Electrical

 

1.Q For what voltage is my system designed ?

A. All systems are designed for the power requirements indicated at the time of the original order. This information is generally listed on a label located inside the control enclosure. It can also be found on the control panel data sheet inside the Installation, Operation and Maintenance Manual (IOM).

 

2.Q. Can the voltage of the system be changed once delivered and installed ?

A. Changing from low voltage (230VAC, 3∅) to high voltage (460VAC, 3∅) can usually be accomplished with minor component changes but is not usually done without factory assistance and the aid of a competent technician. Changing from high voltage (460VAC, 3∅), to low voltage ((230VAC, 3∅) is usually not possible due to the numerous component and wiring changes required. In either circumstance, if the wrong voltage was specified and received, it may be more practical to install a buck/boost transformer of sufficient size or have your service provider install another control panel. The factory should be consulted in either case.

 

3.Q. What are the limitations of the power applied to my pump station ?

A. Generally the voltage applied should be + 10% of the specific design voltage. The frequency should be + 1Hz of the specific design frequency.The larger the motor the more important it is to maintain a tighter voltage and frequency tolerance especially under full load conditions with all pumps running. Remember that “soft” power can be damaging “Soft” power is such that under higher current demands, the voltage drops precipitatously low causing high current and possible damaging heat in the motor.

 

4.Q. Why does my motor keep overloading even though there is low demand on the pump?

A. Many things can cause a motor to trip even though lightly loaded. The windings may be deteriorating. A wire may be loose in the control panel or disconnect switch. A contactor may have damaged contact points or a weak coil. The overload relay may be weak or defective. All of these conditions require the inspection by a qualified electrician or service technician with the proper equipment. Contact your SyncroFlo representative or the factory for the name of a qualified service provider.

 

5.Q. If my pump keeps tripping, can I increase the overload setting or install fuses of a larger amperage rating?

A. Never do either as a fire may result possibly causing extreme damage to property and personnel.

 

6.Q. My main or pump disconnect trips as soon as it if turned to the “on” position. Why does this happen and what should I do ?

A. The disconnects are circuit breakers that trip when an excessive load is drawn by the protected equipment. This could be an overload condition but more likely is due to a short circuit, a burned out motor for instance.Do not reset the breaker and keep trying to start the pump. (An inspection by a trained service technician or electrician should reveal the cause.) The circuit breaker may be at fault as they can become weak and break down over time. (Again, a inspection by a trained service technician or electrician should reveal the cause.)

 

7.Q. Inside my control panel there is a device with numerous small lights that turn on and off, what is it and how does it effect my systems operation ?

A. Many pump station are controlled by a PC or PLC (Programmable Controller or Programmable Logic Controller). It is usually a plastic enclosure with multiple LED’s (light emitting diodes), which represent inputs from various devices and outputs to other control devices.The inputs are interpreted by a program that is written by SyncroFlo engineers to allow the system to function automatically and normally under various conditions. If the PLC detects a hardware or software problem exists it will inhibit its own operation requiring manual operation of the pumps controls.

SyncroFlo retains copies of the PLC programs and any change requests must be processed through the engineering department.

8.Q. What size wire should be used to connect power to my SyncroFlo control panel ?

A. The NEC (National Electric Code) dictates what size of wire should be used based on ambient temperature, type of installation and current demands of the system components. The recommended minimum size and type of wire can be found on the label inside the control panel and on the control panel data sheet inside the IOM (Installation, Operation and Maintenance) manual.

9.Q. What type of maintenance is usually required inside my control panel?

A. The tightening of all wiring connections should be performed at start up and then once per year by a competent electrician or trained service technician. Additionally, contactors may require should be determined by a visual inspection performed during annual maintenance. Any service performed inside the control panel should only be done with power off and any remote disconnect locked out.

 

WARNING !! All circuits must be de-energized during servicing of the system. Dangerous voltages may be present on control systems connected to the pump system control panel.

 

10.Q. Can I connect other electrical components to the 120VAC power available in my SyncroFlo control panel ?

A. No, as the control power transformer and it’s protective fuses are rated to handle only the power demands of the control components themselves. Blown fuses may result if devices are connected that exceed the capacity of the transformer.

 

11.Q. Can I modify my control panel without adversely affecting the UL and ETL labels?

A. Generally, the anser is “no” as any modification that changes the wiring voids the UL label and therefore, also voids the ETL label.Components can be replaced with “like” components as needed to perform repair service as long as the wiring configuration is not modified.Contact the SyncroFlo Technical Support Department with specific inquires on this subject.

Hydraulic

 

1.Q. My system pressure won’t regulate and goes high under low flows, what should I check ?

A. Under normal conditions, certain types of systems should be expected to have a pressure rise under low or no flow conditions. Typically such rises should be 5-10psi. If the pressure goes even higher, then the control piloting on the PRV (pressure regulating valve), or the valve itself may be at fault. (First confirm that all air has been bled from the valve cover) Disassembly and cleaning of the piloting may be necessary to accurately determine the cause. Further, the valve cover may need to be removed for inspection of the diaphragm, stem, stem guide bushings, seat and seat seal.

It is recommended that a valve repair kit for the specific size and brand of valve involved be on hand prior to disassembling the control valve.

A troubleshooting guide is usually found inside your system owners manual or can be faxed or mailed to you upon request..

 

2.Q. My system pressure goes low whenever there is demand on the pump station. What should I look for ?

A. First, verify that all motors are turning in the proper direction. Close coupled and flex coupled pumps should rotate clockwise when viewed from the top. (Opposite of the drive end), of the motor. Vertical turbine pumps should rotate counter-clockwise when viewed from the top of the motor.

 

If the pumps in question are relatively new with little expectation of substantial wear, we must consider 3 other situations. 1), the pressure regulating valve(s) may be incapable of opening as fully as required to pass the sufficient volume of water to adequately maintain the design pressure or, 2), the suction pressure may be less than the minimum specified for the system or, 3) the hydraulic demand on the pump is in excess of the designed system capacity.

 

BEWARE !! Uninformed and random adjustments to the system will most likely make matter worse. It is best to contact your service provider or SyncroFlo Technical Support. A troubleshooting guide can be faxed or mailed to your when requested.

 

3.Q. My system shuts down on a “low suction” alarm and requires manual resetting. What can I do to rectify this nuisance tripping?

A. The low suction alarm is provided to protect your pump from damage of running dry. If the alarm is a repeating occurrence, your suction pressure should be monitored closely to determine if it is a supply problem, a backflow preventer issue, a partially closed valve on the suction line or a demand in excess of the suction line’s capacity.

In may cases, the control panel has a relay installed so that instantaneous dips in suction pressure will latch the alarm. The relay can be exchanged for a timer which allow alarm delays of up to 30 seconds if needed. An 8-10 second delay is SyncroFlo’s normal recommendation. Systems supplied with Programmable Controllers utilize the program to include an 8-10 second delay.

Remember, many systems are “boosters” that require suction pressure. To perform at full duty, the absolute minimum suction pressure must be provided. Some systems will not perform adequately if the suction pressure is too low.

 

4.Q. Can I adjust the system pressure of my pump station? How do I do it?

A. Most pump station system pressure can be adjusted using the CRD (control regulating device), on the PRV (pressure regulating valve), piloting. Typically, a small flow of 20-25gpm must be established and maintained throughout the adjustment procedure. Some pumps and systems have more adjustability than others. Pay close attention to the pump curve and amperage draw. Systems provided with VFD’s (variable frequency drives) usually have their discharge pressure adjusted by entries to the OIT (operator interface terminal) call the factory for specifics of this procedure.