Pentair Aurora 770 Manual

NOTE! To the installer: Please make sure you provide this manual to the owner of the equipment or to the responsible
party who maintains the system.
MODELS 770 and 790
BOOSTER SYSTEMS
INSTRUCTION AND INSTALLATION MANUAL
Part # A-03-255 | © 2012 Pentair Ltd. | 12/01/12
Standard 770 Duplex System with Horizontal Pumps Standard 790 Packaged System

2
INSTRUCTION AND INSTALLATION MANUAL
MODELS 770, 790
BOOSTER SYSTEMS
2
SECTION 2ITEM 770, 790
DATED OCTOBER 2003
ATTENTION: SAFETY WARNINGS:
Read and understand all warnings before installation or servic-
ing pump.
SYSTEM RECEIPT INSPECTION:
• Inspect system and components for signs of damage during
shipment.
• Check system for missing parts.
• Check system for loose parts.
SYSTEM INSTALLATION:
•Mount and anchor system in properly prepared location.
-Verify system is level and piping aligned with building
system piping.
•Connect building piping to booster system, ensure no pipe
stress is transferred to booster system.
•Ensure system disconnect switch is in the off position.
•Ensure pump H-O-A switches are in OFF.
•Have qualified electrician route power to system control panel.
• Grout system base using a "non-shrinking" grout.
• Route pump thermal relief valve discharges to appropriate
floor drain.
•If system includes the optional, remote hydropneumatic tank,
install tank in a suitable location and connect to booster system
manifold.
Hydropneumatic tank is shipped from the factory with the iso-
lation valve closed. Tank MUST be pre-charged to system pres-
sure with air prior to opening isolation valve and admitting
water.
SYSTEM STARTUP:
•Open all system isolation valves.
•Slowly open booster system supply from building system.
•Open the petcocks on pumps and system manifolds to allow
air to bleed from system.
•Turn booster control panel disconnect to ON.
•Jog pump motor #1 and observe direction of rotation. Take
corrective action as required.
•Jog pump motor #2 and observe direction of rotation. Take
corrective action as required.
•Turn pump #1 H-O-A switch to the hand position. Bleed air
from the pressure reducing valve at the highest point on the
valve by opening any fitting.
•Place pump #1 H-O-A switch to OFF.
•Turn Pump #2 H-O-A switch to the hand position. Bleed air
from the pressure reducing valve at the highest point on the
valve by opening any fitting.
•After all air is bled from the system, place system in operation
by placing both pump H-O-A switches to AUTO.
OPERATION:
NOTE
Aurora booster systems are tested and adjusted at the factory
prior to shipment. System pressure switches are factory adjusted
to the specifications provided at time of order.
NOTE
Failure to properly vent system could result in erratic or sluggish
operation due to air trapped in the system PRVs.
OPERATION (NO TANK):
When pump H-O-A switches are placed in AUTO, the lead pump
will run continuously to maintain system pressure.
Check system suction pressure with pump #1 running. The low
suction pressure switch is typically set at the factory at 5 psi OFF
and 20 psi ON. The pressure switch setting can be changed as
CAUTION
Standard 770 Duplex System with Horizontal Pumps
Standard 770 Duplex System with Horizontal Pumps
INSTRUCTION AND INSTALLATION MANUAL
MODELS 770, 790
BOOSTER SYSTEMS
2
SECTION 2ITEM 770, 790
DATED OCTOBER 2003
ATTENTION: SAFETY WARNINGS:
Read and understand all warnings before installation or servic-
ing pump.
SYSTEM RECEIPT INSPECTION:
• Inspect system and components for signs of damage during
shipment.
• Check system for missing parts.
• Check system for loose parts.
SYSTEM INSTALLATION:
•Mount and anchor system in properly prepared location.
-Verify system is level and piping aligned with building
system piping.
•Connect building piping to booster system, ensure no pipe
stress is transferred to booster system.
•Ensure system disconnect switch is in the off position.
•Ensure pump H-O-A switches are in OFF.
•Have qualified electrician route power to system control panel.
• Grout system base using a "non-shrinking" grout.
• Route pump thermal relief valve discharges to appropriate
floor drain.
•If system includes the optional, remote hydropneumatic tank,
install tank in a suitable location and connect to booster system
manifold.
Hydropneumatic tank is shipped from the factory with the iso-
lation valve closed. Tank MUST be pre-charged to system pres-
sure with air prior to opening isolation valve and admitting
water.
SYSTEM STARTUP:
•Open all system isolation valves.
•Slowly open booster system supply from building system.
•Open the petcocks on pumps and system manifolds to allow
air to bleed from system.
•Turn booster control panel disconnect to ON.
•Jog pump motor #1 and observe direction of rotation. Take
corrective action as required.
•Jog pump motor #2 and observe direction of rotation. Take
corrective action as required.
•Turn pump #1 H-O-A switch to the hand position. Bleed air
from the pressure reducing valve at the highest point on the
valve by opening any fitting.
•Place pump #1 H-O-A switch to OFF.
•Turn Pump #2 H-O-A switch to the hand position. Bleed air
from the pressure reducing valve at the highest point on the
valve by opening any fitting.
•After all air is bled from the system, place system in operation
by placing both pump H-O-A switches to AUTO.
OPERATION:
NOTE
Aurora booster systems are tested and adjusted at the factory
prior to shipment. System pressure switches are factory adjusted
to the specifications provided at time of order.
NOTE
Failure to properly vent system could result in erratic or sluggish
operation due to air trapped in the system PRVs.
OPERATION (NO TANK):
When pump H-O-A switches are placed in AUTO, the lead pump
will run continuously to maintain system pressure.
Check system suction pressure with pump #1 running. The low
suction pressure switch is typically set at the factory at 5 psi OFF
and 20 psi ON. The pressure switch setting can be changed as
CAUTION
Standard 770 Duplex System with Horizontal Pumps
Standard 770 Duplex System with Horizontal Pumps
CALIFORNIA PROPOSITION 65 WARNING:
This product and related accessories
contain chemicals known to the State of California to
cause cancer, birth defects or other reproductive harm.

