Pressure Perfect: Troubleshooting the Pressure Boosting System
Pressure booster system applications
Pressure booster systems are critical components in various applications, from residential buildings to industrial facilities. They ensure consistent water pressure, which is not only vital for customer comfort but also for the efficient functioning of plumbing systems, firefighting systems, irrigation, and more. Troubleshooting these systems is essential to:
- Ensuring consistent water supply
- Preventing system failures
- Enhancing efficiency and performance
- Minimizing safety risks
- Improving cost savings
- Meeting regulations and compliance
- Optimizing system performance
By regularly troubleshooting and maintaining booster systems, you can ensure they operate effectively, safely, and efficiently, providing reliable water pressure and reducing the risk of unexpected failures and costly repairs.
Booster Troubleshooting Chart
A pump may not start due to several potential issues, often related to electrical, mechanical, or operational problems.
| Issue: Pump does not run | |
|---|---|
| Causes | Solutions |
| No power to the motor | Check for voltage at motor terminal box Check for tripped circuits, reset circuits Check main switch, switch to “on” |
| Fuse defective | Check fuses, replace if necessary |
| Low water or low suction pressure | Check intake pressure |
| Starting pressure is set too high or lower than incoming pressure | Check settings, and correct if necessary |
| Valve closed at pressure sensor | Inspect, open isolation valve if necessary Gently unscrew pressure sensor to release air |
| VFD fault has triggered | Check VFD manual for fault code and additional troubleshooting |
Pumps may fail to switch off due to several underlying issues, commonly involving system leaks, pressure switch malfunctions, or incorrect settings.
| Issue: Pump(s) do not switch off/not hit pressure | |
|---|---|
| Causes | Solutions |
| Intake pressure fluctuates severely | Check intake pressure, if necessary, take measures to stabilize supply pressure (e.g. pressure reducer) |
| Intake pipe blocked or shut off | Check inlet pipe, remove blockage or open check valve |
| Inlet pipe installed incorrectly, or too small | Check inlet pipe, replace if necessary |
| Air in system | Check, if necessary, seal pipes. Vent pumps. |
| Impellers blocked | Check pump, if necessary, repair or replace |
| Non-return valve leaking or blocked | Check, if necessary, replace seal or non-return valve (leaking valve) or remove blockage or replace non-return valve (blocked) |
| Flow volume too large | Check pump sizing |
| Valve closed at pressure sensor | Inspect, open isolation valve if necessary Gently unscrew pressure sensor to release air |
| Discharge pressure setpoint too high | Check setting and correct if necessary |
| Direction of motor rotation backwards | Check direction of rotation and correct if necessary (Clockwise CO-Helix and counterclockwise CO-MVI) |
| Transducer scaling | HMI Advanced Settings ->pressure transducer to adjust setting |
A pump experiencing high switching frequency or fluttering is often a sign of issues within the pressure system, such as improperly sized pressure tank, incorrect pressure switch settings, or system leaks.
| Issue: System responds too quickly or too slowly to pressure changes | |
|---|---|
| Causes | Solutions |
| No diaphragm pressure vessel present (option accessory) | Retrofit diaphragm pressure vessel |
| Supply pressure at existing diaphragm pressure vessel incorrect | Check supply pressure and correct if necessary |
| Valve on existing diaphragm pressure vessel closed | Check valve and open if necessary |
| Existing diaphragm pressure vessel defective | Check diagraph vessel and replace if necessary |
| System responds too slowly or too quickly to pressure changes | Check PID settings |
A dry-running protection system may switch off a pump even when water is present due to issues such as sensor malfunctions, electrical faults, or incorrect calibration.
| Issue: Dry-running protection system switches off, although water is present | |
|---|---|
| Causes | Solutions |
| Suction pressure setpoint too high | Adjust setpoint in HMI Advanced settings->Alarm Settings |
| Transducer scaling | HMI Advanced Settings ->pressure transducer to adjust setting |
| Transducer failure | Check wiring, replace sensor if necessary. |
A dry-running protection system that fails to switch off despite low water levels can lead to severe damage to the pump. This issue may arise from sensor malfunctions, such as a faulty or mis-calibrated sensor that incorrectly detects water presence, preventing the system from initiating a shutdown.
| Issue: Dry-running protection system does not switch off, although water low | |
|---|---|
| Causes | Solutions |
| Suction pressure setpoint too low | Adjust setpoint in HMI Advanced settings->Alarm Settings |
| Transducer scaling | HMI Advanced Settings ->pressure transducer to adjust setting |
| Transducer failure | Check wiring, replace sensor if necessary. |
Troubleshooting pressure booster systems is a critical process that ensures consistent water pressure, operational efficiency, and system longevity. By systematically identifying and addressing common issues such as low pressure, continuous running, noisy operation, frequent cycling, and sensor malfunctions, users can maintain optimal performance and prevent costly repairs. Regular maintenance, including checking electrical connections, calibrating pressure settings, and inspecting mechanical components, is essential to keep the system functioning correctly.
Wilo is Your Solutions Provider
People and customers are always the center focus at Wilo USA. When it comes to our service promise there is no difference, Wilo provides Service Beyond Expectations.
The Wilo Aftermarket Team and Wilo’s expansive external network of service partners around the country are designed to support users in all aspects of new, and existing, pumping equipment sales. Wilo USA’s Aftermarket Team consists of sales professionals who are dedicated to helping customers source OEM parts, providing factory service & warranty support, and assisting with in-field equipment commissioning, troubleshooting, and repairs. Reach out to our skilled team of experts and experience the best service our Industry has to offer. By choosing the Wilo USA Aftermarket Team for pump service & repairs, you can rest assured that your equipment will perform to OEM standards, thereby providing your clients with the cost?savings and satisfaction guarantee they’ve come to expect and deserve.
July 2024 | tlk