Xylem Bell & gossett ecocirc xl User manual

Installation, Operation, and

Maintenance manual

ecocirc®XL

Table of Contents

1 Introduction and Safety............................................................................................................................................................. 3

1.1 Introduction.................................................................................................................................................................................. 3

1.2 Safety terminology and symbols................................................................................................................................................3

1.3 Environmental safety................................................................................................................................................................... 3

1.4 Spare parts....................................................................................................................................................................................3

2 Transportation and Storage.......................................................................................................................................................3

2.1 Inspect the delivery..................................................................................................................................................................... 3

2.2 Transportation guidelines...........................................................................................................................................................3

2.3 Storage guidelines.......................................................................................................................................................................4

2.3.1 Storage location...................................................................................................................................................................4

3 Product Description...................................................................................................................................................................4

3.1 Pump design................................................................................................................................................................................ 4

3.2 Product nomenclature.................................................................................................................................................................4

3.3 Technical data.............................................................................................................................................................................. 4

3.4 Sound pressure levels................................................................................................................................................................. 5

3.5 Scope of delivery......................................................................................................................................................................... 5

3.6 Accessories...................................................................................................................................................................................5

4 Installation................................................................................................................................................................................. 5

4.1 Pump handling.............................................................................................................................................................................5

4.2 Tools required for pump installation.........................................................................................................................................5

4.3 Facility requirements...................................................................................................................................................................5

4.3.1 Pump location...................................................................................................................................................................... 5

4.3.2 Minimum inlet pressure at the suction port..................................................................................................................... 5

4.3.3 De-rating table..................................................................................................................................................................... 5

4.3.4 Piping requirements............................................................................................................................................................6

4.4 Electrical requirements............................................................................................................................................................... 6

4.5 Pump installation......................................................................................................................................................................... 6

4.6 Change the position of the motor housing.............................................................................................................................. 6

4.7 Electrical installation....................................................................................................................................................................7

4.7.1 Power supply connection................................................................................................................................................... 7

4.7.2 I/O connections....................................................................................................................................................................8

4.7.3 Connection assignment......................................................................................................................................................8

5 System Description................................................................................................................................................................... 8

5.1 User interface............................................................................................................................................................................... 8

5.1.1 User interface locking/unlocking.......................................................................................................................................8

5.2 Functions.......................................................................................................................................................................................8

5.2.1 Control mode.......................................................................................................................................................................8

5.2.2 Night mode...........................................................................................................................................................................8

5.2.3 ∆p-T control .........................................................................................................................................................................8

5.2.4 T-Constant temperature control........................................................................................................................................ 8

5.2.5 ∆T constant ..........................................................................................................................................................................9

5.2.6 External start/stop................................................................................................................................................................9

5.2.7 Analog Input.........................................................................................................................................................................9

5.2.8 Signal relay........................................................................................................................................................................... 9

5.2.9 External sensors (optional)................................................................................................................................................. 9

5.2.10 Communication bus .........................................................................................................................................................9

5.2.11 Automatic two-pump operation ..................................................................................................................................... 9

6 System Setup and Operation.................................................................................................................................................... 9

6.1 Conﬁgure the pump settings...................................................................................................................................................10

6.1.1 Change the communication parameters........................................................................................................................10

6.1.2 Change the control mode................................................................................................................................................ 10

6.1.3 Change the set point.........................................................................................................................................................10

6.1.4 Change the displayed unit of measurement..................................................................................................................10

6.2 Start or stop the pump..............................................................................................................................................................10

6.2.1 Automatic air venting procedure.................................................................................................................................... 11

6.2.2 Twin pump conﬁguration setup...................................................................................................................................... 11

6.2.3 Activate automatic two-pump operation .......................................................................................................................11

7 Maintenance............................................................................................................................................................................11

8 Troubleshooting.......................................................................................................................................................................11

8.1 Periodic inspection....................................................................................................................................................................11

8.2 Display messages...................................................................................................................................................................... 11

8.3 Fault and error codes (Red LED)..............................................................................................................................................11

Table of Contents

ecocirc®XL Installation, Operation, and Maintenance manual 1

8.4 Alarm codes (Orange LED)...................................................................................................................................................... 12

8.5 Faults, causes, and remedies................................................................................................................................................... 12

9 Other Relevant Documentation or Manuals............................................................................................................................ 12

9.1 Embedded Software and Driver Software License Agreement.......................................................................................... 12

10 Product warranty................................................................................................................................................................... 13

Table of Contents

2 ecocirc®XL Installation, Operation, and Maintenance manual

1 Introduction and Safety

1.1 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 in-

jury 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.

