RIVERFLOW PUMP INSTALLATION GUIDE

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2 By: TABLE OF CONTENTS RIVERFLOW SYSTEM OVERVIEW COMPONENTS CHECKLIST & ACTIVATION MOTOR MOUNT COVER CONTRACTOR S FINAL CHECKLIST PLUMBING INSTALLATION OVERVIEW SUCTION & RETURN FIXTURES PUMP DETAIL EXAMPLE STEEL SCHEDULE HYDROSTATIC PRESSURE TEST PROCEDURE ELECTRICAL INSTALLATION OVERVIEW MOTOR INSTALLATION MOTOR DRAIN PLUG REMOVAL RIVERFLOW VFD & MOTOR WIRING WIRELESS PUMP CONTROL WIRED PUMP CONTROL -2-

3 By: RIVERFLOW SYSTEM OVERVIEW The Riverflow system is composed of six elements. The Riverflow Pump is an ultra high volume, axial flow, flooded suction, propeller pump. All wetted components are chlorine and salt water compatible. The external components are corrosion proof aluminum alloy, thermoplastic and stainless steel to insure long life in any environment. The Riverflow pump is silent, energy efficient and includes a 5-year warranty. The High Efficiency Motor is three-phase 230-volts, designed for continuous industrial operation. Our motors are totally enclosed and fan cooled. The copper windings are Class F insulated and rated for inverter duty. The motor is premium efficient and will deliver many years of cost saving performance. The Variable Frequency Drive (VFD) is the brain of the system which allows the user full adjustability of the swim current generated by the pump. Our VFD is working behind the scenes to provide system protection and control. This feature rich unit provides full time ground fault protection (GFCI), a Line Reactor for input voltage anomalies, an internal cooling fan and an array of sophisticated power transmission and diagnostic components. The VFD converts single-phase residential power to three-phase industrial power. The Remote Controls by Riverflow offer infinite current speed adjustment for the swimmer and are available in wired and wireless models. The Supply Sump Boxes and Grates are NSF tested and certified for structural and hydraulic safety. These attractive grates are mounted flush in a vertical wall with no intrusion into the swimming pool. These fiber reinforced sump boxes are bonded to PVC pipe couplings for ease of installation. The Trueflow return assemblies are computer designed to provide optimum flow from the pump. These assemblies deliver current into the pool with flow characteristics best suited for counter-current swimming, aquatic exercise and Lazy River current. These components finish flush with the pool wall without intrusion into the swimming pool or immediate pool area. NOTE: The Riverflow system is completely independent of the pool s circulation, heating and filtration system. The Riverflow pump requires a flooded suction and develops a maximum operating pressure of less than 2-PSI. If pressure testing is required, refer to the hydrostatic test protocol in our installation manual. -3-

4 20 SINGLE SUCTION 10 OR 12 COUPLING VARIABLE FREQUENCY DRIVE (VFD) RIVERFLOW SYSTEM - COMPONENTS 23 WIRELESS PUMP CONTROL DUAL SUCTION Ø16 8 RIVERFLOW PUMP FASTER SLOWER LEARN CLEAR 10 COUPLING 18 7/8 START/STOP TRUEFLOW RETURN 2 5/8 19 3/4 8 1/4 MOTOR 10 PIPE SOCKET MOTOR 58 1/4 WIRED PUMP CONTROL SPEED /4 Ø /4 27 5/8 14 3/ OFF ON /2 13 1/2 19 3/4 10 PVC PIPE NIPPLE Ø10 3/ PIPE NIPPLE -4-

