Xylem IM112 User Manual [en, es, fr]
ITT
Goulds Pumps
AquaBoost™ Controller
Variable Speed Pump Control
Installation, Operation &
Maintenance
Models Covered:
1AB1 – 1 HP (4.8A) – Single Phase
2AB1 – 2 HP (7A)
Residential Water Systems
3AB1 – 3 HP (10A)
Software
Goulds Pumps is a brand of ITT Residential and
Commercial Water.
www.goulds.com
Engineered for life
INDEX
Index
System Design ................................................................................................................................3
Important Safety Instructions ........................................................................................................4
Installation Procedures ..................................................................................................................5
1) Pump / AquaBoost Installation ..................................................................................................5
2) Installation Confi guration .........................................................................................................6
3) Electrical Connections ...............................................................................................................6
4) Pump Priming ...........................................................................................................................9
5) Run Test ....................................................................................................................................9
Operator Displays ...........................................................................................................................9
• Error Signals ................................................................................................................................... 9
Appendix A – Pressure Transducer Data .........................................................................................11
Appendix B – AquaBoost Controller Drive Head Technical Data .....................................................12
Limited Warranty .......................................................................................................................... 13
2
System Design
System Design
Note
Systems MUST be designed by qualifi ed technicians only and meet all applicable state and local
code requirements.
The following diagrams show a typical system using the AquaBoost Controller. Connection can be made directly to
a water supply or water can be drawn from a supply tank. Diagram #1 shows a typical set up for a supply tank.
Home Supply
Check Valves
Well Supply
Disconnect
Diagram 1
AquaBoost Installation
for Well Pump System
Circuit Breaker
AquaBoost Control
Tank
Gauge
Relief
Valve
To Drain
Isolation Valve
Atmospheric
Storage Tank
Unions
Check Valves
Diagram #2 shows a set-up for municipal water connection. This allows pump maintenance without main line
shut-off.
Home Supply Water Main
Check Valves
Circuit Breaker
AquaBoost Control
Disconnect
Isolation Valve
Unions
Relief
Valve
Check Valves
To Drain
Diagram 2
AquaBoost Installation
for Municipal Water
System
Tank
Gauge
A diaphragm pressure tank is used on the discharge side of the pump to maintain pressure in the line when
there is no demand. This will keep the pump from continuing to run. With the AquaBoost Controller, it is not
necessary to have a large tank for supply purposes. In selecting a tank, make sure it can withstand system pressure. The tank should have a capacity of at least 10% of the maximum pump fl ow rate in gpm. Typically, pumps
used with the AquaBoost controller use a V6P or larger Goulds Pumps Hydro-Pro
®
Tank. Pre-charge the tank to
the following:
PSI Set Pressure 15 30 45 60 75
PSI Tank Pre-charge 12 21 37 52 64
3
Safety Instructions
Important: Read all safety information prior to installation of the
AquaBoost Controller.
Note
This is a SAFETY ALERT SYMBOL. When you see this symbol on the pump or in the manual,
look for one of the following signal words and be alert to the potential for personal injury or
property damage.
DANGER
WARNING
CAUTION
NOTICE Indicates special instructions which are very important and must be followed.
1. This manual is intended to assist in the installation, operation, and repair of the AquaBoost Controller and
must be kept with the AquaBoost Controller.
Warns of hazards that WILL cause serious personal injury, death, or major property
damage.
Warns of hazards that CAN cause serious personal injury, death, or major property
damage.
Warns of hazards that CAN cause personal injury or property damage.
Note
All operating instructions must be read, understood, and followed by the operating personnel.
Goulds Pumps accepts no liability for damages or operating disorders which are the result of
non-compliance with the operating instructions.
2. To avoid serious or fatal personnel injury or major property damage, read and follow all safety
instructions in this manual.
3. Installation and maintenance MUST be performed by properly trained and qualifi ed personnel.
4. Review all instructions and warnings prior to performing any work on the AquaBoost Controller.
5. Any safety decals MUST be left on the AquaBoost Controller unit and pump.
Note
Inspect AquaBoost Controller for any damage after unpacking from shipping crates. Report any
damage immediately to the carrier or distributor/dealer immediately.