3
MODELS 770-790
needed for the field condition. (See Controller Operation,
Appendix A)
When flow demands increase beyond the pump design point the
system pressure will begin to decrease.
The low system pressure switch is typically set at the factory at
10 psi below system pressure. The pressure switch setting can be
changed as needed for the field conditions.
When system pressure reaches the pre-determined set point, the
lag pump starts in response to the lower pressure. The lag pump
will run as required until flow demand decreases and system
pressure rises above the set point. When system pressure reaches
the set point the lag pump will shutdown automatically and the
lead pump will continue to run. During periods of low system
demand/shutoff operation both pumps are provided with a ther-
mal relief valve for protection. (See Controller Operation,
Appendix A)
OPERATION (WITH OPTIONAL TANK):
When pump H-O-A switches are placed in AUTO, the tank
pressure switch sequences the lead pump under no flow condi-
tion. The tank fills to its capacity and tank pressure starts to
build up. This increase in tank pressure will stop the lead pump
when the pre-determined set point is reached and after the mini-
mum run time is satisfied. The tank will supply all "leak" loads.
As tank pressure drops due to further system demands the lead
pump will start after a time delay. The tank switch will continue
to cycle the lead pump off and on as required to maintain
tank/system pressure.
NOTE
Tank pressure switch high set point must be lower than the pump
shutoff head.
Set the tank pressure switch high set point 5 psi above system
pressure. Set the tank pressure switch low set point to normal sys-
tem pressure.
Check system suction pressure with pump #1 running. The low
suction pressure switch is typically set at the factory at 5 psi OFF
and 20 psi ON. The pressure switch setting can be changed as
needed for the field condition. (See Controller Operation,
Appendix A)
With the lead pump running if the system pressure continues to
fall due to flow demands the lag pump will start and run with the
lead pump until the system demand is satisfied and the minimum
run time setting is met. Pumps stop in the reverse order.
The low system pressure switch is typically set at the factory at
10 psi below system pressure. The pressure switch setting can be
changed as needed for the field conditions.
In the event of tank pressure switch failure both pumps are pro-
vided with a thermal relief valve for protection.
APPENDIX A
APPLICATION:
Standard (Typical) Systems: These controllers are used to con-
trol one or more pump motors. On multiple pump installations,
the pumps may be equal in size (horsepower) or may be differ-
ent sizes. The most common systems are duplex systems with
one small and one larger pump and triplex systems with one
small and two larger motors, where the larger motors are typi-
cally of the same size. In standard units where one pump is
smaller than the other(s) it is meant to run continuously. If it is
in a duplex system, the pumps won't be alternated from Lead to
Lag.
Alternation schemes:
Equal Size Pumps:
Yes for Duplex (both), and Triplex (all three).
Unequal Size Pumps:
No for Duplex, Yes for Triplex (Pumps #2 and #3). Pump #1
(the smaller pump) runs continuously.
Pressure Regulated Systems: Standard systems utilize a pres-
sure regulating valve (PRV) for each pump. The pump motor
controller responds to the system pressure to start and stop (con-
trol) the pump or pumps. When the system pressure drops
below a preset amount, usually just below the PRV setting(s),
the controller causes the next pump to start. When the pressure
rises sufficiently, the controller stops the last pump started, usu-
Standard 790 Packaged System

4
APPENDIX A (continued) MODELS 770-790
3
ally after a minimum running interval. A low pressure alarm
and shutdown is included in standard systems to protect the
pump(s) form running dry or cavitating on absent or low inlet
pressure.
OPTIONAL SYSTEMS
Pressure Transducer Systems: The controller uses a solid state
pressure transducer to control the operation (starting and stop-
ping) of the motor(s). This takes the place of the System
Pressure Switch. The transducer signal is connected to the PLC
which has programmable start and stop set points. When the
system pressure drops below the preset pressure, usually just
below the PRV setting(s), the controller causes the next pump to
start. Rising pressure causes the controller to cycle the pump(s)
off.
Pressure Tank Systems: The booster pump system (package)
may include an optional pressure tank to improve system per-
formance. In this case the controller responds to pressure in the
tank to maintain the tank pressure at a level above the system
pressure in order to provide adequate pressure to the pressure
regulating valve or valves. When the pressure rises sufficiently,
the controller stops the last pump started, normally after a mini-
mum running interval.
SEQUENCE OF OPERATION
General: These units control one or more booster pump motors
to maintain the pressure in a system within a selected range.
This is accomplished with a pressure switch which has a fixed
differential (4 lbs @ 100psi). Refer to the wiring or schematic
diagram for details. Standard units have one or more motor
starters, a Control Power Transformer (CPT) and secondary and
dual primary fuses for same. Standard units include a PLC for
logic sequencing, timing and control. Standard units also
include an audible alarm, which can be silenced, and one or
more visual alarm lights. The standard unit also includes one or
more Pump Running signal lights, L2 & etc.
Power Wiring: The input lines (mains) connect to the top of the
Disconnect Switch (DS) or Circuit Breaker CB. Power flows
through the short circuit protection motor Line (Mains) Fuses
1F & etc., or Circuit Breaker CB, and then to the Motor Starter,
which is horsepower rated. The Motor Starter consists of Motor
Contactor (1M & etc.) and Overload Relay OL-1 & etc.. When
the Motor Contactor Coil 1M, or etc., is energized, Motor
Contactor 1M contacts close to feed power through the
Overload Relay to its output terminals where the motor is con-
nected. This energizes the motor to start the pump.
Control Transformer: Control power is supplied by a Control
Power Transformer (CPT). Its primary is supplied by two pri-
mary side line fuses. The secondary output of the transformer is
protected by a secondary fuse. See the controller Schematic
Diagram for the fuse designations. Secondary control power is
115 Vac (110 - 120 Vac) at 50 or 60 Hz depending on the line
(mains) frequency. Secondary power is used for the motor con-
tactor coils, indicator (pilot) lights, audible alarm, the PLC and
any additional control relays or components.
Overload Relay: The Overload Relay furnished in the motor
starter provide protection from excessive currents. The over-
load relay has been sized and set to trip open when the motor
exceeds 125% of the Full Load Current (FLA) multiplied by the
rated Service Factor (SF). Trip times vary depending on the
magnitude of the current overload, the number of previous
starts, the ambient temperature of the controller, and the size of
the overload element. Briefly, the Overload Relay is sized to
allow initial starting currents while protecting the motor from
excessive long starting currents or excessive running currents.
(See Installation Instructions - Protection for proper sizing).
Power Available Light: A Power Available pilot light (L1) indi-
cates then the disconnect switch (DS) or main circuit breaker is
closed, and when power is supplied to the unit and when the
CPT primary and secondary fuses are not blown.
Control Selector Switch: One selector switch, HOA-1 & etc., is
included for each motor. The switch includes a "MAN"
(Manual, Hand) position, an "OFF"(Safety) position, and an
"AUTO" (Automatic Control) position. In the manual position,
the Pressure Switch and all automatic control is bypassed so the
contactor coil is continuously energized by the selector switch.
The Overload Relay contacts also override the manual position
to protect the motor.
"OFF" (Safety) Position: In the "OFF" position, the Motor
Contactor coil is de-energized to prevent the motor from run-
ning.
"MAN" Position (Manual Control): Control power wiring is
tapped off the incoming power on the load (down-stream) side
of the Line Fuses or Circuit Breaker. It is routed to the three
position (Auto-Off-Manual) selector switch. In the manual
position, the all pressure switches and all automatic control is
bypassed so the contactor coil is continuously energized by the
selector switch. The Overload Relay contacts also override the
manual position to protect the motor. The Minimum Run Timer
does not operate with the selector switch in the MANUAL posi-
tion.
"AUTO" (Automatic Control) Position: In this position, the
motor starter is connected to the appropriate output terminal of
the PLC (Programmable Logic Controller) which enables auto-
matic control of the pump motor by the PLC. Note that over-
load relay operation is independent of the PLC or any other
control circuitry to protect the motor.
Motor Running Light(s): The Pump 1 Running light activates
when ever the motor contactor (starter) for Motor No. 1 is
closed under either manual or automatic control.
AUTOMATIC (PLC) CONTROL
Alarm Circuit: The standard unit includes alarm circuitry to
annunciate failure or fault conditions. The standard alarm con-
dition is Low Suction Pressure as sensed by the Low Suction
Warning:
Use care when using the MANUAL (MAN) position of the
control switch to avoid causing system Over Pressure.
Warning:
Use care when using the MANUAL (MAN) position of the
control switch to avoid causing system Over Pressure.