5 By: PLUMBING INSTALLATION OVERVIEW Riverflow Plumbing notes Review the following plumbing installation overview prior to installing the Riverflow system. All elevation measurements should be referenced from the pool's normal water line. We recommend that ALL Riverflow components, pipe and fittings be present at the job site before plumbing begins. Complete plumbing layout prior to poured concrete, Gunite or Shotcrete to verify angles and elevations. Large diameter PVC fittings vary in size and dimension. Measure fittings for actual dimensions. Use only primer and solvent cement rated for 10-in. diameter or larger PVC pipe. (IPS Weldon 717) To insure sound glue joints, all pipe ends should be beveled and fully seated in fittings. The top of the Trueflow return fitting should be 5-in. below water line. A level run from that point to the pump discharge outlet is recommended. The Riverflow suction run(s) are normally level from pool to pump. However, Riverflow suction fittings can be installed up to a minimum of 12-in. below water line. Keep all plumbing runs from pump to pool as straight as possible. Always use 45º elbow(s) rather than 90º elbow when possible. If the return run exceeds three 45º elbows, contact Riverflow support at Current Systems Inc. PST (866) or EST (888) All trenching and excavations must be backfilled and compacted to meet industry standards to support the Riverflow pump, fittings and pipe. Upon completion of plumbing and prior to motor installation, a 24 x 24 x 3 concrete stabilizing collar should be poured around the pump housing, leaving 1-in. clearance below the pump head nuts. Keep dirt, standing water, and shrubs off the pump head. NOTE: All wall penetrations edges should be back-cut while cement is wet. Dry pack with hydraulic cement or simillar industry approved material before the application of finish plaster. -5-

6 By: PLUMBING INSTALLATION SUCTION & RETURN FIXTURES Suction Box Installation Riverflow suction assemblies are designed for installation in vertical walls of poured concrete, Gunite or Shotcrete swimming pools. Always cover the finish edge of the box and the grate to protect the parts from damage and overspray during installation. The top of the suction box should be 12-in. or more below water line and separated by at least 12-in. (3-ft. on center) The boxes are designed to finish flush with the interior surface of the pool wall. Suction grates are secured to the suction box with factory installed stainless steel fasteners. If these grates are removed they must be replaced using all of the original fasteners. WATER LINE RETURN POOL SUCTION TRUEFLOW RETURN SUCTION BOX Trueflow Return Installation The Trueflow return fitting is designed for installation in a vertical wall of a poured concrete, Gunite, or Shotcrete swimming pool. Always cover the Trueflow assembly for protection from damage or overspray during installation. The top of the Trueflow opening should be 5-in. below water level. The Trueflow should be supplied by at least 4-ft. of straight 10-in. pipe after any bends. The Trueflow assembly should be aimed carefully along the length of the swimming pool to ensure a balanced current. The internal vanes must be inserted in the Trueflow before gunite. Prior to filling the pool the vanes should be set in place with silicone or epoxy. WATER LINE 5 12 POOL COPING & DECK 4 ft. MIN. Ø10 PIPE TRUEFLOW RETURN NOTE: During shotcrete, perimeter edges of wall fittings must be scooped out to accomodate dry pack with hydraulic cement. HYDRAULIC CEMENT FIXTURE SHOTCRETE -6-

7 PLUMBING INSTALLATION PUMP DETAIL MOTOR 19 3/4 RETURN CONCRETE STABILIZING COLLAR POOL WATERLINE 8 1/4 2 5/8 POOL WATERLINE 14 3/4 10 PIPE SOCKET POOL WATERLINE RETURN 3 10 PIPE SOCKET 24 SQ. 27 5/8 SUPPLY 14 MOTOR 14 3/4 10 PIPE NIPPLE Ø10 3/4 SUPPORT POINT SUPPORT POINT SUPPORT POINT Ø10 3/4 SUPPLY 10 PIPE NIPPLE 27 5/8 8 1/4 19 3/4 2 5/8 VERTICAL PUMP INSTALLATION HORIZONTAL PUMP INSTALLATION -7-

8 By: PLUMBING INSTALLATION EXAMPLE STEEL SCHEDULE 16 1/2 13 1/2 WATER LINE 5 POOL STEEL USE ONLY #5 REBAR 10 PVC PIPE NIPPLE POOL WALL DIFFUSER RETURN FRONT VIEW 3 MIN 3 MIN DIFFUSER RETURN BOX SIDE VIEW 4 OVERLAP 25 or 44 4 OVERLAP POOL WALL POOL STEEL 3 20 USE ONLY #5 REBAR 10 OR 12 COUPLING SUCTION BOX FRONT VIEW 3 MIN 3 3 MIN SUCTION BOX SIDE VIEW WATERLINE 3 3 TRUEFLOW RETURN SUCTION BOX TOP VIEW POOL STEEL #5 REBAR NOTE: This is an example steel schedule. Verify with structural engineer prior to installation of Riverflow system. DUAL SUCTIONS WITH 10 COUPLING FROM BACK OF BOX 36 SECTION VIEW OF POOL WALL INSTALLATION -8-

