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Chapter#1Assemblyprocedureofmechanical part

1.Safety Guidelines 2
2.Installation 2
3.Attached picture 12

Chapter#2Linesarrangementofboostersystem

1.Corrugated hose selection table 17
2.Corrugated hose arranging requirements 17

Chapter #3 Procedure of control cabinet testing and troubleshooting

1.Safety Guidelines 18
2.Installation 18
3.Control cabinet power on 19
4.Function testing 96
5.Precautionofonsiteinstallation 98
6.Solution of common problems 99
7.Limited liability. 103
8.Manufacturer is not responsible for the following situation 104

Chapter #4 Equipment inspection and maintenance procedures

1.Safety Guidelines 105
2.Purpose 105
3.lnspection events and procedure 105
4.After-sales Service Guide 108

·Safety Guidelines ·Installation ·Attached Drawings

1 Safety Guidelines

Warning! Only professional techniciaWarning!Do not try to installor disassemble inner spare parts when equipment is operating.
Warning!When moving this equipment,operator should be careful.
4Warning!This manual must be read before the equipment is installed.

2 Installation

2.1 Installation Conditions

·Installation site:Indoor
·Environmenttemperature: 4 - 4 0 ^ { \circ } C （20
·Power supply:380V/3P
·Minimum suction pressure：non-negative pressure equipment: 0 . 5 {kg } / {cm } ^ { 2 } （204号
·The equipment should be instaled in a place without obvious vibration,concrete structure foundation canbeused,and the ground shouldbe flat.

2.2 Common installation tools

·Screwdriver
·Wrench14"17"19"24"
·Pipe Wrench
·Adjustable wrench 12"
·Hammer drill

2.3Installation procedure

·The equipment is divided into non-negative pressure water supply equipment and constant pressure variable frequencywatersupply equipmentaccording to different functions. ·These two types of equipment are divided into ball valve connection and butterfly valve connection according to thediameterof the pipeline. ·To distinguish the formand connection method of the device,please refer to the assembly drawing (see Figure1to Figure5onpage12-16 fordetails).

2.3.1 Inst branch pipes below DN50 (inclusive)

2.3.1.1 Fixing of the base (34)

·Place the equipment base (34)on the concrete base and selectthe location.Fix with expansion bolts after the equipment is installd.Level of the equipment base should be calibrate before fixing.

2.3.1.2 Assembly of the water pump (33) and the base (34)

·Place the water pump(33)on the base (34),add anti-vibration washers to the fourfixing holes corresponding to the base (34) under the water pump,and fix the water pump with bolts (14).Pre-tighten the bolts (14) diagonally.(do not tighten up),the force should be equal and not biased. ·The direction of the water pump (33) generally adopts the water outlet facing forward and the water inletfacing backward; if theequipment is NQ system,the junction box of the motor should face to wateroutlet directionof the pump (special requirements shall be executed according to the drawings).

2.3.1.3 Assembly of pipelines (4,28)

Assembly rules: It is generally required that the pipeline (4,28)should beassembled horizontally with the base (34),and vertical with the water pump (33) to meet the requirements of no leakage. ·Prepare the piping (4,28)and other accessories according to the identification of pipe accessories. ·The assembly sequence of the pipeline can be carried out according to the equipment structure. 1）Assembling the water outlet pipe (4):prepare the check valve (13),washer(12)and bolt (10)firstly, raise the pipeline to the heightof thewateroutletof thewaterpump (33),and thread the bolts (10)into the two holes at the botom of the joint flange (11)and the water outlet flange of the water pump (33), screw the nuts with two teeth.Then put the rubber washers (12)on both ends of the check valve (13) (note that the direction of the check valve is the same as the direction mark of the water pump.) Put them into both joint flange (11)and the outlet flange of the water pump (33)．and insert the remaining bolts (10) to tighten the nuts.At thisstep,the boltsshould not be tightened.
2)Assembly of the water inlet pipe (28):Raise the pipe to the height of the water inlet of the water pump (33),and insertthebolts (30)into two holesatthe botomof jointflange (31)and inletflange of the water pump (33).screw the nuts with 2 teeth.Then put the rubber washer(32)into joint flange (31) and inletflange of thewater pump (33)respectively,and insert the remaining bolts (30)to fasten the nuts.At this step,the bolts should be tightened.

3)Adjustthe heightand levelness of the inlet and outlet pipes (4/28)to ensure thatthe inletand outlet pipesat same height and level with the base (34).At the same time,adjust the height of the check valve and rubber washer with screwdriver,so that the center is consistent with the height of the water inlet and outlet of the water pump and the height of the joint flange,then tighten allbolts (10) and bolts (30),and finally tighten the bolts to fix the water pump.

2.3.1.4 Assembly of the pressure tank (21)

·The pressure tank of BP series constant pressure frequency conversion equipment is generally placed directlyon the concrete base.After the location isselected,makea mark and punch holes with an impact drill,and then put in M8 expansion bolts for reinforcement. ·Putthe two ends of the armored hose (19) into special washers,connect one end to the bottom joint (20)of the pressure tank (21),and the other end to the joint (6)of the water outlet pipe (4),and then tighten themat last.

2.3.1.5 Assembly of control cabinet(18)

·The assembler should place the control cabinet (18)on the base (34)and fix it with M10 bolts (16).

2.3.1.6 Connectionmethod and requirementsof stainless steel bolts

·Ensure thatthe direction and length of the stainless steel bolts on the same component are the same.Tightening boltswith equal strengthand inacross-symmetrical order. ·For the connection of two flanges,the rubber washer must be placed in the right direction during installation,the fastening boltsshouldbe tightened diagonally,so that therubberwasher will be evenlystressed in the flange,and the dimensional tolerance of the distance between the end faces of the two flanges should be controlled within 0 . 5 \mathsf {mm } Inside,ensure that the stainless steel equipmentdoesnotleakorseepwater.

