O & M - Pressurizer VS - Catalog
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1. 4 m 49y 18 AHH INCOMING POWER AND GROUND NOTE USE L1 L2 AND L3 FOR 3 PHASE USE L1 AND L2 FOR 208 240 SINGLE PHASE VOLTAGE MOTOR GROUND CONDUIT BOX 460V 3PH 1 3 2 4 7 5 8 6 9 208 230V 3PH 1 7 3 9 2 8 4 5 6 MOTOR Figure 6 2 1 Figure 6 2 2 S3 ON DRIVE SN ON DRIVE A2 ON DRIVE V ON DRIVE 19919 138 m Low Suction Switch Pressure Transmitter Figure 6 2 3 Figure 6 2 4 132. Thrush Co inc Pressurizer VS PB VSI Series Variable Speed Water Booster System Manual 9636 1400 Rev B Operation amp Maintenance Manual 340 West 8 Street Peru IN 46970 PH 765 472 3351 FX 765 472 3968 www thrushco com COPYRIGHT THRUSH CO INC 2014 Thrush Manual 9636 1400 Table of Contents Section No Description Page No 1 General Product Information 1 2 Safety Information Warnings 2 3 Component and Operational Information 3 5 4 Installation Initial Setup and Operation 6 10 5 Maintenance Information 11 6 Electrical Drawings 12 13 THIS DOCUMENT CONTAINS INFORMATION THAT THRUSH DEEMS CONFIDENTIAL AND PROPRIETARY IN CONSIDERATION FOR THE RECEIPT OF THIS DOCUMENT RECIPIENT AGREES NOT TO REPRODUCE COPY USE OR TRANSMIT THIS DOCUMENT OR THE INFORMATION CONTAINED HEREIN IN HOLE OR IN PART OR TO PERMIT OTHERS TO DO SO FOR ANY PURPOSE WITHOUT FIRST OBTAINING THE EXPRESS WRITTEN PERMISSION FROM THRUSH COPYRIGHT THRUSH CO INC 2014 Thrush Co Manual 9636 1400 Section 1 General Product Information 1 1 Overview The Thrush Pressurizer VS Figure 1 1 has been carefully assembled and factory tested to provide years of trouble free service This manual provides information to allow the installer operator to install operate service and maintain the Pressurizer VS In this manual the installer operator will find multiple Pressurize
3. 100 80 80 25 PB VSI 200 35 35 25 PB VSI 200 50 200 50 60 25 65 58 50 PB VSI 200 60 60 25 This is field adjustable to fit specific duty points provided you stay within the capabilities of the pump Figure 4 4 Factory Settings amp Performance Capabilities 4 5 Definition of Terms in Figure 4 4 Maximum Flow total amount of water that the specific Pressurizer VS is capable of pumping while maintaining the boost capabilities of the unit Maximum Boost The amount of water pressure increase boost that the specific Pressurizer VS is capable of adding to of the suction pressure over the flow capabilities of the unit Suction Pressure boost pressure discharge delivery pressure Maximum boost can only be achieved if maximum flow is not exceeded Factory Discharge Set Pressure The factory set point for the Pressurizer VS Suction Pressure The pressure supplied to the suction of the Pressurizer WS during factory setting of the Discharge Set Pressure Site conditions with suction pressure other than this will affect the sleep speed activation points and other settings of the VFD Cut Out after Sleep Boost The Pressurizer VS incorporates a unique Sleep Boost feature which will speed up the motor and adds additional pressure to fill the hydro pneumatic tank before going into sleep mode Wake Level from Sleep The pressure in which the VFD starts the pump after sleep mode Tank Pre Charge The pressure in
4. the air side of the hydro pneumatic tank with zero pressure no water in tank and connection is open to atmosphere in the water side of the tank This pressure should be checked and corrected upon installation of the Pressurizer VS If the operating conditions of the unit need to be adjusted in the field the pre charge in the tank should be adjusted also For optimal performance the pre charge in the tank should be set to 10 PSIG below the Discharge Set Pressure Thrush Manual 9636 1400 Section 5 Maintenance Information 5 1 Maintenance Information The information in this section details the proper maintenance procedures for the components of the Pressurizer VS Because this manual serves multiple models of Pressurizer VS the information may be general in some instances If there are any questions concerning maintenance procedures that are not clearly explained in this manual contact your representative The design simplicity of the Thrush Pressurizer VS results in a minimum of required maintenance Electrical Components The VFD pressure switch and pressure transmitter should require only periodic inspection to avoid possible problems such as loose connections worn contacts etc Refer to Section 6 for wiring of components Pump Seal Replacement A Cartridge Seal Kit includes the mechanical seal a pump body gasket and installation instructions Pump Motor Consult the motor manufacturer maintenance manual via their webs