9 By: PLUMBING INSTALLATION HYDROSTATIC PRESSURE TEST PROCEDURE 1. Scope 1.1 This standard describes a method for testing plastic piping installed as the main flow conduit in current-generating systems for swimming pools. Such conduits generally have two parallel horizontal sections joined by a vertical section, with the horizontal sections opening into the pool and functioning as inlet and outlet. The conduits are typically 10-inch to 12-inch nominal plastic pressure pipe. 1.2 This method uses test plugs and a standpipe to measure leak rate at a hydrostatic pressure of a approximately 4.5 psi at highest elevation in the system. It is suitable for use in testing openended plastic piping runs which normally operate with maximum static pressure of approximately 3-psi or less. It is not suitable for leak testing of closed plastic pressure piping systems. 1.3 This standard does not support to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and to determine the applicability of regulatory limitations prior to use. -9-

10 By: PLUMBING INSTALLATION HYDROSTATIC PRESSURE TEST PROCEDURE 2. Summary of Test method 2.1 Test plugs are installed at the inlet and outlet of the piping loop. A standpipe is installed in the upper test plug. Water is introduced through the lower plug while air is vented from the high point in the loop, to expel all air and completely fill the loop and begin to fill the standpipe. When the standpipe is filled above the highest elevation in the loop. The height of the water column in the standpipe is monitored. Leak rate is determined from the rate of change in the water in the standpipe versus elapsed time. 3. Significance and Use 3.1 This test can be used to measure the leak rate of the plastic piping loop. The test is capable of measuring leaks as small as gallons per hour under conditions of thermal equilibrium. 3.2 This test cannot be used when the water level in the swimming pool is above the lowest point of the pipe loop inlet. The test should be performed before the pool is filled when testing new construction. 4. Interferences 4.1 This test cannot differentiate changes in water volume due to thermal contraction from leakage. Therefore, valid results can only be obtained under condition of approximate constant temperature. 4.2 The longer the test is run at approximate constant temperature, the greater the sensitivity of the test. 4.3 In a typical installation with the volume of the tested piping approximately 200 gallons, a one-degree C change in the temperature of the pipe and water will change the apparent water volume by approximately 0.03 gallons. Decreasing temperature will cause the standpipe level to fall; increasing temperature will cause the standpipe level to rise. -10-

11 By: PLUMBING INSTALLATION HYDROSTATIC PRESSURE TEST PROCEDURE 5. Apparatus 5.1 Test plugs sized for the inlet and outlet piping diameters, typically 10-inch and 120- inch IPS nominal inside diameter. Cheme Industries T-handle pipe plugs in 10-inch and 12-inch sizes are suitable. Where venting air through the pump port is practical, the upper plug may be unvented. 5.2 Adapter for the inlet test plug: to convert to garden=hose female, or other appropriate water source. 5.3 Standpipe adapter for the outlet test plug: short length of PVC pipe with male NPT threaded end, 90-deg elbow, and 1-inch nominal NPT female threads foot length of 1-inch nominal IPS schedule 40 PVC pipe male NPT threads at one end foot length of transparent plastic pipe with inside diameter equal to 1.00 inches, with fitting to connect to 1-inch nominal diameter PVC pipe. 5.6 Steel tape measure, 12-foot minimum length with graduations of 1/16-inch or less. 5.7 Stopwatch, clock or other timer capable of measuring intervals of up to 300 minutes with accuracy of 0.01 minute or better. 6. Hazards 6.1 Hydrostatic testing such as described in this method minimizes energy stored in the system during the test, and thus avoids the hazards associated with pneumatic testing. Nevertheless, the hydrostatic force on the test plugs and the mass of the test plugs are sufficient to cause injury of dislodged during the test. Use caution in installing test plugs and use appropriate secondary safety restraint, such as a cable or chain. 6.2 The PVC piping loop to be tested must have adequate mechanical support prior to filling with water. Specific job condition may require that the pipe loop be braced or otherwise supported with temporary structures so testing can be performed prior to backfilling. 6.3 Do not use the higher standpipe than specified in this method. Do not close off the standpipe to create a closed system. -11-