·Do not useanyadhesive tape to temporarily fix the rubber washer when adding rubber washer to the check valve,so as to avoid hidden dangers.

·Flexible jointsand butterfly gate valvesare directly connected to the flange without rubber washers,but the installation position should be straight,the tightening bolts should be tightened diagonally,and the force should be uniform.Aftertightening dimensional tolerance of the distance between two flanges should be controlled within 0 . 5 \mathsf {mm }

2.3.1.7 Control cabinet and motor wiring

·When wiring,connect yellow,green,and red wires which corresponding to three terminals U,V, and Wof the motor to the yellow (U1),green (Vl),and red 》1) terminals in the control cabinet. ·When the control motor starts in the star-delta step-down starting mode,the wiring is divided into two groups. One group is to connect yellow (1U1)，green (1V1)and red (1W1) connecting terminals in control cabinet with yellow,green,red wires stand for U1、Vl、W1of motor,the other group is to connect yellow (2U2),green (2V2),on the red (2W2) connecting terminals in control cabinet with yellow, green,red wires stand for U2、V2、W2 of motor.

·After connecting thewires,fixthecorrugated hoseonwater pump withacable tie,which is should beneat and beautiful.

·Please refer to the attached table 1 for corresponding cross-sectional area of wire to power.

2.3.2 Installation (butterfly valve connection method) of BP series constant pressure variable frequency complete set and branch pipe above DN65 (inclusive)

2.3.2.1 Fixing of base (33)

·Place the base(33)onthe concrete baseand selectthe location.And fixitwith expansion bolts,level the base before fixing it.

2.3.2.2Assembly of the water pump (32) and the base (33)

·Place the water pump (32) on the base (33),add anti-vibration washers to fourfixing holes of the base (33)under the water pump,and fixthe water pump with bolts (15),bolts (15)should be pre-tighteneddiagonally (do not tighten) with evenstrengthand not biased. ·The direction of the water pump (32) generally adopts the water outlet facing forward and the water inletfacing rearward;if the equipmentis NQ system,the junction box of the motor should face to water outlet direction of the pump (special requirements shall be executed according to the drawings).

2.3.2.3Pipeline (4/29)Assembly

Assembly rules: It is generally required that the pipeline (4/29) should beassembled horizontally with the base (33)and vertical with the water pump (32),and should meet the requirements of no leakage. ·Prepare the pipeline (4/29)and various accessories according to the pipeline identification label. ·For pipelines with branch pipes exceeding DN65 (inclusive),the water inlet is assembled by adding a butterfly valve (31),and the wateroutlet addinga shortconnector (11) and a butterfly valve (6). 1）Assemblyofthe water inlet pipeline (29):liftthe pipeline to the heightof the water inletof the water pump (32),and insert the bolts (30)into the holes offlangeof branch pipe,buterfly valve (31) and flange of the water pump inlet respectively.Then screw the nuts on but don not tighten the bolt. 2）Assembling the water outlet pipe (4):prepare the check valve (14),washer (13)and bolt (12)firstly， raisethe pipeline to the heightof the water outletof the water pump (32),and thread the bolts (10) into the two holes at the botom of the joint flange (11)and the water outlet flange of the water pump (32), screw the nuts with two teeth.Then putthe rubber washers (13)on both ends of the check valve (14)

(note that the direction of the check valve is the sameas the direction mark of the water pump.) Put theminto both joint flange (11)and the outlet flange of the water pump (32)．and insertthe remaining bolts (12) to tighten the nuts.At this step,the bolts should not be tightened. 3）Adjust the height and levelness of the inlet and outlet pipelines (4/29)to ensure that the inlet and outlet pipesat same height and level with the base (33).At the same time,adjust the height of the check valve,rubber washer,outletshortconnectorand buterfly valve witha screwdriver,so that the centeris consistent with the height of the water inlet and outletof the water pump and the height of the joint flange,then tightenall bolts,and finally tighten the bolts(15)to fix thewater pump.

2.3.2.4 Assembly of pressure tank (22)

·The pressure tank of BP series constant pressure variable frequency system is generally placed directly on the concrete base.After the location is selected,mark itand punch holes with an impact drill,andthenputinM8expansionboltsforreinforcement.
·Putthe two ends of the armored hose (20) into special washers,connect one end to the bottom joint (21)of the pressure tank (22),and the other end to the joint (7)of the water outlet pipe (4),and then tighten them at last.

2.3.2.5 Assembly of control cabinet (18)

·The assembler shall place the control cabinet (18)on the base (33)and fix it with M10 bolts.

2.3.2.6 Connection method and requirements of stainless steel bolts

·Refer to 2.3.1.6

2.3.2.7 Control cabinet and motor wiring

·Referto2.3.1.7

2.3.3Installation (butterfly valve connection method)of DNP series constant pressure variable frequency systemand branch pipe under DN5o (inclusive)

2.3.3.1 Fixing of base (39)

·Place the base(39)on the concrete baseand selectthe location.And fixitwith expansion bolts,level the base before fixing it.

2.3.3.2 Assembly of the water pump (38) and the base (39)

·Place the water pump (38)on the base (39),add anti-vibration washers to four fixing holes of the base (39)under the water pump,and fixthe water pump with bolts (14),bolts (14) should be pre-tightened diagonally(do not tightenup) with even strength and not biased. ·The directionof the water pump (38)generally adopts the water outlet facing forward and the water inletfacing rearward;if the equipment is NQ system,the junction box of the motor should face to water outlet direction of the pump (special requirements shallbe executed according to the drawing)

2.3.3.3Pipeline (4/34)Assembly

Assembly rules: It is generally required that the pipeline (4/34) should beassembled horizontally with thebase (39)and vertical with the water pump (38),and should meet the requirements ofno leakage ·Prepare the pipeline (4/34)and variousaccessories according to the pipeline identification label. ·The assembly sequence of the pipeline (4/34) can be carried out according to the equipment structure.

