PACO

PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

PACOFLO 9000, LEVEL 1

INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL

S/N:
DATE:

PACO
PUMPS

F9d.1 - Level 1
4/06
Supercedes 5/00

PACOFLO 9000, LEVEL 1

TABLE OF CONTENTS
1. Introduction
a) Narrative
b) Major System Components Drawings
2. Receipt & Installation
a) Receipt, Storage and Moving of the System
b) Mechanical Installation
c) Electrical Installation
d) Electrical Check Out
e) Hydro-pneumatic Tank Installation
3. Start-up
a) Start Up Check List
b) Placing the System into Operation
4. Components & Features
a) Motor Starters
b) Trip Module
c) Control System (PLC)
d) Data Acquisition and Sensing Systems
e) Sequencing Devices
f) Sequence Variations
g) Alarm, Options and Other Features
5. Adjustments and Field Settings
a) Overview of Factory Settings
b) Adjustment of Pressure Settings
6. Troubleshooting
a) Electrical Troubleshooting
7. Appendix
a). System Settings
b). Panel and Pump Nameplate Information
c). System Nameplate Information
d). Diagrams
1. Triplex Booster, with Pressure Sequencing (4 pages)
2. Duplex Booster, with Pressure Sequencing (4 pages)
3. Triplex Booster, with Flow Sequencing (4 pages)
4. Duplex Booster, with Flow Sequencing (4 pages)
e). Pressure Reducing/Check Valve
1. General
2. Operation Matrix
3. Recommendations & Requirements
4. Installation Start-up Continued
f). Blank pages for Notes
8. Index
9. Warranty
2

Attachments may include: Pump IOM, Sales and Service Centers Guide

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PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

INTRODUCTION
The Pacoflo 9000, Level 1 booster system is a complete, factory assembled water booster system.
The system operates with multiple pumps in parallel. The booster system's U.L. panel provides
controls for the system sequencing and alarm functions. The booster system takes water from a
source and boosts the pressure for final use at the discharge of the unit. Pump sequencing is
provided with a wide range of devices and the exact configuration of the unit will depend on how the
unit was ordered. The system comes complete, ready for installation and operation, and is intended to pump clean, fresh water.
This booster system has been fabricated and preset at the factory to the required system and flow
specifications. Final system adjustments may be required to place the system in operation. The
booster system has been designed to operate over the range of pressures and flows as described
in Paco Pumps catalog and is built to the customers specifications and jobsite requirements.
This system will perform as set at the factory and will continue to provide satisfactory service when
properly installed and maintained. Periodic maintenance is necessary for continuous trouble free
service. Service assistance in maintaining the system can be provided by Pacos factory trained
service organizations. Service by unauthorized agencies should be avoided.
All PACO booster systems are identified with a system nameplate and individualized label, located
on and in the control panel. A sample nameplate and label is included at the end of this IOM. In
addition, the individual pumps have nameplates. When referring to this system, please include
all nameplate information.
With the nameplate and label information, spare or replacement parts can be easily identified and
ordered. All normally required parts are available in kit form, as shown in the replacement parts
guide included in this IOM.
A form has been included near the end of the IOM for your use to fill out nameplate information that
can be used when contacting our service representatives.
It is recommended that the system nameplate and label be immediately examined and information
contained therein be immediately recorded on the forms in this IOM to insure proper identification
in the event of future nameplate or label damage.
THE ENTIRE CONTENTS OF THIS MANUAL SHOULD BE COMPLETELY READ BEFORE ANY
INSTALLATION, OPERATION, OR MAINTENANCE.

PACO
PUMPS

F9d.1 - Level 1
4/06
Supercedes 5/00

PACOFLO 9000, LEVEL 1

MAJOR SYSTEM COMPONENTS

NOTE:
4

System is typical. End suction pumps shown.

Pump type and number will vary with system type.

PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

SYSTEM INSTALLATION
RECEIPT OF SYSTEM
The booster system is to be inspected upon receipt for indications of possible transit damage. If
there is any damage, contact the freight carrier immediately and report any damage. File a
freight claim directly and immediately with the freight carrier.
Inspect the entire system for components that may have loosened in the transporting of the system. Repair or tighten the affected components. Open the electrical panel door and inspect the
interior of the panel. Check all wires for tightness and all components to make sure they have not
loosened nor been inadvertently disconnected.
STORAGE
The system must be stored indoors, out of the weather. Avoid any temperature extremes. Storage
temperatures should range from 40 degrees F to 104 degrees F.
Whether the system is stored at the final site of the booster system or at a separate site, the system
must be loosely covered with a plastic or canvas cover. If the system may be exposed to moisture,
the cover is to be moisture proof. Allowances should be made to allow for proper ventilation and air
circulation.
If the system will be exposed to dirt and dust before system startup, a plastic or canvas cover is to
be used to keep the system clean.
MOVING THE SYSTEM
This packaged system can be moved with a fork lift truck. The forks of the lift truck should be
placed under the side or end of the baseplate of the system. The system should be secured to the
fork lift mast to prevent the system from shifting or falling from the forks.
Do not attach a sling or other type of convenience to any of the system components or move the
system in any way through the system components. If a sling is used to move the system, the sling
can be placed under the base. Dollies or other wheeled devices can also be used to transport the
system.

PACO
PUMPS

F9d.1 - Level 1
4/06
Supercedes 5/00

MECHANICAL INSTALLATION
The site for the installation should be clean, level, and free from all debris.
Place the Pacoflo 9000, Level 1 booster system at the installation location and check for approximate alignment with suction and discharge piping. Check the clearance between the electrical
panel door and any obstruction to make sure the distance is in compliance with the National Electric Code, and any local codes. Correct any discrepancies.
Mark the location of the baseplate anchor bolt holes on the floor and install anchors in the floor. Install the anchor
bolts and secure the baseplate using flat washers and lock washers under the bolt heads.
Use a level to level the booster system baseplate. Shim the base plate at the anchor bolt locations until the level in various planes is satisfied at several points on the baseplate.
When the system has been leveled, apply grout to the base and completely fill in the space
between the baseplate and the floor. Allow the grouting to dry before attempting any connection
of the system piping. Without proper grouting, the booster system may be noisy and susceptible
to vibration.
CONNECTING THE SYSTEM TO THE BUILDING PIPING
Follow any local codes when making final connections of the system.
System Isolation valves must be provided at the connection points of the booster system suction and discharge manifolds with the system piping. Flexible couplings can also be used, as specified.
Flushing of the system prior to installation is required. Check the booster system manifolds to
make sure they are free of debris. Also check building piping for any obstructions or debris before
connecting the booster system to the building piping. Piping to the system must be free from obstructions that will prevent proper flow to and from the system, or otherwise damage the system.
The building piping must be piped TO the manifolds of the booster system. Do not pipe
from the booster system to the building piping. Tighten all piping securely and adjust the final fittings
to the flanges or fitting of the system.
The booster system manifolds are not to be used as supports for the building piping. Supports
for the building piping must be provided. Do not put stress on the booster system manifolds by
using them to "close up" any poor fit of the building piping to the booster system.
Good piping practices and proper fittings are required to prevent any air pockets from being
created in the piping from the supplied suction line.
Pipe the thermal purge valve to the floor drain or other type drain.
6

PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

ELECTRICAL INSTALLATION
Electrical Safety.... Electrical circuits pose a potential danger. DO NOT attempt to connect an
electrical panel to the main power supply with out proper and complete electrical training in electrical safety and proper electrical maintenance skills. The following section is written to assist an
EXPERIENCED AND QUALIFIED ELECTRICIAN in connecting the panel to the main power.
Use only electrical testing devices and protection equipment that have been verified as safe and
reliable. All testing devices used to indicate voltage and current must be of known reliability. Do not
use a strange or untested electrical measuring device to troubleshoot or verify any electrical circuit.
The power to the panel must be connected in compliance with the National Electric Code (NEC)
and any local codes. Voltage variations greater than 10% of the supply voltage or frequency variations greater than 5% will cause poor performance and damage the electrical components of the
system. Correct any variations of voltage or frequency before connection to the system.
The booster system nameplate, located on the upper left hand corner of the panel front, contains the
correct voltage, phase, and frequency of the panel and Pacoflo 9000, Level 1 electrical components. The supply voltage, phase and frequency must match the panel nameplate information.
Double check by checking the motor nameplates to verify the required voltage. If there is a discrepancy, contact PACO Pumps for assistance. Test the voltage at the branch circuit disconnecting
device to verify the correct voltage before connecting the wires to the panel.
The wires coming to the system must be copper wire and correctly sized by the electrical contractor or engineer.
Make sure the booster system electrical panel disconnecting switch(es) and all H-O-A (HANDOFF-AUTO) switches are in the OFF position before applying power to the panel.

