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
Installation
Installation
Field connections
Review the field piping diagrams and wiring diagrams before you install and operate the
unit.
Electrical precautions
WARNING:
Electrical shock hazard. The electrical supply must match the control panel nameplate
specification. Incorrect voltage can cause a fire, which damages the electrical components
and voids the warranty. Failure to follow these instructions could result in serious personal
injury or death, or property damage.
NOTICE:
Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local rules.
Power wiring
Select power wire types and sizes based upon conformance with the National Electrical
Code and all local codes and restrictions. In addition, only copper (Cu) wire rated for at
least 167°F (75°C) can be used for the power connections. Refer to the input current as
listed on the motor nameplate when sizing wire.
Power supply requirements
The power supply required for the AquaBoost CS unit depends on its model number. It
can be one of the following with a dedicated ground wire:
• 115/1/60
• 230/1/60
• 208, 230, 460/3/60
• 380/3/50
• 575/3/60
The power supply required for the AquaBoost VS unit depends on its model number. It
can be one of the following with a dedicated ground wire:
• 115/1/60
• 230/1/60
• 208, 230, 460, 575/3/60
• 380/3/50
WARNING:
Electrical shock hazard. Conduit grounds are not adequate. You must attach a separate
earth (ground) wire to the earth (ground) lug provided in the enclosure in order to avoid
potential safety hazards. Failure to follow these instructions can result in serious personal
injury, death, or property damage.
Input voltage tolerance
The input voltage tolerance is ±10% of the voltage indicated on the nameplate.
14 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Overload protection for constant-speed units
1
2
3
4
5
6
7
8
9
10
Motor type Overload protection Description
Single-phase Internal
Installation
• Disconnecting means
• Fuses for short-circuit protection
Three-phase External in the control panel
Overload protection for variable-speed units
Variable-speed units have a single-point power panel with fuses for protection against
voltage spikes. In addition, the controllers have inherent features that protect the unit
against:
• short circuit
• undervoltage
• overload
• motor temperature
• dead heading
• run out
• suction loss
• sensor fault
• bound pump
• overvoltage
• static discharge
Field piping diagrams
• Disconnecting means
• GV2Ps / manual starters with
thermal overload for short-circuit
protection in the control panel
AquaBoost CS simplex
Typical field piping arrangement for the AquaBoost Constant Speed simplex pumping
package.
1. Anchor the pipe securely if vibration eliminators are used.
2. If a bypass line is installed, then this valve must be kept closed during normal operation. Do not install a
3. Suction gauge, recommended
4. Optional tank
check valve.
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 15
1
2
3
4
5
6
7
8
9
10
RS000010
Installation
_ _ _ _ Dashed lines indicate field installation.
AquaBoost CS duplex
5. Discharge gauge
6. Optional pressure reducing valve
7. Vibration eliminator
8. 1/4 in. inlet tap on the check valve for low-suction pressure switch
9. City supply
10. To system
Typical field piping arrangement for the AquaBoost Constant Speed duplex pumping
package.
1. 1/4 in. tap on the suction manifold for low-suction pressure switch
2. Optional tank
3. Discharge gauge
4. Optional pressure reducing valve
5. Vibration eliminator
6. Anchor the pipe securely if vibration eliminators are used.
7. If a bypass line is installed, then this valve must be kept closed during normal operation. Do not install a
check valve.
8. Suction gauge, recommended
9. City supply
10. To system
_ _ _ _ Dashed lines indicate field installation.
16 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
AquaBoost VS simplex
1
2
3
4
5 6
7
8
10
9
RS000011
Installation
Typical field piping arrangement for the AquaBoost Variable Speed simplex pumping
package.
1. Anchor the pipe securely if vibration eliminators are used.
2. If a bypass line is installed, then this valve must be kept closed during normal operation. Do not install a
check valve.
3. Suction gauge, recommended
4. Optional tank
5. Discharge gauge
6. Vibration eliminator
7. 1/4 in. inlet tap on the check valve for low-suction pressure switch
8. Controller: AquaBoost II or Aquavar CPC
9. City supply
10. To system
_ _ _ _ Dashed lines indicate field installation.
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 17
1
2
3 4 5
6
7
8
9
10
RS000012
Installation
AquaBoost VS duplex
Typical field piping arrangement for the AquaBoost Variable Speed duplex pumping
package.
1. 1/4 in. tap on the suction manifold for low-suction pressure switch
2. Optional tank
3. Discharge gauge
4. Vibration eliminator
5. Anchor the pipe securely if vibration eliminators are used.
6. If a bypass line is installed, then this valve must be kept closed during normal operation. Do not install a
check valve.
