DISTRIBUTION PUMP SYSTEM

OPERATION & MAINTENANCE MANUAL

GRUNDFOS CRI PUMPS

Manufactured With Pride

In The USA

www.ameriwater.com • 800-535-5585
AmeriWater • 1303 Stanley Avenue • Dayton, OH 45404

P/N 98-0119
Rev. E
P/N 98-0119
Rev. E
TABLE OF CONTENTS

THEORY OF OPERATION ...……………………………………….1

INSTALLATION ......…………………………………………………2

START-UP .……………………………..………………………………3

PUMP CURVES ....……………………………………………………4

PUMP CONNECTIONS ..……………………………………………5

RATED CURRENT……………………..……………………………..5

ADJUSTING THE TIMER (DUAL PUMPS ONLY) .....…......6

SPARE PARTS LISTING .…………………………………………..7

DIAGNOSING SPECIFIC PROBLEMS .…………………………8

DRAWINGS .…………………………………………………………..11

P/N 98-0119
Rev. E
DISTRIBUTION PUMP
THEORY OF OPERATION

The AmeriWater distribution pump takes the water from the storage tank, pumps
it through the distribution loop to the points of use for dialysis and re-circulates
water back through the piping to the storage tank. This provides pressurized
water to each dialysis wall box in addition to re-circulating the water. Re-
circulating the water keeps it “fresh” by minimizing bacteria growth by the
constant movement of water.

When the water is at the minimum level (always controlled by the lowest float
switch on the storage tank), the distribution pump is not allowed to automatically
operate through the distribution controller. When the water level is below the
minimum level, the distribution pump will not operate in “AUTO”, but may be
operated in “HAND” (manual operation). The distribution pump should only be
placed in “HAND” to empty the storage tank. It should not be left unattended
during this process. Running the distribution pump for an extended period
without water will result with overheating and damage to the pump.

The distribution pumps are available as a single pump or a dual pump. All
distribution pumps are available in 115V and 220V single phase, 208V 3 phase,
230V 3 phase and 460V 3 phase. The distribution pumps have a capability of
running at rated volumes between 60 to 80 PSI.

The distribution pump controllers have either fuses or overloads to protect the
pumps and wiring from overload damage.

The controllers for the dual distribution pumps have an alternating feature that
will allow the pumps to alternate from #1 pump to #2 pump that is controlled by a
timer set at 5 hours.

WARNING: Both pumps need to be in auto mode for normal operation.

If one pump is taken down, ensure that the second pump is set to manual
mode. If this is not done, the controller will attempt to cycle between them.
The system should only be run in manual mode for the length of time it will
take to bring the second pump back on line.

Another AmeriWater standard feature for the dual distribution pump controller is
to have an overload sensor for each pump. If a pump has an overload condition,
the controller will automatically switch to the pump that does not have an
overload. This will prevent a possible water delivery shutdown during the dialysis
procedure. An indicator light is on the front panel of the controller to show which
pump has an overload failure.

P/N 98-0119E 1
INSTALLATION

The following guidelines should be met at installation.

1. Customer is to provide properly sized wiring to the distribution pump control

enclosure.

2. Place the pump system on firm, level floor and anchor to the floor to prevent
movement from vibration or bumping.

3. Inlet piping and / or hoses from the storage tank to the pump system should
be equal to or greater in diameter than the inlet piping on the pump system.

4. Outlet piping and / or hoses of the pump system should be equal to or greater
in diameter than the outlet piping on the pump system.

5. Locate the pump control on a wall as close to the pump system as possible.
When installing a distribution pump along with an AmeriWater Central Water
System, refer to the Plumbing and Instrumentation Diagram (P&ID) for the
best location and where connections are made.

6. Follow all local plumbing and electrical codes.

7. After guidelines have been met, connect the distribution pump wiring to the
motor contactor located in the control panel (refer to the control wiring
diagram provided in this manual and with the distribution pump control).
Connect the three phase or single phase power source to the Main ON/OFF
disconnect switch located inside the control panel.