1）Assembling the water outlet pipeline (4):prepare the check valve (13),washer (12)and bolt (10) firstly,raise the pipeline to the heightof the wateroutletof the water pump (38),and thread the bolts (10)into the two holes at the bottomofthe joint flange (11)and the water outlet flange of the water pump (38),screw the nuts with two teeth.Then put the rubber washers (12)on both ends of the check valve (13) (attntion to the direction of thecheck valve) Put them into both joint flange (11)and the outletflange of the waterpump (38)．and insert theremaining bolts (10)to tighten the nuts.At this step,the bolts should not be tightened.

2)Assemblyof the water inlet pipe (34):Raise the pipe to the height of the water inletof the water pump (38),and insert the bolts (36)into two holes at the botom of jointflange (37)and inlet flange of the water pump (38).screw the nuts with 2 teeth.Then put the rubber washer(44)into joint flange (37) and inletflange of the water pump (38)respectivelyand insert the remaining bolts (36)to fasten the nuts.At this step,the bolts should be tightened.

3)As the system has manyby-passes,after inlet/outlet pipeline located,put check valves(42)and washers(41) into by-passes,and thread bolts (43)in,screw the nuts on but do not tighten up. 4)Adjust the height and levelness of the inlet and outlet pipelines (4/34)to ensure that the inlet and outletpipelinesatsame heightand level with the base (39).Especially the heightand levelnessof the welded flangesofby-pass.Atthesame time,adjust the heightof thecheck valve and rubber washer withscrewdriver,so thatthecenter isconsistent with the heightof thewater inletandoutletof the waterpumpandtheheightof the jointflange,weldedflange,then tightenallbolts,andfinallytighten the bolts(14) to fix the water pump.

2.3.3.4Assemblyof stainless steel regulating tank (23)

·Fix the soft joint (31)to the outlet of theregulating tank (23)with bolts (30),put the M10 bolts (18) into the four bolt slots of the base (39)reversely,then place the tank onto the base.After four fixing holes of the tank body aligned to the base bolts (18),screw nuts onas to ready for tightening. ·Inorderto installthe butterfly valve (32)between the water inletofthe pipeline and the soft joint (31), firstlyadjust theregulating tank toproperposition,then thread the bolts(33)intoinletflange of the water inlet pipe (34),the buttrfly valve (32),and the flange of the soft joint (31),and tighten the nuts. ·Finally determine the position of the regulating tank (payatention on deflection),and tighten the bolts (18) that fix the regulating tank.

2.3.3.5Assembly of the pressure tank (22)

·The assembler selects the pressure tank (22)for this equipment,and places it on the base (39)with thepressure gauge facing outwardsand the label of the tank without pressure gauges facing outwards.

·The bolt holes on the legs of the pressure tank (22) correspond to the three bolt holes on the base (39),and are finally fixed with M8 bolts.

·Put the two ends of the armored hose (2O) into special washers,and connect one end to the bottom joint (21)of the pressure tank (22),connectanotherend to the joint (6)of the water outlet pipe (4),and then tighten it up.

2.3.3.6 Assembly of control cabinet (19)

·The assembler shall place the control cabinet (19)on the base (39)and fix it with M10(16) bolts. Please refer to theattached table1for corresponding cross-sectional area of wire to power

2.3.3.7Connectionmethodand requirementsofstainlesssteel bolts

·Refer to2.3.1.6

2.3.3.8 Control cabinet and motor wiring

·Referto2.3.1.7

2.3.3.9Assemblyof stainlesssteel filter (25)

·The assemblerchooses the stainless steelfiter(25)for thissystem,and places iton the water inlet of thestainless steel steady flow tank (23) (payattention to the installationdirection),place thefilter washer (24) in the middle,and fix it with bolts (26).

2.3.4 Installation (butterfly valve connection method) of DNP series constant pressure variable frequency systemand branch pipe above DN65 (inclusive)

2.3.4.1 Fixing of base (39)

·Place the base (39)on theconcrete baseand selectthe location.And fixitwith expansion bolts,level the base before fixing it.

2.3.4.2Assembly of thewater pump (38)and the base (39)

·Place thewater pump (38)on the base (39),add anti-vibration washers to fourfixing holes of the base (39)under the water pump,and fixthe water pump with bolts (15),bolts (14)should be pre-tighteneddiagonally (donottighten)withevenstrengthandnotbiased. ·The direction of the water pump (32) generally adopts the water outlet facing forward and the water inletfacing rearward;if the equipmentisNQsystem,the junction box of themotorshould face to water outlet direction of the pump (special requirements shall be executed according to the drawings).

2.3.4.3Pipeline (4/35) Assembly

Assembly rules: It is generally required that the pipeline (4/35) should beassembled horizontally with the base (39)and vertical with the water pump (38),and should meet the requirements of no leakage. ·Prepare the pipeline (4/35)and various accessories according to the pipeline identification label. ·For pipelines with branch pipes exceeding DN65 (inclusive),the water inlet is assembled by adding a butterflyvalve (37),and the water outlet adding a short connector (11) and a butterfly valve (6). 1)Assemblyofthewater inlet pipeline (35):lift thepipeline to the heightofthe water inletofthe water pump (38),and insert the bolts (36)into the holes offlange of branch pipe,butterfly valve (37)and flange of the water pump inlet respectively.Then screw the nuts on but don not tighten the bolt. 2）Assembling the water outlet pipe (4):prepare the check valve (14),washer(13)and bolt (12)firstly, raise the short connector (11) of outlet to the height of the water outlet of the water pump (38),and thread the bolts (12)into flange of short connectorand the two holesat the botomof the outlet flange of the water pump (38),screw the nuts with two teeth.Then put the rubber washers (13)on both ends of the check valve (14) (be careful of the directionof the check valve),Put them between short connector (11)and the outletflange of the water pump (38),and insert the remaining bolts (12),screw the nutson,slightly tightenup.Raise the outlet pipeline tocenter heightof shortconnector,thread bolts (5)intothe holes of branch pipe flange,buterfly valve(6)and outlet short connector,screw the nuts on but not tighten it.