12 By: PLUMBING INSTALLATION HYDROSTATIC PRESSURE TEST PROCEDURE 6.4 Assure that the pump petcock or other high-point air vent is fully open prior to filling the pipe loop with water, and also that it is opened before draining water from the loop. 6.5 remove hydrostatic pressure by draining the system of water before removing either test plug. 7. Sampling, Test, Specimens, and Test Units 7.1 The sample is the actual circulation piping open loop as installed in as swimming pool. The test is typically performed prior to backfilling. 8. Procedure 8.1 Install the test plug in accordance with the manufacturer s recommendations. Install the plug with the hose fill port in the inlet (lower) end of the loop Install the plug with the standpipe adapter in the outlet (upper) end of the loop, with the 1-inch threaded opening at the top. Install the pipe plugs as recommended by the manufacturer. 8.2 Thread the 8-foot PVC pipe into the standpipe adapter. Align the pipe vertically. If the transparent pipe is not already connected to the PVC pipe, connect it. 8.3 Attach a water-supply garden hose or other suitable water sources to the port in the lower plug. Open the air vent at the high point of the loop, at the circulating pump,. Open the valve on the plug. 8.4 Continue adding water through the lower plug until the water level is approximately at the midpoint of the transparent pipe. Turn off the water supply and close the valve at the plug inlet. 8.6 Mark the water level and note the time. This is 0 elapsed minutes. 8.7 After 10.0 minutes, record the change in water level to the nearest 0.1 inch, relative to the original marked level, record an increase in level as a positive and decrease as a negative. 8.8 repeat 87 at 10-minute intervals. Obtain at least 4 readings. Additional readings may be obtained as needed; record the elapsed time for these reading from the start of the test. It is convenient for these to be hourly intervals, but other intervals are acceptable of accurately recorded. -12-

13 By: PLUMBING INSTALLATION HYDROSTATIC PRESSURE TEST PROCEDURE 9. Calculation or Interpretation of Results 9.1 Plotting the relative height vs. elapsed time for the readings taken may be useful in determining periods of thermal equilibrium. Under thermal equilibrium, the water level will remain constant if the leak rate is zero; the rate of decrease in the height of the column is proportionate to the leak rate. However, if the water temperature in the system changes, thermal expansion or contraction will also affect the water column height. 9.2 Table 1 gives apparent leak rate as a function of change in the water level in the standpipe for a given interval. The following equation may be substituted for the table. LR = * H / t, where: LR is leak rate in gallons per hour, H is change in water column height,, inches t is the time during which the water column height change occurred, minutes 10. Report 10.1 Report column height change vs. time, and the associated apparent leak rate, for at least three consecutive intervals. 11. Precision and Bias 11.1 No data regarding the precision of the method is available at the time this new method is being written There is no alternate or reference test available to determine the bias, if any, of this method. 12. Keywords 12.1 Leak rate, water, plastic pipe, swimming pool. -13-

14 By: ELECTRICAL INSTALLATION OVERVIEW Riverflow electrical notes The variable frequency drive (VFD) converts single-phase to three-phase power The Riverflow Pump is driven by a three-phase industrial duty motor The VFD is rated for indoor installation, ventilated closet, garage, equipment room etc. If an outdoor installation is required, the VFD must be mounted in a properly sized outdoor enclosure Control wiring requires a shielded, 6 conductor, #18 or #20 gauge cable The Riverflow wired remote control box is weatherproof but should not be submerged in water Important! Do not start pump before programming the VFD with an authorized Riverflow technican at, Current Systems Inc. PST (805) or EST (888)