5
APPENDIX A (continued) MODELS 770-790
Pressure switch (PS-1). When the pressure drops to less than
the trip setting of this pressure switch, it's contacts close. This
signals the PLC that the condition has occurred. The PLC acti-
vates the Low Suction Audible Alarm. The standard audible
device is a solid state (Sonalert) annunciator. The PLC also
activates a Low Suction alarm signal light. The alarm can be
silenced by momentarily operating the Alarm Silence switch
(SW-1) which signals the PLC to de-activate the audible alarm.
The alarm light stays lit until the Low Suction Pressure switch
resets. The alarm circuit resets itself and re-activates on the
next occurrence of low suction pressure.
General: In the AUTO position, motor operation is under the
control of the PLC. The PLC utilizes an internally stored pro-
gram to control the operation (starting and stopping) of the
motor. The PLC responds to the Low Suction Pressure switch
and to System Pressure Switch as a minimum. The PLC pro-
gram also includes various timing functions as outlined below.
Pressure Sensing: The standard unit is pressure controlled by
sensing either the system pressure or by sensing the pressure in
a tank, if supplied. Multiple pump systems (Duplex & Triplex)
may employ equal size pumps or one pump may be smaller than
the others.
Alternation: The standard system employs one smaller pump
and one or more later pumps. If there is more than one larger
pump (Triplex) they are usually equal in size to one another.
The small pump is meant to run continuously. The controller
cycles the larger pump or pumps as needed to maintain system
pressure. Alternation of the pumps in not used in Duplex sys-
tems of this type. The smaller pump which runs continuously is
considered the "Lead" pump and the other pump or pumps are
considered the "Lag" pump or pumps.
When all pumps are of the same size, a duplex controller may
be set up to alternate which of the two, or more) pumps operates
as the Lead pump and which pump or pumps operates as the
Lag pump or pumps.
Minimum Run Timing: The standard unit includes timers to
control the Minimum Running time of the pump or pumps to
prevent short cycling of the pump motor(s). This avoids over-
heating the motors which can occur if they are started too fre-
quently. This allows the motor fan to cool down the motor
windings from the last start before the pump is shut down.
Restart Delay Timing: The Restart delay prevents starting a
pump which is still spinning down from the last running. This
can occur when the demand is less than needed for the pump
but more than what can be supplied by the other pump(s). In
this case, when the pump shuts down, the pressure can drop
rapidly enough to immediately signal the pump to start again. If
the pump is still spinning, this can cause mechanical shock to
the pump and motor and can also cause large spikes (momentar-
ily large transient) currents which can blow fuses or trip circuit
breakers. This occurs when the motor magnetic flux vector
angle is out of phase with the power line phase angle by large
enough difference. The Restart delay lets the motor come to
rest or near rest which also allows the motor magnetic flux to
decay. In this state, the motor can be safely restarted with out
excessive transients and mechanical shock.
Alternation Times: Note: The Alternation Times apply only to
controllers for two or more motors (Duplex & Triplex). The
Alternation Time is the clock time that must elapse before the
PLC changes the pump from being a Leading pump into a
Lagging pump. The Alternation Times are independent of the
motor actual running time.
Alternator Overlap Time: When one or more pumps are not
running, alternating the pumps can cause a momentary pressure
drop when the running pump spins down before the other pump
comes up to full speed. The overlap timer is an over run timer
that causes a delay before the pump is shut down. This allows
the second pump to come up to full speed while the first pump
continues to run. After a typical setting of a few seconds, the
controller shuts down the first pump if it is not needed for the
system demand.
CONTROLLER SET-UP AND ADJUSTMENTS
Preliminary Steps: Before attempting to adjust the pressure
switch in pressure controlled systems, adjust the pump pressure
regulating valves for the desired system pressure(s). Remove
the covers from the pressure switch(s). A system pressure
gauge is required for setting the System Pressure Switch.
Timer (TIM) Settings: Note: Changing the timers requires one
of three procedures. 1) The times are set at the factory using a
lap-top computer with the appropriate program and communica-
tions cable, or 2) an optional memory chip can be programmed
at the factory for the new times and added to the PLC in ques-
tion, or 3) an HMI display and setting module can be installed
onto the PLC for the purpose of changing the timer settings.
Contact the factory for details on how this module is used. All
timer settings are in seconds. The standard timers are factory
set at the following settings:
T0 + T9 = Alternation Time on Pump # 2 = 24hr.
(Note: T0(65535sec) + T9(20865sec) = 86400 seconds = 24 Hours)
T1 + T10 = Alternation Time on Pump # 1 = 24hr.
(Note: T1(65535sec) + T10(20865sec) = 86400 seconds = 24 Hours)
T3 = System Pressure Start Delay = 2 Seconds.
(Motor Restart Delay)
T4 = Pump # 1 Alternation Overlap Time = 5 Seconds.
(Pump Over-run Timer)
T5 = System Pressure Minimum Run Time = 4 Minutes.
T6 = Pump # 2 Alternation Overlap Time = 5 Seconds.
(Pump Over-run Timer)
Low Pressure (Cut-Off) Pressure Switch: Set the pressure
switch to the desired cut-off pressure as indicated on the indica-
tor dial. One example of a setting for a booster pump drawing
suction from a municipal main would be 20 to 30 psi for the trip
point of this switch.
Pressure Switch Set-up: To set the System Pressure switch (PS-
2) remove its cover. Start the (lead) pump manually ("MAN"
position) and modulate the system flow until the pressure drops
just below the desired set point. Adjust the pressure switch On
(Start) adjustment until the Input I-0 LED on the PLC lights.
Set the pressure switch Off (Stop) setting as close as practical to
the On setting. Typical settings on a 100 PSI nominal system
would be trip (start) at 98 psi and reset at 102 psi. Verify the
settings by modulating the system flow and observe when the
PLC Input I-0 LED actuates and extinguishes.
Warning: Shock Hazard
Some settings require observing or adjusting PLC settings
and LED indicators. Use Caution to avoid contact with any
electrical terminals, fuses, or connections to avoid electrical
shock.