5. Amps Current Discharge Pressure SOFT KEY 2 Function changes according to state of panel UP Changes parameters and their value increase reference HELP HELP button providing manual information START Initiates operation of drive Figure 4 3 1 ABB Controller Standard AUTO The drive will start in Auto Mode UP Changes parameters and their value increase reference DOWN Changes parameters and their value decrease reference HAND Initiate Operation of Drive SEQ REF REMOTE FWD REV ALARM DRIVE Rdy Auto Set Point U1 01 60 00 PSI 01 02 0 00 2 U1 91 20 PSI Drive Status U1 01 Drive Set Point U1 02 Current Drive Speed U1 91 Current Discharge Pressure MENU Scrolls through 5 main menus MENU 5 m T DATA MONITOR ENTER RESET RUN 5 lt gt HAND OFF ESC Returns to previous Screen DATA ENTER Enter menus and parameters sets values RESET Selects digit to be changed OFF Ceases operation of drive Figure 4 3 2 YASKAWA Controller Optional 4 Thrush Co Manual 9636 1400 3 Initial Startup Procedure Continued Read and fully understand Safety Information Warnings in Section 2 before continuing 1 Never work on the VFD wiring motor or other component when electrical power is energized Disconnect the pow
6. FD Variable Frequency Drive 4 gt The VFD regulates the motor and provides constant output pressure regardless of fluctuating supply pressure or changing flow demand The VFD allows for a narrower pressure deadband the amount of pressure that must be g removed before the pressure switch contacts reset after actuation level has been reached which insures a constant pressure supply at fixtures The low suction switch acts as a safeguard for the pump If suction pressure is below the factory set point the low suction b switch will prevent the pump from turning on and potentially causing damage 3 1 5 Low Suction Switch 3 1 6 Inline Check Valve The inline check valve is located at the pump discharge to prevent possible damage to the pump from water backflow and back pressure This compact design reduces the overall footprint of the Pressurizer VS Thrush Co Manual 9636 1400 3 1 7 Pressure Gauge Pressure gauges are located on the suction inlet and discharge outlet sides of the pump These gauges allow the user to monitor activity of the piping system and troubleshoot potential problems Discharge pressure suction pressure total system boost 3 2 Optional Equipment Although the standard Pressurizer VS was designed to meet customer requirements the need for optional equipment may arise Thrush can provide options to ensure that our Pressurizer VS meets your needs Listed below are some of the options av
7. ailable 3 2 1 Suction Spool Mounting Brackets The optional suction spool and mounting brackets can be used to mount the unit to the floor or wall These IN fs brackets also help properly support the piping system If if 7 these brackets are not used pipe supports must be yA e N installed following common plumbing guidelines 3 2 2 Isolation Valves Isolation valves are used to isolate the unit from system piping for maintenance or repair Depending on the Pressurizer VS model isolation valves will be ball valves Ls with NPT connections or lug style butterfly valves for use ST with class 125 150 flanges Thrush Co Manual 9636 1400 Section 4 Installation Initial Start Up and Operation 4 1 Piping Installation The following procedures are to aid the operator in installing operating and maintaining the Thrush Pressurizer VS All procedures are to be performed by experienced trained and certified personnel only Before the unit is installed the unit should be visually inspected for any irregularities that may have occurred during shipping If any parts are missing or damaged contact your representative no issues are detected continue with installation Before making any piping connections assure that all piping is clean and free of any foreign materials such as debris or scale Foreign material in the piping can cause damage to the unit and or affect the performance and operation Manual shutoff valv
