Xylem AquaBoost CS User Manual
Installation,
Constant Speed Variable Speed
Operation, and
Maintenance Manual
AquaBoost CS and VS Pumping
Packages
Table of Contents
Introduction and Safety.........................................................................................................................3
Introduction..........................................................................................................................................3
Safety.....................................................................................................................................................3
Safety terminology and symbols....................................................................................................3
Environmental safety........................................................................................................................4
Recycling guidelines........................................................................................................................5
User safety............................................................................................................................................5
Precautions during work..................................................................................................................5
Wash the skin and eyes....................................................................................................................6
Product warranty.................................................................................................................................6
Transportation and Storage..................................................................................................................7
Inspect the delivery.............................................................................................................................7
Inspect the package.........................................................................................................................7
Inspect the unit..................................................................................................................................7
Transportation guidelines..................................................................................................................7
Lifting methods.................................................................................................................................7
Storage guidelines..............................................................................................................................7
Storage location................................................................................................................................7
Long-term storage............................................................................................................................7
Table of Contents
Product Description...............................................................................................................................9
General description............................................................................................................................9
Operational limits.............................................................................................................................9
Package information........................................................................................................................9
Nameplate information....................................................................................................................12
Owner's information......................................................................................................................13
Installation.............................................................................................................................................14
Field connections..............................................................................................................................14
Field piping diagrams....................................................................................................................15
Wiring diagrams.............................................................................................................................19
Earth (ground) connections.............................................................................................................25
Pump package location guidelines................................................................................................25
Foundation requirements................................................................................................................25
Level the base on a concrete foundation.......................................................................................26
Connect the optional storage tank.................................................................................................26
Connect the optional low-suction pressure switch.......................................................................27
Piping checklist..................................................................................................................................27
Fastening.........................................................................................................................................28
Commissioning, Startup, Operation, and Shutdown......................................................................29
Preparation for startup.....................................................................................................................29
Final installation checks.................................................................................................................29
Final adjustments............................................................................................................................30
Pump package operation description............................................................................................32
Constant speed operation............................................................................................................32
Variable speed operation..............................................................................................................37
Maintenance.........................................................................................................................................38
Precautions.........................................................................................................................................38
Monthly maintenance.......................................................................................................................38
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 1
Table of Contents
Troubleshooting...................................................................................................................................39
Pump station troubleshooting.........................................................................................................39
The pump station does not power up.........................................................................................39
The station powers up, but the pumps do not run....................................................................39
The pumps run but do not build desired pressure....................................................................40
The pump station experiences excessive vibration...................................................................41
The pump station does not shut down and no water is used...................................................41
The pump station cycles or hunts erratically...............................................................................42
Other Relevant Documentation or Manuals.....................................................................................43
Manuals for AquaBoost components.............................................................................................43
2 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Introduction and Safety
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the
product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the
unit.
Introduction and Safety
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is
over-pressurized. Take all necessary measures to avoid over-pressurization.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment. This includes
any modification to the equipment or use of parts not provided by Xylem. If there is a
question regarding the intended use of the equipment, please contact an Xylem
representative before proceeding.
• This manual clearly identifies accepted methods for disassembling units. These methods
must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion
and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in
their removal.
• Do not change the service application without the approval of an authorized Xylem
representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in
physical injury, damage, or delays.
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent
these hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 3
Introduction and Safety
Hazard levels
Hazard level Indication
Hazard categories
DANGER:
WARNING:
CAUTION:
NOTICE:
Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
A hazardous situation which, if not avoided, will result in
death or serious injury
A hazardous situation which, if not avoided, could result
in death or serious injury
A hazardous situation which, if not avoided, could result
in minor or moderate injury
• A potential situation which, if not avoided, could
result in undesirable conditions
• A practice not related to personal injury
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard
levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
Environmental safety
The work area
Always keep the station clean to avoid and/or discover emissions.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable
environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
4 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Electrical installation
Recycling guidelines
User safety
General safety rules
Introduction and Safety
WARNING:
Do NOT send the product to the Xylem manufacturer if it has been contaminated by any
nuclear radiation. Inform Xylem so that accurate actions can take place.
