For a stable supply of water with the necessary pressure values, it is not enough just to buy a pump station. Equipment must also be set up, started up and properly operated. Admit, not all of us are familiar with the intricacies of tuning. And the prospect of spoiling the devices with incorrect actions does not appeal too much, do you agree?
We are ready to share with you valuable information on how to adjust the pumping station. In our article, methods and rules for eliminating work disturbances associated with insufficiently high pressure are given.
You will learn about the causes of the pressure drop and get acquainted with the methods of eliminating them. Graphic and photo applications will explain how to properly configure pumping equipment.
Features of the pump station
A ready-made pump station equipped by the manufacturer is a mechanism for forced water supply. The scheme of its work to the limit is simple.
A pump pumps water into an elastic tank located inside a hydraulic accumulator, also called a hydraulic tank. When filled with water, it stretches and presses on that part of the tank that is filled with air or gas. Pressure, reaching a certain level, causes the pump to turn off.
During the intake of water, the pressure in the system drops, and at a certain moment, when the values set by the owner are reached, the pump starts working again. The relay is responsible for turning the device off and on, the pressure level is controlled by a pressure gauge.
Abnormalities in the operation of a household pumping station can cause damage to plumbing equipment
The article recommended by us will familiarize you in more detail with the principle of operation, varieties and proven schemes for installing a pumping station.
Causes of hardware problems
The statistics of malfunctions in the operation of household pumping stations says that most often problems arise due to a violation of the integrity of the hydraulic accumulator membrane, pipeline, leakage of water or air, and also due to various contaminants in the system.
The need for intervention in its work can arise due to many reasons:
- Sand and various substances dissolved in water can cause corrosion, lead to malfunctions and lower equipment performance. To prevent clogging of the device, water purifying filters must be used.
- The decrease in air pressure in the station causes frequent pump operation and premature wear. It is recommended that you measure the air pressure from time to time and adjust it if necessary.
- The lack of tightness of the joints of the suction pipe is the reason that the engine runs without shutting down, but cannot pump the liquid.
- Incorrect adjustment of the pressure of the pumping station can also cause inconvenience and even breakdowns in the system.
In order to extend the life of the station, it is recommended to periodically conduct an audit. Any adjustment work must be started by disconnecting from the mains and draining the water.
Periodically check the power consumption and maximum head. Increased energy consumption indicates friction in the pump. If the pressure drops without leaks detected in the system, the equipment is worn
Error correction in work
Before embarking on a more serious intervention in the operation of the equipment, it is necessary to take the simplest measures - clean the filters and eliminate leaks. If they do not give results, then proceed to further steps, trying to identify the root cause.
The next thing to do is adjust the pressure in the accumulator tank and adjust the pressure switch.
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Conditions for normal operation of the pumping station
Filling the suction pipe and the working cavity with water
Prohibition of use without water consumption
Prevent air from entering the suction pipe
Pumping equipment in a dry basement
Installation of the unit in the utility room
Pumping from an open reservoir
Operation of the station in winter
Below are the most common disturbances in the operation of a household pumping station, which the user can try to solve on their own. For more serious problems, you must contact the service center.
Violation of the rules of operation
If the station is continuously working without shutting down, the probable cause is incorrect adjustment of the relay - a high shutdown pressure is set. It also happens that the engine is running, but the station does not pump water.
The reason may lie in the following:
- At first start-up, the pump was not filled with water. It is necessary to correct the situation by pouring water through a special funnel.
- The integrity of the pipe is broken or an air plug has formed in the pipe or in the suction valve. To detect a specific reason, you must make sure that: the suction valve and all connections are tight, there are no bends, contractions, hydraulic locks along the entire length of the suction pipe. All malfunctions are eliminated, if necessary, replace damaged areas.
- The equipment works without access to water (dry). It is necessary to check why it is not there or to identify and eliminate other causes.
- Pipeline clogged - it is necessary to clean the system from contamination.
It happens that the station is very often triggered and turned off. Most likely this is due to a damaged membrane (then it is necessary to replace it), or there is no pressure required for operation in the system. In the latter case, it is necessary to measure the presence of air, check the tank for cracks and damage.
Before each start-up, it is necessary to pour water into the pumping station through a special funnel. She should not work without water. If it is likely that the pump will run without water, purchase automatic pumps equipped with a flow controller.
Less likely, but it may happen that the check valve is open and blocked due to the ingress of debris or an object. In such a situation, it is necessary to disassemble the pipeline in the area of possible clogging and eliminate the problem.
Engine malfunctions
The engine of the household station does not work and does not make noise, possibly for the following reasons:
- The equipment is disconnected from the power supply or there is no voltage in the network. It is necessary to check the wiring diagram.