1.2 Safety terminology and symbols

Hazard levels

Hazard level Indication

DANGER:

A hazardous situation which, if not

avoided, will result in death or se-

rious injury

WARNING:

A hazardous situation which, if not

avoided, could result in death or

serious injury

CAUTION:

A hazardous situation which, if not

avoided, could result in minor or

moderate injury

NOTICE:

• A potential situation which, if

not avoided, could result in

undesirable conditions

• A practice not related to per-

sonal injury

Hazard categories

Hazard categories can either fall under hazard levels or let speciﬁc sym-

bols replace the ordinary hazard level symbols.

Electrical hazards are indicated by the following speciﬁc symbol:

Electrical Hazard:

Hot surface hazard

Hot surface hazards are indicated by a speciﬁc symbol that replaces the

typical hazard level symbols:

CAUTION:

Qualified personnel

WARNING:

This product is intended to be operated by qualiﬁed person-

nel only.

1.3 Environmental safety

The work area

Always keep the station clean.

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.

CAUTION: Radiation Hazard

Do NOT send the product to Xylem if it has been exposed to

nuclear radiation, unless Xylem has been informed and ap-

propriate actions have been agreed upon.

Electrical installation

For electrical installation recycling requirements, consult your local

electric utility.

Recycling guidelines

Always follow local laws and regulations regarding recycling.

1.4 Spare parts

WARNING:

Only use original spare parts to replace any worn or faulty

components. The use of imitation spare parts may cause mal-

functions, damage, and injuries as well as void the warranty

and the UL listing.

2 Transportation and Storage

2.1 Inspect the delivery

1. Inspect the package for damage or missing items upon delivery.

2. If applicable, unfasten the product by removing any screws, bolts,

or straps. For your personal safety, be careful when you handle

nails and straps.

3. Remove packing material from the product.

4. Dispose of all packing material in accordance with local regula-

tions.

5. Inspect the product to determine if any parts have been damaged

or are missing.

Contact your local B&G representative if there are any issues.

2.2 Transportation guidelines

Precautions

WARNING:

• Observe accident prevention regulations in force.

• Crush hazard. The unit and the components can be

heavy. Use proper lifting methods and wear steel-toed

shoes at all times.

Check the gross weight that is indicated on the package in order to se-

lect proper lifting equipment.

Position and fastening

The unit should be transported in an upright position as indicated on

the package. Make sure that the unit is securely fastened during trans-

portation and cannot roll or fall over. The product can be safely trans-

ported at ambient temperature from -40°F to +158°F (-40°C to +70°C)

with humidity <95% (non-condensing) and protected against dirt, heat

source, and mechanical damage.

1 Introduction and Safety

ecocirc®XL Installation, Operation, and Maintenance manual 3

2.3 Storage guidelines

2.3.1 Storage location

NOTICE:

• Protect the product against humidity, dirt, heat sources, and me-

chanical damage.

• The product must be stored at an ambient temperature from

-13°F to +131°F (-25°C to +55°C) and humidity < 95% (non-con-

densing).

3 Product Description

3.1 Pump design

•The ecocirc XL is a large wet rotor pump with energy efﬁcient,

electronically commutated permanent magnet motor.

• The pump is designed for systems with variable ﬂow rates to opti-

mize pump operation thus reducing energy consumption. The

pump can be set to any one of the multiple operating modes

available, with each designed for a speciﬁc application to achieve

high performance and maximum energy savings.