For electrical installation recycling requirements, consult your local electric utility.
Always follow local laws and regulations regarding recycling.
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash
hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment
within the work area:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
Electrical connections
Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local regulations. For more information about
requirements, see sections dealing specifically with electrical connections.
Precautions during work
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.
Observe these safety precautions when you work with the product or are in connection
with the product:
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level
control.
• Beware of the starting jerk, which can be powerful.
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 5
Introduction and Safety
• Rinse the components in water after you disassemble the pump.
• Do not exceed the maximum working pressure of the pump.
• Do not open any vent or drain valve or remove any plugs while the system is
• Never operate a pump without a properly installed coupling guard.
Wash the skin and eyes
pressurized. Make sure that the pump is isolated from the system and that pressure is
relieved before you disassemble the pump, remove plugs, or disconnect piping.
Follow these procedures for chemicals or hazardous fluids that have come into contact
with your eyes or your skin:
Condition Action
Chemicals or hazardous
fluids in eyes
Chemicals or hazardous
fluids on skin
Product warranty
Coverage
Xylem undertakes to remedy faults in products from Xylem under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an Xylem representative within the warranty period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in
use.
• All service and repair work is done by Xylem-authorized personnel.
• Genuine Xylem parts are used.
• Only Ex-approved spare parts and accessories authorized by Xylem are used in Exapproved products.
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
Limitations
The warranty does not cover faults caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting
Xylem
• Incorrectly executed repair work
• Normal wear and tear
Xylem assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Warranty claim
Xylem products are high-quality products with expected reliable operation and long life.
However, should the need arise for a warranty claim, then contact your Xylem
representative.
6 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Transportation and Storage
Inspect the delivery
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the
distributor.
Inspect the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.
Transportation and Storage
Transportation guidelines
Lifting methods
WARNING:
• Assembled units and their components are heavy. Failure to properly lift and support
this equipment can result in serious physical injury and/or equipment damage. Lift
equipment only at the specifically identified lifting points. Lifting devices such as
eyebolts, slings, and spreaders must be rated, selected, and used for the entire load
being lifted.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods
and wear steel-toed shoes at all times.
Storage guidelines
Storage location
The product must be stored in a covered and dry location free from heat, dirt, and
vibrations.
NOTICE:
• Protect the product against humidity, heat sources, and mechanical damage.
• Do not place heavy weights on the packed product.
Long-term storage
If the unit is stored for more than 6 months, these requirements apply:
• Store in a covered and dry location.
• Store the unit free from heat, dirt, and vibrations.
• Rotate the pump shaft by hand several times at least every three months.
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 7
Transportation and Storage
Treat bearings and machined surfaces so that they are well preserved. Refer to the drive
unit and coupling manufacturers for their long-term storage procedures.
For questions about possible long-term storage treatment services, please contact your
local Xylem sales representative.
8 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Product Description
3
2
4
6
5
1
RS000002
General description
AquaBoost CS pumping package
Depending upon the pumping capacity required, a simplex (one-pump) type or a duplex
(two-pump) type is used. In both types, a pressure switch starts and stops the pump.
The AquaBoost Constant Speed pumping package operates pumps across the line to
increase the domestic water pressure up to 55 psi above that of the city water pressure.
AquaBoost VS pumping package
The AquaBoost Variable Speed pumping package can precisely match the pump
discharge pressure to the system pressure by varying the speed of the pump. This is
accomplished by using the variable-speed controllers such as the AquaBoost II and
Aquavar CPC.
The pressure transducer monitors the system pressure, allowing the controller to start and
regulate the pump speed. AquaBoost VS is available in simplex and duplex configurations.
Operational limits
Ambient temperature and humidity
All electrical equipment is susceptible to failure if operated in ambient temperatures
outside of its rating. Do not operate the unit outside these extremes.