6. In addition to instructions contained in this manual, you must meet any local safety, electrical or plumbing
codes and requirements. Installation, maintenance or repair work must only be carried out by trained,
skilled and qualifi ed personnel.
7. The AquaBoost Controller drive head must be disconnected from the main power supply before
attempting any operation in the electrical or mechanical part of the system.
Note
When in operation, the motor can be stopped, but power remains at the drive head. The motor
and pump could start unexpectedly and produce serious injury. When the Aquaboost Controller
drive head is connected to the main power supply, the inverter power supply and master control
unit are also connected to the power supply.
WARNING
Hazardous voltage
can shock, burn or
cause death.
WARNING!
FAILURE TO DISCONNECT ELECTRICAL POWER BEFORE ATTEMPTING ANY MAINTENANCE
CAN CAUSE SHOCK, BURNS OR DEATH.
4
4
Installation Procedures
Step 1 – Pump / AquaBoost
Installation
1) Refer to the pump manual for instructions
on proper installation of the pump.
2) Mount the AquaBoost Controller on a wall in
a well-ventilated area.
1AB1
3/8” NPT
AUX. POWER
0.19
2 PLS
4.38
0.63
2 PLS
3) Pressure Transducer Installation: Locate
the pressure transducer and cable. The
threaded end of the transducer is 1/4" NPT.
Install the transducer in the tee or on the
downstream side of the check valve or foot
valve.
4) Connections in the Conduit Box: (when
using controller with other pumps) The
free end of the motor cable should now be
routed through the strain relief on the
conduit box. Connect the motor leads using
the motor nameplate as a reference. Place
the thermistor terminal in the conduit box
and fasten so that the sensor will contact
the motor shell. Note: Step 4 is completed
at the factory for complete AquaBoost pump
kits with pumps.
5) Input Power Cable Installation: The cable
has been pre-wired to the AquaBoost
Controller. Cut the loose end to length, strip
the wires and install the appropriate mating
connector or wire directly to a junction box
or distribution panel providing 208-230V,
single phase power. An all leg disconnect
switch should be provided. Follow local
electrical codes and NEC.
1/2”
NPT
INPUT
POWER
CORD
3/8” NPT
TRANSDUCER
PORT
Diagram 3
2AB1 and 3AB1
3 THRU HOLES
Ø .47
2 THRU HOLES
Ø .63
2 THRU HOLES
Ø .87
1/2”
NPT
OUTPUT
POWER
CORD
6.188
0.41
2 PLS
BACK VIEW AQUABOOST MOUNTING
0.78
7.25
0.38
0.19
2 PLS
4.38
6.00
0.25
Diagram 4
5
Installation Procedures
Installation Confi guration
Step 2 – Electrical Connections
WARNING
WARNING!
FAILURE TO DISCONNECT AND LOCKOUT ELECTRICAL POWER AND WAIT FIVE MINUTES
FOR CAPACITOR DISCHARGE BEFORE SERVICING AQUABOOST CONTROLLER CAN CAUSE
Hazardous voltage
can shock, burn or
cause death.
SHOCK, BURNS, OR DEATH.
Note
Installation and maintenance must only be performed by properly trained and qualifi ed personnel equipped with the proper tools.
WARNING
Hazardous voltage
can shock, burn or
cause death.
WARNING!
INSTALL, GROUND AND WIRE ACCORDING TO NATIONAL, STATE AND LOCAL CODE
REQUIREMENTS.
INSTALL AN ALL LEG DISCONNECT SWITCH NEAR THE MOTOR.
DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING.
ELECTRICAL SUPPLY MUST MATCH PUMP’S AND AQUABOOST CONTROLLER NAMEPLATE
SPECIFICATIONS. INCORRECT VOLTAGE OR WIRING CAN CAUSE FIRE DAMAGE, AND VOIDS
WARRANTY.
MOTORS WITH AUTOMATIC THERMAL PROTECTION MAY OPEN THEIR ELECTRICAL CIRCUIT
WHEN A THERMAL OVERLOAD EXISTS. THIS CAN CAUSE THE MOTOR TO START UNEXPECTEDLY AND WITHOUT WARNING.