• A single pump can handle heating, cooling, and plumbing appli-

cations with a choice for cast iron or bronze lead-free body pumps

to handle HVAC and potable water applications. The pumps are

also suitable for a 50/50 percent water/glycol circulating ﬂuid. The

built-in electrical overload and dry run protection provide safety

and protection to pump from damage.

Intended use

WARNING:

California Proposition 65 warning! This product contains

chemicals known to the state of California to cause cancer

and birth defects or other reproductive harm.

The pump is suitable for:

• Potable hot water (only with bronze pump body models)

• Hot water heating systems

• Cooling and cold water systems

The pump can also be used for:

• Solar systems

• Geothermal applications

Improper use

DANGER:

Do not use this pump to handle ﬂammable and/or explosive

liquids.

WARNING:

Unintended use of the pump may create dangerous condi-

tions and cause personal injury and damage to property.

WARNING:

Do NOT install this pump in swimming pools or marine areas.

Failure to follow these instructions could result in serious per-

sonal injury, death and/or property damage.

THIS IS A NON-SUBMERSIBLE PUMP

WARNING:

Do NOT exceed the maximum working pressure of the

pump. This information is listed on the nameplate of the

pump.

NOTICE:

Do not use this pump to handle liquids containing abrasive, solid, or

ﬁbrous substances, toxic or corrosive liquids, potable liquids other than

water, or liquids not compatible with the pump construction material.

Water pH must be maintained between 7-9 and water hardness must

not exceed 14 grains/ gallon.

An improper use of the product leads to the loss of the warranty.

3.2 Product nomenclature

Example: ecocirc XL B 15–75

ecocirc XL high efﬁciency pump series

B Pump type:

Blank = Cast iron

B = bronze pump body for pota-

ble hot water pumping

-15 Maximum pump head (FT)

-75 Maximum pump ﬂow rate (GPM)

3.3 Technical data

Feature Description

Motor model Electronically commutated motor with perma-

nent magnet rotor

Series ecocirc XL

Rated voltage 1 x 115 V ±10%

1 x 208–230 V ±10%

Frequency 50/60 Hz

Power consumption The maximum power consumption is indicated

on the pump nameplate.

IP protection IP 44

Insulation class Class 155 (F)

Maximum working

pressure The maximum pressure is indicated on pump

nameplate

175 PSI (12 bars)

Liquid temperature

range 14°F (-10°C) to 230°F (110°C)

Up to 149°F (+65°C) is recommended for do-

mestic hot water pumps

Ambient tempera-

ture range 32°F (0°C) to 104°F (40°C)

Ambient humidity ≤ 95% non-condensing

Pumping media Water and water/glycol mixtures1up to 50%.

Sound pressure See Sound pressure levels (page 5).

EMC (electromag-

netic compatibility) EN 55014-1:2006 + A1:2009 + A2:2011, EN

55014-2:1997 + A1:2001 + A2:2008, EN

61000-3-2:2006 + A1:2009 + A2:2009, EN

61000-3-3:2008, 61800-3:2004+A1:2012.

Leakage current < 3.5 mA

I/O auxiliary +15

VDC power supply Imax < 40 mA

Fault signal relay Vmax < 250 VAC

Imax < 2 A

CSA certiﬁcation NSF/ANSI-372 compliant (bronze body parts)

UL/cUL Listed UL 778 - Motor operated water pump

UL60730, UL1004

1The pump can be used with water/propylene glycol mixtures up to 50% with a maximum viscosity of 50cST at 14°F (-10°C). The pump has built-in overload and

thermal protection to protect the pump from overload due to increased ﬂuid viscosity. Pump performance is based on 77°F (25°C). Therefore pumping of glycol

mixtures will affect max performance, depending on mixture concentration and temperature.