7. Suction gauge, recommended
8. Controller: Aquavar CPC
9. City supply
10. To system
_ _ _ _ Dashed lines indicate field installation.
18 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Wiring diagrams
RS000013
AquaBoost CS simplex – 230/1/60 up to 5 hp
Installation
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 19
Installation
AquaBoost CS simplex – 575/460/208-230/3/60, 380/3/50 up to 5 hp
20 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
AquaBoost CS simplex – 115/1/60 up to 2 hp
RS000015
Installation
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 21
RS000016
Installation
AquaBoost CS duplex – 575/460/208-230/3/60, 380/3/50 up to 5 hp
22 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
AquaBoost CS duplex – 115/1/60 up to 1.5 hp
Installation
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 23
RS000018
Installation
AquaBoost CS duplex – 230/1/60 up to 3 hp
24 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Earth (ground) connections
WARNING:
Electrical shock hazard. Conduit grounds are not adequate. You must attach a separate
earth (ground) wire to the earth (ground) lug provided in the enclosure in order to avoid
potential safety hazards. Failure to follow these instructions can result in serious personal
injury, death, or property damage.
A grounding terminal is provided for a dedicated earth (ground) wire connection. You
must follow all provisions of the National Electrical Code and local codes.
Pump package location guidelines
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.
Guideline Explanation/comment
Make sure that the space around the pump package is
sufficient.
If you require lifting equipment such as a hoist or tackle,
make sure that there is enough space above the pump
package.
Protect the unit from weather and water damage due to
rain, flooding, and freezing temperatures.
Do not install and operate the equipment in closed
systems unless the system is constructed with properlysized safety and control devices.
Installation
This facilitates ventilation, inspection, maintenance, and
service.
This makes it easier to properly use the lifting equipment
and safely remove and relocate the components to a safe
location.
This is applicable if nothing else is specified.
Acceptable devices:
• Pressure relief valves
• Compression tanks
• Pressure controls
• Temperature controls
• Flow controls
If the system does not include these devices, consult the
engineer or architect in charge before you operate the
pump.
Take into consideration the occurrence of abnormal noise
and vibration.
The best pump location for noise and vibration
absorption is on a concrete floor with subsoil underneath.
Foundation requirements
Requirements
• The foundation must be able to absorb any type of vibration and form a permanent,
rigid support for the unit.
• The foundation must weigh at least 2-1/2 times the weight of the pump unit.
• Provide a flat, substantial concrete foundation in order to prevent strain and distortion
when you tighten the foundation bolts.
• Sleeve-type and J-type foundation bolts are most commonly used. Both designs allow
movement for the final bolt adjustment.
• Tie the concrete pad in with the finished floor.
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 25
1
2
RS000019
1
2
RS000021
1
2
RS000020
1
2
RS000022
Installation
Level the base on a concrete foundation
1. Place the pump package on its concrete foundation.
2. Place 1.00 in./(25.40 mm) thick steel shims or wedges on both sides of each anchor
bolt in order to support the pump package.
Make sure you also place the shims or wedges midway between the bolts.
This also provides a means of leveling the base.
Connect the optional storage tank
1. If the unit is a simplex configuration, then install the tank to the top connection of the
discharge cross as shown:
Constant speed Variable speed
1. Storage tank
2. Discharge gauge
1. Storage tank
2. Discharge gauge
2. If the unit is a duplex configuration, then connect the tank to the discharge manifold as
shown:
Constant speed Variable speed
1. Storage tank
2. Discharge gauge
1. Storage tank
2. Discharge gauge
26 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
3. Precharge the tank according to the tank-specific IOM.
1
RS000023
1
RS000025
1
RS000024
1
RS000026
Connect the optional low-suction pressure switch
1. If the unit is a simplex configuration, then install the low-suction pressure switch piped
to the 1/4 in. inlet tap on the check valve as shown:
Constant speed Variable speed
Installation
2. If the unit is a duplex configuration, then install the low-suction pressure switch piped
Piping checklist
WARNING:
• The heating of water and other fluids causes volumetric expansion. The associated forces
can cause the failure of system components and the release of high-temperature fluids.
In order to prevent this, install properly sized and located compression tanks and
pressure-relief valves. Failure to follow these instructions can result in serious personal
injury or death, or property damage.
• Avoid serious personal injury and property damage. Make sure that the flange bolts are
adequately torqued.
• Never force piping to make a connection with a pump.
1. 1/4 in. inlet tap on check valve
1. 1/4 in. inlet tap on check valve
to the 1/4 in. tap on the suction manifold as shown:
Constant speed Variable speed
1. 1/4 in. inlet tap on check valve
1. 1/4 in. inlet tap on check valve
Check Explanation/comment Checked
Check that the suction and discharge pipes are
supported independently by use of pipe hangers near
This eliminates pipe strain on the pump
station.
the pump station.
