Commissioning
Do not attempt to start the pump even to check the direction of rotation until the system has been filled with water, and both the pump and the system have been vented.
Pay attention to the direction that any water will take and ensure that the escaping water does not cause injury to persons or damage or enter and subsequently damage the pump motor/motor terminal box.
Before carrying out any of the commissioning procedures on the following pages please ensure that the following connections and checks have been carried out on the booster set.
- The discharge manifold is connected to the system flow pipework.
- The suction manifold is connected to cold water supply pipework.
- The electrical supply cables are connected correctly to the isolator switch.
- If applicable connect the low water level switch into the pump motor terminal box using terminals 2 and 3.
- Check that the precharge pressure in the pressure tanks is set to 70% x the required discharge (setpoint) pressure.
- Check that the pump shaft is free to turn, by rotating the motor coupling by hand. This is particularly important where the booster set may have been in storage for a long time.
- Check that both suction and discharge pipework mounted isolating valves are open.
- Check that all isolating valves on the booster set are open.
- Check the booster set manifold to pipework connections for leaks.
- Vent the pumps, undo the vent screw at the top of the pump casing, and wait until water with no air comes out, then re-tighten. For details on how to vent the pumps correctly, please refer to the pump installation and operating instructions supplied with the booster set covering the pump model fitted.
Vessel Pre-Charge Pressure
When adjusting the vessel precharge pressure, the vessel connection must effectively be open to atmosphere.
Failure to set the precharge pressure correctly will cause incorrect operation of the booster set.
The pressure vessel precharge must be set to 70% of the required pump discharge (setpoint) pressure. Example, if the required discharge pressure is 3.0 bar, then the precharge pressure must be set to 0.7 x 3.0 = 2.10 bar.
The vessel precharge pressure should be adjusted before the pump is filled with water. If the system has already been filled and the pump run, then:
- Switch off the pump.
- Close both inlet and outlet isolating valves.
- The water pressure in the vessel can then be released using the drain cock beneath the pressure vessel.
The precharge pressure can now be checked and adjusted using a car tyre pressure gauge. The drain cock should be left open while adjusting the precharge pressure.
For small pressure adjustments a foot pump can be used. If large amounts of gas are required then dry nitrogen should be used in order to prevent corrosion within the vessel.
Discharge Pressure Setting
The Max-E Boost discharge (setpoint) pressure is factory set to 3 bar. The maximum discharge pressure setting should not be set higher than 4.5 bar. If set higher the pump will not stop with a no water demand condition, and will result in heating of the liquid in the pump, and possible shaft seal damage.
- Determine the pump discharge pressure required. As a guide the setpoint is the height of the system plus 0.5 to 1 bar.
- Partially open an outlet supplied by the Max-E Boost.
- Switch on the electricity supply to the pump, the pump will now start to run.
- Monitor the pump pressure on the pressure gauge.
- Use the up/down arrow buttons on the pump motor terminal box to adjust the pump discharge as shown on the gauge.
- The pump discharge setpoint pressure is now set.
If the discharge pressure setting is changed, the pressure vessel pre-charge pressure must also be adjusted accordingly. The pre-charge pressure must be set to 70% of the required pump discharge (setpoint) pressure, see above section Vessel Pre-charge Pressure.
Low Level Float Switch
The float switch protects the Max-E Boost against dry running, should the level of cold water storage tank fall too low.
The float switch should be installed and the trip point set such that the water level is above the tank connection feeding the pump.
An allowance of 100mm above the tank connection should be made in order to prevent vortex formation and air being drawn in.