6
APPENDIX A (continued) MODELS 770-790
5
REPLACEMENT PARTS LIST
SYMBOL PART NO. DESCRIPTION NOTES
DS 302400 Disconnect Switch, 600 Vac, 30/40 Amp (Internal Switch only)
DS 302401 Disconnect Switch, 600 Vac, 60/80 Amp (Internal Switch only)
DS 302402 Disconnect Switch, 600 Vac, 100 Amp (Internal Switch only)
--- 400939 Disconnect Switch Handle Operator only, (30 thru 100 Amp)
HOA 401199 Auto-Off-Manual Selector Switch
--- 401992 Contact Block (N.O.)
PS* 305420 Standard Pressure Switch
PS4 305421 Tank Pressure Switch
PLC 305580 Programmable Logic Controller (standard units only)
--- 305040 Control Power Transformer, 50 VA, 208/240/460 Vac
--- 305041 Control Power Transformer, 50 VA, 208/380/575 Vac
Note: One or more renewal parts such as fuses, heaters, contacts, and etc. may be obtained from local electrical distributor(s).
IMPORTANT: When ordering replacement parts, be sure to specify the complete MODEL NUMBER and SERIAL NUMBER of
controller in which they are to be used.
SERVICE AND ASSISTANCE:
Contact either the Aurora Pump field agent or Factory customer Service for assistance. The factory can be contacted at the address and
numbers show below.
Aurora Pump
800 Airport Road
North Aurora, IL 60542 USA
Phone: [phone] Fax: [phone]
Web Page: http://www.aurorapump.com
Email: [email protected]

7
APPENDIX A (continued) MODELS 770-790
PUMP 1
RUNNING
PUMP 2
RUNNING
POWER
AVAILABLE
LOW SUCTION
PRESSURE
ALARM
SILENCE
LOW SUCTION
PRESSURE SWITCH
PS - 1
SYSTEM
PRESSURE SWITCH
PS - 2
PUMP 1 PUMP 2
AUTO
AUTO HAND
HAND
OFF OFF
Notes:
Enclosure: 16 Guage Sheet Steel
Finish: Grey Baked Enamel
Application: For Indoor Use. NEMA 1
Mounting: Wall Mount
Max. Shipping Weight: 42 lbs. (20kg)
R
LISTED

8
7
APPENDIX A (continued) MODELS 770-790
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
To 3Ø AC
Supply
(Branch
Ck t
Protection
Req'd)
DS
L1
L2
L3
T1
T2
T3
L1
L2
L3
T1
T2
T3
L1
L2
L3
T1
T2
T3
L1
L2
L3
T1
T2
T3
L1
L2
L3
T1
T2
T3
1F
2F
3F
1M OL-1 MOTOR-1
MTR-1
MOTOR-2
MTR-2
OL-2
2M
4F
5F
6F
8F
7F
38
44
(13) (14)
480Vac
120Vac
H1 H4
X2
X1
XFMR-1
9F
(17)
(17)
(17)
(17)
(17)
(17)
(18)
(19)
14
13
13 14
1M
2M
L1
L2
L3
W
G
G
POWER
AVAILABLE
PUMP 1
RUNNING
PUMP 2
RUNNING
(16)
(16)
(16)
(16)
(16)
(16)
(16)
(16)
L4 RLOW
SUCTION
ALARM
HORN
(17)
(27)
(28)
MAN HOA-1
(SW-2)
MOTOR-1
CONTACTOR
AUTO
1M
O/L-1
(31) A1 A2 (33)
(95) (96) 3,4,5,19
9,10,11,21
MAN HOA-2
(SW-3)
MOTOR-2
CONTACTOR
AUTO
2M
O/L-2
(32) A1 A2 (34)
(95) (96)
OFF
(17)
(29)
(30)
Q-3
GND
Q-2
Q-1
Q-0
ComO
N
PLC
L
24VDC
0V
DC IN
Com
I-1
I-2
1-0
I-3
(24)
(23)
4
(20)
(20)
(20) (22)
(21)
(20)
LOW SUCTION
(PS-1)
ALARM
SILENCE
(SW-1)
SYSTEM
(PS-2)
3
Notes:
Internal PLC Timers (in Sec.) Factory settings:
T0+9 = Alternation Time on Pump 2 (24 hrs)
T1+T10 = Alternation Time on Pump 1 (24 hrs)
T3 = System Pressure Start Delay (2sec)
T4 = Pump 1 Alternation Time Overlap (5sec)
T5 = System Pressure Minimum Run (4min)
T6 = Pump 2 Alternatin Time Overlap (5 sec)
R
LISTED

