INSTRUCTION MANUAL FOR - Pentair

1 AUTOMATIC WATER PRESSURE SYSTEMSINSTRUCTION MANUALFORCBI-SeriesTelephone 131 PUMP 131 PUMP Pentair policy is one of constant improvement, we reserve the right to makespeci cation changes without notice and without incurring liability. A division of Pentair Flow Control Paci c Pty Ltd 83 000 922 690 These instructions act as a guide only and do not cover every aspect. Owners notfamiliar with pumping equipment should seek advice from their pump dealer orSouthern Cross CBI series Pressure Systems are designed for pumping non-aggressivewater, and water not containing solid particles. Never install the pump in areas wherethe ambient temperature exceeds 40 C. The temperature of the pumped liquid shouldbe within the range of +4 C to +60 C. Before installing the pump ensure the rotatingparts turn pump should be installed as close as possible to the liquid source, and coveredby a weather-proof housing, well ventilated to allow motor heat to escape.

2 The pumpfoundation should be rigid enough to absorb any vibration from the motor, and the pumpshould be securely bolted to the foundation. It is also recommended that the plumber/installer provides an adequate draining system to avoid damage in case of leakage,particularly when installed suction line should be as short and straight as possible, with aminimum of bends. The internal diameter of the suction pipe mustbe equal to, or greater than the ports of the pump. Theconnection between the suction line and pump must beairtight, and the suction pipe must be positioned so it hasan upward slope to the pump (thus avoiding the formationof air pockets) and must be fitted with a reliable checkvalve(supplied with unit) for correct operation. Whenused on a suction lift a footvalve should be fittedon the suction line, below the liquid level. For longsuction pipes or high suction lifts over four metres,the suction pipe should be of greater diameterthan the suction port.

3 On all installations wherewater is drawn from wells, dams and creeks, anadditional strainer must be fitted to the inlet tothe suction line, to ensure any solids in the waterdo not enter the pump. If hose is used as thesuction line, it must be minimise pressure drop the discharge pipe should be at least the same size as thedischarge port of the pump. All piping should be independently supported and in noway apply any strain to the pump casing with all pipe joints securely tightened andsealed using a jointing : All wiring should be carried out by a fully qualified the mains voltage is the same as the value shown on the motor plate and thatthe pump is safely connected to ground/earth. All single phase (240 V) motors aresupplied with a 3 pin plug and lead and can be connected directly to the mains single phase pumps /motors are fitted with a thermal overload protection which willautomatically reset when the temperature returns to normal.

4 Do not start the pump untilit has been Tank Unit Fault FindingFaultPossible CausePump starts and stops rapidly- Incorrect pressure switch Incorrect pressure tank Punctured diaphragm in pressure Faulty footvalve or Leaking emitted from air valve- Punctured diaphragm Tank will not hold air pressure- Faulty air Unit Fault FindingFaultPossible CausePump does not start- Electronic card is faultyPump does not stop- Electronic card is faulty- Flow detector is blocked in the upper position- Reset button is stuck- System has leaks present which are greater than the minimum flow of L/minPump continually starts- Electronic card is faulty and stops- System has leaks present which are less than the minimum flow of L/min- Float valve in a watering trough in the systemPump does not pump liquid- Electronic card is broken - Column of water between the highest tap and the Presscontrol unit exceeds 15 metres- Unit diaphragm is brokenPresscontrol will allow the pump to automatically perform all its normal functions, however if there is an operational breakdown (ie.)

5 Lack of water, blockage in suctionpipe, etc) the unit will recognise the breakdown, send a stop signal to the pump andsubsequently light the red Failure LED. Once the problem has been rectified, theunit can be restarted by pressing the Reset Fault FindingFaultPossible CausePump won t prime/- Footvalve may be liquid delivered- Suction lift too Air leak or blockage in suction Footvalve not installed below lowest water Footvalve/checkvalve installed in the wrong Voltage or wiring of motor Strainer Pump speed too Pump impeller runs at - Suction lift too capacity- Suction or discharge line Pump impeller partly blocked by Footvalve/checkvalve or strainer partly Air leak in suction Pump speed too low - check Damaged impeller or Discharge pressure too does - Power supply start- Defective Impeller Incorrect Thermal overload switching on- Pressure tank pre-charge off when no- Footvalve/checkvalve is being used - Discharge or suction line stops - Motor thermal overload operation- Voltage too Blocked/damaged impeller causing it to