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 27
Installation
Check Explanation/comment Checked
Fastening
Check that there is a strong, rigid support for the
suction and discharge lines.
Check that the suction or discharge lines are not
forced into position.
Check that fittings for absorbing expansion are
As a rule, ordinary wire or band hangers are not
adequate to maintain proper alignment.
Component failure will result if suction or
discharge lines are forced into position.
This helps to avoid strain on the pump.
installed in the system when considerable
temperature changes are expected.
Check that eccentric reducers, if used, are installed
This eliminates air pockets.
with the flat side on top.
Check that a three-valve bypass has been installed
This is a recommended field option.
between the suction and discharge connections.
Check that the piping to which optional vibration
This is necessary for maximum effectiveness.
eliminators are connected is properly anchored to the
floor.
WARNING:
• Only use fasteners of the proper size and material.
• Replace all corroded fasteners.
• Make sure that all fasteners are properly tightened and that there are no missing
fasteners.
28 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Commissioning, Startup, Operation, and Shutdown
Commissioning, Startup, Operation,
and Shutdown
Preparation for startup
DANGER:
Electrical hazard sufficient to kill. Always disconnect and lock out the power before you
service the unit.
WARNING:
• Failure to follow these precautions before you start the unit will lead to serious personal
injury and equipment failure.
• Always disconnect and lock out power to the driver before you perform any installation
or maintenance tasks. Failure to disconnect and lock out driver power will result in
serious physical injury.
• Operating the pump in reverse rotation can result in the contact of metal parts, heat
generation, and breach of containment.
Precautions
NOTICE:
• Verify the driver settings before you start any pump.
You must follow these precautions before you start the pump:
• Flush and clean the system thoroughly to remove dirt or debris in the pipe system in
order to prevent premature failure at initial startup.
• If temperatures of the pumped fluid will exceed 200°F (93°C), then warm up the pump
prior to operation. Circulate a small amount of fluid through the pump until the casing
temperature is within 100°F (38°C) of the fluid temperature.
At initial startup, do not adjust the variable-speed drivers or check for speed governor or
over-speed trip settings while the variable-speed driver is coupled to the pump. If the
settings have not been verified, then uncouple the unit and refer to instructions supplied
by the driver manufacturer.
Final installation checks
Installation checklist
CAUTION:
Serious damage to the pump may result if it is started dry. Make sure that the pump is
completely filled with liquid before it is started.
Check Checked
Check that the unit base is properly leveled and secured.
Check that all lubrication points are properly lubricated.
Check that the shut-off valves to the suction and discharge lines are open.
Check that the system is purged of debris and air. This includes the pumps and PRVs.
Check that the pump and motor shafts are properly aligned.
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 29
Commissioning, Startup, Operation, and Shutdown
Check Checked
Check that the pump rotation is correct.
Final piping checklist
Check Checked
Check that the bypass valve is closed, if used.
Check that the piping is properly supported. This prevents strain on the unit.
Electrical wiring and control checklist
WARNING:
• Electrical shock hazard. Conduit grounds are not adequate. You must attach a separate
earth (ground) wire to the earth (ground) lug provided in the enclosure in order to avoid
potential safety hazards. Failure to follow these instructions can result in serious personal
injury, death, or property damage.
• Always disconnect and lock out power to the package and the driver before you perform
any installation or maintenance tasks. Failure to disconnect and lock out driver power will
result in serious physical injury.
NOTICE:
Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local rules.
Check Checked
Check that the feeder line voltage corresponds to the unit voltage. Check the unit
nameplate or motor terminal connection.
Check that the feeder wires are correctly sized according to local and NEC codes.
Final adjustments
Make the final adjustments on these adjustable devices in order to match the exact system
requirements.
Low-suction pressure switch (optional)
WARNING:
Always disconnect and lock out power to the package and the driver before you perform
any installation or maintenance tasks. Failure to disconnect and lock out driver power will
result in serious physical injury.
The pressure switch is piped into the suction line. An adjusting dial is located inside of the
control. This adjustment controls the low-suction cutout. The differential pressure setting is
fixed at 1.5 psi. Therefore cut-in pressure will be the switch setting plus 1.5 psi.
Although the scale is calibrated in psi, it may not correspond exactly to the actual suction
gauge indication. Therefore, for critical installations, the setting should be adjusted
according to the gauge reading. The approximate settings should be set prior to placing
the unit in operation in order to suit the pressure conditions at the installation.