PACO
PUMPS

F9d.1 - Level 1
4/06
Supercedes 5/00

ELECTRICAL CHECK OUT

On systems equipped with self-protected starters, see the TRIP MODULE ADJUSTMENT section
for additional information.
Make sure all HAND-OFF-AUTO (H-O-A) switches are in the OFF position. Open the panel door
and use a voltage meter or other electrical instrument to verify that the incoming voltage matches
the nameplate information. The voltage can be checked at the power distribution block or panel
disconnecting switch. If Voltage is not present, check the Branch Circuit disconnecting device to
see if the device is ON.
Inspect the panel for any abnormal conditions, loose wires, loose components, missing components, etc. Check the motor starters to see if the heaters have been installed on heater-type overload relays, or that the amp settings are correct on adjustable overload relays. Correct heater sizes,
trip module adjustments and/or overload adjustment are based on the motors nameplate FLA
value.
If the motors are protected with fuses, make sure the fuses are present. If the fuses are not present,
consult PACO Pumps for correct fuse sizing. If fuses are required to be installed, use an insulated
fuse installation tool. If the motors are protected with circuit breakers and the panel has a main
disconnect, make sure the breakers are in the "ON" position.
Make sure water is present at the suction side of the pumps and at the correct suction pressure
(See page 7, Applying Water to the System). Close the panel door and turn on the panel main
disconnect(s) so that power is applied to the panel. If an alarm horn sounds, press the silence reset
button to silence the horn. Momentarily move the HAND-OFF-AUTO switch to the HAND position
and back to OFF, and observe the rotation of each pump. Rotation is indicated by an arrow on the
pump and is observed through the motor bracket opening. A chalk mark placed on the shaft end
prior to energizing may prove a valuable aid in ease of observation. For vertical turbines, rotation
should be verified before by coupling pump to motor.
If the rotation is incorrect on all of the system pumps, change any two incoming panel wires on three
phase systems. If one motors rotation is incorrect, change any two wires at the motor starter to
correct the rotation. Single phase systems will require a change at the motor junction box, and
information on these connections will be inside the junction box.
If the motor starter does not energize, check the circuit breaker or fuses and the overload reset on
the starter. Also check to make sure you have control voltage at the down stream side of the control
power fuse(s).

PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

HYDROCUMULATOR TANK
CAUTION

If a Hydrocumulator tank has been included as a part of this booster system, the tank requires
proper air charging before water pressure is applied. Damage to the tank bladder can occur if
water under pressure is introduced into the tank with no air charge.
AIR CHARGE
The specific air charge will vary depending upon the tank manufacturer. When there are no instructions provided with the tank, the recommended setting of the air charge pressure is 20 PSI below
the system pressure. If the system pressure were 100 PSI, the tank air charge will be 100 - 20 = 80
PSI.
Make sure the temperature of the tank is as close as possible to the ambient temperature before
making any pressure tests or readjustments.
Check the pressurizing stem for any obstructions or debris prior to checking the tank pressure or
adding air to the tank. Check the air charge with a pressure gauge. Add or release air as required.
Air can be added with a hand tire pump or with an air compressor. Do not over pressurize beyond
the tank nameplate maximum pressure. Damage to the tank internal bladder will result.
SYSTEM PRESSURE is defined as system boost pressure plus minimum suction pressure. Each
particular system pressure value is listed in the booster system label.
After clearing all of the air from the system, and the system is working on automatic, open the tank
isolation valve slowly to allow water to enter the tank. Gradually open the valve all the way.
TANK AIR CHARGE= System Pressure (PSI) minus 20 PSI.

F9d.1 - Level 1
4/06
Supercedes 5/00

PACOFLO 9000, LEVEL 1 STARTUP CHECK LIST

PACO
PUMPS

PRELIMINARY
_____ 1.
Confirm nameplate information.
_____ 2.
If unit has a tank, air charge tank to system pressure (PSI) minus 20 PSI before applying any water pressure to booster system.
_____ 3.
Fill system with water.
_____ 4.
Bleed air at top of pumps, prv's, gauges and at pressure switches.
_____ 5.
Bleed air from any other high point in the system.
_____ 6.
Check pressure reading on suction gauge (make sure it's at minimum).

CAUTION:
FINAL ELECTRICAL CONNECTIONS AND PANEL CHECKOUT SHOULD
BE MADE BY A QUALIFIED ELECTRICIAN!
ELECTRICAL
_____ 7.
Turn HOA switches to "OFF" position.
_____ 8.
Check settings on trip modules inside panel.
_____ 9.
Apply power to panel.
_____ 10.
Check supply voltage to panel and verify correct voltage with nameplate data.
_____ 11.
Close and secure panel door, (push "ALARM SILENCE" button if alarm is sounding).
_____ 12.
Bump each motor and verify proper pump rotation.
(on vertical turbine systems, check rotation before coupling pump to motor).
GETTING READY TO RUN
_____ 13.
When building is ready to accept water pressure, turn on pump #1 in "HAND" mode.
_____ 14.
Open building fixtures to establish approximately 15-25 GPM flow.
_____ 15.
Observe system pressure gauge, (check to see if pressure is as required).
_____ 16.
If incorrect, readjust PRV to desired pressure reading.
_____ 17.
Check remaining pumps and PRV's in same manner.
SETTING SYSTEM & SUCTION PRESSURES TO PC
_____ 18.
Confirm pressure switches adjusted to correct pressure set point.
SYSTEM IS NOW READY FOR "AUTO" OPERATION
_____ 19.
Put all "HOA" switches in "AUTO" mode.
_____ 20.
Open and close fixtures or valves in building to check flow switch settings and verify
"AUTO" operation of booster system. IF FURTHER DETAILS ARE REQUIRED,
SEE F9d.2.
10

PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

PLACING THE SYSTEM INTO OPERATION

APPLYING WATER TO THE SYSTEM
Before applying water to the booster system, close all of the isolation valves on the booster system.
Slowly open the building suction shut off valve and allow water to fill the booster system suction
manifold.
All air must be removed from the system. If all air is not removed from the system, improper operation of the system will result, and possible permanent damage to the system may occur.
Loosen the suction pressure gauge line at the gauge and bleed all air. Retighten the connection.
Open the suction valve to each pump, one at a time, and observe for leaks. Report any leaks
immediately to Paco Pumps. Open a plug or other fittings at the top of each pump to discharge any
and all air from the pumps. Replace and retighten the fittings.
Loosen the discharge pressure gauge line at the gauge and bleed all air. Retighten connection.
Check the pressure gauge and determine that the suction pressure corresponds to the Paco-flo
9000, Level 1 design settings, and falls between the minimum and maximum conditions indicated on the system label. This label is located on the interior of the electrical panel.
Check for leaks in the piping to the manifold and any leaks that may appear in the manifold. Repair
any leaks in the building piping and report any leaks in the Pacoflo 9000, Level 1 immediately to
Paco Pumps.
Open the discharge isolation valves at each pump. If the system has a PRV/pump, open the vent
(nut) on each PRV and vent each line to remove all air. Bleed air for at least 30 minutes. Close the
vent.
Open the building system valve. Check the building piping and repair all leaks.
SYSTEM CHECK OUT
For venting the system, open a valve at the top or extreme end to the piping system. Direct the valve
to a drain or other sink that will take the expected water discharge. Place the lead pump motor in
the HAND position and run the pump until clear water is coming from the valve. Monitor the suction
pressure to make sure the pressure stays above the minimum acceptable value.
Close the valve used to vent the system and place all of the HAND-OFF-AUTO switches in theAUTO position. Reset any alarms that may occur by pressing the ALARM-RESET button. The
system should stop after a no flow condition has existed for three minutes. (Note: Systems without
a no flow circuit will continue to run).
11

F9d.1 - Level 1
4/06
Supercedes 5/00

PACO
PUMPS

Open a valve to discharge water from the building piping. The valve should be large enough to
handle total system flow. The booster system should restart when the system pressure has dropped
below the set pressure. Close the valve and the system should shut down after three minutes. Open
the valve again and increase the flow until the first main pump starts. (Note: On a duplex system the
second pump will start.) Continue to open the valve until the third pump starts. Close the valve and
each main pump will stop after a time delay. The lead pump will stop after three minutes
SETTING PRVs
If the PRV (s) have been installed at the factory, they have been set to the system pressure. If a
single PRV will be added to the system at the jobsite, the PRV must be set to the required system pressure. Follow PRV instructions.
SUMMARY
When the system is completely checked out and properly adjusted, the system will be ready for use.
If problems develop, check the sections in the manual that cover the problem area for solutions to
the problems.

