Mizer Single Pump and Starter Box

Transcription

1 Mizer Single Pump and Starter Box

2 Table of Contents Line Diagram... 2 Overview... 3 Booster Pump Specifications... 3 Water... 3 Electrical... 3 Models... 3 Mounting... 4 Electrical... 6 Motor Rotation... 6 Electrical Operation... 6 Plumbing... 7 Inlet Plumbing... 7 Outlet Plumbing... 7 Settings... 7 Outlet Pressure... 7 Water Temperature Relief... 8 Booster Pump Parts Diagram... 9 P Pump Part Listing...10 P Pump Part Listing...11 Starter Box Overview...13 Starter Box Specifications...13 Dimensions...13 Electrical...13 Models...13 Mounting...14 Electrical...15 Power Raceway & Feed...15 Pump Connections...15 Control wiring...15 Wire Connection Points...16 Motor Starter Protector...17 Schematic Component Location...18 Schematic Sheet 1 High Voltage Connections...19 Schematic Sheet 2 Low Voltage Connections...20 Starter Box Parts Diagram...21 P Parts Listing...22 P Parts Listing...23 Cleaning Systems Inc. 1 P Rev. 06

3 Line Diagram Cleaning Systems Inc. 2 P Rev. 06

4 Overview The Mizer booster pumps are multistage centrifugal pumps constructed of a stainless-steel casing with cast iron end caps. The impellers are made from a composite material capable of withstanding water temperatures up to 145 F. All models include water temperature and pressure relief valves to protect and accurately regulate the pump outlet pressure at varying flow rates. The unit comes pre-plumbed to connect directly to the Mizer base panel using a quick disconnect coupling. All units are prewired with a 6 cord and plug to connect to an optional starter box or electrician mounted receptacle. All units are supplied with a wall mount bracket to securely mount to most masonry walls. See the Mizer Panel installation manual for recommended layout of system components. This manual provides specifics to mounting the pumps, plumbing to the booster pumps and interconnection between the pump units. Water Booster Pump Specifications Flow Requirements: 10gpm or psi Temperature: 140 F. Max Inlet Connection (Hose barb supplied): 10gpm pump - 1 hose connection to pump (customer supplied) 20gpm pump - 1-1/4 hose connection to pump (customer supplied) Outlet Connection (To Mizer Panel): 10-feet of 3/4 hose with a quick disconnect fitting to connect directly to the Mizer Base Panel is provided Electrical (See motor nameplate for motor specifications) Models Horsepower Flowrate Voltage (3-PH) Rated Current Frequency 2 HP 10 GPM / / 2.8 A 60 Hz 3 HP 10 GPM A 50 Hz 2 HP 10 GPM A 60 Hz 3 HP 20 GPM / / 3.9 A 60 Hz 3 HP 20 GPM A 60 Hz P HP (10GPM) Pump Assembly /480VAC 60Hz P HP (10GPM) Pump Assembly VAC 50Hz P HP (10GPM) Pump Assembly 575VAC 60Hz P HP (20GPM) Pump Assembly /480VAC 60Hz P HP (20GPM) Pump Assembly 575VAC 60Hz Cleaning Systems Inc. 3 P Rev. 06