9
PUMP 1
RUNNING PUMP 2
RUNNING
POWER
AVAILABLE
LOW SUCTION
PRESSURE
ALARM
SILENCE
LOW SUCTION
PRESSURE SWITCH
PS - 1
SYSTEM
PRESSURE SWITCH
PS - 2
PUMP 1 PUMP 2
AUTO
AUTO HAND
HAND
OFF OFF
PUMP 3
AUTO
HAND OFF
PUMP 3
RUNNING
APPENDIX A (continued) MODELS 770-790
8
R
LISTED
Notes:
Enclosure: 16 Guage Sheet Steel
Finish: Grey Baked Enamel
Application: For Indoor Use. NEMA 1
Mounting: Wall Mount
Max. Shipping Weight: 42 lbs. (20kg)

10
9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
To 3ØAC
Supply
(Branch
Ck t
Protection
Req'd)
DS
L1
L2
L3
T1
T2
T3
L1
L2
L3
T1
T2
T3
L1
L2
L3
T1
T2
T3
4F
5F
6F
2M
OL-1
MOTOR-2
MTR-2
MOTOR-3
MTR-3
8F
7F
35
(13) (14)
480Vac
120Vac
H1 H4
X2X1
9F
(17)
(17)
(17)
(17)
(18)
(19)
14
13
13 14
1M
2M
L1
L2
L3
W
G
G
POWER
AVAILABLE
PUMP 1
RUNNING
PUMP 2
RUNNING
(16)
(16)
(16)
(16)
(16)
(16)
(16)
L4 RLOW
SUCTION
ALARM
HORN
(17)
(27)
(28)
MANHOA-1
(SW-2)
MOTOR-1
CONTACTOR
AUTO
1M
O/L-1
(31) A1 A2 (33)
(95) (96) 8,9,10,19
2,3,4,21
MAN
HOA-2
(SW-3)
MOTOR-2
CONTACTOR
AUTO
2M
O/L-2
(32) A1 A2 (34)
(95) (96)
OFF
(17)
(29)
Q-3
GND
Q-2
Q-1
Q-0
ComO
N
PLC
L
24VDC
0V
DC IN
Com
I-1
I-2
1-0
I-3
(24)
(23)
4
(20)
(20)
(20) (22)
(21)
(20)
LOW SUCTION
(PS-1)
ALARM
SILENCE
(SW-1)
SYSTEM
(PS-2)
3
Notes:
Internal PLC Timers (in Sec.) Factory settings:
T3 = System Pressure Start Delay(LEAD) (2sec)
T5 = System Pressure Minimum Run(LEAD) (6min)
T11 = Lag Pump Minimum Run (4min)
T12 = Lag Pump Start Delay (12sec)
MOTOR-1
MTR-1
36.
L1
L2
L3
T1
T2
T3
OL-3
42
43.
L1
L2
L3
T1
T2
T3
OL-2
35 . 41
L1
L2
L3
T1
T2
T3
10F
11F
12F
3M
1F
2F
3F
1M
L1
L2
L3
T1
T2
T3
XFMR-1
(16) 8,9,10,23
HOA-3
(SW-4)
MOTOR-3
CONTACTOR
3M
O/L-3
(32) A1 A2 (34)
(95) (96)
OFF
MAN
AUTO
(17)
(17)
(17)
(42)
14
13
3M
L8 GPUMP 3
RUNNING
(16)
(17)
(29)
(30)
(17)
(16)
(45)
Q-4
Com1
APPENDIX A (continued) MODELS 770-790
R
LISTED

11
APPENDIX A (continued) MODELS 770-790
R
R
R
R
R
R
(20)
PLC
PS-5
(20)
PS-2
(20)
PS-3
(49) (50) (16)
L11
INPUT OUTPUT
PLC
(36) (39) (16)
L5
INPUT OUTPUT
PLC
(24) (51) (16)
L12
I-O OUTPUT
PLC
(20) (40) (16)
O/L-1
INPUT OUTPUT
(20) (41)
O/L-2
INPUT OUTPUT
(20) (43)
O/L-3
INPUT OUTPUT
O/L-1
O/L-2
O/L-3
(20)
L6
L7
L9
9897
9897
9897
O/L-3 NOT PROVIDED ON DUPLEX CONTROLLERS
(PS-2 IS STANDARD)
Option B
Option A
HIGH SYSTEM PRESSURE SWITCH, LIGHT AND ALARM
HIGH SUCTION PRESSURE SWITCH, LIGHT AND ALARM
LOW SYSTEM PRESSURE SWITCH, LIGHT AND ALARM
OVERLOAD TRIP, LIGHT AND ALARM
Option C
Option E
NOTE:
ALARM HORN AND SILENCE P.B. SHOWN ON MAIN SCHEMATIC

12
APPENDIX A (continued) MODELS 770-790
11
To 3ØAC Supply
(Branch Ckt
Protection Req'd)
Option G
CIRCUIT BREAKERS IN PLACE OF LINE FUSES
CB1
TO 1M
CB2
CB3
TO 2M
TO 3M
CB1 REPLACES 1F - 3F.
CB2 REPLACES 4F - 6F.
CB3 REPLACES 10F - 12F.
CB3 NOT PROVIDED ON DUPLEX CONTROLLERS.
Option T TANK PRESSURE SWITCH
PS-4
(20) (35) PLC
I-3
(PS-4 REPLACE JUMPER BETWEEN PLC-24VDC & I-3)
Option W
ELAPSED TIME METER
(31) (33)
1M
A1 A2
ETM-1
(32) (34)
2M
A1 A2
ETM-2
(39) (41)
3M
A1 A2
ETM-3
ETM-3 NOT PROVIDED ON DUPLEX CONTROLLERS