12

PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

MOTOR STARTERS
The majority of Pacoflo 9000, Level 1 systems are equipped with state-of-the-art self protected
starters. Check the control panel to determine whether self protected starters or separate starters/
overload protection are present.
SELF PROTECTED STARTERS / TRIP MODULES
The self protected starter has a removable module called the "TRIP MODULE". This module is
adjustable for both the motor overloads and motor short circuit protection. All settings have been
factory set, and adjustment is not normally required.
MODULE TRIPPING PROBLEMS
Most module tripping problems occur when the motor is drawing more amps than its nameplated
FLA value. If the module continuously trips or if tripping is a problem, check the settings on the trip
modules, as well as the motor amperage draw.
TRIP MODULE ADJUSTMENTS
OVER CURRENT DIAL
There are two dials on the front of the module. The left-hand dial is set for short circuit protection.
The right-hand dial is set for motor overload protection.
The left-hand dial and the portion of the trip module controlled by its setting is similar to a Motor
Circuit Protector (MCP). The dial is set to 13 times the motor nameplate FLA value. For example,
a motor that has a FLA value of 10 amps has a correct dial setting of 130. Do not increase the dial
setting to more than 13 times the motor FLA value. If the dial can not be adjusted to the correct
value, then the TRIP MODULE must be changed. Please contact a PACO Service Technician.
To order a new trip module, check the motor nameplate FL amps, and from the TRIP MODULE
table on page 10, determine the part number for the correct trip module.
OVERLOAD DIAL
The right-hand dial controls the motor overload part of the TRIP MODULE. On the trip module,
check the setting of the dial on the right-hand side of the module and adjust the dial to the correct
motor nameplate FLA value. Do not increase the setting of the dial to more than 15 percent
above the motor nameplate FLA rating. If motors with a service factor other than 15% are used,
do not exceed the motor nameplated FLA plus the nameplated service factors. If the range of the
trip module does not correspond to the nameplate amps, select trip module from the table on
page 10.
If nuisance tripping continues after the proper adjustments have been made, the switch point to
bring on the next pump in the sequence needs to be checked. (If the motor is over amping at the
switch point, adjustment to the switch point is required). See the appropriate sequencing section
for check out and adjustment. If the trip module continues to trip after all of the preceding checks
have been made, the trip module may be defective.
13

PACO
PUMPS

F9d.1 - Level 1
4/06
Supercedes 5/00

TRIP MODULE
SELF PROTECTED TRIP MODULE PART NUMBERS

Model

AMPS

18A
32A
63A

18A
32A
63A

Complete Starter & Coil

(Less the Trip Module)
96035209
96035210
96035211

PACO PART
NUMBER

RANGE-AMPS
MOTOR F.L. AMPS

96035200

2.5 TO 4

96035201

4 TO 6

96035202

6 TO 10

96035203

10 TO 16

96035204

16 TO 25

96035205

23 TO 32

96035206

28 TO 40

96035207

35 TO 50

96035208

45 TO 63

Replacement Coil Only

96035209 - Coil
96035210 - Coil
96035211 - Coil

NOTE: To order a complete Self protected starter assembly, select both the "Complete Starter
and Coil" and the appropriate "Trip Module".

14

PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

CONTROL SYSTEM (PLC)

All booster systems require some method of control for purposes of automating the system and
sequencing the pumps. The Control System typically involves three steps, as follows:
1. Data Acquisition or Sensing of existing system conditions
2. Processing of the input data.
3. Control Signal Output and Sequencing.
It is important to note that a control system has both primary and secondary functions. The primary
function of a control system is to monitor, process and control pump sequencing in order to provide
efficient automation of the pump system. A secondary, but equally important function is to monitor,
process and control the system safety and protective operations.
PACOFLO 9000, LEVEL 1 booster systems are provided with a programmable logic controller
(PLC) for purposes of controlling the booster system. A PLC is a control device which efficiently and
effectively processes incoming and outgoing data.
Like a computer, the PLC contains both hardware and software. The PLC is a solid-state microprocessor with data input and output capability, used specifically for control functions. The PLC is
able to read incoming data from the sensors, process that data according to the programming
software, and provide control signal output via relay contacts on the PLC.
The PLC is preprogrammed at the factory with a standardized control program (software) written
specifically for PACOFLO 9000, LEVEL 1 booster systems. All programs are thoroughly tested and
debugged. The standardized programs may be tailored for specific jobs by adding/removing pretested programming modules related to the available booster system options. The program is also
loaded with specific, job related set-point data. Once complete, the finalized program is flashed
into memory. The memory is non-volatile, which means that the programming data is not lost with a
loss of power. Therefore, a back-up battery power source is not required to maintain program
storage.
Note that a back-up battery is not required and therefore not supplied with the booster system. A
"Battery Low" LED will remain lit on the PLC as a result.

15

PACO
PUMPS

F9d.1 - Level 1
4/06
Supercedes 5/00

DATA ACQUISITION AND SENSING SYSTEMS

The PACOFLO 9000, LEVEL 1 booster system may use several methods of Data Acquisition to
monitor current conditions of the booster system. These methods are the eyes and ears of the
booster and are used to monitor and signal various conditions.
Pressure based Alarms & Functions:
Level 1 boosters use pressure switches as the standard means of monitoring for given pressure
conditions such as high system pressure alarm and low suction pressure alarm. Independent pressure switches are used for each condition to be monitored. In most cases, the pressure switches
provide a single, discrete close contact signal upon initiation of condition. That signal maintains
closed until the condition subsides.
Flow based Alarms & Functions:
Level 1 boosters use a flow switch as the standard means of monitoring for given flow conditions
such as No Flow condition. In most cases, flow switches provide a single, discrete close contact
signal upon initiation of condition. That signal maintains closed until the condition subsides.
Sequencing Devices:
Sequencing Devices are critical part of data acquisition. These devices serve a specific function,
and are discussed in detail in the following section.

16

PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

SEQUENCING DEVICES
Sequencing Device is the term used to describe a sensing mechanism that is used specifically for
monitoring and signaling the point of activation and sequencing of the pumps on the skid. This is the
unit that indicates when it is appropriate to activate a pump, or if a pump is already running, to
activate an additional pump.
There are many methods to determine when it is appropriate to activate a pump. Common methods
include flow sensing, pressure sensing and current sensing. The PACOFLO 9000 Level 1uses a
Pressure Sensing Sequencing Device.
Pressure Sensing
Pressure sensing is the standard sequencing indicator method for the PACOFLO 9000, LEVEL 1
booster. Pressure sensing is accomplished by means of a pressure switch. This pressure switch
may be identical to other pressure switches used on the system to monitor the alarm conditions.
For pressure sensing, the pressure switch setting or set point is equal to the System Pressure.
Upon a drop in pressure below System Pressure, the switch closes contact to indicate the condition. This signal is then processed by the PLC, and based upon the programming, a pump may be
activated. Typically, when the pump activates, pressure is restored and the switch opens. Otherwise, if demand is very large, the pressure switch may remain closed, and the PLC may call to
activate an additional pump.
The sequence of pump activation may vary, and is discussed in the next section Sequence Variations.

17

PACO
PUMPS

F9d.1 - Level 1
4/06
Supercedes 5/00

SEQUENCE VARIATIONS
Pumps may be sequenced in many variations in order to meet demand (flow) requirements. For a
given demand, it may be possible to satisfy that demand by activating two pumps in parallel within
the booster system. However, it may also be possible to satisfy that same demand by activating one
large pump. Other demands may be satisfied with one small and one large pump. An effective
sequence variation allows for the minimum amount of pumping power to be activated, to meet
system requirements. For instance, if demand can be satisfied by two 5HP pump, it is not efficient
to activate a third 5 HP pump to meet that demand.
Sequence variations are typically described in terms of the number of sequencing steps or more
comprehensively in terms of percentage of total flow. Sequence variations are also dependent on
the original capacity split design of the pumps. Typically, the greater the number of steps, the better
chance of minimizing the pumping power for any given demand. Below is a table of capacity splits
and sequencing variations.
Common Sequence Variations
Capacity Split
50/50 Duplex
30/70 Duplex
20/40/40 Triplex

Sequencing Variation
50%, 100%
30%, 100%
30%, 70%, 100%
20%, 60%, 100%
20%, 40%, 100%
20%, 40%, 60%, 80%, 100%

Pumps activated
A, A+B
A, A+B
A, B, A+B
A, A+B, A+B+C
A, B, A+B+C
A, B, A+B, B+C, A+B+C

There are many adaptations of the above sequencing variations as well, especially when capacity
splits are tailored for specific system demands. A 65/65 split will follow the same sequencing variation as a 50/50 split.
In addition to those listed above, there are systems where pump capacity splits and sequencing
variations are designed for system redundancy, emergency back-up, or over-capacity capability.
With these systems, the total flow of all pumps exceeds the total demand requirement of the system.
This is done to provide additional back-up pumping, should one pump become inoperable. Below
is a table of capacity splits and sequencing variations for redundant systems.
Redundant Sequence Variations
Capacity Split
50/50/50 Triplex
30/70/70 Triplex
30/70/100 Triplex

18

Sequencing Variation
50%, 100%,
30%,100%
30%, 70%, 100%
30%, 100%
30%, 70%, 100%

Pumps Activated
A, A+B (C as backup)
A, A+B (C as backup)
A, B, A+B (C as backup)
A, A+B (C as backup)
A, B, A+B (C as backup)

PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

ALARMS, OPTIONS AND OTHER FEATURES

ALARM LIGHTS (Standard)
Each alarm or shutdown condition indicated herein has an individual, labeled alarm light. Alarm
lights will remain lit until the alarm condition is relieved.
AUDIBLE ALARM (Standard)
The audible alarm is a high frequency solid state horn that will sound when an alarm condition
occurs. The alarm can be silenced with the ALARM SILENCE button and will clear itself when all
alarm conditions are corrected.
PUMP ALTERNATOR (Standard)
The control system has two methods of alternating the main pumps. Primary alternation of the main
pumps occurs at the completion of every first stage cycle. Cycle completion is determined by a first
stage start and subsequent stop after the mnimum run time. If additional stages are signaled to run
and stop during the same cycle, the called main pump sequence will remain.
The control system also includes a timed method of main pump alternation. The alternation time is
factory set at 12 hours. Alternation time is initiated by a first stage start signal. If the alternation time
is completed before the end of the run cycle, main pumps alternate positions. If the run cycle is
completed before the alternation time elapses, then the alternation time is reset and the main pumps
alternate based on cycle completion. Alternation will occur only if main pump H-O-A selectors are
in the auto mode and no main pump failure has been sensed.
PUMP FAILURE PROTECTION AND ALARM (Standard)
When a pump is called to run, controller monitors the motor starter auxiliary contact input for the
respective pump as a confirmation that pump is running. Failure to receive signal within 2 seconds
after pump is called to run is interpreted as a pump failure. Controller locks out said pump from the
pumping sequence and calls the next available pump to operate. Respective "Pump Failed" light
is illuminated. Manual reset required before pump is re-instated into pumping sequence.
LOW SUCTION PRESSURE (Shutdown and alarm Standard)
If the suction pressure falls to preset minimum suction pressure value (as indicated on the panel
label), the low suction pressure light will be lit and the alarm will sound, after a delay of 10 seconds.
The system will shut down and not run in the alarm condition. The alarm is self clearing when the
suction pressure returns to normal parameters.
LOW SUCTION LEVEL ( Shutdown and Alarm optional)
When the level of the reservoir or tank drops below a set point (as determined by the placement of
the float switch), the level switch closes and the system will shut down after a 10 second delay. The
condition is indicated by a visible light and alarm horn. The system restarts when the reservoir or
tank level rises above the set point and reopens the level switch. Electrical runslonger than 200 feet
to the float switch may cause poor panel performance and should be avoided.

19

F9d.1 - Level 1
4/06
Supercedes 5/00

PACO
PUMPS

THERMAL PURGE SYSTEM

If a pump continues to operate when flow (demand) is not present, the condition is called dead
heading the pump. Pumps which dead head can build up heat within the pump case. The
system is equipped with a thermal purge system to prevent excessive build up of heat in the pump
from damaging the pump seal and system components. The thermal purge may be a thermalmechanical valve or a thermostat & solenoid valve combination. Thermal purge systems may be
provided one per pump or one per system depending on the original ordering criteria.
TIMED SHUT-OFF (STANDARD WITH TANK)
If a booster system is provided with a hydro-cumulator tank, the system is provided with a Timed
Shut-Off circuit as standard. This feature allows the booster system to shut off upon satisfying the
system pressure requirements for a minimum of 10 minutes. After 10 minutes of operation, the
system will shut off for energy savings, and allow pressure to be maintained by the hydro-cumulator
tank. If demand (flow) remains, the system will reactivate upon reaching the Low Pressure Start set
point. Systems which are supplied with a No-Flow Shut-off option, are not equipped with the Timed
Shut-Off feature. This feature is not provided on systems that do not have a hydro-cumulator or
hydro-pneumatic tank, as those systems have no means of maintaining pressure while pumps are
de-activated.
NO-FLOW SHUT-OFF (OPTIONAL WITH TANK)
If a booster system is provided with a hydro-cumulator tank, the system may be equipped with an
optional No Flow Shut-off circuit instead of the standard Timed Shut-Off feature. When flow diminishes below a set point, and system pressure is maintained, the No-Flow switch closes and a
minimum run timer counts for 180 seconds before shutting off the pumps. If demand (flow) remains,
the system will reactivate upon reaching the Low Pressure Start set point.
AUXILIARY ALARM CONTACTS
Auxiliary alarm contacts are relays (dry contacts) which are paralleled with the alarm option.
When the alarm option is activated, the relay closes and provides remote alarm indication.
The customer will supply the correct voltage for the remote alarm option from the remote alarm
indicating station.
PHASE FAILURE - LOW VOLTAGE FAILURE
When the Phase failure/low voltage option is installed, the panel control power will be shutoff if a low
voltage or phase failure condition exists. The low voltage or phase failure (or reversal) condition
must be cleared before the system will restart.
HIGH SYSTEM PRESSSURE SHUTDOWN AND ALARM (OPTIONAL)
When the system pressure reaches the maximum flange design rating of the system, the system is
shut down and an alarm light and horn sound. A two second delay is provided to consider momentary high pressure spikes. The system requires a manual reset to restart. The system maximum
design rating is the maximum pressure the system is designed to withstand on a continuous basis.
Typically, these pressures are: 175 PSI, 250 PSI and 400 PSI, depending on installation design.

20

PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

OVERVIEW OF FACTORY SETTINGS

PACOFLO 9000 Booster Systems are pre-programmed at the factory. Low Pressure Start
settings and Low Suction Pressure settings have been set according to specific job data supplied
to PACO at time of purchase. All pressure settings are field adjustable, as required for fine tuning
purposes. Pressure Setting Adjustment procedures are described in this manual under "Adjustment of Pressure Setting".
Time delay settings are programmed as necessary to protect the booster system and related
components. The timer settings indicated below have been found most appropriate to ensure
proper system operation. Time delay settings are stored internally on the system PLC and require
servicing by a trained technician. Reprogramming and adjustment of the time delay settings is
inadvisable, without direct factory assistance.

FEATURE
Timed Shut Off
No-Flow Shut Off
Low Pressure Start
Minimum Run Timer, lead pump
Minimum Run Timer, main pumps

Std/
Opt.

SETTING

Std.* Upon maintained System Pressure

Opt.* Flow of approx. 5 GPM
Std. 10 PSI below System Pressure ***

TIME DELAY

RESET

10 Minutes Not Applicable

Dependent** Not Applicable
2 Seconds Not Applicable

180 Seconds Not Applicable

Std. Not Applicable
30 Seconds Not Applicable
Std. Not Applicable
Std. Upon Failure to start
2 Seconds
Manual
Pump Failure Alarm
Low Suction Pressure Alarm & Shutdown Std. 10 PSI below Minimum
10 Seconds
Automatic
Suction Pressure ***
Upon close of float switch contact
Opt.
10 Seconds
Automatic
Low Suction Level Alarm & Shutdown
High System Pressure Alarm & Shutdown Opt. Pressure rating of System components 2 Seconds
Manual
Phase reversal & low voltage Shutdown Opt. Phase loss, reversal, voltage drop
Instantaneous Upon Correction
of 10%

* Timed Shut-Off and No-Flow Shut-off are provided only with systems utilizing hydro-pneumatic or
hydro-cumulator tanks.
** Upon detection of No Flow condition, individual pump Minimum Run Timers define the time delay
for Shut Off.
***Minimum Suction Pressure and System Pressure are values as defined by Customer at placement of Order.

21

PACO
PUMPS

F9d.1 - Level 1
4/06
Supercedes 5/00

ADJUSTMENT OF PRESSURE SETTINGS

The Pacoflow 9000, Level 1 booster system is equipped with pressure switches to monitor the
system start setpoint as well as low suction and optional high discharge pressure conditions. The
pressure switches include set point adjusting nuts. Each switch is factory set for conditions provided for the system; however, field adjustment may sometimes be necessary.
The system was tested under simulated pressure and flow conditions at the factory. If the on site
pressure conditions of the discharge (building side) or the suction (supply side) are different than
the settings on a label on the interior of the panel door, then follow the instructions in the next paragraphs.
To set the pressure set points of the system, place the system into service as outlined in PLACING
THE SYSTEM INTO OPERATION. Set the PRVs. Insure that the suction pressure is at its design
point or higher, and the discharge pressure is at the design point. The pressure set points can now
be set.
HOW TO ADJUST THE PRESSURE SWITCH SETTINGS
Each pressure switch has a setpoint actuation nut with scaled dial. Turn the self locking adjustment
nut clockwise to raise and counterclockwise to lower the actuation point. All dials are calibrated for
increasing settings.
Capture pressure in the suction and discharge pressure lines to the gauges and pressure switches
by closing the gauge line isolation valves. Bleed excess pressure in the lines to attain the correct
low suction pressure and minimum system pressure readings on the respective gauges. Open
panel door open where the PLC input LEDs are visible. Apply control power to the PLC. Adjust the
pressure switch actuation nut as necessary to the setting that will actuate the correct PLC input
LED; see system PLC drawings for input designation. When correct LED illuminates, correct
setpoint has been attained. No further adjustment is needed. Open isolation valves to resume
normal operation.

