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

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

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.

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

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

Installation Procedures

Installation Conﬁ guration

Step 2 – Electrical Connections

CONTROL TERMINALS

MAIN SUPPLY (INPUT POWER) 1Ø 230 VOLT

— L2 (BLACK)

— L

(BLACK)

TERMINALS FOR RS485

MOTOR CONNECTIONS U – BLACK V – RED W – BLUE

Purple Leads

Jumper

Transducer Connection

U V W

GRD #2 #1 (GREEN)

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

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

GND

AQUABOOST

CONTROLLER

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

Control Wiring

PURPLE

Motor Thermistor

Connection

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).

▼

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.

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

⁄4" NPT THREAD

+ out (0.5 – 4.5 V)

GND

Pressure Transducer Plug

+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.

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