3 Product Description

4 ecocirc®XL Installation, Operation, and Maintenance manual

3.4 Sound pressure levels

Nominal pump HP Sound pressure level (approxi-

mate values)

1/6 ≤ 43 dB (A)

1/2 ≤ 48 dB (A)

1 ≤ 52 dB (A)

2 ≤ 55 dB (A)

3.5 Scope of delivery

Inside the package you will ﬁnd:

• Pump unit

• Insulating shells for pump body — for heating applications

• O-ring to be used as replacement between motor housing and

pump body

• Two (2) gaskets for ﬂanged connection

• 20 mm x ½” NPT electrical ﬁtting

• IOM and Quick Start guide

• Two (2) M16 x 1.5 connection cable ﬁtting

3.6 Accessories

• Companion ﬂanges

• Fastener Packs consisting of 4 bolts and 4 nuts (for 2–bolt models)

•Fastener Packs consisting of 8 bolts and 8 nuts (for 4–bolt models)

• Pressure sensor (for details see section 5.2.10 of this manual)

• Temperature sensor (for details see section 5.2.10 of this manual)

• Wireless module

• RS–485 module

4 Installation

Precautions

WARNING:

• Observe accident prevention regulations in force.

• Use suitable equipment and protection.

• Always refer to the local and/or national regulations,

legislation, and codes in force regarding the selection of

the installation site, plumbing, and power connections.

4.1 Pump handling

WARNING:

Observe local codes and regulations setting the limits for

manual lifting or handling.

Always lift the pump by the motor housing or pump body. If the pump

weight exceeds the manual handling limits, use lifting equipment with

lifting straps.

4.2 Tools required for pump installation

• T-Handle with allen screw

• Control screw driver – with 2 mm blade size

Nominal HP Allen screw size (mm) T-handle length (in)

1/12 5 8

1/6 5 8

1/2 6 10

1 8 12

2 8 12

4.3 Facility requirements

4.3.1 Pump location

DANGER:

Do not use this unit in environments that may contain ﬂam-

mable/explosive or chemically aggressive gases or powders.

Guidelines

Observe the following guidelines regarding the location of the prod-

uct:

• Make sure that the installation area is protected from any ﬂuid

leaks, or ﬂooding.

•If possible, place the pump slightly higher than the ﬂoor level.

•Provide shut-off valves on the suction and discharge sides of the

pump.

•The relative humidity of the ambient air must be less than 95%

non-condensing.

•This pump is suitable for indoor use only.

CAUTION:

CAUTION: PROPERTY DAMAGE HAZARD. It is not advisable

to install circulators in an attic or upper ﬂoor over ﬁnished liv-

ing space. If the circulator must be installed over head, or

over expensive equipment, provide adequate drainage in

the event of leakage. Failure to follow these instructions

could result in property damage.

4.3.2 Minimum inlet pressure at the suction port

The values in the table below are the inlet pressures above the atmos-

pheric pressure.

Nominal Suction

Diameter Fluid tempera-

ture 77°F (25°C) Fluid tempera-

ture 203°F

(95°C)

Fluid tempera-

ture 230°F

(110°C)

1½” 4.5 PSI 16 PSI 25 PSI

2” 4.5 PSI 16 PSI 25 PSI

3” 7.5 PSI 19 PSI 28 PSI

NOTICE:

• Ensure that the suction pressure is never below the values speci-

ﬁed above, as this could cause cavitation and damage the pump.

•The inlet pressure plus the pump pressure against a closed valve

must be lower than maximum admissible system pressure.

4.3.3 De-rating table

The following table indicates percent decrease in input power draw,

with the increase in temperature of circulating water and the ambient.

Ambient

temperature

Fluid Temperature (°C)

-10 60 95 110

32°F–77°F

(0°C–25°C) 100% 100% 100% 100%

4 Installation

ecocirc®XL Installation, Operation, and Maintenance manual 5

Ambient

temperature

Fluid Temperature (°C)

-10 60 95 110

86°F (30°C) 100% 100% 80% 70%

104°F (40°C) 100% 100% 70% 55%

4.3.4 Piping requirements

Precautions

CAUTION:

• Use pipes suited to the maximum working pressure of

the pump. Failure to do so can cause the system to rup-

ture, with the risk of injury.

• Make sure that all connections are performed by quali-

ﬁed installation technicians and in compliance with the

regulations in force.

• Do not use a shut-off valve on the discharge side in the

closed position for more than a few seconds. If the

pump must operate with the discharge side closed for

more than a few seconds, a bypass circuit must be instal-

led to prevent overheating of the water inside the

pump.