15 By: ELECTRICAL INSTALLATION MOTOR INSTALLATION Follow these steps before wiring or setting motor on motor mount. KEY MOTOR SHAFT SET SCREW COUPLER SLEEVE PUMP SHAFT KEY PUMP SHAFT MOTOR MOTOR BOLTS AND WASHERS MOTOR SHAFT HUB PUMP SHAFT HUB SET SCREW KEY WAY 1. Staring with the pump, slide a coupler hub onto pump s shaft so the end of the hub and the shaft key are flush with the end of the pump s shaft. 2. Slide the coupler sleeve completely on to the pump shaft hub and tighten the set screw on the hub. 3. On the Motor, slide the remaining hub on to the motor s shaft exposing 1/2-in. beyond the end of the hub pump shaft and tighten set screw. 4. Carefully set the motor into position allowing the coupler sleeve to mesh with the motor shaft hub. 5. Rotate the motor body to verify that it has seated properly in the motor mount recess. 6. Rotate the shaft assembly to verify that the pump and motor turn freely. 7. Install and tighten the 4 motor mount bolts and washers to attach the motor. 8. Loosen the set screw on the motor shaft hub. Slide the hub firmly into the coupler sleeve so that the sleeve is fully captured between both hubs and retighten the motor shaft hub s set screw. GREASE FITTING PUMP 9. Again rotate the shaft assembly. If the shaft rotate freely, the motor installation is complete. If the shafts do not turn freely, contact Riverflow support at Current Systems Inc. PST(866) or EST(888) NOTE: Grease every 500 hours. -15-

16 By: ELECTRICAL INSTALLATION MOTOR DRAIN PLUG REMOVAL Drain plug removal The factory installed drain plug(s) must be removed prior to start up. Locate the drain plug at the lowest point based on the installation orientation as shown below. If you are unsure of where drain plug is located on the motor, contact Current Systems Inc. PST (805) or EST (888) MOTOR DRAIN PLUGS DRAIN PLUG LOCATIONS LOCATIONS MAY VARY MOTOR LOWEST AREA MOTOR LOWEST AREA VERTICAL PUMP INSTALLATION HORIZONTAL PUMP INSTALLATION -16-

17 By: ELECTRICAL INSTALLATION RIVERFLOW VFD & MOTOR WIRING MAINTENANCE OR SUB-PANEL VARIABLE FREQUENCY DRIVE (VFD) WITH INTERNAL GFI SINGLE-PHASE 230VAC NON-GFI -50 AMP BREAKER 10HP RIVERFLOW -40 AMP BREAKER 7.5HP RIVERFLOW 230 VAC 230 VAC GROUND DISCONNECT BOX NON-FUSED (IF REQUIRED) U1 W1 GROUND V2 U2 W2 GROUND MOTOR THREE-PHASE OUTPUT TO MOTOR PUMP Motor direction counter clockwise looking at the opposite shaft end of the motor. Refer to the wiring diagrams for complete wiring and operation instructions. If the motor is covered, allow adequate ventilation with at least 6-in. clearance around the motor. Open area of vents, top and bottom, on the enclosure must total at least 100-sq. in. each. CCW -17-

18 By: ELECTRICAL INSTALLATION WIRELESS PUMP CONTROL TRANSCEIVER REMOTE CONTROL REMOTE CONTROL ABB DC BUS VFD 1 9 NEMA 4X ENCLOSURE FASTER SLOWER START/STOP LEARN CLEAR ORANGE - AUX BLUE or PURPLE - COMMON YELLOW - DOWN RED - UP Programming the Remote Control: Step 1: On the Transceiver, press learn/clear button once Step 2: On the Remote Control, press any button once Finished: The remote control is now programmed Controling the pump speed: Step 1: Press up arrow to increase pump speed by 5% per push Step 2: Press down arrow to decrease pump speed by 5% per push Remote Control care: Do not submerge Dry off after use Replace batteries with CR2032, Qty. 2 BLACK - 120V WHITE - NEUTRAL GREEN - GROUND 120VAC SOURCE IMPORTANT: Parameters on ABB VFD must be set to: 1001 to DI to DI 3U, 4D -18-

19 By: ELECTRICAL INSTALLATION WIRED PUMP CONTROL ABB DC BUS VFD CONTROL COVER SPEED OFF ON WHITE RED BLACK JUMPER CONTROL BASE GND X1 X2 JUMPER JUMPER NEMA 4X ENCLOSURE 24 NOTE: Use 18-gauge shielded 6-conductor cable to connect the Control to VFD. -19-

20 By: RIVERFLOW SYSTEM WARRANTY ACTIVATION REQUIRMENTS Follow these steps to begin the process of activating the warranty for your Riverflow Pump. Step 1: Current Systems Inc. must have digital photos clearly showing the Riverflow pump installation with: Entire pump and motor installed A close up view of the shaft coupling Motor wiring inside motor junction box Line and load wiring of mounted VFD Dedicated non-gfi circuit breaker Non-fused disconnect (if required) Visit to submit your photos and fill out the warranty validation form. Step 2: Licensed electrician must call Current Systems Inc. PST (805) or EST (888) prior to applying power to the Riverflow pump motor for start up. A factory authorized technician will instruct the electrician in programming the VFD. -20-