3）Adjust the height and levelness of the inlet and outlet pipelines (4/35)to ensure that the inlet and outlet pipes at same height and level with the base (39).At the same time,adjust the height of the check valve,rubber washer,outlet shortconnectorand butterfly valve with a screwdriver,so that the center is consistent with the height ofthe water inletand outletof the water pump and the height of the joint flange,then tightenall bolts,and finally tighten the bolts(15) that fixes the water pump.

2.3.4.4 Assembly of stainless steel regulating tank (24)

·Fix the soft joint (32)to the outletof theregulating tank (24)with bolts(31),put the M10 bolts(19) into the four bolt slots of the base (39)reversely,then place the tank onto the base.After four fixing holes ofthe tank body aligned to the base bolts (19),screw nuts onas to ready for tightening. ·In order to installthe butterfly valve (33) between the water inlet ofthe pipeline and the soft joint (32), firstlyadjust the regulating tank toproper position,then thread the bolts (34)into inletflange of the water inlet pipe (35),the butterfly valve (33),and theflangeofthesoft joint (32),and tighten the nuts. ·Finally determine the position of the regulating tank (pay atention on deflection),and tighten the bolts (18) that fix the regulating tank.

2.3.4.5 Assembly of the pressure tank (23)

·The assembler selects the pressure tank (23)for this equipment,and places iton the base (39) with thepressure gauge facing outwards and the label of the tank without pressure gauges facing outwards.
·The bolt holes on the legs of the pressure tank (23) correspond to the three bolt holes on the base (39),and are finally fixed with M8 bolts.
·Putthe two ends of the armored hose (21)into special washers,and connect one end to the bottom joint (22)of the pressure tank (23),connect another end to the joint (7)of the water outlet pipeline (4), and then tighten it up.

2.3.4.6 Assembly of control cabinet (20)

·Theassembler shallplace the control cabinet (20)on the base (39)and fix it with M10(17) bolts.
Please refer to the attached table 1 for corresponding cross-sectional area of wire to power.

2.3.4.7 Connection method and requirements of stainless steel bolts

·Referto2.3.1.6

2.3.4.8 Control cabinet and motor wiring

·Refer to 2.3.1.7

2.3.4.9 Assembly of stainless steel filter (26)

·The assemblerchooses the stainless steelfiter(26)for this system,and places iton the water inlet of thestainless steel steady flow tank (24) (payattention to the instalationdirection),place the filter washer (25) in the middle,and fix it with bolts (27).

2.3.5 Installation of upturning equipment on outlet pipeline

·Wateroutletpipelineassembly:Raise the pipeline to the heightof the wateroutletof thepump,insert two connecting boltsinto the lowerflange of the elbow of the pipelineand the holes of the wateroutlet flange according to (Picture 5),and tighten the nuts.Then put the washer between the two flanges (pay attention to the alignment),thread the remaining boltsand pre-tighten (do not tighten). ·For installation of other parts except theoutletpipeline,pleaserefer toabove equipment instalation methods.

2.3.6 Other types of equipment other than above mentioned, installaccording to its specially madeequipment operating instructions orequipment function table.

Picture 1:Assembly drawing of BP booster system (DN50 and below)

1:Electric connecting pressure gauge
2:Pressure sensor
3：Three way stop valve
4:Outlet pipeline
5:Outlet ball valve
6:One-piece ball valve
7:Blind plate washer
8:Blind plate
9:Blind plate fasteners:nuts,bolts,flat
washer,spring washer
10:Outlet check valve fasteners:nuts,
bolts,flatwasher,springwasher
11:Outlet joint flange
12:Washer of outlet check valve

13:Outlet check valve
14:Pump fasteners:bolts,flatwasher,
springwasher,anti-vibrationwasher
15:Base fasteners:expansion bolts
16:Control cabinet fasteners:bolts,flat
washer,springwasher
17:Pressure tank fasteners:bolts,flat
washer,springwasher
18:Control cabinet
19:Armored hose
20:Elbow with internal tread
21:Pressure tank
22:Inlet blind plate fasteners: nuts,
bolts,flat washer,spring washer

23：Inlet blind plate
24:Inlet blind plate washer
25:Threeway joint of lowwater level
26:Air relief plug
27:Low water level sensor
28:Inlet pipeline
29:Inlet ball valve
30:Inlet fasteners:nuts,bolts,flat
washer,spring washer
31:Inlet joint flange
32:Inlet check valve washer
33:Pump
34:Base
35：Concrete base station
1:Electric connecting pressure gauge
2:Pressure sensor
3:Three way stop valve
4:Outlet pipeline
5:Outlet butterfly valve fasteners:nuts,
bolts,flat washer,spring washer
6：Outlet butterfly valve
7：One-piece ball valve
8:Blind plate washer
9:Blind plate
10:Blind plate fasteners:nuts,bolts,flat
washer,spring washer
11:Outlet short connector
12:Outlet check valve fasteners:nuts,

Picture 2:Assembly drawing of BP booster system (DN65 and above)

bolts,flat washer,spring washer
13:Washer of outlet check valve
14:Outlet check valve
15:Pump fasteners:bolts,flat washer,
springwasher,anti-vibrationwasher
16:Base fasteners:expansion bolts
17:Control cabinet fasteners:bolts,flat
washer,spring washer
18:Pressure tank fasteners:bolts,flat
washer,spring washer
19:Control cabinet
20:Armored hose
21:Elbow with internal tread
22:Pressure tank