8. Once the power source has been connected, verify that the voltage on the
pump matches what is indicated on the overload of the motor starter.

9. Check the rotation of the pump(s). Turn the disconnect switch to the ON
position. Jog the pump(s) by momentarily turning the pump power switch to
the HAND position. A second person may be needed to see which way the
motor armature is turning just before it coasts to a stop. If the rotation is
backwards, switch any two of the three non-ground pump wires on the motor
contactor inside the panel.

WARNING: When using chlorine for disinfection, AmeriWater recommends a

maximum chlorine concentration of 500 ppm (parts per million) with a total
contact time not to exceed 60 minutes. Chlorine concentrations greater than 500
ppm or contact times longer than 60 minutes may result in chlorides degrading
the stainless steel components, potentially resulting in harm to the patient!

P/N 98-0119E 2
START-UP
1. Open the inlet and outlet valves to the pump and allow the water in the
storage tank to “flood” the inlet of the distribution pump. If the storage
tank does not have water in it, fill it to above the lowest float switch before
attempting to use the pump.

2. When starting the pump the first time, be sure to open the priming vent
plug until a steady stream of airless water runs out of vent, then close.

3. Turn the switch on the controller to HAND. Allow water to flow to re-
circulate through the loop and back in to the storage tank for a few
minutes. Water flow can be verified by observing the flow meter on the
return header of the storage tank. If this is a dual pump system, place
pump #1 into HAND mode to ensure that there is adequate flow through
the system at the holding tank flow meter. Once verified, repeat this for
pump #2.

4. Place the system into auto mode to verify that the low level cut off switch
operates correctly. For a dual pump system, this will need to be done for
each pump.

5. For the dual pump system only, the timer will need to be verified. This is
accomplished by setting the timer to its minimum value and ensuring that
the system is alternating between the pumps. See page 6 for details on
adjusting the set-point.

6. The inlet and outlet valves are provided to allow for isolation of each pump
if maintenance is needed. During operation, leave all of the inlet and
outlet valves open.

7. When performing a start-up of your distribution pump that is connected to

a central system storage tank, adjust the pressure relief valve on the
storage tank header so that the pressure gage at the pump is no higher
than 80 PSI. Refer to the manual that was provided with your storage tank
system for proper adjustments. See pump curves on page 4.

P/N 98-0119E 3
 Pump Curves

P/N 98-0119E 4
Pump Connections

Rated Current

P/N 98-0119E 5
Adjusting the Timer

With the power off and the system properly locked out, open the control panel. In the
middle of the box, you will see the timer as shown below. To adjust the timer, simply
insert a small screwdriver into the screw lower right hand face of the timer. Rotating
this will toggle between time interval modes that are displayed on the face of the timer.

Time
Interval

Adjustment
Screw

Once all validation of your set-up is complete, you must re-set the timer to 5 hours to
meet the AAMI standards.

P/N 98-0119E 6
Spare Parts List

Part # Description
80-0138 Pump,3/4HP,Single Phase,115/230V
80-0139 Pump,3/4HP,Three Phase,208-230/460V
80-0140 Pump,1HP,Single Phase,115/230V
80-0141 Pump,1HP,Three Phase,208-230/460V
80-0142 Pump,1.5HP,Single Phase,115/230V
80-0143 Pump,1.5HP,Three Phase,208-230/460V
80-0144 Pump,2HP,Single Phase,115/230V
80-0145 Pump,2HP,Three Phase,208-230/460V
80-0149 Pump,2HP,Three Phase,208-230/460V
80-0158 Pump,2HP,Three Phase,208-230/460V
80-0195 Pump,3HP,Three Phase,208-230/460V
43-0021 Gauge,0-100,.25,CBM,2.5,LF,SS/SS
55-0014 Check Valve ,1”FIP,PVC Sch40
041732001 Ball Valve,1.25”,TU,PVC80
041720169 Ball Valve,1”,TU,PVC80
63-0009 Fuse 10A FNM
63760133 Fuse, 2A, 250V
64760225 Timer, 8-Pin, 120V
64760108 Base, Timer, 8-Pin
61-0002 Relay, 30 AMP, 300V, SPST, NO, 120V-Coil

