button is pressed again

Water Level is displayed in a numerical format in real-time

If more than one Water Level Control device is configured, select the device by pressing the selection buttons. The current selection will highlight in green

The Desired Water Level (in inches) that the pond fill pump will maintain.

The Window is the deviation from the set point to start the fill pump (Set Point- Window). When the level reaches the set point the fill pump will stop.

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Water Level Screen, continued

Pressing the Edit Labels button displays this screen, where the names of the fill sources can be customized

Flow in GPM and total Gallons per 1000 is displayed if the fill source has a flow meter

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Inlet Filter Screen Note: Some options may not be present on your specific pumping system.

Many fields on these screens use the keypad for configuring settings. Refer to the Data Entry Keypad later in this section.

The Flush Frequency setting determines the amount of…