Sunday, May 17, 2015 Pressure Booster Service. Sunday, May 17, 2015 Booster Service Basics Control...

Tuesday, April 18, 2023

Pressure Booster Service


Booster Service Basics

• Control Panel Components• Setting a pressure switch• Setting a current relay• Adjusting the Easy PLC Relay• Understanding and Adjusting a PRV


Control Panel Components• High Voltage:

Disconnect, Starters, Overloads, Transformer

• Low Voltage: Current Relays, PLC, pressure switches


Setting Overloads

• Factory Set• Verified in the field


Pressure Switch Basics

• Pressure switches have a Set Point and Re-Set• Re-set value always below the Set Point • Set Point and Re-Set are dependant on the

purpose of the pressure switch


Pressure Switch Adjustment

Set Point Adjustment

Differential Adjustment

PSI Scale Reading


Pressure Switch Adjustment

• Differential Setting 4-150 Psig switch

Differential adjustment A B C D E F G H I J K L

Approximate value (PSI) 0.75 1 1.5 2 5 10 15 20 25 27 32 35

• Differential Setting 6-250 Psig switchDifferential adjustment A B C D E F G H I J K L

Approximate value (PSI) 1 1.5 2 5 10 15 25 35 45 50 55 60


Pressure Switch Applications

• Low suction pressure protection• No-Flow shutdown pump call on• Pump sequencing control• High and low pressure alarms


Low Suction Pressure Protection

• Purpose: Stop pump in case of low inlet pressure

• Set Point (Cut-In): 15 PSI - Pump Start• Re-Set (Cut-Out): 5 PSI - Pump Stop• differential: 10 PSI


No-Flow Shutdown Pump Call-On

• Purpose: Start pump on drop in system pressure

• Set Point (Cut-Out): 5 PSI below system pressure - Pump Off

• Re-Set (Cut-In): 6 PSI - Pump On• differential: 1 PSI


Pump Sequencing Control• Purpose: Start pump on drop in system

pressure• Set Point (Cut-Out): 5 PSI above system

pressure - Pump Off• Re-Set (Cut-In): 5 psi below system pressure -

Pump On• differential = (cut- in) - (cut - out)


High Suction Pressure Alarm

• Purpose: Stop pump if inlet pressure is sufficient to supply building

• Set Point (Cut-Out): @ approx. system pressure - Pump Off

• Re-Set (Cut-In): approx. 5-10 PSI below system pressure - Pump On

• differential: 5-10 PSI


Low System Pressure Cut-Out Alarm

• Purpose: Stop pump if outlet pressure is too low

• Set Point (Cut-In): approx. 5-10 PSI below system pressure - Pump On

• Re-Set (Cut-Out): 30 PSI below system pressure- Pump Off



Low System Pressure Next Pump Starts Alarm

• Purpose: Start next pump if outlet pressure is too low. Requires manual reset

• Set Point (Cut-In): approx. 5-10 PSI below system pressure - Pump On

• Re-Set (Cut-Out): 30 PSI below system pressure - Pump Off



High System Pressure Cut-Out Alarm

• Purpose: Stop pump if outlet pressure is too high

• Set Point (Cut-Out): 20 PSI above system pressure - Pump Off

• Re-Set (Cut-In): System Pressure - Pump On• differential: 20 PSI


Current Relay Adjustment



• On-Delay Time Scale (0-1) & (0-30)



• On-Delay Time Setting



• Threshold (Ie Value)



• Hysteresis - not used - set to zero


Easy PLC Relay


Easy PLC Relay

• Contains sequencing logic for pump sequencing

• Alarm condition activation• Timer values


Easy PLC Relay

• Program written in ladder logic• Program changes require a programming

device• Does not require in-field adjustment• Program access is password protected