30 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
System pressure switches for constant speed units
1 2
RS000032
WARNING:
Always disconnect and lock out power to the package and the driver before you perform
any installation or maintenance tasks. Failure to disconnect and lock out driver power will
result in serious physical injury.
The simplex unit has one switch and the duplex unit has two switches: one for each pump.
Each switch is piped to the discharge piping.
Two adjusting screws are located on the top of the control. Facing the switch, the screw on
the right-hand side sets the cutout pressure. Make this adjustment first.
The screw to the left and towards the front sets the cut-in point. Turn this screw until the
proper cut-in pressure is obtained.
Commissioning, Startup, Operation, and Shutdown
1. The silver adjusting screw on the left front is for cut-in adjustment.
2. The yellow adjusting screw on the right is for cutout adjustment.
Although the scales are calibrated in psi, they may not correspond exactly to the actual
discharge gauge indication. Therefore, for critical installations, adjust the settings
according to the gauge reading.
For the proper settings of the system pressure switches on a duplex unit, see the wiring
diagram for AquaBoost CS duplex – 575/460/208-230/3/60, 380/3/50 up to 5 hp (page
22).
Minimum run timer
For a constant speed simplex unit the minimum run timer is set at the factory to 5 minutes.
Verify the setting before placing the unit into operation; adjust if a shorter minimum run
time is desired.
For the constant speed duplex unit, use the programmable pump sequence control
module to set the minimum run timer for each pump.
Programmable pump sequence control module settings
The constant speed duplex package uses a smart relay as its control module.
This table shows the user-adjustable settings of the smart relay. You can manually set
parameters using the backlit LCD display and buttons.
Parameter description Default setting
Lead pump minimum run timer 30 0-999
Lag pump minimum run timer 30 0-999
Lead pump start delay timer 1 0-99
Lag pump start delay timer 5 0-99
(seconds)
Variable range
(seconds)
Field setting
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 31
Commissioning, Startup, Operation, and Shutdown
Parameter description Default setting
Pump fail to start proof timer 5 0-99
Low suction/high temperature off proof timer 5 0-99
Low suction/high temperature on proof timer 5 0-99
Duty/standby 0
Staging on proof timer 30 0-99
For more details on these settings see Sequence of operation for the duplex pumping
system (page 36).
Aquastat
The aquastat for high temperature cutout is set at the factory for 100°F (38°C). Adjust the
setting if a different cutout temperature is desired. Do not set the switch above 225°F
(107°C).
Optional tank
A variety of different tanks can be used with either the simplex or duplex units. Refer to the
specific IOM that was shipped with the tank for installation and operating instructions.
Pump package operation description
(seconds)
Variable range
(seconds)
0 = disabled
1 = enabled
Field setting
CAUTION:
A unit that shows symptoms of possible problems, such as overflow, noise, leaks,
vibrations, or continual operation, must be corrected immediately.
Constant speed operation
Constant speed simplex – for capacities up to 110 gpm
Condition Description
The city water pressure falls below the setting of the
system suction pressure switch (2PS).
The system pressure rises above the setting of the system
pressure switch.
Constant speed duplex – for capacities up to 220 gpm
Condition Description
The city water pressure falls below the setting of the
system suction pressure switch (2PS).
The system pressure rises above the setting of the system
pressure switch.
The system demand increases beyond the capacity of the
lead pump and the system pressure does not satisfy the
pressure switch settings.
The system pressure rises above the settings of Pump 1
and Pump 2 discharge pressure switches (2PS and 3PS).
The pump starts through a power relay.
The pump stops, provided the minimum run timer has
expired.
The lead pump starts through a power relay.
The lead pump stops, provided the minimum run timer
has expired.
The system automatically starts the lag pump and both
pumps run.
Both pumps stop, provided the minimum run timers
have expired.
32 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Condition Description
The lead pump fails.
Conditions that cause the unit to cut out
Simplex and duplex units run when there is demand unless one of the following conditions
occurs:
Condition Description Resolution
Low city pressure The optional low-suction pressure
Pump deadheading The high temperature cutout switch
switch (1PS) trips.
trips.
Commissioning, Startup, Operation, and Shutdown
The lag pump starts and acts as the lead pump.
To reinstate the lead pump do the following:
1. Before fixing the failed pump, turn the HOA
switch to the OFF position.
2. After the lead pump has been fixed, place the
lead pump HOA into the AUTO position and then
press the RESET button to reset the unit.
3. The pump returns to its operational state.
The low suction condition resets automatically
when the city pressure returns to an acceptable
level.
The unit resets automatically when there is demand
by drawing cooler water through the unit and
across the temperature sensor. This cools the sensor
and causes it to change state and restart the pump.