Piping checklist

• Pipes and valves must be correctly sized.

• Pipe work must not transmit any load or torque to pump ﬂanges.

• Be sure to minimize any pipe-strain on the pump:

• Support suction and discharge piping by the use of pipe

hangers near the pump.

• Line up the vertical and horizontal piping so that the bolt-

holes in the pump ﬂanges match the bolt-holes in the pipe

ﬂanges.

•Do not attempt to spring the suction or discharge lines in po-

sition. This may result in unwanted stress in the pump body,

ﬂange connections and piping.

• The code for pressure piping (ANSI B31.1) lists many types of

supports available for various applications.

4.4 Electrical requirements

• The NEC and local codes must be followed at all times. If a branch

circuit is ﬁtted with ground fault circuit breaker, ensure that the cir-

cuit breaker is suitable for use with inverter-driven appliances.

Electrical connection checklist

Check that the following requirements are met:

•The electrical wires are protected from high temperature and vi-

brations.

•The current type and power supply voltage connection must cor-

respond to the speciﬁcations on the name plate on the pump.

• Use wires at least 14 AWG to supply power to the pump. Follow

all local and NEC wiring codes and practices.

The electrical control panel checklist

NOTICE:

The electrical supply must match the electrical rating of the pump. Im-

proper combination could fail to guarantee protection of the unit.

Check that the following requirements are met:

• The control panel circuit breaker is sized properly to protect the

pump against short-circuit.

• The pump has built in overload and thermal protection, no addi-

tional overload protection is required.

The motor checklist

Electrical supply and grounding wires must be suitable for at least

194°F (90°C).

4.5 Pump installation

1. Install the pump according to the liquid ﬂow direction.

• The arrow on the pump housing shows the ﬂow direction

through the pump body.

•The pump must be installed with the motor in a horizontal

position. For more information about allowed positions, refer

to the following image:

Figure 1: Allowed pump installation

2. If necessary, rotate the position of the motor for better visibility of

the user interface.

Section 4.6 below describes the procedure of changing of motor

orientation.

3. If applicable, install the thermal insulation shells.

• Only use the pump thermal shells that are included in the de-

livery. Do not insulate the motor housing, the electronics can

overheat and cause the pump to thermally overload.

• The thermal shells that are included with the pump must only

be used in hot water circulation applications with ﬂuid tem-

perature above 68°F (20°C). The thermal shells are permea-

ble to water vapor.

• If the customer installs the vapor barrier insulation shells for

cold water application, then the pump housing must not be

insulated above the motor ﬂange. The drain opening must

be kept unobstructed in order that the accumulated conden-

sation can run out.

4.6 Change the position of the motor

housing

WARNING:

• Drain the system if possible or close the service valves

on both sides of the pump before disassembling the

pump. The pumped ﬂuid can be pressurized and may

be scalding hot.

• There is the risk of escaping vapor when the motor is

separated from the pump housing.

Electrical Hazard:

Before starting work on the unit, make sure that the unit and

the control panel are isolated from the power supply and

cannot be energized.

CAUTION:

Burn hazard. During operation various surfaces on the unit

will become hot. To avoid burn injury, use heat protective

gloves.

WARNING:

• A strong magnetic ﬁeld is created when the rotor is re-

moved from or inserted into the motor housing. This

magnetic ﬁeld can be harmful to pacemaker wearers

and others with medical implants. In addition, the mag-

netic ﬁeld may attract metal parts to the rotor which can

cause injuries and/or damage the bearing of the pump.

4 Installation

6 ecocirc®XL Installation, Operation, and Maintenance manual

465

Figure 2: Change the position of the pump head

1. Loosen the four hex-head screws (2) that ﬁx the motor to the

pump housing (4) using the T-handle allen wrench described.

2. Rotate the motor (1) in 90° steps to the desired position.

3. In case of separation of the motor housing from the pump body

(4):

a) avoid removing the rotating assembly from motor housing;

b) pay attention to the magnetic hazard listed before.