23:Inlet blind plate fasteners:bolts,flat
washer,springwasher25Filterwasher
24:Inlet blind plate
25:Inlet blind plate washer
26:Threeway joint of lowwater level
27:Air relief plug
28:Lowwater level sensor
29:Inlet pipeline
30:Inlet Butterfly valve fasteners:
nuts,bolts,flat washer,spring washer
31:Inlet Butterfly valve
32:Pump
33:Base
34Concrete base station
1:Electric connecting pressure gauge
2:Pressure sensor
3:Three way stop valve
4:Outlet pipeline
5:Outlet ball valve
6:One-piece ball valve
7:Blind plate washer
8:Blind plate
9:Blind plate fasteners:nuts,bolts,flat
washer,spring washer
10:Outlet check valve fasteners: nuts,
bolts,flat washer,spring washer
11:Outlet joint flange
12:Washer of outlet check valve
13:Outlet checkvalve
14:Pump fasteners:bolts,flat washer,
spring washer,anti-vibrationwasher
15:Base fasteners: expansion bolts
16:Control cabinet fasteners:bolts,flat

Picture 3:Assembly drawing of DNP booster system (Branch pipe DN50 and below)

washer,springwasher
17:Pressuretank fasteners:bolts,flat
washer,spring washer
18:Steady flow tank fasteners:bolts,flat
washer,spring washer
19:Control cabinet
20:Armored hose
21:Elbow with internal tread
22:Pressure tank
23:Steady flow tank
24:Filterwasher
25:Filter
26:Filter fasteners:nuts，bolts,flat
washer,spring washer
27:Negative pressure gauge
28:Stop valve
29:Low water level sensor
30:Flexible joint fasteners:nuts,bolts,
flatwasher,springwasher
31:Flexible joint
32:Butterfly valve
33:Butterfly valve fasteners:nuts,
bolts, flat washer,spring washer
34:Inlet pipeline
35:Inlet ball valve
36:Inlet fasteners:nuts,bolts，flat
washer,spring washer
37:Inlet joint flange
38:Pump
39:Base
40：Concrete base station
41:Check valve washer of by-pass
42:By-pass check valve
43:By-pass check valve fasteners:
nuts,bolts,flat washer, spring washer
44:Nlet joint flange washer
1:Electric connecting pressure gauge
2:Pressure sensor
3:Three way stop valve
4:Outlet pipeline
5:Outlet butterfly valve fasteners:nuts,
bolts,flat washer,springwasher
6:Outlet butterfly valve
7:One-piece ball valve
8:Blind plate washer
9:Blind plate
10:Blind plate fasteners:nuts,bolts,flat
washer,springwasher
11:Outlet short connector
12:Outlet check valve fasteners: nuts,
bolts,flat washer,springwasher
13：Washerofoutletcheckvalve
14:Outlet check valve
15:Pump fasteners:bolts,flatwasher,
springwasher,anti-vibrationwasher
16:Base fasteners:expansion bolts
17:Control cabinet fasteners:bolts,flat
washer,springwasher
18:Pressure tank fasteners:bolts,flat
washer,springwasher
19:Steady flow tank fasteners:bolts,flat
washer,spring washer
20:Control cabinet
21:Armored hose
22：Elbowwith internal tread
23:Pressure tank
24:Steady flowtank
25:Filter washer
26:Filter
27:Filter fasteners:nuts,bolts,flat
washer,springwasher
28：Negative pressure gauge
29:Stop valve
30:Low water level sensor
31:Flexible joint fasteners:nuts,
bolts,flat washer,spring washer
32：Flexible joint
33：Butterfly valve
34:Butterfly valve fasteners:nuts,
bolts,flat washer,spring washer
35:Inlet pipeline
36：Inlet Butterfly valve fasteners:
nuts,bolts,flat washer,springwasher
37:Inlet Butterfly valve
38:Pump
39:Base
40:Concrete base station
41:Check valve washer of by-pass
42:By-pass check valve
43:By-pass check valve fasteners:
nuts,bolts,flat washer,spring washer

2.Corrugated hose arranging requirements

1）The corrugated hose should not be pulled too tightly when arranging.
2)The hose should be as straight as possible without bending;
3）There should be some allowance for hose in the connection parts such as pressure sensor, secondary protection device and pressure gauge to prevent the connector from faling off due to over-tightening;
4）The corrugated hose and the equipment joint should be wrapped with black tape and fixed with cable ties to ensure that the line is consistent;
5)The motor cable should hang down naturally along the motor and be tied beside the motor with a cable tie.
·Safety Guidelines
·Installation
·Energize control cabinet
·Functional testing
·Precautions for on-site installation and testing
·Troubleshooting common problems
·Limited Liability
·The manufacturer is not responsible for the following

1 Safety Guidelines

Warning! Only professional techniciansare allowed to installand test this equipment!
Warning !Even if the motor has stopped,there is still dangerous voltage on the inverter power terminals U1,W1,V1.
Warning! Dangerous voltages exist when the main circuit power is energized.Wait 5 minutes after the power is disconnected before operating.

Warning!Do not attempt to install or remove internal accessories while the device is powered on.