22

PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

SYSTEMS PERFORMANCE TROUBLESHOOTING GUIDE

The following guide covers some of the problems that you may encounter when operating the booster system.
Addiditonal troubleshooting of the electrical system can be found in the electrical and programmable controller
section.
Condition

Possible Cause/Question

Pump does not

operate in Hand or
Auto position.

Power: Examine panel. Is there Restore power to panel.

a loss of power to the panel?

Check list for other causes.

-or- Contact PACO.

Breaker: Examine pump

breaker. If breaker has tripped,
can you reset the breaker?

Motor operating at more than

nameplate FLA. Reset breaker.
Investigate reason for over
amperage.

Refer to following section in

trouble shooting guide.

Starter: Turn HOA switch to

Hand. Does pump "run light"
energize but starter not "click"
or energize?

Starter coil is defective or coil

wire is loose. Examine and
repair or replace as necessary.

Check list for other causes.

-or- Contact PACO.

Motor/Wiring: Turn HOA switch

to Hand. Does breaker trip
immediately?

Motor short circuit protection is Check list for other causes.

open, wires from starter to motor -or- Contact PACO.
are disconnected or motor is
bad. Examine and repair accordingly.

Open Circuit: Turn HOA switch

to Hand. Does pump "run light"
energize, starter energizes and
motor still not run?

Motor short circuit protection is Check list for other causes.

open, wires from starter to motor -or- Contact PACO.
are disconnected or motor is
bad. Examine and repair accordingly.

Pump does not

operate in Hand or
Auto position,
breaker will
not reset.

Breaker: Does breaker reset

when main power supply is off?

Breaker is defective or undersized or the wiring is grounded.

Contact PACO.

Trip module is still hot from

last overload condition or
breaker is defective.
Contact PACO.

Pump will not

operate in Auto
condition, but will
operate in Hand.

No Flow: Examine system for

flow. Is there no flow in the
system?

Pumps will shut down in the

automatic mode if there is no
demand in the system. Pumps
will re-activate upon demand.

Check list for other causes.

-or- Contact PACO.

Adequate Suction Pressure:

Examine suction pressure.
Does the suction pressure meet
or exceed the require system
pressure indicated on the panel
nameplate?

Pumps will shut down in the

automatic mode if there is
adequate suction pressure.
Pumps will re-activate if needed
to boost pressure to meet
requirements.

Check list for other causes.

-or- Contact PACO.

Answer = Yes

Answer = No

Alarms: Examine panel for alarm Pumps will not operate under
conditions. Is an alarm condicertain alarm conditions. Refer
tion indicated?
to Alarm section of IOM. Correct
the system condition indicated
by alarm.
HOA & Wiring: Examine internal Repair accordingly.
wiring, HOA switch and PLC.
Are any wires loose or bad
switch?

Check list for other causes.

-or- Contact PACO.

PLC: Examine PLC. Is the PLC Repair or replace PLC or

off, burned, or indicating an error programming accordingly.
code.

Check list for other causes.

-or- Contact PACO.

Check list for other causes.

-or- Contact PACO.

23

PACO
PUMPS

F9d.1 - Level 1
4/06
Supercedes 5/00
Condition

Possible Cause/Question

Answer = Yes

Answer = No

Pump Does Not Run

in Auto but runs in
Hand.

Demand Is there a demand

present?

Pumps will not activate if

there is no demand.

Check list for other causes.

-or- Contact PACO.

Pump starts in Hand,

but trips breaker
periodically.

Amperage: Check amperage

of pump motor with amp
meter. Does amperage
exceed motor nameplate?

Motor is drawing excessive

amps. Contact PACO.

The trip module is adjusted

too low or is undersized.
Adjust accordingly or contact
PACO. Note: Amperage will
fluctuate with flow.

Pumps Cycle On
and Off continuously
with demand.

Demand Is demand fluctuating?

Pumps will activate and

deactivate to meet demand.

Check list for other causes.

-or- Contact PACO.

Pumps Cycle On
and Off continuously
with NO demand.

Discharge leakage: Close the

main system discharge valve
and allow system shutdown in
automatic mode. Does
system stop cycling, and
remain off?

A demand still exists in

the system. Check for
system leakage. Inspect
hydrocumulator tank to
maximize drawdown during
low flow. (see hydropneumatic tank troubleshooting)

See "Suction leakage" below.

Suction leakage: Close the

main system discharge valve,
allow system to charge up
system pressue, close the
main system suction valve and
allow system to shutdown in
automatic mode. Does
system stop cycling, and
remain off?

The check valves or

checking PRVs are not
sealing. Pressure is
leaking back to suction
side. Clean or replace
check valves or checking
PRVs.

System set points are out of

range, or fault in programming.
Contact PACO.

Hydro-pneumatic Tank: Does

your system have a hydropneumatic tank either on the
skid or remotely located?

Refer to Tank troubleshooting section of this manual.

Check list for other causes.

-or- Contact PACO.

Improper Rotation: Inspect

pumps to determine direction
of rotation. Are the pumps
rotating in the wrong direction?

Reverse any two leads on

starter of motors that have
incorrect rotation. If all
motors have incorrect
rotation, reverse any two
leads on power supply to
panel.

Check list for other causes.

-or- Contact PACO.

Air Bound. Crack open bleed

fittings from top of piping,
manifolds and pump volutes.
Is there air in the piping?

Vent pumps, manifolds,

pressure regulating valves
and piping.

Check list for other causes.

-or- Contact PACO.

Incorrect voltage: Use voltage

meter to verify that the
incoming power supply. Is
the supply voltage different
than that listed on the panel?

Panel voltage rating must

match supply voltage.
Contact PACO

Check list for other causes.

-or- Contact PACO.

Isolation Valves: Examine

valves. Are the isolation
valves partially closed?

Open valves.

Check list for other causes.

-or- Contact PACO.

Discharge pressure
is too low.

24

PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00
Condition

Possible Cause/Question

Answer = Yes

Answer = No

Exceeding Capacity:
If equipped with flow meter, does
meter reading exceed the rated
flow of the booster system?

Reduce the system demand or

contact PACO for options on
increasing the flow capacity of
the system.

Check list for other causes.

-or- Contact PACO.

If no flow meter is present, close

the main discharge valve and
examine the pressure gauge.
Did the pressure increase?

Reduce the system demand or

contact PACO for options on
increasing the flow capacity of
the system.

Check list for other causes.

-or- Contact PACO.

Suction Pressure: Examine

suction pressure gauge. Is the
suction pressure less than the
minimum suction pressure
indicated on the panel?

Examine suction line for block- Check list for other causes.
age, clogged strainers, partially -or- Contact PACO.
closed valves, restrictive PRVs.
Correct as able or contact PACO
for options on increasing the
booster pressure of the system.

Gauge: Remove gauge and

examine. Does gauge appear
defective?

Replace gauge.

Check list for other causes.

-or- Contact PACO.

Refer to PRV troubleshooting

PRV: Examine pressure upstream of the pressure reducing section of this manual.
valves (PRV). Is upstream
pressure adequate?

Check list for other causes.

-or- Contact PACO.

Check list for other causes.

-or- Contact PACO.

Discharge
pressure
is too high.

PRV: Is your system equiped

with one or more pressure
reducing valves (PRV)?

Refer to PRV troubleshooting

section of this manual.

PRV not opening

or too restrictive.

Diaphragm: Is water leaking

from vent hole?

Diaphragm is ruptured. Replace. Check list for other causes.

-or- Contact PACO.

Installation: Inspect PRV. Is

valve installed with flow in the
opposite direction of the arrow
on the valve?

Water flow should be in the

direction of the arrow. Reverse
valve orientation.

Check list for other causes.

-or- Contact PACO.

Isolation valve: Inspect isolation

valves in pilot tubing. Are any
isolation valves closed?

PRV can not vent pressure.

Open valve.

Check list for other causes.

-or- Contact PACO.

Clean or replace speed control

Speed control valves: Inspect
speed control valves by opening valve, and reset the speed
fully and closing fully (return to setting.
original setting). Was the valve
closed or frozen?
Failed pilot regulator.

Refer to PRV manual or contact

PACO

Check list for other causes.

-or- Contact PACO.

Refer to PRV manual or

contact PACO

25

PACO
PUMPS

F9d.1 - Level 1
4/06
Supercedes 5/00
Possible Cause/Question

Answer = Yes

Air Charge: Close isolation valve Bladder is ruptured and must be

replaced. Contact PACO.
to hydropneumatic tank. Drain
water from tank. Check pressure
with gauge. See
Hydropneumatic tank section for
settings. Recharge to correct air
pressure. Allow to set for 10
minutes. Check air pressure
again. Has pressure fallen?

Open isolation valve to refill

tank. Recheck system
operation now that tank
pressure setting has been
re-established.

Alarm Conditions: Review the

systems conditions relating to
the specific alarm that has
activated. Does the alarm
condition exist?

The system is designed to

shutdown to protect system
components. Restore proper
operating conditions and reset
alarm.

System may have entered

an alarm condition earlier
and now requires resetting.
-Or- See other possible
causes listed below.