8. er and verify that power to the Pressurizer VS is off 2 Assure that the suction and discharge isolation valves are closed 3 Verify that the tank pre charge pressure is set per Figure 4 4 Make pressure adjustments to the tank pre charge if necessary using the air charging valve stem on the tank 4 Slowly open the suction isolation valve to fill the Pressurizer VS and check for any leaks Repair any leaks before proceeding If the suction pressure gauge indicates suction pressure equal to or above suction pressure per Figure 4 4 you may continue to step 5 If the suction pressure gauge indicates the suction pressure is below that shown in Figure 4 4 you do not have adequate incoming pressure You must correct this before continuing to step 5 see Section 4 1 paragraph 4 5 Slowly open the discharge isolation valve and check for any leaks in the discharge piping 6 Turn on the electrical power the VFD controller will be illuminated when power is energized 7 Introduce 6 to 10 GPM of flow into the system by opening 3 or 4 plumbing fixtures such as faucets A typical faucet delivers approximately 2 5 GPM 8 To initiate operation of the VFD press Start ABB or Auto Yaskawa on the VFD controller The VFD should bring the pump up to speed to the factory discharge set pressure as shown in Figure 4 4 See step 9 if adjustment is necessary if adjustment is not necessary go to Step 10 9 To adjust the discharge set press
9. es should be installed upstream and downstream of the system to act as an isolation device These valves should be in the closed position and remain so until the installation is complete CLEARANCE Las le ISOLATION VALVE S gt SUCTION SPOOL OPTIONAL W MOUNTING FEET MOUNTING FEET OPTIONAL OPTIONAL PIPE SUPPORTS PIPE SUPPORTS Figure 4 1 Pipe Supports 1 Pressurizer VS should be located in a clean open area where it is easily accessible for inspection service and repair 2 standard Pressurizer VS is installed in line of the system piping Optional mounting feet can be used for floor mounted or wall mounted installations See paragraph 3 2 1 and Figure 4 1 3 Note that a minimum 6 of clearance above the drive mounting bracket is recommended to allow for maintenance and repair of the motor and pump Thrush Co Manual 9636 1400 4 1 Piping Installation Continued Suction piping directly affects the overall operation of the Pressurizer VS and is critical to performance The pipe size should be sized to allow adequate flow at a minimal head loss and be at minimum the same size as the Pressurizer VS connections The use of fittings elbows tees and couplings should be kept to a minimum as well The same considerations should be applied when sizing and laying o
10. hertz phase supply power Check the VFD and all electrical devices for any loose or damaged connections See figures in Section 6 1 ABB Drive or 6 2 Yaskawa Drive Do not operate the Pressurizer VS until all loose or damaged connections have been repaired All electrical components are wired at the factory Only main power connections to the VFD are required The main power wires should be brought into the bottom side of the VFD and connected to the power input terminal lugs see Figure 6 1 1 or 6 1 2 An additional disconnect panel located near the VFD may be required to meet et local electrical codes All electrical wiring should meet standard and local code requirements Thrush Manual 9636 1400 4 3 Initial Startup Procedure The Standard Pressurizer VS is equipped with an ABB Drive Figure 4 3 1 also available is an optional Yaskawa Drive Figure 4 3 2 Displays and controls for each controller are described below SOFT KEY 1 Function Changes according to state of panel DOWN Changes parameters and their value decrease reference LOC REM Changes drive state from local control control panel to remote control I O or other external source Ceases operation of drive LOC 100 au liz 7 _PSI DIR MENU LOC gt REM 7 a 7 lt STOP START Drive Set Point this reading is equal to system set point in PSI Current Drive Speed Current Motor