2 Installation

2.1Installation conditions

·Installationsite-indoor ·Ambienttemperature-4-40° ·Power supply-—3 Phase 380V

2.2Installation tools

·Cross screwdriver ·Wire stripper ·Multi-meter

2.3Wiring alignment

Electrical part:Firstly the testing technicianshould check whether the wiring iscorrect or not and component model isconsistent with the materialtable or notaccording to electric drawing,and adjust thesetting current of the thermal relay according to the motor power;

Final assembly part: whether the pipeline is assembled (whether the pressure tank and the steady flow tank are installed in right position),whether therange of the negative pressure gaugeand the electric contact pressure gauge is consistentwith the system requirements;

Afterchecking,closeallswitchesand measure if thereexists short-circuit of wiring in the control cabinet underall kinds of states that three-phase-to-ground resistance cannot be zero,and the phase-to-phase resistance cannot be zero.Strong electricity and weak electricityare strictly distinguished,and must not be connected incorrectly,otherwise,the system may be burned.

2.4 Connect the power cable

Disconnect all the air switches from bottom to top,turn the POWER two-position switch on the panel to the"OFF"position,turn the master control switch to "STOP",turn the three-position switch of each pump to the stopposition in middle,and connect the main power supplyof the control cabinet, The neutral wire and the ground wire of control cabinet correctly according to the technical requirements.

2.5Pipeline water supply

Before supply the water,make sure allthe pipelinesare washed，open the valve of the water inlet and outlet pipes to ensure that water can in&out normally,open the outlet valve of the water pump and exhaust air from each pump until the air is exhausted to ensure no leakage of the pipelines.

2.6 Caution onwatersupplyof the regulating tank

Slowlyopen the water inlet valve to ensure the gas in the pipe discharged evenly which is in order toprevent triggering thealarm by large gas exhausting caused bywater flow in too fast.

3Energize control cabinet

Useamulti-meter to measure theupper end oftheairswitch,whetherthe line voltage between any two phases of L1,L2,and L3 is 3 8 0 \lor ± 1 0 % ,and whether the phase voltage between any one phase and the neutral line is 2 2 0 \vee ± 1 0 % .When the main air switch is powered on,it must be when the lower-level switches suchassingle-pole switch are disconnected,after the mainair switch is turnedon forthefirsttime,turnedoffitimmediately,check ifeverything isright thenopen itformally andenergize the lower-level switches level by level.

3.1Power on single-stage switch

When the control circuit of the equipment control cabinet is powered on for the first time,close the single-poleair switchand then disconnectit immediately.Afterobserving thatthere is noabnormality， close it formall.If the manual indicatorlight does not ight up,the fuse core of the power supply or the indicator light may be damaged and needs to be replaced.

Note:During the testing process,the technicianmust highly concentrate,and they mustlisten,look, andlisten carefully.If abnormal situation occurs,such as burning smell in the control cabinet,electric sparks,sizzling sound that the relay cannot be pulled in,or if the protection switch is dropped,the technicianshould immediatelyturnoff thecontrolcabinetand findoutthe reason.If the reason cannot be found out,consult relevant technical personnelto recover the equipment back to normal beforere-testing.

3.2Preheating

Aftertheequipment places foraperiod,if the environmentis humid,firstlysolve the humidity problem,and then preheat theequipment without load formore than 30 minutesbefore carrying out on-load testing.

4 Function testing

4.1 Inverter testing

After the control cabinet ispowered on,it is necessary todebug the inverter,see the wiring and parameter tableofvarious typesof inverters fordetails.

4.1.1Parameteradjustment conditions

Whenadjusting the parameters,the invertermust be off.

4.1.2 Inverterwiring diagram

Seeelectrical diagram fordetails (Dooch,ABB)

4.1.3Datasheet

XQ Inverter:Press MENU to adjust parameter,enter PUMP，DRIVE,COM sections,etc

NQ Inverter parameter seting （Pressure “up&down"keys simultaneously toadjust the param-eter，enterPr,St,Drsection）

User's Manual For Booster Pump N747D Controller

Contents

Chapter#1 Thecompositionand featuresofcontroller

1.Featuresofcontroller 33
2.Major Functions of controller 34
3.Composition of controller 35

Chapter#2Linesarrangementofboostersystem

1.Key operation of user setting 38
2.Display of user setting 38
3.Change of user setting(1) 39
4.Change of user setting(2) 43
5.Change of user setting(3) 49

Chapter#3Keyoperationofinstaller

1.Keyoperationof installersetting 56
2.Display of user setting 56
3.Change of installer setting(1) 56
4. Change of installer setting(2) 62
5.Change of installer setting(3) 65

Chapter #4 Equipment inspection and maintenance procedures

1.Confirmation of pump operation history 73
2.Confirmation of alarm history 74

Chapter #5Key operation of test operation

1.Test operation key 77

Chapter#6 Other Keys

1.Inverter reset Key 80
2.Keyof Initial display 80
3.AlarmdisplayandReaction 80

Chapter #7 Appendix

1.Control Board Arrangement and Description 83
2.Check items 86
3.Pump Test operation 88
4.Emergency Operation 89
5.RS-485 Communication 91

Chapter #1

Thecompositionand featuresofcontroller

1.Featuresofcontroller
2.Functions of controller
3.Compositionof controller

1.Features of controller

Thisadvanced computer control device has been achieved itscontroling of pump's RPMby inverter through the newest electronic technology,and equipped with presumptive terminal pressure control technology and various inteligent functions which can determine and control the pressure of water supply according to the amount of supplied water and usage.

Up to 6pumps can be controlled with functions generally such as;stopping low flow using pressure tank,control,scheduledoperation,warningabnormalstate,fullautomatedsequentialoperation,inter val shift operation,skipping failed pumpautomatically,displaying operationdataand data storing.

Remote controlling and monitoring functionsby remote modem communication,and easy operating for anyone by displayingof all screenview in Korean./ English/Chinese.

2.Major functionsof controller

3.Composition of controller

Controller is consisted ofLCD playand operation Keys.

-LCDDisplay:It displayssystem information.

-OperationKey:Itisfordatasettingand checkupdata.