For a manual purge run the unit in Hand mode for
about 5 seconds. Then put the unit back into Auto
mode for normal operation.
The smart relay control module
The AquaBoost CS duplex pumping package uses a smart relay for its control module. You
can adjust control settings via the front panel of the smart relay.
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 33
1 2
Q1
1 2
Q2
1 2
Q3
1 2
Q4
8
7
6
5
4
Outputs
Q1…Q4: Relay 8A
1 2 3
Inputs I1…I6
100…240VAC
100…240VAC
L N
I1 I2 I3 I4 I5 I6
SR2A101FU
Menu / OK
RS000027
1
2
RS000028
Commissioning, Startup, Operation, and Shutdown
Smart relay front panel
1. Screw terminal block for the power supply
LCD display
2. LCD display
3. Screw terminal block for discrete inputs
4. Slot for backup memory or PC connection cable
5. Shift key, white
6. Menu/OK key, green, for selection and confirmation
7. Relay output screw terminal block
8. Navigation Z push buttons, gray
This illustration show an example of LCD display elements in the input-output screen:
1. Program version
2. Contextual menus, pushbuttons, icons that indicate operating modes
34 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Control keys
RS000029
RS000031
The keys located on the front panel of the smart relay are used to configure, program, and
control the application and to monitor the progress of the application.
• The shift key is the white key located on the right side of the LCD screen.
• The green Menu/OK key is used for all confirmations: menu, sub-menu, program,
parameter.
• The gray keys, labeled Z1 through Z4, have arrows below them indicating the
directions of navigation.
Navigate through user-adjustable parameters
Commissioning, Startup, Operation, and Shutdown
When the controller is turned on, the Lead Pump Minimum Run Timer screen appears:
• Press the left-most gray key, Z1, in order to navigate to other user-adjustable
parameters.
Modify parameters
1. In order to modify the preset value, press and hold the white shift key and press the
right-most navigation key, Z4.
The current preset value will start to blink.
2. Modify the parameter value with the up and down arrow keys.
3. When the desired value is displayed, confirm the changes by pressing the green
Menu/OK button.
Navigate to and from the main screen
• Continuously press the Z1 left arrow key until the main screen appears:
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 35
Commissioning, Startup, Operation, and Shutdown
• From the main screen, press the Z1 left arrow key two times to go to the user-adjustable
parameters screen.
The Lead Pump Minimum Run Timer screen will appear.
Sequence of operation for the duplex pumping system
Starting the lead pump
The lead pump can be started from either of the two pressure switches (2PS or 3PS) that
are provided on the right-hand side of the controller. The same applies to the lag pump.
This provides redundancy in the event of a failure of either pressure switch. Fully automatic
alternation is included in the standard controller. Pumps alternate any time that both
pumps stop.
Staging pumps together
Pumps can stage together if the pressure switch indicates that the system pressure is
unable to meet the required demand. This is the default setting of 0, which means that the
duty/standby switch is disabled. The pump stage/de-stage function is disabled when the
duty/standby switch is enabled by switching the setting to 1. When the duty/standby
switch is enabled, only one pump can run at a time; the other pump remains in standby
state.
Maintaining system pressure
If two pumps are running together to maintain the required system pressure, and the
system pressure increases, the system de-stages (stops) the lag pump. After the lag pump
has been de-staged and system pressure is still maintained, the system then stops the lead
pump as well.
The time interval between the lead pump stop and the lag pump stop must be at least 30
seconds. This is a fixed timer and no adjustments can be made.
Start delay
The start delay timer for both lead and lag pumps is a user-adjustable parameter that
prevents short cycling of pumps or false starting of pumps. The start delay timer for the lag
pump starts after the lead pump starts so that it is impossible for both pumps to be started
at the same time.
Minimum run time
Each pump has a minimum run timer. Pumps continue to run during that minimum run
time unless a failure occurs, such as pump failure or overload. The pump minimum run
timer is a user-adjustable parameter. Pump failure can be detected by a differential
pressure switch or by an overload failure. The pump fail proof timer is a user-adjustable
parameter.
Pump failure
When one pump is running and the system detects a failure on that pump, the system
stops the failed pump. The system then automatically switches to the other pump and
replaces the failed pump in order to meet the system demand. When pump failure occurs,
the pump failure indicator light illuminates.
Before you fix the failed pump, put the HOA switch in the OFF position. After the failed
pump is fixed, put the HOA switch in the Auto position.
You must manually reset the pump. Press the RESET button to turn off the pump failure
indicator light and return that pump to operational state.
Low-suction or high-temperature shutdown
A low-suction/high-temperature shutdown proof timer provides instantaneous shutdown
and prevents immediate restarting of the pumps. The proof time is adjustable between 0
to 99 seconds; the default setting is 5 seconds.