5 Mounting Booster pumps are shipped pre-plumbed to be mounted vertically using supplied wall mount brackets. If horizontal mounting position is desired, the bracket can be mounted so the regulator would be facing upward. Note that if it is mounted in the horizontal position, the gauge will need to be rotated 90 degrees. The booster pump motors have an IP55 environmental rating and are not necessarily protected from exposure to water. The booster pumps should not be mounted directly under the Mizer panel outlets or other plumbing connection points where leaking or spray is possible. The booster pump should be mounted in a spot so that it can easily reach the quick disconnect on the Mizer panel with the supplied 10 hose. A 6 electrical cord is also supplied, verify the cord and plug will reach the receptacle on the optional starter box or the receptacle supplied by the electrician. Mount bracket as shown. Locate and mark the bolt hole locations of the mount bracket in a location where the Mizer booster pump is to be located. Note: Directions refer to mounting bracket to a solid or block concrete wall only. If mounting to other material structures, proper fasteners will need to be supplied by customer. Drill the bracket mount holes (4) with a 3/8 diameter concrete drill bit at least 3 deep. Anchor the mount bracket to the wall using the four (4) supplied 3/8 expansion anchors by inserting the anchors through the ½ hole of the bracket then into the drilled hole and hand tighten until snug. Once bracket is plumb and level tighten in place. Bolt the booster pump to the bracket using the 3/8 bolts, washers and nuts provided. Place a flat washer onto the bolt and place the bolt through the upper back mount hole of the booster pump so the bolt head is on the bracket side of the pump unit (as shown below). Align the pump and single bolt to the proper hole on the mount bracket. Install washer and nut to hold pump in place on bracket. Insert other three (3) bolts, washers and nuts in the remaining mount holes. Straighten booster pump and tighten bolts to hold in place. Cleaning Systems Inc. 4 P Rev. 06

6 System Mounting Example (units in inches) Cleaning Systems Inc. 5 P Rev. 06

7 Electrical The pump unit operates on three-phase power. The pump unit requires a motor starter protection system as included in the optional starter boxes. Each booster pump unit is supplied with a 600VAC 6 cord. The /480V pump motors are supplied wired for VAC. If desired to run the system on 480VAC the motors need to be tapped for 480VAC (High) operation (See Motor Tap below). The 400V and 575V pump motors are supplied wired for each of their rated voltages. Motor Rotation The pump motor should be turning in a clockwise rotation when looking at the motor end cover. Jog the motor to verify rotation. Motor rotation can be observed through the fan guard at the top of the pump motor. If the rotation is incorrect: When an optional starter box is being used, switch two of the incoming power feed lines (phase) in the feed terminals. When an electrician supplied starting device is used, switch two of the wires (phase) supplying the receptacle for the booster pump on the bottom of the motor starter protector. Note: It is very critical that the pump rotation is correct as noted on the booster pump body. Incorrect rotation can cause catastrophic failure to the pump, resulting in no pump output pressure, and will void warranty. Electrical Operation If the pump is connected to a system other than the Mizer starter box, a contactor and motor protection needs to be supplied to operate motor at the correct voltage. (See the motor nameplate on the booster pump for ratings). The motor contactor needs to turn on when any of the Mizer panel solenoid valves are energized. It is recommended to prevent short cycling of the booster pump by overlapping functions controlling the Mizer solenoids or adding a 10 second off time delay on the booster pump motor. Cleaning Systems Inc. 6 P Rev. 06

8 Inlet Plumbing Plumbing The booster pump should be supplied from a water source that can handle the flow of the total maximum output flow of the Mizer panel injectors. The booster pumps are rated at either 10GPM or 20GPM (depending on 180PSI boost but can reach higher flows at lower pressure boosts. Typically, 1 hose (10GPM pump) or 1-1/4 hose (20GPM pump) plumbing from a city water source to the pump inlet is more than sufficient. If water source is from a tank an additional pump will have to be provided to meet requirements. It is sometimes necessary to install a spring check valve on the water supply where the pump inlet hose connects to the water source. This will prevent the booster pump from chattering the relief valve due to large pressure fluctuations in the water pressure or water hammer from other connections to the water source. Outlet Plumbing A 10-foot 3/4 hose with a quick disconnect fitting is supplied from the booster pump. Securely connect the quick disconnect fitting to the Mizer panel by pulling back the retaining ring, inserting the female (hose end) onto the male Mizer panel inlet fitting and release the retaining ring. Verify the fitting is fully engaged by gently pulling on it. The hose supplied on the booster pump can be cut to desired length to clean up the installation and prevent the hose from rubbing. To do this, loosen the hose clamp by the quick disconnect fitting, remove the hose off of the hose barb, cut hose to length, replace hose back on the hose barb and tighten the hose clamp to secure hose to barb. Outlet Pressure Settings The booster pump outlet pressure is factory set to 180psi. To adjust the pressure, loosen the relief valve stem jam nut, turn the relief stem clockwise (Viewing from the valve stem end of the valve) to increase and counter clockwise to decrease the boosted pressure and retighten the jam nut. Turn the pump on and off two times to verify the pressure stays at the correct setting. It is typical to have a variance in pressure from the original set point when larger pressure adjustments are made. Cleaning Systems Inc. 7 P Rev. 06