Product Description
Characteristic Specification
Operating temperature range 32°F to 105°F (0°C to 40°C)
Maximum relative humidity 95% non-condensing
Package information
AquaBoost CS simplex
1. Pump: NPE with TEFC motor
2. Control panel with disconnect switch
3. Pressure switch
4. Temperature limit switch
5. Check valve, stainless steel
6. Stainless steel pump trim assembly
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 9
3
2
5
4 6
1
RS000003
5
3
2
4
1
6
7
RS000004
Product Description
AquaBoost CS duplex
AquaBoost VS simplex
1. Pump: NPE with TEFC motor
2. Control panel with disconnect switch
3. Pressure switch, one per pump
4. Temperature limit switch
5. Discharge header: copper L-type
6. Suction header: copper L-type
This variable-speed configuration uses the AquaBoost II controller model 1151AB2 or 2AB2 (for single-phase
power supply: 115V – 0.75 hp; 230V – 1.5 to 2 hp range).
1. Pump: NPE with TEFC motor
2. AquaBoost II controller
3. Transducer assembly
4. Safety switch
5. Temperature relief valve
6. To drain
7. To controller
10 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
5
3
1
2
4
6
7
RS000005
5
3
1
6
7
2
4
RS000006
Product Description
This variable-speed configuration uses the AquaBoost II controller model 3AB2 or 5AB2 (for single-phase
power supply: 3V – 5 hp motors).
1. Pump: NPE with TEFC motor
2. AquaBoost II controller
3. Transducer assembly
4. Safety switch
5. Temperature relief valve
6. To drain
7. To controller
This variable-speed configuration uses the Aquavar CPC controller (for 3–phase power supply: 1.5 to 5 hp
range).
1. Pump: NPE with TEFC motor
2. Temperature relief valve
3. Transducer assembly
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 11
4. Aquavar CPC controller
5. Safety switch
6. To drain
7. To controller
2
3
5
6
7
7
4
1
8
9
RS000007
Model number
Serial number
Voltage
Phase
Hz
SCCR
FLA
Max. HP
Product Description
AquaBoost VS duplex
This variable-speed duplex configuration uses the Aquavar CPC controller (for 3–phase
power supply: 1.5 to 5 hp range).
1. Pump: NPE with TEFC motor
2. Safety switch single-point power panel
3. Aquavar CPC controller
4. Temperature relief valve
5. Discharge header: copper L-type
6. Suction header: copper L-type
7. Pressure transducer assembly
8. To controller
9. To drain
Nameplate information
Nameplate
Every pump station has a nameplate that provides information about the pump station.
The pump station nameplate is located on the outside of the control enclosure door.
When ordering spare parts, please be prepared to identify the nameplate information
when contacting the factory.
• Model
• Size
• Serial number
• Item numbers of the required parts
Nameplate field Explanation
Model number The model number of the pump station
Serial number The serial number of the pump station
Voltage Input voltage required for the pump station
Phase Single-phase or 3–phase
Hz Frequency
12 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Nameplate field Explanation
SCCR Short circuit current rating
FLA Full load amps
Max. HP Maximum horsepower
Model number designation
Number of
pumps
1 A (1x1-1/4, 3600) 05 =
2 B (1-1/4x1-1/2,
*Variable speed only
Product Description
Pump model / rpm HP Voltage / Phase Impeller diameter
(inches)
1 = 115/1/60 A = 4-5/8 –CS = constant speed
1/2
3600)
07 =
3/4
2 = 208/3/60 B = 5-1/16 –VS = variable speed
10 = 1 3 = 380/3/50 C = 5-3/16
15 =
4 = 460/3/60 D = 5-3/4
1.5
20 = 2
30 = 3
50 = 5
5 = 575/3/60 E = 5-15/16
6 = 230/1/60 F = 6-1/8
7 = other Z = other
8 = 230/3/60
A = 208–
230/3/60*
B = 208–
230/1/60*
Control
Owner's information
Fill in the right-hand column with the information specific to your pump station.
AquaBoost CS/VS model number
Pump model number
Pump serial number
Control panel model number
Dealer
Dealer phone number
Date of purchase
Date of installation
Electrical ratings at startup Current
Voltage
Phase
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 13
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