- Blown fuse. In this case, you need to replace the item.
- If it is not possible to turn the fan wheel, it means it is jammed. Find out why.
- The relay is damaged. You need to try to adjust it or, if it fails, replace it with a new one.
Malfunctions in the engine most often force the user to use the services of a service center.
Problems with water pressure in the system
The lack of water pressure in the system can be explained by several reasons:
- The water or air pressure in the system is set to an unacceptably low value. Then it is necessary to configure the relay in accordance with the recommended parameters.
- The piping or impeller of the pump is blocked. Cleaning the elements of the pumping station from contamination may help to solve the problem.
- Air enters the pipeline. Checking the pipeline elements and their connections for leaks can confirm or refute this version.
Poor water supply is also due to the fact that air is drawn in due to loose connections of the water pipes or the water level has fallen so much that air is pumped into the system when it is drawn in.
Poor water pressure can cause significant discomfort when using the plumbing system.
Storage tank revision
Starting work on adjusting the equipment, disconnect the system from the network, close the pressure valve on the water intake side. Unscrew the tap and drain the water, and the residues are lowered through the pressure hose, disconnecting it from the membrane tank. First check the air pressure in the tank of the accumulator.
The role of the accumulator in the system
The membrane tank of the pumping station is, in fact, a metal tank with a rubber bulb located inside, which is designed to collect water.
Air is pumped into the free space between the rubber bulb and the tank walls. In some models of hydraulic accumulators, the tank is divided in half by a membrane, which delimits the tank into two compartments - for water and air.
The accumulator tank maintains pressure in the system and creates a small supply of water. Once a month, the pressure in the hydropneumatic tank should be checked with the pump turned off and the water drained from the supply pipe
The more water enters the device, the more it compresses the air, increasing its pressure, which tends to push the water out of the tank. This allows you to maintain a stable pressure of water even during inactivity of the pump.
The hydraulic accumulator requires regular maintenance, removal of air from the pear, which enters it together with water in the form of small bubbles and gradually accumulates there, reducing the usable volume.
For this, a special valve is provided on top of large tanks. With small containers, you have to trick in order to remove air: turn off the system and drain and fill the tank several times.
The selection of the tank by volume is based on the highest value of water consumption for a particular consumer. The permissible number of starts per hour, specified by the manufacturer, as well as the nominal values of the on-pressure, off-pressure and user-specified pressure in the hydraulic tank, are taken into account
Air pressure control
Although the manufacturer adjusts all the elements of the pumping station at the production stage, it is necessary to double-check the pressure even in new equipment, since at the time of sale it may slightly decrease. The device that is being operated is inspected up to two times per year.
For measurements, the most accurate pressure gauge is used, because even a small error of 0.5 bar can affect the operation of the equipment. If it is possible to use a car gauge, with a scale, with the lowest graduation, this will provide more reliable results.
The air pressure indicator in the diaphragm tank must correspond to 0.9 times the switching pressure of the pump station (set using a relay). For tanks with different volumes, the indicator can be from one to two bars. The adjustment is carried out through the nipple, pumping or bleeding excess air.
For normal operation, the station is equipped with mandatory control and regulatory devices:
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Mandatory components of the pumping station are the pressure switch, which allows you to adjust the pressure in the system, and the pressure gauge necessary for its control
To adjust the pressure parameters in the system, the relay is equipped with two springs, which allow setting the upper and lower pressure limits in the water supply circuit
In order to increase the upper limit of the pressure parameters at which the pump stops automatically, nut 1 is rotated clockwise. In this case, the nut 2, which is responsible for the lower limit, must be raised by the same amount
All actions to configure the pressure switch must be carried out with a parallel control of changes with a pressure gauge. Differential upper and lower pressure limits recommended in the range of 1.2 - 1.6 bar
Mandatory components of the pumping station
Springs for setting pressure switches
Specificity of pressure change by relay
Using a pressure gauge when setting up a relay
The less air is pumped into the system, the more water it can accumulate. The water pressure will be strong when the tank is full, and more and more weaken when the water is drawn.
If such differences are comfortable for the consumer, then you can leave the pressure at the lowest acceptable level, but not less than 1 bar. A lower value can lead to friction of a water-filled pear against the tank wall and damage it.
To establish a strong water pressure in the water supply system, it is necessary to fix the air pressure within about 1.5 bar. So, the difference in pressure with a filled and empty tank will be less noticeable, providing an even and strong flow of water.
Using a relay to adjust pressure
The pressure switch is responsible for the automation of the system - a device that controls the pump station, performing the function of turning the device on and off. It also prevents the system from creating excessive pressure.