Alarm Setting: Review/adjust

alarm settings as instructed in
this manual. Are settings
correct?

Check list for other causes.

-or- Contact PACO.

Re-adjust switch settings

accordingly.

Defective Switch: Manually test

the alarm indicator switch or
transducer. Does the switch
function properly?

Check list for other causes.

-or- Contact PACO.

Replace the switch/

transducer.

Defective Switch: Manually test

the alarm indicator switch or
transducer. Does the switch
function properly?

Check list for other causes.

-or- Contact PACO.

Replace the switch/

transducer.

Alarm Setting: Review/adjust

alarm settings as instructed in
this manual. Are settings
correct?

Check list for other causes.

-or- Contact PACO.

Re-adjust switch settings

accordingly.

Time Delay: Verify time delay

setting for this alarm. Has the
condition existed continuously
for the entire delay cycle?

Check list for other causes.

-or- Contact PACO.

A time delay is utilized with

this alarm to avoid inappropriate shutdown due to
common pressure fluctuations. System is operating
properly.

Wiring: Examine internal wiring, Repair accordingly.

and PLC. Are any wires loose
or bad switch?
Wiring. Inspect wiring. Is there
a loose wiring connection?

Repair wiring accordingly.

Bulb: Remove wires to light and Wiring or PLC contact is bad.

provide external 120VAC power Contact PACO.
source to light. Does light
energize now?

26

Answer = No

Check list for other causes.

-or- Contact PACO.
Continue to next step

Bulb or fixture is defective.

Replace.

PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

Condition

Possible Cause/Question

Answer = Yes

Answer = No

Horn will not

sound when alarm
condition exists.

Wiring. Inspect wiring. Is there

a loose wiring connection?

Repair wiring accordingly.

Continue to next step

Horn will not

silence.

Remote alarm will

not work.

Horn. Remove wires to horn and Wiring or PLC contact is bad.

provide external 24VDC power
Contact PACO.
source to horn. Does horn sound
now?

Horn is defective. Replace.

Wiring. Inspect wiring. Is there

a loose wiring connection?

Repair wiring accordingly.

Continue to next step

Button: Apply a jumper across

terminals of Silence button.
Does horn stop now?

Silence button is defective.

Replace.

Wiring or PLC contact is

bad. Contact PACO.

Relay:Inspect the relay, are the Check list for other causes.
contacts clear and does the coil -or- Contact PACO.
cause the contacts to close
when energized/

Relay is defective, replace

accordingly.

Wiring. Inspect wiring. Is there

a loose wiring connection?

Continue to next step

Repair wiring accordingly.

Remote Power: Is power supply Check list for other causes.

verified at remote location.
-or- Contact PACO.

Remote alarms often

require separate power
supply. Restore power at
remote location.

27

PACO
PUMPS

F9d.1 - Level 1
4/06
Supercedes 5/00

APPENDIX A SYSTEM SETTINGS

PERMANENT RECORD OF SYSTEM SETTINGS
Data Indicated Herein Should Correspond to Panel Label Information.
SYSTEM GPM
PUMP #1 GPM
PUMP #2 GPM
PUMP #3 GPM
SYSTEM DESIGN PRESSURE

175

250

400

(Circle One)

SYSTEM PRESSURES
MAXIMUM SUCTION PRESSURE
MINIMUM SUCTION PRESSURE
SYSTEM PRESSURE

SYSTEM SEQUENCE
%

28

PACO
PUMPS

F9d.1- Level 1
4/06
Supercedes 5/00

APPENDIX B
PUMP AND PUMP NAME PLATE INFORMATION
The following panel nameplate information is obtained from the booster system nameplate on the
upper left-hand corner of the front of the electrical panel.
MODEL NO. ___________________________________________
SERIAL NO. ___________________________________________
HP(1)____________ HP(2)____________ HP(3)______________
VOLTAGE______________________ HZ____________________
PANEL AMPS___________________ PH____________________
DRAWINGS: ___________________________________________
PANEL NAMEPLATE

PACO

PUMPS

CONTROL

BROOKSHIRE, TX
MODEL:
SERIAL:
HP (1)

(2)

(3)

VOLTS:

HZ:

MAX. AMPS:

PHASE:

DRAWINGS:

PUMP NAMEPLATE

PACO PUMPS
BROOKSHIRE, TX

SMART PUMP

CAT:
STOCK:
SER:
GPM:

TDH:

IMP DIA:

29

PACO
PUMPS

F9d.1 - Level 1
4/06
Supercedes 5/00

APPENDIX C SYSTEM NAMEPLATE INFORMATION

Duplex

PACOFLO 9000, LEVEL 1

Constant Pressure Duplex System

System Flow

System Serial Number

GPM

Suction Pressure: MIN.

System Boost

PSI MAX.

PSI

PSI

System Pressure
Capacity Split:

Pump

PSI
%

Low Suction Pressure

Fused Motor Protection

GPM

TDH

Trim

CONTROL PANEL NEMA PANEL

Model No.

3R

12

Low Suction Level

Remote Alarm Contacts
High Discharge Pressure

Volts
Motor

HP

RPM

HZ
ENCL

Fuse

Phase

FLA

Manufacturer

1
2

Wiring Diagram No.

Sequencing Device:

Manifold
Size
PRV:

"X
"X

Suction
Discharge

"
"

Standard Sequencing 50% 100%

Non-Standard Sequencing
%
%

#ANSI
#ANSI

1 Per Pump
1 Per System
0 Per System
Tank
Gallons
PSI

Remote

Pressure Sensing
Thermal Purge Option
1 Per System
1 Per Pump

Triplex

PACOFLO 9000, LEVEL 1

System Flow

Constant Pressure Triplex System

System Serial Number

GPM

Suction Pressure: MIN.

System Boost

PSI MAX.

PSI
Pump

PSI

System Pressure
Capacity Split:

PSI
%

Model No.

GPM

TDH

Trim

1
%

3
CONTROL PANEL NEMA PANEL
Low Suction Pressure
Fused Motor Protection

3R

12

Remote Alarm Contacts

Low Suction Level

Motor

HP

Volts
RPM ENCL

Fuse

HZ
FLA

Phase
Manufacturer

1
2

Wiring Diagram No.

3
Sequencing Device:

Manifold
Size
PRV:

30

"X
"X

"
"

Suction
Discharge

1 Per Pump
1 Per System
0 Per System
Tank
Gallons
PSI

#ANSI
#ANSI

Remote

Standard Sequencing 20% 60% 100%

Non-Standard Sequencing
%
%
%
%
Pressure Sensing
Thermal Purge Option:
1 Per System
1 Per Pump

PACO
PUMPS

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DUPLEX BOOSTER
WITH PRESSURE SEQUENCING

31

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DUPLEX BOOSTER
WITH PRESSURE SEQUENCING

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DUPLEX BOOSTER
WITH PRESSURE SEQUENCING

33

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DUPLEX BOOSTER
WITH PRESSURE SEQUENCING

34

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TRIPLEX BOOSTER
WITH PRESSURE SEQUENCING

35

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TRIPLEX BOOSTER
WITH PRESSURE SEQUENCING

36

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TRIPLEX BOOSTER
WITH PRESSURE SEQUENCING

37

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TRIPLEX BOOSTER
WITH PRESSURE SEQUENCING

38

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DUPLEX BOOSTER
WITH FLOW SEQUENCING

39

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DUPLEX BOOSTER
WITH FLOW SEQUENCING

40

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DUPLEX BOOSTER
WITH FLOW SEQUENCING

41

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DUPLEX BOOSTER
WITH FLOW SEQUENCING

42

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TRIPLEX BOOSTER
WITH FLOW SEQUENCING

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TRIPLEX BOOSTER
WITH FLOW SEQUENCING

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TRIPLEX BOOSTER
WITH FLOW SEQUENCING

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TRIPLEX BOOSTER
WITH FLOW SEQUENCING

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APPENDIX E1 PRESSURE REDUCING/CHECK VALVE

FUNCTION
REDUCES A HIGHER INLET PRESSURE TO A CONSTANT, LOWER, OUTLET \PRESSURE.
CLOSES WHEN OUTLET/DOWNSTREAM PRESSURE EXCEEDS INLET/UPSTREAM PRESSURE.

OPERATION
FIGURE 115-3 PRESSURE REDUCING/CHECK VALVE is controlled by a
Pressure Reducing Control. The control is
normally open, held open by an adjustable
spring to maintain a constant discharge
pressure from the main valve.
As the downstream pressure (OUTLET)
increases to the pressure reducing setpoint, the Pressure Reducing Control
throttles towards closed, restricting flow
through the control tubing. This action
increases pressure in the main valve
cover chamber, modulating the main valve
towards closed an appropriate amount.
Closing speed is regulated by an adjustable needle valve.
As downstream pressure decreased, the
Reducing control throttles towards open,
increasing the flow through he control
tubing. This action decreases pressure in
the main valve cover chamber, modulating
the main valve towards open an appropriate amount, maintaining the desired outlet
pressure. Opening speed is regulated by
an adjustable flow control.