36 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
When a low-suction or high-temperature thermal cutout situation occurs, the red light
indicator illuminates. An auto reset feature is provided in order to return the pumps to
operational state.
Variable speed operation
Variable speed simplex – for capacities up to 110 gpm
The pressure transducer monitors the system pressure and sends a feedback signal to the
controller. Depending upon the feedback, the controller then changes the speed of the
pump.
Condition Description
The system pressure falls below the set point. The pump starts automatically and pump speed
The system pressure rises above the set point. The pump automatically reduces speed until the system
Variable speed duplex – for capacities up to 220 gpm
The pressure transducer monitors the system pressure and sends feedback signal to the
controller. Depending upon the feedback, the controller changes the speed of the pump
or stages/de-stages the other pump.
Commissioning, Startup, Operation, and Shutdown
continues to ramp up until the system pressure satisfies
the set point.
pressure reaches the set point, provided the minimum
run timer has expired.
Condition Description
The system pressure falls below the set point. The pump starts automatically and pump speed
The system pressure rises above the set point. The pump automatically reduces speed until the system
Low-suction pressure switch
Simplex and duplex units will run when there is demand unless the optional low-suction
pressure switch trips due to low city pressure.
The low-suction condition resets automatically when city pressure returns to an acceptable
level.
Temperature relief valve
The variable-speed units have a temperature relief valve that senses water temperature
inside the pump.
The valve opens and closes depending on the water temperature. This modulating action
maintains a relatively constant fluid temperature even as operating conditions vary.
Condition Description
The water temperature exceeds the valve opening
temperature, typically 120ºF (49°C).
The water temperature falls below the opening
temperature by 10º F (5.5°C).
continues to ramp up until the system pressure satisfies
the set point.
pressure reaches the set point, provided the minimum
run timer has expired.
The valve automatically opens to allow relatively cooler
supply water to refill the pump as the hot water is
discharged to the drain or low pressure return.
The valve automatically closes in order to conserve water
and reduce waste.
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 37
Maintenance
Maintenance
Precautions
DANGER:
Electrical hazard sufficient to kill. Always disconnect and lock out the power before you
service the unit.
WARNING:
• 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.
• Make sure that each pump and the package are isolated from the system and that
pressure is relieved before you disassemble the pump, remove plugs, open vent or drain
valves, or disconnect the package piping.
• Always disconnect and lock out power to the package and the driver before you perform
any installation or maintenance tasks. Failure to disconnect and lock out driver power will
result in serious physical injury.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods
and wear steel-toed shoes at all times.
Monthly maintenance
Motor lubrication checks
• For grease-filled bearings, make sure that grease is not all over the inside of the motor
and in the bottom of the motor. This could be a sign of overfilling. Refer to the
lubrication instructions from the motor manufacturer.
Close-coupled pumps
• For a horizontal pump, verify that the mechanical seal is not leaking between the pump
and the motor.
Sound and visual checks of the whole station
• Listen for any odd sounds that rub or grind, electrical arcing, and check for anything
that is binding or unusual. These conditions can indicate a serious problem.
Note that there is going to be some harmonic vibration with the pumps and motor.
Listen for excessive vibration or noise as this requires immediate service. Do not
operate the pump if there is excessive vibration.
• Confirm that the building cooling and ventilation systems are operating and clear of all
obstructions. The maximum operating range for equipment is 104°F (40°C).
• Verify that water, grease, oil, and hardware are not leaking or loose on the pump
station.
Station skid
• Visually inspect for leaks in the station piping, valves, and other components.
• Visually inspect the piping and skid for any stress cracks in the welds.
• Visually inspect the station for loose or damaged paint or areas of rust.
38 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Troubleshooting
Pump station troubleshooting
DANGER:
• Personal injury hazard. Troubleshooting a live control panel exposes personnel to
hazardous voltages. Electrical troubleshooting must be done by a qualified electrician.
Failure to follow these instructions will result in serious personal injury, death, and/or
property damage.
• Electrical hazard sufficient to kill. Always disconnect and lock out the power before you
service the unit.
WARNING:
Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local rules.
Note that some troubleshooting procedures apply to only constant speed systems or only
variable speed systems.
Troubleshooting
The pump station does not power up
Cause Remedy
The site voltage does not match the pump station
voltage.
Line-to-line voltage is not balanced. Check incoming voltage and amperage. Line-to-line
The power fuses are blown or breakers are tripped. Check power fuses and breakers. Breakers are shipped in
The pump station is not properly grounded (earthed). Check that proper grounding (earthing) techniques have
There is a fault. Check for fault codes or fault lights on the PLC. Correct
The station powers up, but the pumps do not run
Cause Remedy
Pumps are not enabled. Check the PLC to make sure that the pumps are enabled.