Chapter #2

Keyoperation ofuser

1.Key operation of user setting
2.Displayofusersetting
3.Change of user setting(1)
4.Change of user setting(2)
5.Change of user setting(3)

1. Key operation of user setting

2.Display of usersetting

User setup display [1] User setup display [2] USER SETUPI11 USERSETUP[2] Run Value 3.00Kgf/m Time&Date:008/11/13/12:00ITHE] Pump1 RunValue:03.00Kgf/a000SEC HighAlarmSetup：03.00Kgf/cm000SEC Pump1 StopValue:03.00Kgf/00oSEC LowAlarmSetup:03.00Kgf/cn000SEC Step RunValue :03.00Kgf/m000SEC Schedule Setup ：NOTUSED StepStopValue :03.00 Kgf/m 00oSEC User Password ：0000 Pump Shift Time： 00OHOUR

User setup display [3]

The display of User setup [3] is related with User setup [2]

USER SETUPISI USERSETUP[3] USER SETUPI3] MONTHLY SETUP WEEKLY SETUP TIME SETUP JAN:O.Okgf/ar JUL:OO.O kg/r FEB:00.0kgt/af AUG:00.0kgf/ MOENDAAY 0.8 ：5 MAR:00.0kgf/af SEP:00.0 kgf/ APR:00.0kgf/aOCT:00.0kg/ WEDNESDAY:00.00Kgf/m 04:00\~05:59-00.016:00\~17:59-00.0 MAY:00.0kgf/a NOV:0O.0kgf/ THURSDAY:00.00Kgf/a 06:00\~07:59-00.018:00\~19:59-00.0 JUN:00.0kgf/af DEC:00.0kgf/l FAITURDAY 00.00kgf/a 08:00\~09:59-00.020:00\~21:59-00.0 10:00\~11:59-00.022:00\~23:59-00.0 <Displayof Monthlyoperation> <Display of weekly operation> <Displayof timelyoperation>

3.The change of user setup[1]

1.Press installer setup on main display

2.Input password and save (initial password is ^ { { { s } } } 0 0 0 0 ^ { { { \prime } \prime } }

2.SAVEBUTTONINPUT

3.Inuser setup[1],move to desire displaywith cursor.

4.Move to desire display with cursor

\ast Cursorcanbemoved to left/right.

5.Settingvaluecanbe changedby figureKeys.

6.After setting,press “save”.

Theadjustable items in theusersetting[1] areasbelow.

-Setting pressure: Target water pressure to operate.

Change of predetermined pressure.

(Example: In case current set value is 0 3 . 0 0 { ~kg } { f } / {cm } ^ { 2 } ）

1. Using → ↓

Key,select

Run Value:03.0OKgf/cm

2.Initially the first " 0 " of the " 0 3 . 0 0 " blinks.

3. Using

Key,selectpositionto bechanged in * 0 3 . 0 0 { ~kg } { f } / {cm } ^ { 2 } ：

4.After change using T Key,make sure to press SAVE Key.

/ideontimes Setvalue isnot changed until input key is pressed.

/ideontimes When predetermined pressure is changed, the high pressure value becomes settingpressure + 2kg \uparrow / \mathsf {cm } ^ { 2 } automatically.

-The change of auxiliary stop pressure

(Example:In case current set value is 0 0 . 2 {kg } \mathsf { f } / \mathsf {cm } ^ { 2 } .

1. Using Key,select

Pump1 RunValue:00.2Kgf/cni000SEC

2.Initially the first " 0 " of the * 0 0 . 2 0 ^ { \prime } blinks.

3. Using

Key,select position to be changed in ‘O0.20 kgf/cm².

4.After change using 9 Key,make sure to press SAVE Key.

-Auxiliarystoppressure : it means the pressure to stop the auxiliary pump.

When current pressure decreases hoigher than “setting pressure ^ + auxiliaryoperation pressure", then auxiliary pump will stop.If setting pressure is 0 3 . 0 0 {kg } { f } / \mathsf {cm } ^ { 2 } and auxiliary pressure is 00.50kgf/cm²,Oo5 second,and current pressure is higher than 3 . 5 \mathsf {kg } \mathsf { f } / \mathsf {cm } ^ { 2 } thenauxiliary pumpwill stopafter5 seconds.

Change of auxiliary stop pressure.

(Example:In case current set value is 0 0 . 3 0 {kg } { f } / {cm } ^ { 2 } ）

Pump1StopValue:00.30Kgf/cmi000SEC

2.Initially the first " 0 " of the * 0 0 . 3 0 ^ { \prime } blinks.

3. Using

Key,select position to be changed in * 0 0 . 3 0 { ~kg } { { f } } / { {cm } } ^ { 2 } 业

Using 0 9 Key, change to required value,then make sure to press SAVE Key.

/ideontimes Setvalue isnot changed until input keyis pressed.

-Step operational pressure(Emergent operational pressure):

When“step operation 1"has been set by user or inverter error occurs,pump runs if "setting pressure-current pressure"is lower than specified emergent operating pressure. Change of step operational pressure.
(Example: In case current set value is 0 0 . 5 0 {kg } { f } / {cm } ^ { 2 } ）

1. Using ↑ Key,select

Step StopValue :00.50 Kgf/cm00oSEC

2.Initiallythe first " 0 " of the * 0 0 . 5 0 ^ { * } blinks.

3. Using

Key,select position to be changed in * 0 0 . 5 0 { ~kg } { f } / {cm } ^ { 2 }

Key,change to required value,thenmakesure to press

SAVE Key

/ideontimes Setting value will not be changed until input key is not pressed.

-Step stop pressure (emergent stop pressure):

When “step operation 1"has been set by user or inverter error occurs,pump runs if "setting pressure-current pressure"is lower than specified emergent operating pressure. Change of stepl stop pressure.
(Example: In case current set value is 0 0 . 5 0 {kg } { f } / {cm } ^ { 2 } ）

1. Using

Key,select

2.Initially the first " 0 " of the * 0 0 . 5 0 ^ { * } blinks.