An integral check feature guards against reverse

flow. When downstream pressure exceeds upstream pressure, the main valve cover chamber is
flooded, driving the valve closed.

WATTS/MUESO Automatic Control Valves are hydraulically operated, diaphragm actuated, pilot controlled, globe or
angle valves of packless design. The stem assembly is the only moving part in the main valve and is guided top and
bottom. Positive drip-tight closure is accomplished by a quad-ring or O-ring seat seal. The basic valve is available in
Cast Iron., Steel, and Aluminum in a variety of sizes, end connections, and options. Consult the WATTS/MUESCO
factory for further information.
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APPENDIX E-2
OPERATION MATRIX
This matrix of the operation illustrates the cause and effect sequence for proper functioning. The
diagram begins with the system status and ends with the main valve action
SYSTEM
STATUS

REDUCING
CONTROL

CHECK
FEATURE

MAIN VALVE
COVER
CHAMBER

MAIN VALVE
ACTION

PRESSURE
INCREASE

MORE
RESTRICTIVE

PRESSURE REDUCING FUNCTION

DOWNSTREAM
PRESSURE
INCREASE
>SET POINT

DOWNSTREAM
PRESSURE
DECREASE
<SET POINT

THROTTLES
TOWARDS
CLOSED

THROTTLES
TOWARDS
OPEN

NO EFFECT

NO EFFECT

PRESSURE
DECREASE

LESS
RESTRICTIVE

CHECK FUNCTION
DOWNSTREAM
PRESSURE
>INLET
PRESSURE

NO EFFECT

FLOODS MAIN
VALVE COVER

PRESSURE
INCREASED

CLOSES

< = Below
> = Above

SCHEMATIC

COMPONENTS
1 Basic Valve
2 Reducing Control*
3 Check Valve
4 Needle Valve-Adjustable Restriction Closing
5 Flow Control-Adjustable Opening Speed
LOCATION OF ACCESSORIES
L Limit Switch
P Position Indicator
X Isolation Cocks
Y Y-Strainer
FC Flo-Clean Strainer
Assembled valve will vary in appearance but will
conform with drawing in regard to component
locations and functions.

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*Model number of the actual control used is

dependent upon valve size and materials.

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APPENDIX E-3
RECOMMENDATIONS & REQUIREMENTS

Angle Valve
Stem Horizontal

As with all automatic control valves, isolation valves

should installed in the line before and after the automatic control valve so that the valve may be isolated
from pressure for inline servicing. At tempts to
service the valve without isolation from pressure may
prove hazardous.

Globe Valve
Stem Horizontal

Should installation require the valve stem to be horizontal (cover pointed sideways), factory should be
consulted concerning valves of 6" and larger.

SIZING

Proper sizing of the automatic control valve to hydraulic conditions is of paramont importance. Refer to
Series Brochure 115, Valve Sizing section.

INSTALLATION/STARTUP

Clear the line of lag and other debris.

Install the valve so that the FLOW ARROW marked on the valve body matches flow through the line.

Close upstream and downstream isolation valves.

Open ball valves or isolation cocks in the control tubing, if the main valve is so equipped. Failure to open
these will prevent the valve from functioning properly.

Install pressure gauge on main valve (downstream side port), or another downstream location in the system. Valves equipped with a 263 AP pilot have a 1/4" N.P.T. pressure gauge port in the pilot body.
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INSTALLATION/START-UP CONTINUED

Start-up of an automatic control

valve requires that proper
procedures be followed. Time
must be allowed for the valve to
react to adjustments and the
system to stabilize. The
objective is to bring the valve into
service in a controlled manner.

REDUCING CONTROL
ADJUSTING SCREW
CHECK VALVE
ISOLATION COCKS

FLOW CONTROL - ADJ. OPENING SPEED

NEEDLE VALVE - ADJ. RESTRICTIONCLOSING
CHECK VALVE

Step 1
Turn Pressure Reducing Control
adjustment screw counterclock
wise (OUT), backing pressure off
the spring, Prventing possible
overpressuring of the system.
Step 2
Back opening speed flow control
adjustment screw out one half
turn from closed. Back closing
speed needle valve adjustment
screw out one and a half turns
from closed. Loosen a turb fitting
at a valve highpoint to allow
venting of air.
Step 3
Open upstream isolation valve
SLOWLY to a full open position to
allow controlled filling of the
valve. Air is vented through the
loosened fitting. Tighten fitting
when liquid begins to vent.
Step 4
Open downstream isolation valve
partially to establish flow through
the valve, observing downstream
pressure change. If downstream
pressure is outside the desired
pressure range, turn the Reducing Control adjustment screw
clockwise (IN) to increase, or
counterclockwise (OUT) to
decrease,until pressure is near
the desired setting.
50

Y-STRAINER
CLEAN OUT PORT
ISOLATION COCK

MAIN VALVE

Step5
Gradually open the downstream
isolation valve until full open.
Step6
Allow the system to stabilize.
Step 7
Fine-tune Pressure Reducing
Control adjustment to the setpoint, as detailed in Step 4.
Step 8
Opening Speed Adjustment: The
opening speed flow control
allows free flow into the cover of
the main valve.
If recovery of pressure is slow
upon increased downstream
demand, turn the adjustment
screw counterclockwise (OUT),
increasing the rate of opening.
If recovery of downstream pressure is too quick, as indicated by
a rapid increase in pressure,
possibly higher than the desired
set-point, turn the adjustment
screw clockwise (IN), decreasing
the rate of opening.

Step 9
Closing Speed Adjustment: The
closing speed needle valve
regulates the fluid pressure into
the main valve cover chamber,
controlling the valve closing
speed. If the downstream
pressure fluctuates slightly
above the desired set-point turn
the adjustment screw
counterclockwise (OUT), increasing the rate of closing.
Step 10
No start-up is required for the
check feature.

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INDEX
ALTERNATOR, 19
ADJUSTABLE OVERLOADS, 13
ALARM OPTIONS AND OTHER OPTIONS,
19, 20
APPLYING WATER TO THE SYSTEM, 11
AUDIBLE ALARM, 19
AUXILIARY ALARM CONTACTS, 20
PLC MEMORY, 15
BOOSTER SYSTEM NAMEPLATE
29 & 30
BUILDING PIPING, 6

PRESSURE SETTINGS, 22
PRESSURE SEQUENCING, 17
RECEIPT OF SYSTEM, 5
SETTING PRESSURES, 22
SETTING PRV'S, 50
STORAGE, 5
SYSTEM CHECK OUT, 8, 10
SYSTEM PRESSURE, SETTING, 22
SYSTEM TROUBLESHOOTING TABLES, 23-27
SYSTEM SETTINGS, 28

ELECTRICAL CHECK OUT, 8

ELECTRICAL INSTALLATION, 7
THERMAL PURGE VALVE, 6, 20
HYDROPNEUMATIC TANK INSTALLATION, 9
TIMER SETTINGS, 21
SELF PROTECTED STARTER, 13
TRIP MODULE ADJUSTMENTS, 13
TRIP MODULE PART NUMBER, 14
LOW SUCTION CONDITION, 19, 21
TROUBLESHOOTING, 23-27
LOW SUCTION CONDITION SHUT DOWN
DELAY, 21
MECHANICAL INSTALLATION, 7
MINIMUM RUN TIMES, 21
MOVING THE SYSTEM, 5
NO FLOW SHUT-OFF, 12, 20
OPTIONS, 19-21
PANEL INSPECTION, 7, 8, 10
PANEL NAMEPLATE INFORMATION, 30
PHASE FAILURE - LOW VOLTAGE FAILURE,
20
PLACING THE SYSTEM INTO OPERATION,
10,11
PRESSURE REDUCING VALVES, 47-50

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Terms And Conditions Of Sale