21 IMPORTANT Pool must be filled before running the Riverflow Pump Bump start to verify counter clockwise motor rotation Select NO when prompted to run startup assistant Set time and date Use the attached check list to edit and confirm parameter values Backup parameter settings To activate warranty fax or completed start-up form Parameters Mode 1. Select PARAMETERS in the Main Menu. 2. Press UP/DOWN to highlight the appropriate parameter group, then press SEL. 3. Press UP/DOWN to highlight the appropriate parameter in a group. NOTE! The current parameter value appears below the highlighted parameter. 4. Press EDIT. 5. Press UP/DOWN to step to the desired parameter value. NOTE! To view the parameter default value: In the set mode, press UP/DOWN simultaneously. 6. Press SAVE to store the modified value or press CANCEL to leave the set mode. Any modifications not saved are cancelled. 7. Press EXIT to return to the listing of parameter groups, and again to return to the main menu. Use the Parameters mode to view and edit parameter values: ABB TECH SUPPORT (800) Press 4 and then 3 and have your model number. 24 Hour 7 Day support

22 MOTOR ROTATION Fax completed form CCW to: (805) COUNTER CLOCKWISE for warranty activation Parameters must be set prior to operating system Code Parameter Description Selected Group 99 Enter Values From Motor Data Plate * 9901 Language English American (AM) 9902 Applic Macro ABB Standard 9905 Motor Nom Volt Voltage * 9906 Motor Nom Current Motor FLA * 9907 Motor Nom Freq Hertz * 9908 Motor Nom Speed Motor RPM * 9909 Motor Nom Power Motor HP * Group 10 Command Inputs 1001 Ext1 Commands DI Direction Forward Group 11 Reference Select 1103 Ext Ref1 Select (Wireless) DI 3U, 4D Wired Remote Settings AI1 Group 12 Constant speeds 1201 Constant Speed Sel Not Sel Check When Completed Job name Startup Date Model Serial Number Code Parameter Description Selected Group 20 Limits 2003 Max Current Motor FLA * 2007 Minimum Freq 15 Hz 2008 Maximum Freq 60 Hz Group 21 Start/Stop 2102 Ramps Ramp Group 22 Accel/Decel 2202 Acceleration Time 1 10 Sec 2203 Deceleration Time 1 10 Sec 2205 Acceleration Time 2 10 Sec 2206 Deceleration Time 2 10 Sec Group 26 Motor Control 2606 Frequency 8HZ 2607 Frequency Switch On Group 30 Fault Protection 3005 Mot Therm Prot Fault Check When Completed Group 34 Display 3401 RPM's Speed

23 By: RIVERFLOW SYSTEM MOTOR MOUNT COVER MOTOR Contents of Kit: (2) Motor Mount Cover (1) Drill Bit (4) Washer, Plastic (4) Screw #10, Self tapping Tools Required: Drill Philips Screwdriver Silcone MOTOR MOUNT MOTOR MOUNT COVER PUMP LID C L Step 1. Center the Cover over the opening of the Motor Mount with the bottom resting of the Pump Lid. Step 2. Using the holes in the Cover as a template, drill holes into the Motor Mount with the supplied drill bit. Step 3. Attach the Cover to the Motor Mount using the supplied washer and screw. Be careful not to over tighten the screws. Step 4. Apply a small amount of silcone to the bottom of the Cover and Lid. Finished. -21-

24 By: RIVERFLOW SYSTEM CONTRACTOR S FINAL CHECKLIST Pool is filled and free of debris. Auto and thermal covers are removed. Top of return outlet is 5-in. below waterlevel. Motor and Shaft couplers are secure and free of debris, dirt and sand water. -22-

25 West Coast 1645 Donlon Street, Unit 104 Ventura, CA Toll Free: (866) Local: (805) Fax: (805) East Coast 1835 East Hallandale Beach Blvd, Suite 687 Hallandale Beach, Florida Toll Free: (888) Local: (954) Fax: (954) By: Design Inquiries: Sales Inquiries: Websites: