Manual

Continuous pump operation instructions, Spanish, October 2015:

ontinuous pump operation instructions, English, October 2015:  Rewiring instructions from VFD to capacitors, Spanish, June 2015: Rewiring instructions from VFD to capacitors, English, June 2015: Newest version of the O&M manual, May 2015: 

The newest Word version, Jan. 2015: 

//Figure 1: Pumping System Overview (From left to right: 60HP Booster Pump Panel, 15 HP Submersible Pump Panel and New VFD Panel)//


 * Pumping System Operation Overview **

The pumping system consists of a 15 hp submersible pump and a 60 hp booster pump. Control of the submersible pump is by an across the line motor starter. Control of the booster pump is by a variable frequency drive which provides a soft start and a variable speed for pumping to the two storage tanks. The booster pump will run at full speed when pumping to the upper storage tank and at a reduced set speed when pumping to the lower storage tank. An off-peak mode is provided to run the pumps in automatic for a set time period when electrical rates are lower. There are two level controls located in the booster pump tank which are active when in automatic. One level control is for controlling the submersible pump to ensure it stops on a high level to prevent overfilling the tank. The other is for the booster pump to ensure it stops if the tank level is low to prevent the booster pump from running the tank empty.

//Figure 2a: Submersible Pump Panel Selector Switch, Start/Stop Push Buttons with Green Indicating Light //

//Figure 2b: Modified Booster Pump Panel (In the picture shown below the system is set for manual operation to fill the upper "alta" tank.) //




 * Manual Operation Summary (Please reference Figures 1 and 2a/b above) **

To run the pumping system in manual, both pumps/selector switches must be in "manual" and/or "normal" position. Once selector switches are set for manual, press the green start buttons, first on the submersible pump panel and then the booster pump panel (for the booster pump panel the start button for manual operation is located on the left side of the front panel) to begin operation. To stop operation, press the red button located directly below the start button. Please note the selector switch furthest to the left is for pumping at either the upper tank "alta" or lower tank "bajar."


 * Off Peak/ Automatic Operation Summary ****(Please reference Figures 1 and 2a/b above) **

To run in the "off peak/automatic" mode both pumps must be in automatic and the selector switches must be in "auto" position, before starting operation.

<span style="font-family: Arial,sans-serif;">On the booster pump panel on the right hand side panel is an "auto select switch." This switch allows for "normal" or "reloj/timer" operation. "Normal" operation will activate the level switches in the booster pump tank and will run continuously until it is manually stopped. The "reloj/timer" operation will also activate the level switches but will also implement a preset timer. The start button for "auto" is also located on the right side of the panel - "Baja Demanda Iniciar." When the off peak start button is pressed the off peak operation will run until the off peak stop push button is pressed (located directly below "Baja Demand Detener") or the off peak timer times out.


 * <span style="font-family: Arial,sans-serif;">Submersible Pump Operation **

<span style="font-family: Arial,sans-serif;">When the submersible pump mode selector switch is in the Off position the pump will not run.
 * <span style="font-family: Arial,sans-serif;">Mode SS - Off **

<span style="font-family: Arial,sans-serif;">To run place the mode selector switch in manual and press the start pushbutton. To stop the pump press the stop pushbutton. During manual operation the level control is not active.
 * <span style="font-family: Arial,sans-serif;">Mode SS - Manual **

<span style="font-family: Arial,sans-serif;">Select the automatic method by selecting Normal from the Off Peak selector switch. <span style="font-family: Arial,sans-serif;">Place the Submersible pump mode switch in the automatic position. <span style="font-family: Arial,sans-serif;">Pump will run in automatic and will be controlled by the level control. <span style="font-family: Arial,sans-serif;">Level control will stop the pump on high level and allow it to run once the level falls below the low level
 * <span style="font-family: Arial,sans-serif;">Mode SS – Automatic, Off Peak SS – Normal **

<span style="font-family: Arial,sans-serif;">Select the automatic method by selecting Off Peak from the Off Peak selector switch. <span style="font-family: Arial,sans-serif;">Place the Submersible pump mode switch in the automatic position. <span style="font-family: Arial,sans-serif;">Pressing the Off Peak Start pushbutton will start the off peak timer and allow the pump to run as controlled by the level control. <span style="font-family: Arial,sans-serif;">Level control will stop the pump on high level and allow it to run once the level falls below the low level. <span style="font-family: Arial,sans-serif;">The pump will stop when the Off Peak Stop pushbutton is pressed or when the Off Peak timer times out.
 * <span style="font-family: Arial,sans-serif;">Mode SS – Automatic, Off Peak SS – Off Peak **