AquaBoost
Controller
Transducer
230V, 1Ø
Input
Thermistor
Diagram 5
230V, 3Ø
Output
Tank
Gauge
Discharge
to house
Suction
from main
6
Installation Procedures
Installation Confi guration
Step 2 – Electrical Connections
CONTROL TERMINALS
MAIN SUPPLY
(INPUT POWER)
1Ø 230 VOLT
L
2
— L2 (BLACK)
L
1
— L
1
(BLACK)
TERMINALS
FOR RS485
MOTOR CONNECTIONS
U – BLACK
V – RED
W – BLUE
Purple Leads
Jumper
Jumper
Transducer
Connection
X2
X3
U V W
GRD #2 #1 (GREEN)
NO
12
11
10
9
8
7
6
5
4
3
2
1
4
3
2
1
CC
NC
+ 5V
GND
SIO +
SIO -
slave pump
motor thermistor
low water
external on/off R, 10 kohm, 5 volt DC
+5 V ub (red)
actual value signal 0.5-4.5 VDC, 50 ohm load resistance (white)
shield (black)
RS-485
Diagram 6
7
Installation Procedures
Installation Confi guration
Step 2 – Electrical Connections
AquaBoost I
Connection / Wiring Diagrams
Input/Output P ower Wiring
3Ø Motor 230V
Output
GRN
RED
BLUE
BLK
GRN
GND
U
V
W
GND
L
1
AQUABOOST
CONTROLLER
N
1Ø
208-230 Volt
Supply
Terminal Block X2
1 2 3 4 5 6 7 8 9 10 11 12
BLK
Transducer
Connectors
NOTE 1: J1, J2 factory installed jumpers.
NOTE 2: Motor thermistor installed in back of ODP motor.
NOTE 3: Input supply voltage is measured phase to phase.
WHITE
RED
J1 J2
BLK
BLK
Control Wiring
PURPLE
PURPLE
Motor Thermistor
Connection
8
Installation Procedures
Pump Priming
Refer to your pump operation manual for instructions on pump priming. Ensure suction valve is open
before start up.
Run Test
WARNING
DO NOT APPLY POWER TO THE AQUABOOST CONTROLLER OR PUMP UNTIL ELECTRICAL
CONNECTIONS HAVE BEEN REVIEWED BY A QUALIFIED ELECTRICIAN AND MEET ALL APPLICABLE NATIONAL, STATE AND LOCAL CODE REQUIREMENTS.
Instructions
1) Close discharge valve. Make sure the discharge valve is closed. Apply power to the
AquaBoost Controller.
2) Start the pump with the push button on the front plate of the AquaBoost Controller.
▼
3) Stop the pump after determining rotation by pushing the .
4) If rotation is incorrect, turn off all power to the AquaBoost, open the motor conduit box and ex
change any two lead wires. Close the conduit box and reapply power.
Change Pressure
1) Start the pump with the push button on the front plate of the AquaBoost Controller.
2) Then press the and buttons together for more than 3 seconds.
3) The LED color changes to orange.
4) Now you could change the pressure with the and buttons. The set pressure is read off a
gauge on the pump discharge.
▼
▼
▼
▼
▼
▼
WARNING
DO NOT SET THE REQUIRED PRESSURE FOR MORE THAN 80 PSI SINCE THIS CAN EXCEDE
THE CAPABILITY OF YOUR PLUMBING SYSTEM AND TANK. SERIOUS PROPERTY DAMAGE
OR PERSONAL INJURY COULD RESULT.
5) If there is no change to the setting for more than 5 seconds, the AquaBoost Controller returns to
normal operation automatically, and the new required pressure is stored.
6) The pump can only be STARTED with the button or STOPPED with the button. Both buttons
are on the front plate of the AquaBoost Controller.
▼
▼
LED description
Green Solid – Motor is not running. The unit is stopped with the button on the front plate.
Green Slow Flashing – Controller is active, but the motor has stopped.
Green Fast Flashing – Motor is running.
Red Solid – Error.
Red Flashing – Fatal error (AquaBoost Controller has to be disconnected from the power supply).
9
▼
Operator Displays
Error Signals
The following conditions can cause a fl ashing red or solid red error light. If one of these error indications is visible, troubleshoot the system based on the following:
Low Water Remedy: Check suction pressure. If suction pressure is normal the unit restarts itself.