9 Water Temperature Relief The water temperature relief is set to trip when the water temperature in the bypass loop is in excess of 145 F. The water will flow from the outlet port of the valve until the water temperature drops below the 145 F set point. As a note; during normal operation, the water in the by-pass loop should be the same temperature as the inlet water temperature. If the temperature relief valve is tripping, verify the pump is only running when at least one of the Mizer valve bank solenoids are open (Note that a time delay of up to 30 seconds after the solenoids turn off is acceptable and advised to reduce cycling the pump on and off). Verify that the inlet water temperature is not exceeding 140 F. The temperature relief may trip even if a surge of hot water gets to the Mizer pump unit, an anti scalding temperature valve may need to be installed if system plumbing causes water temperature fluctuations. Cleaning Systems Inc. 8 P Rev. 06

10 Booster Pump Parts Diagram Cleaning Systems Inc. 9 P Rev. 06

11 P Pump Part Listing (2HP, 10GPM, /480VAC) Cleaning Systems Inc. 10 P Rev. 06

12 P Pump Part Listing (3HP, 20GPM /480VAC) **Consult CSI for a parts listing of models not shown** Cleaning Systems Inc. 11 P Rev. 06

13 erview Mizer Single Pump Starter Box Cleaning Systems Inc. 12 P Rev. 06

14 Starter Box Overview The Mizer single pump starter box is designed to control a single 2HP or 3HP booster pump supplying a Mizer Base Unit. The Mizer pump control senses when any of the control valve coils are energized on the Mizer unit turning on the booster pump. The booster pump stays on until the starter box detects that all the valve coils are off and a 10 second off-delay time passes. The time delay is to prevent quick-cycling of the booster pump unit to extend its operational life time. The Mizer pump starter box comes with a pre-wired twist lock receptacle for the Mizer pump unit to plug in to securely. Dimensions Starter Box Specifications 17.5 x15.46 x lbs. Electrical Pump Rating Voltage (3-PH) FLA Interrupt Rating 2 HP /480/ / 3.1 / 2.2 A 5 ka 3 HP /480/ / 4.2 / 3.1 A 5 ka Models P SINGLE PUMP STARTER W/SMART TECHNOLOGY /480VAC P SINGLE PUMP STARTER W/SMART TECHNOLOGY 575VAC Cleaning Systems Inc. 13 P Rev. 06

15 Mounting The starter box should be mounted in a location near the booster pump. The pump plugs directly into the bottom of the starter box and needs to be within the 6 pump cord length without modifications. The electrical enclosure may be mounted directly to a vertical wall through the mount holes located on the top and bottom flanges of the enclosure. Cleaning Systems Inc. 14 P Rev. 06

16 Electrical Raceways and wire gauge required to be determined by your national and local electrical codes. Please reference proper resources for information. The starter box is supplied with a motor starter protector with lockable disconnects. Note: NEVER drill holes at the top of the electrical enclosure. Power Raceway & Feed The starter box is shipped with one 7/8 diameter hole in the upper left side of the enclosure for a standard ½ conduit connection point (Hole may be enlarged if a larger raceway is needed). One three phase 3-wire with ground supply is required to feed the booster pump starter and control transformer. Size the conductor gauge per your national and local codes. Pump Connections The starter box is supplied with a receptacle mounted in the bottom of the enclosure to allow the booster pump unit to be plugged in. Control wiring The common control wire (Neutral) for the Mizer Panel needs to route through the starter box so the current can be sensed to start the booster pump at the correct time. The common wire can be run in the same raceway as the power feed or an additional raceway can be run to the starter box through an additional hole near the power feed raceway connection point. Cleaning Systems Inc. 15 P Rev. 06

17 Wire Connection Points L1, L2, & L3 Three Phase Power Terminals /480V Starter Box: Three phase power and Earth Ground to be provided from a power distribution source. A 208, 240, or 480VAC 60Hz power source is acceptable. Note that the starter box is supplied pre-wired for 208VAC, if a different voltage is used, the control transformer will need to be tapped to the correct voltage by moving the BLACK transformer primary feed wire 1W20 (Sent connected to the 208V terminal 1X5) to the proper terminal location. The Earth Ground is to be connected to the ground lug on the upper left area of the starter box indicated with a terminal marking PE (Protective Earth Conductor). 575V Starter Box: Three phase power and Earth Ground to be provided from a power distribution source. A 575VAC 60Hz power source is required. The starter box is pre-wired for 575V, and no other transformer taps are available. Earth Ground is to be connected to the ground lug on the upper left area of the starter box indicated with a terminal marking PE (Protective Earth Conductor). 120, 208, 240, 277, & 480V Transformer Tap Terminals The proper tap for the control transformer is determined by the supply voltage connected to the /480VAC starter box. Note that there should only be one transformer tap terminal that has two wires attached to it (one connected to the transformer the other from the power source). The unit is supplied with the transformer tapped for 208VAC (Terminal 1X5), to change to a different voltage move the BLACK transformer primary feed wire (located in the upper position of one of the transformer tap terminals) to the corresponding voltage tap of the power source supplied to L1, L2, and L3. Note that the 120 / 277 taps should not be used. Mizer Coil Common Terminals Connect to the terminal Common In with the common (neutral) wire supplying control power (24VAC) to the Mizer panel and the pump starter. From the Common Out terminal route a wire to the common terminal of the Mizer panel C. The common control wire for the Mizer panel is routed through the terminals 1X9 and 1X10. When current is sensed (when one or more of the Mizer valves is energized) the pump starter panel controller will turn on the booster pump. Ground Terminals Connect Earth Ground from the power source to the ground lug located in the upper left corner of the starter enclosure near the raceway connection port. Cleaning Systems Inc. 16 P Rev. 06

18 Motor Starter Protector Motor FLA Setting Motor over current protection required to be set to pump motor full load amperage for the proper voltage supplied. Turn the dial on the face of the motor starter to the proper scale location. Check the motor nameplate on the pump before adjusting the over current protection device. OVERLOAD SETPOINTS 3PH Line-Line Voltage: 208V 230V 460V 400V 575V 2HP Pump N/A 2.0 3HP Pump On-Tripped-Off Switch The MSP is equipped with a lockable disconnect switch. If the switch is in the middle position between the On and Off position it is tripped. The unit can be in the tripped position if it is: Manually tripped via test switch, booster pump running at higher current than set on MSP, power phase loss or short circuit. Reset a MSP trip by turning the disconnect switch to the Off position then back to the On position. Cleaning Systems Inc. 17 P Rev. 06

19 Schematic Component Location Cleaning Systems Inc. 18 P Rev. 06

20 Schematic Sheet 1 High Voltage Connections Cleaning Systems Inc. 19 P Rev. 06

21 Schematic Sheet 2 Low Voltage Connections Cleaning Systems Inc. 20 P Rev. 06

22 Starter Box Parts Diagram Cleaning Systems Inc. 21 P Rev. 06

23 P Parts Listing ( /480VAC) Cleaning Systems Inc. 22 P Rev. 06

24 P Parts Listing (575VAC) Cleaning Systems Inc. 23 P Rev. 06