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Tuesday, April 18, 2023
Pressure Booster Service
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Tuesday, April 18, 2023
Booster Service Basics
• Control Panel Components• Setting a pressure switch• Setting a current relay• Adjusting the Easy PLC Relay• Understanding and Adjusting a PRV
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Tuesday, April 18, 2023
Control Panel Components• High Voltage:
Disconnect, Starters, Overloads, Transformer
• Low Voltage: Current Relays, PLC, pressure switches
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Tuesday, April 18, 2023
Setting Overloads
• Factory Set• Verified in the field
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
Pressure Switch Adjustment
Set Point Adjustment
Differential Adjustment
PSI Scale Reading
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
Pressure Switch Applications
• Low suction pressure protection• No-Flow shutdown pump call on• Pump sequencing control• High and low pressure alarms
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
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)
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
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
• differential: 20-25 PSI
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Tuesday, April 18, 2023
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
• differential: 20-25 PSI
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
Current Relay Adjustment
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Tuesday, April 18, 2023
Current Relay Adjustment
• On-Delay Time Scale (0-1) & (0-30)
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Tuesday, April 18, 2023
Current Relay Adjustment
• On-Delay Time Setting
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Tuesday, April 18, 2023
Current Relay Adjustment
• Threshold (Ie Value)
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Tuesday, April 18, 2023
Current Relay Adjustment
• Hysteresis - not used - set to zero
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Tuesday, April 18, 2023
Easy PLC Relay
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Tuesday, April 18, 2023
Easy PLC Relay
• Contains sequencing logic for pump sequencing
• Alarm condition activation• Timer values
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
Setting Timer• Select
parameters • Toggle timer
value required• Change timer
value by pressing arrow
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Tuesday, April 18, 2023
Understanding and Adjusting PRV
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Tuesday, April 18, 2023
PRV Components
Main Body Valve
Piloting Assembly
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Tuesday, April 18, 2023
PRV ComponentsPressure Regulator
Speed Control
Check Valve
Check Valve
• Diaphragm
•Stem assembly
•Sealing Ring
•Valve Seat
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
PRV Control Logic
Small Area
Large Area
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Tuesday, April 18, 2023
PRV Control Logic
Opening the pilot relieves pressure on top of the diaphragm opening the main valve.
CHECK CLOSED
CHECK CLOSED
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Tuesday, April 18, 2023
PRV Control Logic
Closing the pilot increases pressure on top of the diaphragm closing the main valve.
CHECK CLOSED
CHECK OPEN
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
PRV TROUBLESHOOTING
• Irritants to PRV operation– Dirt, Sand, obstructions of any kind– Air entrapment or entrainment into valve body– Damaged or worn parts– Humans
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Tuesday, April 18, 2023
Types of Problems
• PRV’s will not regulate• PRV’s will not hold pressure • Non operating pump spins when off• Pilot valve leaks
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
PRV TROUBLE SHOOTING conditions
• Valve will not hold pressureBecause of:– Strainer is clogged– Check valve not sealing – Faulty pilot– Insufficient Supply Pressure
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Tuesday, April 18, 2023
Types of Problems
• Non operating pump spins when off– PRV check valves not sealing properly– PRV diaphragm broken– Check valves not sealing
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Tuesday, April 18, 2023
Types of Problems
• Pilot valve leaks– Pilot diaphragm broken
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
Types of Problems
• Pumps come on too soon– Verify motor current against factory test data– Verify current relay settings
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
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
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Tuesday, April 18, 2023
Questions & Answers
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Tuesday, April 18, 2023
Thank You