The pressure switch controls the on / off cycles when the user-specified operating pressure is reached. The operation of the pressure switch is monitored using a pressure gauge.
# 1: Principle of operation of the pressure sensor
The main element of the relay is a group of contacts, which is mounted on a metal base and is responsible for turning the device on and off.
Nearby are two springs of different sizes to adjust the pressure inside the system. From below, a membrane cover is attached to the metal base, under which the membrane itself and the metal piston are placed. From above everything is closed with a plastic cap.
The products of different manufacturers and the principle of its operation are almost identical, they can differ only in insignificant details
In the process of operating the current device, several stages can be distinguished:
- When the tap is turned on, water for some time enters the plumbing point from the filled tank. In this case, the pressure present in the system gradually begins to drop, and the membrane ceases to put pressure on the piston. The contact closes, the pump turns on.
- The pump works by pumping water to the consumer, and when all the taps are turned off, it fills the tank with water.
- When the accumulator tank is gradually filled, pressure increases, and it begins to act on the membrane, and it presses on the piston. As a result, the contacts open and the pump stops.
The frequency of switching on the station, the pressure of the water, and even the service life of the equipment depends on how the relay is configured. If the parameters are set incorrectly, the pump will not operate at all or will operate continuously.
The piston of the pressure switch and the sensitive metal plate reacting to the pressure created by the hydraulic tank membrane are hidden under the body - access to them is completely closed
# 2: Adjustment and calculation of the required pressure
The new device already has factory settings for the relay, but, nevertheless, it is better to additionally check them. Before setting up, it is necessary to find out the values recommended by the manufacturer for setting the permissible pressure threshold (for closing and opening contacts).
In the event of a breakdown of the pumping station due to improper adjustment, the manufacturer has the full right to refuse his warranty obligations.
The calculation of the permissible pressure, when turning on / off the device, the manufacturer carries out taking into account the expected features of operation. They are taken into account in the development of operating parameters for different pumping station models.
The inclusion value is equal to the sum:
- The required pressure at the highest point in the water supply system where water is taken;
- Differences between the height of the highest water withdrawal point and the pump;
- Losses in the water pressure pipeline.
The shutdown rate is calculated as follows: plus one and take one and a half bar to the shutdown pressure. At the same time, it must not be allowed for the shutdown pressure to exceed the maximum allowable pressure that occurs at the pipeline outlet from the pump.
A common mistake affecting the operation of a pumping station is not to take into account the total amount of horizontal and vertical sections, as well as hydraulic losses during transportation of water to the points of tapping
# 3: Setting Recommended Settings
Before changing the settings, it is necessary to fix the previous indicators using a manometer. Turning on the pump, record the pressure values at the time of switching off and on. This will help determine which way to adjust - towards decreasing or increasing.
It must be remembered that any change in the set pressure threshold in the relay also requires corresponding changes in the air compartment of the accumulator
Further actions have the following order:
- Disconnect the station from power, drain the water and open the relay cover with a wrench.
- The pump start pressure is controlled by rotating the nut that holds the large spring (P). Twisting it in the clockwise direction, they achieve compression of the spring and set the required switching pressure. In various models of the device, permissible values can range from 1.1 to 2.2 bar.
- By turning the small nut (∆P) in the clockwise direction, you can increase the gap between the shut-off pressure and the turn-on pressure of the device, which is usually 1 bar. Thus, the shutdown pressure can be fixed at values in the range from 2.2 bar to 3.3 bar.
An important nuance is that a small spring does not regulate the trip threshold, as some people mistakenly understand.
It sets the delta between the values of the inclusion of the station, and its shutdown. That is, a fully weakened spring will not create a difference - the delta will be zero and the on and off values will be the same. But the more you drag it out, the greater the difference between them will be.
The small spring of the pressure switch is more sensitive and must be pressed very carefully
Check the correctness of the set indicators using a manometer. If it was not possible to achieve the required values on the first attempt, adjustment continues.
# 4: Select non-standard pressure values
You can set a different level of pressure in the device, different from the manufacturer's recommendations, adjusting the equipment to individual user requirements. By increasing the range when turning on / off, they achieve more rare station responses.
This makes the service of the device longer, but makes the water pressure uneven. By reducing the difference, they achieve a stable pressure, but this way the pump will operate more often.
Video on what to do if the station often triggers:
Carrying out an independent adjustment of the pumping station, it must be borne in mind that sometimes changes in the factory recommendations can impair the operation of the water supply system. Pump, hoses, plumbing fixtures - all have pressure limits, the violation of which will lead to breakdowns. Therefore, before proceeding with independent actions, it is better to ask for advice from an experienced specialist.
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