3. Using

Key,select position tobe changed in * 0 0 . 5 0 { ~kg } { f } / {cm } ^ { 2 } #

4.Using 0 9 Key,make sure to press SAVE Key.

\ast Set value is not changed until input key is pressed.

- Shift time of main pump :

When the specified time as the shift time of main pump is over, the main pump is changed.However,while thepump is inoperating,itsoperatingmode ismaintained until 2:00am then shifted forcibly.Setting is available up to { \bf \nabla } * { \bf g } { \bf g } ^ { \prime } ,and when setting is in " 0 0 " ,the main pump isshiftedwhenever inverterstops.

Change of main pump shift time (Example:In case current setvalue is 24 hours.)

1. Using

Key,select

Pump Shift Time :24HOUR

2. Initially the first ‘2'of the ‘24'blinks.

3. Using

Key, select position to be changed in 2 4 ^ { 2 } #

4. Using Key,change to required value, thenmake sure to press SAVE Key.
/ideontimes Set value is not changed until input key is pressed.
/ideontimes In case of forced shift,all pump stops fora while.

4.The change of user setup[2]

1.Press user setup on main display.

2.Input password and save (initial password is " 0 0 0 0 " . 0

3.Press user setup key on user seting [1].

USER SETUPI1]

Run Value： 3.00Kgf/cmPump1RunValue：03.00Kgf/cn000SECPump1StopValue:00.20Kgf/cm000SECStep RunValue ：00.50Kgf/cm000SECStepStopValue :00.50Kgf/cm000SECPump Shift Time： 00OHOUR

2.SAVEBUTTONINPUT

4.In user setup [2],move to desire displaywith cursor.

5.Setting value can be changed by figure Keys.

6.After setting,press“save".

Changeable items in usersetting [2] are as below.

-Timesetting \because 2008/11/1312:20 Thursday
It displays in the order of year/month/day time:minute days,and if it does not matched with present time then adjust it.Adjust of time settings.
(Example:In case of change“2008/11/1312:00 Thursday"to “2008/11/13 24:00 Thursday")

1. Using

Key,select

2.The first‘2'of the‘2008/11/13 12:00 Thursday'blinks.

3. Using

Key,enterin the orderof2,0,0,8,1,1,1,3,1,2,0 and0 (Thurs).

When no change is required or in case of wrong input,it'savailableto move to required position

using Key.

The last numbermeans day of the week as below;

1:Mon2:Tue3:Wed4:Thurs5:Fri6:Sat7:Sun

4.After changing to required value,makesure to press SAVE Key.
/ideontimes Set value is not changed until input key is pressed.

When water pressure sustains at above than specified pressure (OO.O O) for more than OO O seconds,alarm is to be given.

Changesettings of high pressurealarm.

(Example:in case of to change 05.00 kgf/cm² 005 seconds to 04.00 kgf/cm² 003seconds)

1. Using

↓ Key,select （204号 High Alarm Setup:05.00Kgf/cm005SEC

2.Initially the first " 0 " of the * 0 5 . 0 0 { ~kg } { f } / \mathsf {cm } ^ { 2 } 0 0 5 second'blinks.

3.Using Key,enter in the order of0,4,0,0,0,O and 3. Incase no change is required or wrong input,moving to desired position is available by

using Key.

4.After changing to required value,make sure to press SAVE Key.

/ideontimes Set value is not changed until input key is pressed /ideontimes Whensetting pressure of user seting [1] is changed,setting pressure of the high pressure alarm settings isautomaticallyset as + 2kg \uparrow / \mathsf {cm } ^ { 2 }

-Settingof lowpressurealarm \because OO.O Okgf/cm²OO Oseconds.

When water pressure sustains at lower than specified pressure (O O.OO) for more than OOO seconds,alarmistobe given.

Change of lower pressure alarm setting.

(Example:in case of to change 00.00 kgf/cm²005seconds to 00.20 kgf/cm² 005seconds)

1. Using Key,select Low Alarm Setup:05.00Kgf/cm 005SEC

2.Initially the first \because ofthe'00.00kgf/cm²005seconds'blinks.

3.Using Key，enter in the orderofO,0,2,0,0,0and5.

Incase no change is required or wrong input,moving to desired position is available by

using Key.

4.After changing to required value,make sure to press SAVE Key.

\ast Set value is not changed until input key is pressed.

- Setting of scheduled operation \because Available to selectamong No use/Monthly operation/Weekly operation /Operation by time frame.Initial seting is‘No use',and operation method can be selected with 0\~3 number keys.Each numberstands for;0:No use 1:Monthly operation2:Weekly operation 3:operation by time frame.

Changesetting ofscheduled operation.

(Example:To change“scheduled operation \because no use”to“scheduled operation \because operation by time frame")

1. Using ↑ √ Key,select Schedule Setup :NOT USED

2.“No use”blinks.

3.Enter“3”among Keys.

(0:No use1:Monthly operation2:Weekly operation 3:operation by time frame)

4.Afterchanging to required value,make sure to press SAVE Key.

※Setvalue is not changed until input key is pressed.

5.To use scheduled operation,the setings shall be changed in“user operation [3]. Referto the changes in“user operation [3]" fordetail information.

Change of user password \because N747D is designed to set password in order to prevent others from tampering settingswithout authorization.Initial password is set as 0000.

Change of user password.

(Example:To change “use password:Oooo"to“ser password:1234")

1. Using

User Password ：0000

2.User password \because Initially the first " 0 " of the'0000'blinks.

3. Using

Key,enter1,2,3,4

4.Afterchanging to requiredvalue,makesure to press SAVE Key.
/ideontimes Set value is not changed until input key is pressed.