Setting Timer• Select

parameters • Toggle timer

value required• Change timer

value by pressing arrow


Understanding and Adjusting PRV


PRV Components

Main Body Valve

Piloting Assembly


PRV ComponentsPressure Regulator

Speed Control

Check Valve

Check Valve

• Diaphragm

•Stem assembly

•Sealing Ring

•Valve Seat


PRV Control Logic

• Outlet pressure of the valve is controlled by the pilot mounted PRV

• Spring setting in PRV pilot determines outlet pressure of the main PRV

• Turning PRV nut clockwise (down) will cause outlet pressure of main valve to increase


PRV Control Logic

Small Area

Large Area


PRV Control Logic

Opening the pilot relieves pressure on top of the diaphragm opening the main valve.

CHECK CLOSED

CHECK CLOSED


PRV Control Logic

Closing the pilot increases pressure on top of the diaphragm closing the main valve.

CHECK CLOSED

CHECK OPEN


PRV Control Logic

• Check Valves in piloting circuit ensure valve closes and stays closed when pumps stop and the pressure reverses

CHECK CLOSED

CHECK OPEN


PRV START UP

• Bleed air off Main Cover & Controls• Start system with pilot valve adjusted to lower

than required value• Adjust to higher pressure as system stabilizes • Make all adjustments slowly, allowing for the

control valve and system to balance the change


PRV TROUBLESHOOTING

• Irritants to PRV operation– Dirt, Sand, obstructions of any kind– Air entrapment or entrainment into valve body– Damaged or worn parts– Humans


Types of Problems

• PRV’s will not regulate• PRV’s will not hold pressure • Non operating pump spins when off• Pilot valve leaks


PRV TROUBLESHOOTING conditions

• Valve will not regulate– Air in control Pilot– Closing speed control not adjusted properly– Clogged strainer or Pilot Valve– Faulty Pilot– Valve stem is jammed in cover bearing – Diaphragm failure


PRV TROUBLE SHOOTING conditions

• Valve will not hold pressureBecause of:– Strainer is clogged– Check valve not sealing – Faulty pilot– Insufficient Supply Pressure


Types of Problems

• Non operating pump spins when off– PRV check valves not sealing properly– PRV diaphragm broken– Check valves not sealing


Types of Problems

• Pilot valve leaks– Pilot diaphragm broken


Types of Problems

• Power on - pumps don’t come on• Pumps on - don’t shut off• Pumps come on too soon• Pumps do not stay off for a long time on No-

flow shut down• Pumps short cycle


Types of Problems

• Power on but pumps don’t come on– Motor overloads tripped– Check inlet pressure and low suction pressure

switch, high suction pressure switch– Check no-flow pressure switch– Check discharge pressure and low discharge

pressure switch


Types of Problems

• Pumps on - don’t shut off– Verify current relay settings– Verify alarm conditions (high Suction pressure, low

system pressure, etc..)– Verify No-Flow shutdown - Aquastat and pressure

switch setting


Types of Problems

• Pumps come on too soon– Verify motor current against factory test data– Verify current relay settings


Types of Problems

• Pumps do not stay off for a long time on No-flow shut down– Verify tank pre-charge– Adjust Aquastat setting– Adjust call on pressure setting lower– Verify tank bladder is not broken


Types of Problems

• Pumps short cycle – Check timer settings– Verify that the Aquastat setting is correct– Adjust pressure switch – Adjust current relay setting– Verify alarm pressure switch settings


Booster Application Knowledge

• 2 pump system recommended for flows up to 300 GPM

• 5 step sequencing recommended for systems over 500 GPM

• Do Not install No-flow shutdown units on continuous demand systems


Booster Application Knowledge

• Booster systems are designed to have a positive supply pressure

• PRV’s are not required when drawing from a tank using single stage pumps

• Tank pre-charge should be set at 5 PSI less than the call on pressure switch setting


Questions & Answers


Thank You

Sunday, May 17, 2015 Pressure Booster Service. Sunday, May 17, 2015 Booster Service Basics Control...

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