11. ite for recommended maintenance intervals Refer to the motor nameplate for manufacturer and model number VFD to Motor Compatibility The VFD on the Pressurizer VS has parameters programmed specifically for the make and model of the motor originally installed by Thrush Motor Rotation The VFD to motor wiring is factory checked to ensure proper motor rotation If the drive is disconnected from the motor proper rotation should be verified before returning the Pressurizer VS back to full service conditions See Figure 6 1 2 ABB or 6 2 2 Yaskawa for proper wiring terminals that dictate rotational direction VFD output is not phase sensitive to the supply phase Reversing the power wires feeding the VFD will not change rotation To change rotation reverse two wires from_ VFD to motor See Figure 6 1 2 ABB or 6 2 2 Yaskawa 5 2 Replacement Parts Replacement parts for the Pressurizer VS are available through your representative 11 Thrush Co Manual 9636 1400 Section 6 Electrical Drawings 6 1 Electrical Drawings for use with ABB Drive Before installation and or servicing electricity to the VFD refer to the ABB user manual supplied with the Pressurizer VS for all safety warnings and cautions The figures in this section illustrate factory wiring for reference in the event a component or the wiring needs replaced on the Pressurizer VS Figure 6 1 1 illustrates incoming power and ground connections to the VFD Figure 6 1 2 m
12. or multiple Pressurizer VS models All the components listed have the same functional purpose throughout each model In Figure 3 1 the Pressurizer VS illustrates available optional equipment Low Suction switch N lt Isolation Valve 2 Optional VFD Options Available A Figure 3 1 Components Pressure Gauge 2 Hydro pneumatic Tank Pressure Transmitter Mounting Bracket 2 gt Optional Vor Thrush Co Manual 9636 1400 3 1 1 TV2q Pump The TV2g series pump utilized on the Pressurizer VS is designed to mount in line to reduce the overall footprint of the system The top pull out feature allows maintenance of the pump mechanical seal without disturbing the piping 3 1 2 Hydro Pneumatic Tank enables the system to react instantaneously upon demand It also prevents the pump from short cycling from small infrequent demands this feature is called Sleep Boost An optional ASME Code tank is also available hydro pneumatic tank is a pre pressurized tank that 3 1 3 Pressure Transmitter 9 pressure transmitter measures pressure at the discharge w side of the system When pressure on the discharge side of the system reaches the set point the pressure transmitter Y sends a signal to shut the pump off The pump will not turn back on until the discharge pressure of the system drops below the set point E 3 1 4 V
13. ormed by experienced trained personnel The Pressurizer VS utilizes electricity The potential exists for severe personal injury or death if proper procedures are not followed gt There is a potential for severe personal injury or death if proper electrical installation procedures are not followed A qualified electrician should make all electrical connections gt Before installation and or servicing electricity to the VFD refer to the VFD manufacturers user manual supplied with the Pressurizer VS for all safety warnings and cautions gt Do not connect and or operate the Pressurizer VS with volts hertz or phase other than that specified on the VFD This may cause damage to the VFD and will VOID the product warranty gt Before making any piping connections assure that all piping is clean and free of any foreign materials such as debris or scale Foreign material in the piping can cause damage to the unit and or affect the performance and operation Manual shutoff valves should be installed upstream and downstream of the system to act as an isolation device These valves should be in the closed position and remain so until the installation is complete Section 3 Thrush Co Manual 9636 1400 Component Identification and Information 3 1 Component Identification The following paragraphs contain functional descriptions for each of the major components of a Thrush Pressurizer VS This manual provides information f
14. otor to VFD 6 1 3 low pressure switch to VFD and 6 1 4 pressure transmitter to VFD ABB TERMINAL ABB TERMINAL ABB GROUND U1 L V1 N wi U2 v2 w2 4 D ABB GROUND 13 19v 18 INCOMING POWER AND GROUND NOTE USE U1 V1 AND W1 FOR 3 PHASE USE U1 AND V1 FOR 208 240 SINGLE PHASE _ VOLTAGE 460V 3PH AHH MOTOR GROUND CONDUIT BOX 1 3 2 4 7 5 8 6 9 208 230V 3PH 1 7 3 9 2 8 4 5 6 MOTOR Figure 6 1 1 Figure 6 1 2 JUMPER JUMPER 14 ON DRIVE 9TO13 10TO11 9ONDRIVE 5 DRIVE 1 1 1 Low Suction Switch Pressure Transmitter Figure 6 1 3 Figure 6 1 4 12 Thrush Co Manual 9636 1400 6 2 Electrical Drawings for use with Yaskawa Drive Before installation and or servicing electricity to the VFD refer to the Yaskawa user manual supplied with the Pressurizer VS for all safety warnings and cautions The figures in this section illustrate factory wiring for reference in the event a component or the wiring needs replaced on the Pressurizer VS Figure 6 2 1 illustrates incoming power and ground connections to the VFD Figure 6 2 2 motor to VFD 6 2 3 low pressure switch to VFD and 6 2 4 pressure transmitter to VFD YASKAWA TERMINAL YASKAWA TERMINAL YASKAWA R L1 S L2 TL3 U T1 V T2 W T3 GROUND YASKAWA GROUND