The desired pressure is satisfied. Check to see if the desired pressure is satisfied. If the
There is a fault. Check for fault codes or fault lights on the PLC. Correct
The motor is tripped. Check for a tripped motor thermal protector. Allow motor
The fuses are blown or breakers are tripped. Check circuit breaker and fuses.
Transducer isolation valves are closed. Make sure that the transducer isolation valves are in the
Automatic mode is faulty. Check to see if the pump can be run in Manual mode on
Make sure that the site voltage matches the pump station
design voltage.
voltage should be balanced. Line-to-ground voltage
should also be balanced.
the OFF position. Replace blown fuses.
been used for the pump station.
the fault.
Check for faults. Correct any faults.
actual pressure is greater than the set point pressure,
then the pumps are automatically stopped.
the fault.
to cool, and then reset the thermal protector.
open position.
the PLC.
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 39
Troubleshooting
Cause Remedy
The impeller is bound. Check to see if you can turn the pump by hand. Check for
A pressure transducer is faulty. Replace faulty pressure transducers.
Motor wiring is loose. Make sure that motor wiring is securely connected.
Motor windings have lost insulation strength. Test the motor leads with a megger in order to check the
Variable speed drive is wired incorrectly. Check corresponding variable speed drive. Make sure
Motor is defective. Repair or replace motor.
Troubleshoot the pump operation
If the pump still does not operate after you have checked initial causes, then use this
procedure to further investigate and correct the problem.
1. Momentarily turn the HOA switch to the HAND position and then back to OFF. Does
the starter pull in?
• If the starter does not pull in, then go to the next step.
• If the starter does pull in, then go to the last step.
2. Turn the HOA switch to the HAND position. Check the voltage across the terminals for
the coil in the starter.
• If voltage is present and the starter is not pulled in, the coil is defective and must be
replaced.
• If no voltage is present, then go to the next step.
3. With the HOA still in the HAND position, check the voltage between the hot side of the
starter coil and the neutral (white) wire. 120 volts should be measured.
• If no voltage is measured, then check incoming power and fuses.
• If voltage is measured, then go to the next step.
4. With the HOA still in the HAND position, check the voltage between the hot side of the
coil and the neutral (white) wire for overload block. 120 volts should be measured.
• If voltage is measured, then replace the GV2P block.
• If no voltage is present, then contact your local Goulds Pumps representative to
service the control circuit.
5. With the starter pulled in, check the voltage at the bottom of the GV2P block. The
voltage should be the same as the incoming power.
• If no voltage is present, then replace the starter.
• If voltage is present, then contact an electrician to check the leads and motor.
a bound impeller.
motor windings.
drive is wired correctly.
For electrical troubleshooting of variable speed units, refer to the manuals of the
corresponding variable speed controllers.
The pumps run but do not build desired pressure
Cause Remedy
Pumps are running off their design curve. Check the application. Is the system running in an open
discharge condition (excessive flow rate)? For example, is
the system filling a large irrigation line for the first time
of the season?
Pumps are running at less than full speed. Check to see if the pumps are running at full speed. If
they are running less than full speed, they could be
experiencing electrical issues. Check the panel for power
status.
The inlet pressure does not match the project
specifications.
A pipe is broken. Check for broken pipes.
40 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Check to see if the inlet pressure matches the project
specifications. Variations in inlet pressure can have
detrimental effects on performance.
Troubleshooting
Cause Remedy
The transducer isolation valves are closed. Check to be sure that the transducer isolation valves are
in the open position.
The NPSH is insufficient. Check the NPSH. Are proper flooded conditions or
positive pressure being delivered to the pump station?
Check for air in the supply lines. Check for properly filled
supply tanks (if applicable). Excessive suction lift or
piping losses will limit the life expectancy of the pumps.
The pump station has lost its prime. Check to be sure that the pump station has been primed
properly. Make sure that all pumps and components are
properly filled with water.
The pump rotation is incorrect. Check the pump rotation. Proper rotation is indicated on
the pump volute. (See the pump IOM.)
A suction or discharge valve is closed or clogged. Check the isolation valves and check valves. Are all
suction/discharge valves open? Could any valves be
plugged? Could the pumps be plugged?
The motor is not operating at the rated RPM. Check the voltage and amperage. Check for possible
phase loss to the motor.
The impeller is worn or plugged. Take the pump to an authorized pump repair facility.
The pump bearings are worn. Take the pump to an authorized pump repair facility.