13
APPENDIX B MODELS 770-790
UL LISTED and CSA Approved
Dimensions: 4-3/4"W x 2-1/4"D x 4-3/8"H
Enclosure: NEMA Type 4 for indoor or outdoor use. Cover –
Die-cast with textured gray powdercoat finish. Base – Plated
Steel with one opening for 1/2” conduit
Pressure Connection: 1/2” NPT Male
Differential Approx. (Not Adj.):
2 lbs. at 20 PSI; 5 lbs. at 175 PSI
Adjustable Range: 10-175 PSI
Maximum Pressure: 250 PSI
Switch Contacts:
One or two Snap Action SPDT (Form C Contacts)
15.0 Amps at 125/250 VAC
0.5 Amps at 125 VDC
0.25 Amps at 250 VDC
Pilot duty Rating: 125 VA 120/240 VAC
Ambient Temperature range:
-40°.180°F (-40°/82°C)
Media Temperature range:
32°/250°F (0°/121°C)
This device is not intended for applications in explosive
environments.
The Model IPS pressure switches are designed to indicate an
increase or decrease in normal system pressure. On the two
switch models the two switches operate independently of each
other and each switch may be adjusted to actuate at any point
within their adjustable range. They are designed for applications
sensing air, water or any fluid or gas not harmful to nylon or sil-
icone.
They are not designed to be used with any fluid or gas classified
as hazardous.
NOTE
To prevent leakage, apply Teflon tape sealant to male threads
only.
MOUNTING:
Device should be mounted in upright position. (Threaded con-
nection down.)
FIELD ADJUSTMENTS:
The operating point of the switch or switches can be adjusted to
any point within their adjustable range. (10-175 PSI). To adjust
the device, turn the adjustment knob(s) clockwise to raise the
actuation point and counterclockwise to lower the actuation
point. On the two switch models the two switches operate inde-
pendently of each other and each switch may be adjusted to
actuate at any point within their adjustable range. The pressure
scales on the devices are approximate. Final adjustment should
be made with a pressure gauge.
STOCK NO. OF PRESSURE PRESSURE
MODEL NO. CONTACTS RANGE CONNECTION
IPS40-1 9000104 1 10-175 PSI NYLON 1/2”
NPT MALE
CAUTION
Warning:
Use of pipe joint cement may result in obstruction of aper-
ture and loss of signal.
ADJUSTMENT
KNOB(S)
ADJUSTMENT
KNOB(S)
COM. N.O. N.C.
PRESSURE
SCALE
ALIGN THE TOP OF
THE ADJ. KNOB TO
THE DESIRED PRESSURE.
FINAL ADJUSTMENTS
SHOULD BE MADE
WITH A PRESSURE GUAGE.

14
APPENDIX C MODELS 770-790
13
FUNCTIONAL DESCRIPTION
Pressure Reducing Function
The pressure reducing function is controlled by the 263AP or
263SS control. The 263 is normally open, adjustable control set
to respond to outlet/downstream pressure changes. An increase
in pressure above the set point of the control throttles the con-
trol towards closed. The main valve modulates towards a closed
position. When pressure drops, the control throttles towards
open, modulating the main valve towards an open position. A
constant outlet/downstream pressure is maintained.
Turning the adjustment screw clockwise (IN) increases the out-
let/downstream pressure, counterclockwise (OUT) decreases the
outlet/downstream pressure.
Opening Speed Control – F.C.
An adjustable flow control adjacent the valve cover port, deter-
mines the opening speed of the main valve. It allows free flow
into the cover and restricted flow out of the cover.
Counterclockwise adjustment for faster opening, clockwise for
slower opening. Complete closure prevents the main valve from
opening.
Hydraulic Check Feature
When main valve outlet pressure exceeds inlet pressure, fluid is
directed from the outlet to the main valve cover. This causes the
main valve to close until inlet pressure / flow is again greater
than outlet.
Main Valve – Description
CP-Boss automatic control valves are hydraulically operated,
diaphragm actuated, pilot controlled, angle valves of packless
design. The stem assembly is the only moving part in the main
valve and is guided top and bottom. Positive, drip-tight, closure
is accomplished by a quad seal and non-edged seat.
Start-Up and Adjustment
Close upstream and downstream isolation valves.
Open any ball valves or isolation cocks in the control tubing.
Failure to open these will prevent the valve from functioning
properly.
Step 1
Pre-set pilots as noted:
Pressure Reducing – Adjust OUT, counterclockwise, backing
pressure off the spring, preventing possible overpressuring of
the system.
Opening Speed – Turn the adjustment screw on the Opening
Speed Control OUT, counterclockwise, 1-1/2 to 2-1/2 turns
from full closed position.
Step 2
Loosen a tube fitting or cover plug at the main valve to allow
air to vent during start-up.
Step 3
Pressurize the line, opening the upstream isolation valve slowly.
Air is vented through the loosened fitting. Tighten the fitting
when a steady stream of liquid begins to vent.
SETTING THE PRESSURE REDUCING CONTROL
Step 4
Slowly open the downstream isolation valve to establish flow
through the system.
Step 5
Fine tune the Pressure Reducing Control to the desired pressure
set point by turning the adjustment screw IN, clockwise to
increase or OUT, counterclockwise to decrease downstream
pressure.
Step 6
Opening Speed Flow Control Adjustment: The opening speed
flow control allows free flow into the cover and restricted flow
out of the cover of the main valve.
If recovery of pressure is slow upon increased downstream
demand, turn the adjustment screw OUT, counterclockwise,
increasing the rate of opening.
If the recovery of downstream pressure is too quick, as indicat-
ed in a rapid increase in pressure, possibly higher than the
desired set-point, turn the adjustment screw IN, clockwise,
decreasing the rate of opening.
CONTROL VALVE FUNDAMENTALS
Main Valve
•Diaphragm : Seat Ratio
-1 1/2 diaphragm area to 1 seat area
Flow Directions
•Under the seat
-Waterworks and all general applications
-If diaphragm wears/leaks, valve still flows
Golden Rules
•Fluid into cover – valve closes
•Fluid out of cover – valve opens
•What the control does, the valve does
-Pilot on outlet
*If it opens, valve opens
*If it closes, valve closes
3
5
43
1
2
CLOSES VALVE
OPENS VALVE
FLOW
COMPONENTS
1-MAIN VALVE
2-REDUCING CONTROL
3-CHECK VALVE
4-FLOW CONTROL - ADJ. OPENING SPEED
5-FIXED ORIFICE
FLOW DIRECTION SHOWN: UNDER THE SEAT
VALVE FUNCTION
-REDUCE HIGHER INLET PRESSURE TO CONSTANT LOWER OUTLET PRESSURE (ADJUSTABLE).
-CLOSE WHEN OUTLET/DOWNSTREAM PRESSURE EXCEEDS INLET/UPSTREAM PRESSURE.