P/N 98-0119E 7
DIAGNOSING SPECIFIC PROBLEMS (SOME POSSIBLE CAUSES MAY NOT APPLY TO YOUR SYSTEM)
Problem Possible cause Remedy
The pump does not run. No power at motor. Check voltage at motor terminal box. If no
voltage at motor, check feeder panel for
tripped circuits and reset circuit.
Fuses are blown or circuit Turn off power and remove fuses. Check
breakers are tripped. for continuity with ohmmeter. Replace
blown fuses or reset circuit breaker. If new
fuses blow or circuit breaker trips, the
electrical installation, motor and wires must
be checked.
Motor starter overloads are Check for voltage on line and load side of
burned or have tripped out. starter. Replace burned heaters or reset.
Inspect starter for other damage. If heater
trips again, check the supply voltage and
starter holding coil.
Starter does not energize. Energize control circuit and check for
voltage at the holding coil. If no voltage,
check control circuit fuses. If voltage,
check holding coil for shorts. Replace bad
coil.
Defective controls. Check all safety and pressure switches for
operation. Inspect contacts in control
devices. Replace worn or defective parts
or controls.
Motor is defective. Turn off power and disconnect wiring.
Measure the lead to lead resistances with
ohmmeter
(RX-1). Measure lead to ground values
with ohmmeter (RX-100K). Record
measured values. If an open or grounded
winding is found, remove motor and repair
or replace.
Defective capacitor Turn off power and discharge capacitor.
(single-phase motors). Check with ohmmeter (RX-100K). When
the meter is connected to the capacitor,
the needle should jump towards 0 ohms
and slowly drift back to infinity (∞). Replace
if defective.
Pump is bound. Turn off power and manually rotate pump
shaft. If shaft does not rotate easily, check
coupling setting and adjust as necessary.
If shaft rotation is still tight, remove pump
and inspect. Disassemble and repair.
The pump runs but at Wrong rotation. Check wiring for proper connections.
reduced capacity or does Correct wiring.

P/N 98-0119E 8
Problem Possible cause Remedy
not deliver water. Pump is not primed or is Turn pump off, close isolation valve(s),
airbound. remove priming plug. Check fluid level.
Refill the pump, replace plug and start the
pump. Long suction lines must be filled
before starting the pump.
Strainers, check or foot valves Remove strainer, screen or valve and
are clogged. inspect. Clean and replace. Reprime
pump.
Suction lift too large. Install compound pressure gauge at the
suction side of the pump. Start pump and
compare reading to performance data.
Reduce suction lift by lowering pump,
increase suction line size or removing high
friction loss devices.
Suction and/or discharge piping Pump spins backwards when turned off.
leaks. Air in suction pipe. Suction pipe, valves
and fittings must be airtight. Repair any
leaks and retighten all loose fittings.
Pump worn. Install pressure gauge, start pump,
gradually close the discharge valve and
read pressure at shutoff. Convert
measured pressure (in psi) to head (in
feet): (Measured psi x 2.31 ft/psi=
___ ft). Refer to the specific pump curve
for shutoff head for that pump model. If
head is close to curve, pump is probably
OK. If not, remove pump and inspect.
Pump impeller or guide vane is Disassemble and inspect pump
clogged. passageways. Remove any foreign
materials found.
Incorrect drain plug is installed. If the proper drain plug is replaced with a
standard plug, water will recirculate
internally. Replace with proper plug.
Improper coupling setting. Check/reset the coupling; see page 18.
Pump cycles too much Pressure switch is not properly Check pressure setting on switch and
adjusted or is defective. operation. Check voltage across closed
contacts. Readjust switch or replace if
defective.
Level control is not properly Check setting and operation. Readjust
adjusted or is defective. setting (refer to level control
manufacturer's data), Replace if defective.
Insufficient air charging or Pump air into tank or diaphragm chamber.
leaking tank or piping. Check diaphragm for leak. Check tank and
piping for leaks with soap and water
solution. Check air to water volume. Repair
as necessary.
Tank is too small. Check tank size and air volume in tank.
Tank volume should be approximately 10
gallons for each gpm of pump capacity.
The normal air volume is 2/3 of the total
tank volume at the pump cut-in pressure.
Replace tank with one of correct size.