Overheating – Motor Possible causes: Insuffi cient cooling ambient temperature is too high, motor
overloaded. After the cause has been remedied, the malfunction has to be reset by cutting off the
power supply for > 30 seconds.
Overvoltage Possible cause: Check main supply, supply voltage too high, peak voltage due to switching heavy loads on the network. Find the cause and take countermeasures (e.g. line fi lter, RC-elements).
Disconnect the power supply for > 30 seconds.
Undervoltage Possible cause: Check main supply, faulty fuse or out of phase.
Overload Possible causes: the pump is working at a capacity signifi cantly in excess of its performance
data. Disconnect the power supply for > 30 seconds.
Overtemp. Heat Sink The thermal sensor on the heat sink indicates over temperature. Possible causes:
insuffi cient cooling, ambient temperature too high or motor overload. After remedy, cut off power for
> 30 seconds to reset.
Sensor Fault A sensor signal of below .5 VDC was received due to bad sensor, broken cable or bad
connection. After remedy cut off power for > 30 seconds to reset.
Note
The above error displays can be viewed only with the external programmer (sold separately).
This can be connected to the jack on the AquaBoost Controller for a more detailed analysis.
Contact your local distributor for more information. Goulds Pumps Part Number: 2415241.
10
Appendix A
Pressure Transducer
The sensor of this transducer is a piezoresistive silicon pressure sensor, mounted on a tape (TAP) fl oating
freely in an oil chamber. The pressure is transferred to the sensor by a separating nickel diaphragm in
the oil chamber.
Specifi cations
Range (FS): 10 Bar (147 psi) Gauge
Over-pressure-Pmax: 300 psi
Class of protection: IP 67
Type Sealed gauge:
Signal Over Range: 0.5 - 4.5 V DC (ratiometric)
Supply: 5 VDC +/- 0.25 VDC
Supply:
+ VCC => red = supply voltage
+ Out => white analog output signal
GND => black ground
Operating Temperature: -20 - +80°C
Storage Temperature: -40 - +100°C
Material: Body Steel and Brass
Diaphragm: Nickel
1
⁄4" NPT THREAD
+ out (0.5 – 4.5 V)
GND
Pressure Transducer Plug
11
+FCC (5VDC)
Appendix B
AquaBoost Controller Drive Head Technical Data
AquaBoost Supply Motor Voltage
Controller Protection
Type Rated output Voltage
AV 1.1 1 HP 1 x 230 V / 40-60 Hz 3 x 230 V 4.8 A 10 Ampere
AV 1.15 2 HP 1 x 230 V / 40-60 Hz 3 x 230 V 7.0 A 10 Ampere
AV 1.2 3 HP 1 x 230 V / 40-60 Hz 3 x 230 V 10.0 A 16 Ampere
Input Voltage: 1 x 230 VAC ± 10% (An input line reactor is highly recommended
for areas which experience voltage fl uctuation.)
Output Voltage: 3 x 230 Volt AC
Max. Frequency: 40 – 60 Hz – selectable
Min. Frequency: 0 - f-max
Electrical Effi ciency: > 95%
Protection against: Short circuit, under-voltage, overheating of the electronics (overload) and
additional protective functions via external switch (motor temperature,
low water).
A power supply fi lter is included to ensure interference immunity.
The AV Series frequency converter complies with the general EMV provisions and has been tested
according to the following standards:
• Radio Interference Suppression EN 50081 Part 2 and EN 50082 Part 2
• High Frequency Field Interference ENV 50140 and ENV 50141
• Static Electricity Discharge EN 61000-4
• Disturbance Voltage EN55011
Ambient Temperature: 5° C – 40° C
Storage Temperature: -25° C – +55° C
(+70° C during max. 24 hours)
Humidity: rH maximum 50% at 40° C, unlimited
RH maximum 90% at 20° C, maximum 30 days per year
Condensation not permitted!
Air Pollution: The air may contain dry dust as found in workshops where there is no
excessive quantity of dust due to machines. Excessive amounts of dust,
acids, corrosive gases, salts, etc. are not permitted.
Controller Enclosure: NEMA 12, IP 55
Approvals: UL, CUL, CE
Altitude: Maximum 3000 feet above sea level. Consult factory for higher altitudes.
12
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