15
APPENDIX C (continued) MODELS 770-790
Piping Schemes
•2-way (T to cover)
-Supply Line
*Restriction in line
*Location of Speed Control
•Control/Discharge Line
-2-way pilot control in line
*On/Off
*Variable restriction
-Valve position varies or modulates
•Supply to Discharge relationship
-Supply restriction is required for valve to regulate
3-Way Piping
•Operation
-#1 – Routes fluid into cover-valve closed
-#2 – Blocks supply – routes fluid out of cover-valve opens
-Control typically used with low capacity pilots or valves
smaller than 4"
*Soleniods
*Altitude
*Float
*Accelerator control
-Used to increase capacity of 3-port controls
GUIDE TO TROUBLE SHOOTING PRESSURE REDUC-
ING V
ALVES
PROPER START-UP
1. Valves should be started in a manner that allows for controlled
pressurizing of the valve and the system.
a. The valve should be pressurized and vented.
i. Bleed the air off of the main valve cover
ii. Bleed the air off of the valve controls
1. Trapped air will give a false reading unless it is
eliminated.
b. Bring pilots into service with a pressure setting lower than
that required.
i. Adjust to higher pressures as the system and valve sta-
bilizes.
c. Pilot Adjustments.
i. Make all adjustments slowly, allowing for the control,
valve and system to read the change
ii. Clockwise adjustments always increase the pressure
setting.
1. Turning the reducing control IN will
INCREASE outlet pressure.
2. Turning the relief/sustaining control IN will
INCREASE the inlet or relief set-point.
iii. Counterclockwise adjustments always
LOWER/DECREASE the pressure setting
1. Turning the reducing control OUT will LOWER
outlet pressure.
2. Turning the relief/sustaining control OUT will
LOWER the inlet or relief set-point.
ABOUT THE MAIN VALVE
1. Almost every function of control valve used in water applica-
tions call for a main valve flow of "under the seat".
a. If a diaphragm fails, the valve continues to allow flow.
i. Failure will be indicated by loss of pressure control or
loss of positive shut-off
b. Control circuit isolation ball valves can be used to isolate
valve cover to allow for diaphragm condition check without
removing the cover.
i. Close inlet ball valve
ii. Close cover ball valve
iii. Close outlet ball valve
iv. Bleed cover fluid
c. Valve will open – fluid will continue to flow if diaphragm is
damaged.
2. VALVE WILL NOT OPEN-CHECK PILOT SYSTEM
a. Check opeing speed control – OPEN.
b. Check on/off devices.
i. Solenoid
ii. Deadman control
iii. Hydraulic check function
c. Check system
i. For flow demand
ii. Inlet pressure
iii. Closed isolation valves
d. Check function of hydraulic controls.
i. See pilot trouble shooting guidelines
1. Take corrective action.
3. VALVE WILL NOT CLOSE
a. Check pilot system.
i. Check closing speed control – OPEN
ii. Check on/of device for complete closing
1. Solenoid
2. Hydraulic check function.
iii. Check function of hydraulic controls
1. See pilot trouble shooting guidelines.
a. Take corrective action.
4. VALVE WILL NOT REGULATE
a. This is normally a problem with the hydraulic controls.
i. Check response to adjustments
1. Service pilots as required.
ii. Check and adjust speed controls
1. Gauge swings to higher than acceptable pres-
sures.
a. Adjust for slower opening speed.
b. Adjust for faster closing speed.
2. Gauge swings to lower pressures than accept
able.
a. Adjust for faster opening speed.
b. Adjust for slower closing speed.

16
APPENDIX D MODELS 770-790
15
Listing/Approvals: UL Standard 508 Guide (NKPZ) and CSA
Standard C22.2 No. 14-M Class (321106) for Pressure Operated
Industrial Control Equipment.
UL Standard 873 Guide (XAPX) and CSA Standard C22.2 No, 24
Class (481302) for Temperature Indicating and Regulating
Equipment.
CE Marked
Ambient/Media Temperature Range:
-4°F to 180°F (-20°C to 82°C)
Construction:
•NEMA Type 4X Enclosure for indoor or outdoor use. (To main-
tain 4X rating, use appropriate Type 4 conduit hub.)
•Forged Brass or 316 S.S. Pressure Connections.
•Aluminum Diecast Base with Polymer Enclosure.
•Beryllium Copper Diaphragm (Stainless steel isolator diaphragm
included for protection of beryllium copper diaphragm on models
with stainless steel pressure connection.)
•Nitrile Pressure Sealing O-ring.
Switch Contact:
Snap Action SPDT (Form C)
15 Amps at 125/250/480 VAC
1/8 HP at 125 VAC
1/4 HP at 250 VAC
General Description
The pressure switch is an Adjustable Deadband Pressure Switch
with independent set and re-set points which are adjustable
throughout the entire operating range of the switch. The minimum
deadband (minimum span between set and reset points) may be
obtained at any point in the operating range of the switch. A
change in pressure greater than the high setting will reposition the
switch mechanism to open or close a single snap-action electrical
switch.
This control device is designed for use as an operating control in
applications sensing air, water, or any fluid not harmful to the
pressure connection, diaphragm or nitrile pressure sealing o-ring.
Where an operating control would result in personnal injury
and/or loss of property, it is the responsibility of the installer to
add devices (safety, limit controls) that protect against, or systems
(alarm, supervisory systems) that warn of control failure.
This device is not intended for applications in explosive environ-
ments or use with hazardous fluids.
ADJUSTMENTS
The two thumb adjustment dials, accessible through the enclosure
cover, are used to adjust the set point and reset point of the switch.
The dial scales and pointer may be used to give an indication of
the low and high set points.
The high setting adjustment dial is calibrated for increasing pres-
sure. The low setting adjustment dial is calibrated for decreasing
pressure. For best accuracy, make the final adjustments with a
pressure gauge at the actual working media pressure and tempera-
ture encountered in the application.
The minimum deadband (minimum span between set and reset
points) may be obtained at any point in the operating range of the
switch.
When the desired settings are obtained, replace the adjustment
cover. The adjustment cover and enclosure cover can be made
tamper resistant by a single sealing wire inserted through the hole
ADJUSTABLE
OPERATIING MINIMUM PROOF FACTORY
RANGE DEAD BAND. PRESSURE SETTING
IPS40-1 9000104 1 10-175 PSI
ADJUSTMENT
COVER ENCLOSURE COVER
LOCKING BAR
WITH HOLE FOR
SEALING WIRE 1/4" - 16 NPT FEMALE PRESSURE CONNECTION
(OPTIONAL 3/8" - 16 NPT FEMALE)
HIGH SETTING
ADJUSTMENT DIAL
ALUMINUM DIECAST BASE
LOW SETTING
ADJUSTMENT DIAL
MANUAL SWITCH
ACTUATOR FOR
TESTING
GROUND SCREW
SNAP-ACTION
SPOT SWITCH
DO NOT LOOSEN OR
REMOVE SCREWS