The pump station experiences excessive vibration
Cause Remedy
The motor, pump, or piping is loose. Make sure that all fasteners and components are
properly tightened.
Pump station vibration dampers are missing or
improperly installed.
Pumps are running off their design curve. Check the application. Is the system running in an open
Air or gases are present in the pumped liquid. Check water supply lines and tanks. Check for air or gases
Discharge piping is plugged. Check discharge piping/valves. Could the piping be
Supply piping has excessive suction/lift conditions or
friction loss.
The impeller is bound or worn. Take the pump to an authorized pump repair facility.
Pumps and pipes are not properly aligned. Correct the alignment between pumps and pipes.
Check for properly installed pump station vibration
dampers.
discharge condition (excessive flow rate)? For example, is
the system filling a large irrigation line for the first time
of the season?
in liquid. Bleed the lines.
plugged? Could the pump be plugged? Are the isolation
valves open? Clear any clogs.
Check for excessive suction/lift conditions or friction loss
on supply piping.
The pump station does not shut down and no water is used
Cause Remedy
The pump station is in Hand or Manual mode. Put the system in the AUTO position.
The system pressure is set beyond capability of the
station.
The RTDs are incorrectly installed. Check to make sure that the RTDs are installed correctly.
There are leaks or broken pipes. Check for broken pipes or leaks. Does the system
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 41
Check the system set pressure. Is this duty point beyond
the capability of the pump station?
(CS only)
pressure decrease if the pump station is turned off?
Troubleshooting
Cause Remedy
The diaphragm tank is faulty. Check for a properly installed diaphragm tank. Has the
The pressure transducers are faulty. Check the pressure transducers. Does the actual
The VFDs are in Local mode. Put the VFDs in Remote mode.
A check valve is malfunctioning. Check for malfunctioning check valves. Does the system
The pump station cycles or hunts erratically
Cause Remedy
The pumps are oversized for the current demand. Check the application. Possibly increase the size of the
The inlet pressure is fluctuating. —
There are leaks or broken pipes. Check for broken pipes or leaks. Does the system
The diaphragm tank is faulty. Check for a properly installed diaphragm tank. Has the
The pressure transducers are faulty. Check the pressure transducers. Does the actual
A check valve is malfunctioning. Check for malfunctioning check valves. Replace faulty
There is an error in the PLC programming. Check the customer programming on the PLC. Correct
tank failed? Has the tank been charged to the proper
operating pressure before installation? (~10 psi below
the desired set point)
mechanical gauge pressure match the pressure
displayed on the VFDs and the PLC?
hold pressure when the pump package is shut down?
Replace faulty valves.
bladder tank for low demand situations.
pressure decrease when the pump station is turned off?
tank failed? Has the tank been charged to the proper
operating pressure before installation? (~10 psi below
the desired set point)
mechanical gauge pressure match the pressure
displayed on the VFDs and the PLC?
valves.
any errors.
42 AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual
Other Relevant Documentation or Manuals
Other Relevant Documentation or
Manuals
Manuals for AquaBoost components
Further information pertaining to the installation, operation, and maintenance of your
AquaBoost Pumping System can be found in the IOMs provided for the associated
equipment:
Equipment Manual
Goulds Pumps Model NPE IM013
Aquavar CPC IM167
Aquaboost II 3AB2-5AB2 IM183
Aquaboost II 115AB2-2AB2 IM156
Tank Model-specific
AquaBoost CS and VS Pumping Packages Installation, Operation, and Maintenance Manual 43
Xylem |’zīləm|
1) The tissue in plants that brings water upward from the roots
2) A leading global water technology company
We're 12,500 people unified in a common purpose: creating
innovative solutions to meet our world's water needs. Developing new
technologies that will improve the way water is used, conserved, and
re-used in the future is central to our work. We move, treat, analyze,
and return water to the environment, and we help people use water
efficiently, in their homes, buildings, factories and farms. In more than
150 countries, we have strong, long-standing relationships with
customers who know us for our powerful combination of leading
product brands and applications expertise, backed by a legacy of
innovation.
For more information on how Xylem can help you, go to xyleminc.com
Xylem Inc.
2881 East Bayard St. Ext., Suite A
Seneca Falls, NY 13148
Tel. 1-800-453-6777
Fax 1-888-322-5877
www.xyleminc.com/brands/
gouldswatertechnology
S100057_1.0_en.US_2012-7_IOM_AquaBoost
Visit our Web site for the latest version of this
document and more information
The original instruction is in English. All nonEnglish instructions are translations of the original
instruction.
©
2012 Xylem Inc.
Goulds is a registered trademark of Goulds
Pumps, Inc. and is used under license.
Loading...