SECTION 1: THE CONTRACT

The Contract shall be comprised of the following terms, together with such terms and conditions as are set forth in
Sellers written proposal or quotation (the Quotation), including any documents, drawings or specifications incorporated
therein by reference, and any additional or different terms proposed in Buyers purchase order (the Purchase Order)
that are accepted by Seller in writing, which together shall constitute the entire agreement between the parties, provided,
however, that preprinted terms on Buyers purchase order or invoice shall not apply and Seller gives notice of objection to
such terms. An offer by Seller in its Quotation that does not stipulate an acceptance date is not binding. This Contract
shall be deemed to have been entered into upon written acknowledgment of the Purchase Order by an officer or
authorized representative of Seller, which may not be modified, supplemented, or waived except in a writing executed by
an authorized representative of the party to be bound.
SECTION 2: PRICE
The price quoted in the Quotation shall be the Purchase Price unless otherwise agreed in the Purchase Order. The
Purchase Price for equipment shall include packing for shipment. Field Services shall be provided at Sellers standard
rates. All other costs, including packing for storage, freight, insurance, taxes, customs duties and import/export fees, or
any other item not specified in the Contract, shall be paid by Buyer unless separately stated in the Quotation and included
in the price quoted. Any sales, use, or other taxes and duties imposed on the transaction or the equipment supplied shall
be paid or reimbursed by Buyer.
SECTION 3: PAYMENT TERMS
Payment shall be due within 30 days of the date of Sellers invoice in U.S. funds unless otherwise agreed. If Buyer does
not observe the agreed dates of payment, Buyer shall pay interest to Seller on overdue amounts at a rate that is the
higher of: 9% per annum or a rate 5% in excess of the rate borne from time to time by new issues of six-month United
States Treasury bills. Seller shall be entitled to issue its invoice for the Purchase Price for equipment upon the earlier of
shipment, or notice to Buyer that Seller is ready to ship, and for services, upon completion. If the Purchase Price exceeds
$250,000 USD, Buyer shall pay the Purchase Price in Progress payments as follows: Fifteen percent (15%) upon
submittal of general arrangement drawings, thirty five percent (35%) after receipt of first Bowl Casting, twenty percent
(20%) after first case/bowl hydro test or bowl machining and thirty percent (30%) after notification of ready to ship.
SECTION 4: ACCEPTANCE AND INSPECTION
All equipment shall be finally inspected and accepted by Buyer within 14 days after delivery or such other period of time
as is agreed in the Purchase Order. Buyer shall make all claims (including claims for shortages), excepting only those
provided for under the warranty clause contained herein, in writing within such 14 day period or they are waived. Services
shall be accepted upon completion. Buyer shall not revoke its acceptance. Buyer may reject the equipment only for
defects that substantially impair its value, and Buyers remedy for lesser defects shall be in accordance with Section 10,
Warranty. If tests are made by Buyer to demonstrate the ability of the equipment to operate under the contract conditions
and to fulfill the warranties in Section 10, Buyer is to make all preparations and incur all expenses incidental to such
tests. Seller will have the right of representation at such tests at its expense, and the right to technically direct the
operation of the equipment during such tests, including requiring a preliminary run for adjustments.
SECTION 5: TITLE AND RISK OF LOSS
Full risk of loss (including transportation delays and losses) shall pass to Buyer upon delivery, regardless of whether title
has passed to Buyer, transport is arranged or supervised by Seller, or start-up is carried out under the direction or
supervision of Seller. Delivery shall be ex works, INCOTERMS 2000. Loss or destruction of the equipment or injury or
damage to the equipment that occurs while the risk of such loss or damage is borne by Buyer does not relieve Buyer of
its obligation to pay Seller for the equipment.
SECTION 6: PATENT OR TRADEMARK INFORMATION
If the equipment sold hereunder is to be prepared or manufactured according to Buyers specifications, Buyer shall
indemnify Seller and hold it harmless from any claims or liability for patent or trademark infringement on account of the
sale of such goods.
SECTION 7: CHANGES
Buyer may request, in writing, changes in the design, drawings, specifications, shipping instructions, and shipment
schedules of the equipment. As promptly as practicable after receipt of such request, Seller will advise Buyer what
amendments to the Contract, if any, may be necessitated by such requested changes, including but not limited to
amendment of the Purchase Price, specifications, shipment schedule, or date of delivery. Any changes agreed upon by
the parties shall be evidenced by a Change Order signed by both parties.
SECTION 8: CANCELLATION OR TERMINATION
Buyer shall have the right to cancel the Contract upon 15 days prior written notice to Seller, and Seller shall stop its
performance upon the receipt of such notice except as otherwise agreed with Buyer. If Buyer cancels the Contract, it shall
pay: (a) the agreed unit price for equipment or components completed and delivered, (b) additional material and labor
costs incurred, and for engineering services supplied by Seller with respect to the canceled items, which shall be
charged to Buyer at Sellers rates in effect at the time of cancellation, but which shall not exceed the contract price for
such items, and (c) such other costs and expenses, including cancellation charges under subcontracts, as Seller may
incur in connection with such cancellation or termination.

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of quotation. Seller shall not be liable for any nonperformance, loss, damage, or delay due to war, riots, fire, flood, strikes
or other labor difficulty, governmental actions, acts of God, acts of the Buyer or its customer, delays in transportation,
inability to obtain necessary labor or materials from usual sources, or other causes beyond the reasonable control of
Seller. In the event of delay in performance due to any such cause, the date of delivery or time for completion will be
extended to reflect the length of time lost by reason of such delay. Seller shall not be liable for any loss or damage to
Buyer resulting from any delay in delivery.
SECTION 10: WARRANTY
Seller warrants that the equipment or services supplied will be free from defects in material, and workmanship for a
period of 12 months from the date of initial operation of the equipment, or 18 months from the date of shipment,
whichever shall first occur. In the case of spare or replacement parts manufactured by Seller, the warranty period shall be
for a period of six months from shipment. Repairs shall be warranted for 12 months or, if the repair is performed under
this warranty, for the remainder of the original warranty period, whichever is less. Buyer shall report any claimed defect in
writing to Seller immediately upon discovery and in any event, within the warranty period. Seller shall, at its sole option,
repair the equipment or furnish replacement equipment or parts thereof, at the original delivery point. Seller shall not be
liable for costs of removal, reinstallation, or gaining access. If Buyer or others repair, replace, or adjust equipment or
parts without Sellers prior written approval, Seller is relieved of any further obligation to Buyer under this section with
respect to such equipment or parts. The repair or replacement of the equipment or spare or replacement parts by Seller
under this section shall constitute Sellers sole obligation and Buyers sole and exclusive remedy for all claims of
defects. SELLER MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WITH RESPECT TO THE
EQUIPMENT OR SERVICES OTHER THAN AS SPECIFIED IN THIS SECTION 10. ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.
For purposes of this Section, the equipment warranted shall not include equipment, parts, and work not manufactured or
performed by Seller. With respect to such equipment, parts, or work, Sellers only obligation shall be to assign to Buyer
any warranty provided to Seller by the manufacturer or supplier providing such equipment, parts or work.
No equipment furnished by Seller shall be deemed to be defective by reason of normal wear and tear, failure to resist
erosive or corrosive action of any fluid or gas, Buyers failure to properly store, install, operate or maintain the equipment
in accordance with good industry practices or specific recommendations of Seller, or Buyers failure to provide complete
and accurate information to Seller concerning the operational application of the equipment.
SECTION 11: TECHNICAL DOCUMENTS
Technical documents furnished by Seller to Buyer, such as drawings, descriptions, designs and the like, shall be
deemed provided to Buyer on a confidential basis, shall remain Sellers exclusive property, shall not be provided in any
way to third parties, and shall only be used by Buyer for purposes of installation, operation and maintenance. Technical
documents submitted in connection with a Quotation that does not result in a Purchase Order shall be returned to Seller
upon request.
SECTION 12: LIMITATION OF LIABILITY
Seller shall in no event be liable for any consequential, incidental, indirect, special or punitive damages arising out of the
Contract, or out of any breach of any of its obligations hereunder, or out of any defect in, or failure of, or malfunction of the
equipment, including but not limited to, claims based upon loss of use, lost profits or revenue, interest, lost goodwill,
work stoppage, impairment of other equipment, environmental damage, nuclear incident, loss by reason of shutdown or
nonoperation, increased expenses of operation, cost of purchase of replacement power or claims of Buyer or customers
of Buyer for service interruption whether or not such loss or damage is based on contract, tort (including negligence and
strict liability) or otherwise.
Sellers maximum liability under this Contract shall not exceed the Purchase Order amount of the equipment or portion
thereof upon which such liability is based. All such liability shall terminate upon the expiration of the warranty period, if not
sooner terminated.
SECTION 13: THIS COMPANY IS AN EQUAL OPPORTUNITY EMPLOYER
This agreement incorporates by reference applicable provisions and requirements of Executive Order 11246 and FAR
Section 52.222-26 (covering race, color, religion, sex and national origin); the Vietnam Era Veterans Readjustment
Assistance Act of 1974 and FAR Section 52.222-35 (covering special disabled and Vietnam era veterans); and the
Rehabilitation Act of 1973 and FAR Section 52.222-36 (covering handicapped individuals). By acceptance of this
agreement Buyer certifies that it does not and will not maintain any facilities in a segregated manner, or permit its
employees to perform their services at any location under its control where segregated facilities are maintained, and
further that appropriate physical facilities are maintained for both sexes. Buyer agrees that it will obtain a similar
certificate prior to award of any nonexempt lower-tier subcontracts.
SECTION 14: LAW AND ARBITRATION
The Contract shall be governed by the law of the State of Texas. Any disputes arising out of this Contract shall be resolved
by informal mediation in any manner that the parties may agree within 45 days of written request for mediation by one
party to the other. Any dispute that cannot be resolved through mediation shall be resolved by binding arbitration
conducted in English in Portland, Oregon under the Commercial Rules of the American Arbitration Association except as
otherwise provided in this Section. The arbitration shall be conducted by three arbitrators chosen in accordance with said
Rules. The arbitrators are not entitled to award damages in excess of compensatory damages. Judgment upon the
53
award may be entered in any court having jurisdiction.

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PACO
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