15. r WS models are covered Visually these different models will look very similar The main difference between models is the flow and boost capabilities of the unit Figure 4 4 The unit is shown with optional equipment throughout this manual If the Pressurizer VS will be stored prior to installation it should be stored in a clean dry environment Model Designation PB VSI 60 30 A B 6 Boost PSI Flow Rate GPM In Line Variable Speed Pressure Booster ja AD Optional Floor Wall Mounting Brackets and Suction Spool shown in Red Optional Isolation Valve Kit shown in Blue Figure 1 1 Overview Thrush Co Manual 9636 1400 Section 2 Safety Information Warnings 2 1 Safety Information Practical safety features have been incorporated into the design and manufacture of the Thrush Pressurizer VS If questions are not answered by this manual or if specific installation operation and or maintenance procedures are not clearly understood contact your Thrush representative before proceeding Personnel must at all times observe all safety regulations while performing maintenance or repairs All installation operation and maintenance procedures should be perf
16. ure press the Up or Down arrow Figure 4 3 1 or 4 3 2 on the VFD controller until desired discharge set pressure is achieved This is labeled Drive Set Point on the VFD controller See Figure 4 4 for capabilities of each Pressurizer VS 10 To verify the low suction pressure switch is working properly cease the operation of the VFD by pressing Stop ABB or Off Yaskawa on the VFD controller Close the suction isolation valve The VFD controller will display an error when pressure drops below the suction pressure in Figure 4 4 Open the suction isolation valve and press Start ABB or Auto Yaskawa on the VFD controller to resume normal operation Thrush Manual 9636 1400 10 4 4 Operation The Pressurizer VS was designed to accommodate your booster application needs Depending on the model water pressure can be boosted from 30 80 psi with flow rates up to 200 GPM Figure 4 4 lists the various Pressurizer VS models factory settings and their performance capabilities 5 Factory Cut Out Maximum Maximum Discharge Set Suction after Sleep Wake Level Tank Model Flow Boost Pressure PSI Pressure PSI Boost from Sleep Pre Charge GPM PSI PSI PSI PSI PB VSI 60 30 30 30 PB VSI 60 40 40 25 65 58 50 PB VSI 60 60 80 60 dal 25 PB VSI 60 80 80 25 PB VSI 100 30 30 30 PB VSI 100 45 45 25 PB VSI 100 65 100 65 50 25 8 58 9 PB VSI
17. ut the discharge piping Isolation valves are required to allow mechanical seal changes and other maintenance operations A by pass line is recommended to allow service of the Pressurizer VS without system shutdown during maintenance operations 4 2 Electrical Installation 3 There is a potential for severe personal injury or death if proper electrical installation procedures are not followed A qualified electrician should make all electrical connections Before installation and or servicing electricity to the VFD refer to the VFD manufacturers user manual supplied with the Pressurizer VS for all safety warnings and cautions Do not connect and or operate the Pressurizer VS with volts hertz or phase other than that specified on the VFD This may cause damage to the VFD and will VOID the product warranty Each Pressurizer VS model has a specific voltage hertz phase supply power requirement This information can be found on the side of the VFD on the tag Verify that the on site power being supplied to the VFD is as stated on the tag located on the VFD The motor on the Pressurizer VS will always be a 3 phase motor regardless of the VFD supply power phase requirements of your model For example if your specific model has been ordered to hook up to single phase supply power to the VFD it will still be equipped with a 3 phase motor Always verify that the VFD is being supplied with the correct voltage
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