P/N 98-0119E 9
Problem Possible cause Remedy
Pump is oversized. Install pressure gauges on or near pump
suction and discharge ports. Start and run
pump under normal conditions, record
gauge readings. Convert psi to feet
(Measured psi x 2.31 ft/psi = ___ ft) Refer
to the specific pump curve for that model,
ensure that total head is sufficient to limit
pump delivery within its design flow range.
Throttle pump discharge flow if necessary.
Fuses blow or circuit Tank is too small. Check voltage at starter panel and motor.
breakers or overload If voltage varies more than -10 % / + 10 %,
relays trip contact power company. Check wire
sizing.
Motor overloads are set too low. Cycle pump and measure amperage.
Increase heater size or adjust trip setting
to a maximum of motor nameplate (full
load) current.
Three-phased current is Check current draw on each lead to the
imbalanced. motor. Must be within -5% / +5 %. If not,
check motor and wiring. Rotating all leads
may eliminate this problem.
Motor is shorted or grounded. Turn off power and disconnect wiring.
Measure the lead-to-lead resistance with
an ohmmeter (RX-1). Measure lead-to-
ground values with an ohmmeter (RX-
100K) or a megaohm meter. Record
values. If an open or grounded winding is
found, remove the motor, repair and/or
replace.
Wiring or connections are faulty. Check proper wiring and loose terminals.
Tighten loose terminals. Replace damaged
wire.
Pump is bound. Turn off power and manually rotate pump
shaft, If shaft does not rotate easily, check
coupling setting and adjust as necessary.
If shaft rotation is still tight, remove pump
and inspect. Disassemble and repair.
Defective capacitor Turn off power and discharge capacitor.
(single-phase motors). Check with ohmmeter (RX-100K). When
the meter is connected to the capacitor,
the needle should jump towards 0 ohms
and slowly drift back to infinity (∞). Replace
if defective.
Motor overloads at higher Use a thermometer to check the ambient
ambient temperature than temperature near the overloads and motor.
motor. Record these values. If ambient
temperature at motor is lower than at
overloads, especially where temperature at
overloads is above
+104 °F (+40 °C), ambient-compensated
heaters should replace standard heaters.

P/N 98-0119E 10
 Single Distribution Single Phase Controller

P/N 98-0119E 11
 Single Distribution 115 & 220V
Single Phase Controller Schematic

P/N 98-0119E 12
 Single Distribution Three Phase Controller

P/N 98-0119E 13
 Single Distribution 208V & 230V
Three Phase Controller Schematics

P/N 98-0119E 14
 Single Distribution 460V Three Phase Controller Schematic

P/N 98-0119E 15
 Dual Distribution Single Phase Controller

P/N 98-0119E 16
 Dual Distribution 220V Single Phase Controller Schematic

P/N 98-0119E 17
 Dual Distribution Three Phase Controller

P/N 98-0119E 18
 Dual Distribution 208V Three Phase Controller Schematic

P/N 98-0119E 19
 Dual Distribution 230 Volt Three Phase Controller Schematic

P/N 98-0119E 20
 Dual Distribution 460 Volt Three Phase Controller Schematic

P/N 98-0119E 21
 Single Distribution Pump Assembly

P/N 98-0119E 22
 Dual Distribution Pump Assembly

P/N 98-0119E 23