A defective O-ring must be replaced. An O-ring is already availa-

ble inside the package as spare part.

4. Properly align and tighten the four hex-head screws (2) that afﬁx

the motor to the pump body (4) according to the torque table giv-

en below in a criss cross pattern.

Nominal HP Screw size Torque

1/12 & 1/6 M6 90 in-lb

1/2 M8 170 in-lb

1 & 2 M10 340 in-lb

CAUTION:

Check for the presence of leaks after reassembling the

pump.

4.7 Electrical installation

Precautions

WARNING:

• Make sure that all connections are performed by a quali-

ﬁed electrician in accordance with all applicable codes,

ordinances and good practices. Failure to follow these

instructions could result in serious injury, death and/or

property damage.

• Before starting work on the unit, make sure that the unit

and the control panel are isolated from the power sup-

ply and cannot be energized.

Grounding (earthing)

WARNING:

Reduced risk of electric shock during operation of this pump

requires the provision of acceptable grounding.

Be sure the following are adhered to. Failure to follow these instruc-

tions could result in serious personal injury, death, and/or property

damage.

• If means of connection to the supply connection box (wiring com-

partment) is other than grounded metal conduit, ground the

pump back to service using a copper conductor at least the size of

the circuit conductors supplying the pump.

• Connect the ground wire to the green grounding terminal in the

wiring compartment.

The number of ON/OFF power cycles for the pump must be less than 3

times per hour and less than 20/24 hours. If more frequent start/stop

cycles are required, the use of a dedicated start/stop input is recom-

mended. See External start/stop (page 9).

4.7.1 Power supply connection

WARNING:

Do not make any connection in the pump control box unless

the power supply has been switched off for at least 2 mi-

nutes.

For models with standard terminal block connection:

1. Open the terminal box cover removing the screws (5).

2. Thread the ½” NPT electrical ﬁtting into the conduit connection of

the pump.

3. Connect the cable according to the wiring diagram.

a. Connect the ground wire, if used.

b. Connect the wires.

4. Close the terminal box cover.

115V

208-230V CB

Figure 3: Wiring diagram

CAUTION:

If stranded wire is used to connect power to the pump, make

sure that all the individual strands enter the terminal block as

the wire is inserted. Peeled back strands can cause a short

circuit hazard at the pump terminal block connections.

Start / Stop

1918

1615

1312

10987654321

CNL NO 15V S+S- P+ P- T+ T- AB GND AB GND

Figure 4: Connection diagram

For cable terminations, see above connection diagram.

4 Installation

ecocirc®XL Installation, Operation, and Maintenance manual 7

4.7.2 I/O connections

1. Open the terminal box cover removing the screws (5). Refer to ﬁg-

ure 2 on page 7. Use control screwdriver described under section

4.2 to access terminal blocks.

2. Connect the appropriate wires according to the terminal block di-

agram and the requirements of section Connection assignment

(page 8) given below in section 4.7.3.

3. Close the terminal box cover.

• For a two-pump connection, wire them through a communication

cable connecting the 2 RS-485 ports at the pumps to terminals 15,

16 & 17.

4.7.3 Connection assignment

• For all electrical connections use heat resistant wires or cable rat-

ed for at least 194°F (90°C). The cables should not touch the mo-

tor housing, the pump or the piping.

• Power and control wires must be run in separate channels.

• Metal conduit for power wiring must only be attached to 1/2” NPT

conduit ﬁtting.

NOTICE:

Cable glands are only available for low voltage wiring to protect

against cable slippage and vapor ingress into the terminal box.

5 System Description

5.1 User interface

Figure 5: User interface diagram

1. Control mode button

2. Control mode indicators

3. Parameter button

4. Parameter indicators

5. Setting buttons

6. Numeric display

7. Power indicator

8. Status / Fault indicator

9. Remote control indicator

Hot Surface:

Burn hazard. During the normal operation, the pump surfa-

ces may be so hot that only the buttons should be touched to

avoid burns.

5.1.1 User interface locking/unlocking

The user interface will automatically lock if no button is pressed for ten

minutes, or if the upper setting button (5) and the parameter button (3)

are pressed for two seconds. See User interface (page 8).