6 Motor continually starting/stopping resulting in thermal overload not switching - Voltage too or taking too - Drop in suction water to switch off- Leak in discharge Pump impeller loses suction- Suction line Air in the pumped Air leaks in suction line. - Suction lift too starting, the pump must be primed. This is done by removing the priming plugand completely filling the pump with clean water. On pumps with suction lift the suctionline should also be filled. Ensure the priming plug is tightened in place once pump hasbeen Installations where the pump inlet is belowthe water supply remove the priming plug andallow the water to flow into the priming chamberuntil all air is expelled. The priming procedureshould be repeated until all air is expelled andthe pump delivers a full stream of water withoutair bubbles. The pump must always be checkedfor prime if not used for a prolonged period.

7 Itis imperative to fill the pump with liquid beforeoperation as dry running causes irreparabledamage to the mechanical pump should be shut down and the troublecorrected if the pump is running at speed andfound to have any of the following problems:- No liquid delivered- Not enough liquid delivered- Excessive vibration- Motor runs hotDo not allow the pump unit to continually start and stop (short-cycle) as this will reducethe motor life. Short-cycling can occur on pressure units when the pressure tank pre-charge drops, or where there is a leak in the discharge and Reset ProceduresFor most applications Southern Cross Pressure Systems need no adjustments to operateunder normal conditions. If problems are experienced, or if the unit is to operate outsidethe factory settings range, adjustments should be made by qualified pump servicetechnicians and MaintenanceUnder normal operating conditions, the pump does not require any maintenance as longas the following points are observed:- if the pump is to remain inactive at temperatures of less than 0 C, the pump bodymust be completely emptied (priming must be carried out before the next start).

8 - periodically check the condition of the footvalve and strainer (if used).- if the pump is to be inactive for long periods, the pump should be rinsed thoroughlywith clean water, then drained and stored in a dry if the pump sticks after long periods of inactivity the unit may need pressure tank air charge should be checked at regular intervals of between 1 to 3 months and after the pump has not been used for a prolonged fitted with Pressure TanksThe Southern Cross range of pressure tanks is designed to be used in a water supplysystem to provide draw-off prior to a pump unit : Always use an accurate pressure gauge to check pre-charge as over-inflating may cause tank to explode, resulting in serious exceed the maximum tank pressure of 1000 kPa (145 psi).Removal of Air Valve from pressurised tank may result in serious : Ensure no sharp objects are placed in the discharge of the tank as thismay puncture the diaphragm.

9 A suitable sealant should be used on all pipe tanks should be installed in a vertical position, under a weather-proof tanks should never be placed between a pump and a flow switch as thedischarge from the tank will activate the flow switch and start the and Adjusting Precharge: (Minimum recommended Personal ProtectionEquipment (PPE) Safety Glasses and Steel Capped, Enclosed Footwear)Before installation, the tank should be precharged and then checked approximatelyevery three months. To adjust the precharge, firstly turn off the power to the a tap on the discharge line and allow all water to escape, leaving the tap openwhen finished. Remove the dust cap from the valve and check the precharge using atyre pressure gauge. The precharge should be 10% below the cut-in pressure of yourpump pressure switch (pre-charge figures are shown below). If necessary, adjust theair charge using a hand or foot pump.

10 Replace valve cap, close tap on discharge lineand turn pump on. Ensure the pump builds up pressure in the tank, then shuts off (thismay take longer than usual as the tank and discharge line will both need refilling).Operating Pressures for Southern Cross Pressure PumpsModelCut-in PressureTank PrechargeCut-out PressurekPa (psi)kPa (psi)kPa (psi)CBI 2-30PT8 140 (20)125 (18)250 (36)CBI 2-40PT18175 (25)150 (22)310 (45)CBI 2-50PT18200 (30)180 (25)380 (55)CBI 2-60PT18300 (43)270 (39)485 (70)CBI 4-40PT18175 (25)150 (22)310 (45)CBI 4-50PT18200 (30)180 (25)380 (55)CBI 4-60PT18250 (35)220 (32)450 (65)Starting: Before connecting the unit to the electrical mains check the suction line andensure the pump is primed. When the power is switched on for the first time the green Power On LED and yellow On (pump in operation) LED light up. The pump willcontinue to operate for a short period until the discharge pipes are filled and requiredpressure reached.