<span style="font-family: Arial,sans-serif;">A green indicating light will illuminate to show when the submersible pump is running.
 * <span style="font-family: Arial,sans-serif;">Running: **


 * <span style="font-family: Arial,sans-serif;">Booster Pump Operation **

<span style="font-family: Arial,sans-serif;">When the booster pump mode switch is in the Off position the pump will not run.
 * <span style="font-family: Arial,sans-serif;">Mode SS - Off **

<span style="font-family: Arial,sans-serif;">To run place the mode selector switch in manual and press the start pushbutton. To stop the pump press the stop pushbutton. During manual operation the level control is not active.
 * <span style="font-family: Arial,sans-serif;">Mode SS - Manual **

<span style="font-family: Arial,sans-serif;">Select the automatic method by selecting Normal from the Off Peak selector switch. <span style="font-family: Arial,sans-serif;">Place the Booster pump mode switch in the automatic position. <span style="font-family: Arial,sans-serif;">Pump will run in automatic and will be controlled by the level control. <span style="font-family: Arial,sans-serif;">Level control will stop the pump on low level and allow it to run once the level goes above the high level.
 * <span style="font-family: Arial,sans-serif;">Mode SS – Automatic, Off Peak SS – Normal **

<span style="font-family: Arial,sans-serif;">Select the automatic method by selecting Off Peak from the Off Peak selector switch. <span style="font-family: Arial,sans-serif;">Place the Booster pump mode switch in the automatic position. <span style="font-family: Arial,sans-serif;">Pressing the Off Peak Start pushbutton will start the off peak timer and allow the pump to run as controlled by the level control. <span style="font-family: Arial,sans-serif;">Level control will stop the pump on low level and allow it to run once the level goes above the high level. <span style="font-family: Arial,sans-serif;">The pump will stop when the Off Peak Stop pushbutton is pressed or when the Off Peak timer times out.
 * <span style="font-family: Arial,sans-serif;">Mode SS – Automatic, Off Peak SS – Off Peak **

<span style="font-family: Arial,sans-serif;">The tank selector switch is used to select which tank the booster pump is pumping to. In the Upper position the upper tank is selected and when the booster pump runs it will run at full speed. In the Lower position the lower tank is selected and the booster pump will run at a reduced speed preset in the booster pump drive.
 * <span style="font-family: Arial,sans-serif;">Tank SS – Upper / Lower **

<span style="font-family: Arial,sans-serif;">A green indicating light will illuminate to show when the booster pump is running.
 * <span style="font-family: Arial,sans-serif;">Running: **

<span style="font-family: Arial,sans-serif;">A red indicating light will illuminate to show when the booster pump drive is faulted.
 * <span style="font-family: Arial,sans-serif;">Fault: **

<span style="font-family: Arial,sans-serif;">An amber indicating light will illuminate to show when the booster pump tank is at low level. A low level condition in the booster pump tank will stop the booster pump when in automatic.
 * <span style="font-family: Arial,sans-serif;">Low Level: **

<span style="font-family: Arial,sans-serif;">A two position maintained key switch is used to turn power on to the drive and controls.
 * <span style="font-family: Arial,sans-serif;">Off Peak Running: **

<span style="font-family: Arial,sans-serif;">Control of the booster pump is by the variable frequency drive. If the drive fails the booster pump can be run by the old soft start controller. In order to run from the soft start wires in the control enclosures must be changed as shown on the schematics. <span style="font-family: Arial,sans-serif;">The following 24 volt wires must be moved to the adjacent terminal: 24C, 24+, 221 <span style="font-family: Arial,sans-serif;">The following 120 volt wires must be moved to the adjacent terminal: 120V, 201, 251, 281 <span style="font-family: Arial,sans-serif;">The following 480 volt wires must be moved to the adjacent terminal: (Inputs) 2L1, 2L2, 2L3, (Outputs) T1, T2, T3
 * <span style="font-family: Arial,sans-serif; line-height: 1.5;">Booster Pump Control Backup **

//Figure 3: Booster Pump Panel Wiring//

For control wires, simply shift wires down to transition from VFD to across the line starter.

//Figure 4: Control wiring for VFD//

//Figure 5: Control wiring for hard start//

//Figure 6: 480V Power Re-wiring, please refer to full electrical schematic.//