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WARRANTY
Seller warrants equipment (and its component parts) of its own manufacture against defects in materials and workmanship under normal use
and service for one (1) year from the date of installation or start-up, or for eighteen (18) months after the date of shipment, whichever occurs
first. Seller does not warrant accessories or components that are not manufactured by Seller; however, to the extent possible, Seller agrees to
assign to Buyer its rights under the original manufacturer's warranty, without recourse to Seller. Buyer must give Seller notice in writing of
any alleged defect covered by this warranty (together with all identifying details, including the serial number, the type of equipment, and the
date of purchase) within thirty (30) days of the discovery of such defect during the warranty period. No claim made more than 30 days after
the expiration of the warranty period shall be valid. Guarantees of performance and warranties are based on the use of original equipment
manufactured (OEM) replacement parts. Seller assumes no responsibility or liability if alterations, non-authorized design modifications
and/or non-OEM replacement parts are incorporated If requested by Seller, any equipment (or its component parts) must be promptly
returned to Seller prior to any attempted repair, or sent to an authorized service station designated by Seller, and Buyer shall prepay all
shipping expenses. Seller shall not be liable for any loss or damage to goods in transit, nor will any warranty claim be valid unless the
returned goods are received intact and undamaged as a result of shipment. Repaired or replaced material returned to customer will be
shipped F.O.B., Seller's factory. Seller will not give Buyer credit for parts or equipment returned to Seller, and will not accept delivery of
any such parts or equipment, unless Buyer has obtained Seller's approval in writing. The warranty extends to repaired or replaced parts of
Seller's manufacture for ninety (90) days or for the remainder of the original warranty period applicable to the equipment or parts being
repaired or replaced, whichever is greater. This warranty applies to the repaired or replaced part and is not extended to the product or any
other component of the product being repaired. Repair parts of its own manufacture sold after the original warranty period are warranted for
a period of one (1) year from shipment against defects in materials and workmanship under normal use and service. This warranty applies to
the replacement part only and is not extended to the product or any other component of the product being repaired. Seller may substitute
new equipment or improve part(s) of any equipment judged defective without further liability. All repairs or services performed by Seller,
which are not covered by this warranty, will be charged in accordance with Seller's standard prices then in effect.
THIS WARRANTY IS THE SOLE WARRANTY OF SELLER AND SELLER HEREBY EXPRESSLY DISCLAIMS AND BUYER
WAIVES ALL OTHER WARRANTIES EXPRESSED, IMPLIED IN LAW OR IMPLIED IN FACT, INCLUDING ANY WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Seller's sole obligation under this warranty shall be, at its
option, to repair or replace any equipment (or its component parts) which has a defect covered by this warranty, or to refund the purchase
price of such equipment or part. Under the terms of this warranty, Seller shall not be liable for (a) consequential, collateral, special or
liquidated losses or damages; (b) equipment conditions caused by normal wear and tear, abnormal conditions of use, accident, neglect, or
misuse of said equipment; (c) the expense of, and loss or damage caused by, repairs or alterations made by anyone other than the Seller; (d)
damage caused by abrasive materials, chemicals, scale deposits, corrosion, lightning, improper voltage, mishandling, or other similar
conditions; (e) any loss, damage, or expense relating to or resulting from installation, removal or reinstallation of equipment; (f) any labor
costs or charges incurred in repairing or replacing defective equipment or parts, including the cost of reinstalling parts that are repaired or
replaced by Seller; (g) any expense of shipment of equipment or repaired or replacement parts; or (h) any other loss, damage or expense of
any nature.
The above warranty shall not apply to any equipment which may be separately covered by any alternate or special warranties.
PERFORMANCE: In the absence of Certified Pump Performance Tests, equipment performance is not warranted or guaranteed.
Performance curves and other information submitted to Buyer are approximate and no warranty or guarantee shall be deemed to arise as a
result of such submittal. All testing shall be done in accordance with Seller's standard policy under Hydraulic Institute procedures.
LIABILITY LIMITATIONS: Under no circumstances shall the Seller have any liability under the Order or otherwise for liquidated
damages or for collateral, consequential or special damages or for loss of profits, or for actual losses or for loss of production or progress of
construction, regardless of the cause of such damages or losses. In any event, Seller's aggregate total liability under the Order or otherwise
shall not exceed the contract price.
ACTS OF GOD: Seller shall in no event be liable for delays in delivery of the equipment or other failures to perform caused by fires, acts of
God, strikes, labor difficulties, acts of governmental or military authorities, delays in transportation or procuring materials, or causes of any
kind beyond Seller's control.
COMPLIANCE WITH LAW: Seller agrees to comply with all United States laws and regulations applicable to the manufacturing of the
subject equipment. Such compliance shall include: The Fair Labor Standards Acts of 1938, as amended; Equal Employment Opportunity
clauses of Executive Order 11246, as amended; Occupational Safety and Health Act of 1970 and the standards promulgated thereunder, if
applicable. Since compliance with the various Federal, State, and Local laws and regulations concerning occupational health and safety,
pollution or local codes are affected by the use, installation and operation of the equipment and other matters over which Seller has no
control, Seller assumes no responsibility for compliance with those laws and regulations, whether by way of indemnity, warranty, or
otherwise. It is incumbent upon the Buyer to specify equipment which complies with local codes and ordinances.
800 Airport Road
North Aurora, Illinois 60542
630-859-7000
www.aurorapump.com