If a button is pressed when the user interface is locked, the display (6)

shows:

To unlock the user interface, press the upper setting button (5) and the

parameter button (3) for two seconds. The display (6) will show:

Now it is possible to change the pump setting as required.

5.2 Functions

The main functions of the pump and control modes are selectable

through the pump user interface and the embedded I/O. Advanced

functions or communication features, can only be set via bus protocol

or the optional Wireless module. See the electronic drive manual at

www.bellgossett.com.

5.2.1 Control mode

Mode Description

Constant pressure

Hset

The pump maintains a constant

pressure at any ﬂow demand. The

desired head of the pump can be

set via user interface. See section

6.1.2 Change set point.

Proportional pressure

Hset

The pump pressure is continuous-

ly increased/decreased depend-

ing on the increased/decreased

ﬂow demand. The maximum head

of the pump can be set via user in-

terface. See section 6.1.2 Change

set point.

Fixed speed control

Max

min

Speed

setpoint

The pump maintains a ﬁxed speed

at any ﬂow demand. The speed of

the pump can be set via user inter-

face. See section 6.1.2 Change set

point.

All the above control modes can be combined with the night mode

function.

5.2.2 Night mode

The night mode cannot be used in cooling systems.

Prerequisite

•The pump is installed between boiler outlet and system supply.

•The night mode feature is initiated when the pump recognizes a

water temperature change brought about by the boiler or high

level control system.

The night mode is active only in combination with:

•Proportional pressure

•Constant pressure

•Fixed speed

This function reduces power consumption of the pump to the minimum

when heating system is not running. An algorithm detects the water

temperature change and automatically adjusts the speed of the pump.

The pump returns to the original set point as soon as the system re-

starts.

5.2.3 ∆p-T control

This function adjusts the nominal differential pressure set point accord-

ing to the temperature of the pumped media.

For details refer to the electronic drive manual on www.bellgos-

sett.com

5.2.4 T-Constant temperature control

This functional mode changes the speed of the pump in order to main-

tain a constant temperature of the pumped media. It is suitable for

5 System Description

8 ecocirc®XL Installation, Operation, and Maintenance manual

heating systems with ﬁxed system characteristics, for example Domes-

tic Hot Water Systems.

For details, refer to the electronic drive manual on www.bellgos-

sett.com

5.2.5 ∆T constant

This function alters the speed of the pump in order to maintain a con-

stant differential temperature of the pumped media.

For details, refer to the electronic drive manual on www.bellgos-

sett.com

5.2.6 External start/stop

The pump can be started or stopped via an external dry contact or a

relay that is connected to terminals 11 and 12. The pump unit is provid-

ed by default, with the terminals 11 and 12 jumpered. See Figure 4 on

page 8.

NOTICE:

• The pump provides 5 VDC through the start / stop terminals.

• No external voltage must be provided to start / stop terminals.

• The cables connected to terminals 11 and 12 shall not exceed 65

feet in length.

5.2.7 Analog Input

The pump integrates a 0-10 V analog input at terminals 7 and 8. See

terminal diagram ﬁgures for changing the setpoint. See Figure 4 on

page 8.

When a voltage input is detected, the pump switches to ﬁxed speed

control mode automatically and starts to run according to the following

diagram:

Vin[V]

Speed

[rpm]

Vset 101.51.2

min

Max

Setpoint

Figure 6: Voltage input detected

Pump stops at 1.2 V

Pump restarts at 1.5 V

5.2.8 Signal relay

A dry contact relay is provided at terminals 4 and 5. See connection di-

agram, ﬁgure 4 on page 8, for location. If there is a fault, the relay con-

tact closes to display a red status light and the error code on the user

interface display. See User interface (page 8). The relay contact closure

can also be used to energize a remote fault display.

Ratings

•Voltage: 115/208 – 230/1

• Imax < 2 A

5.2.9 External sensors (optional)

The pump can be equipped with a differential pressure sensor and a

temperature sensor according to the following table:

Sensor description Type Terminals

Differential pressure

sensor 4-20mA 15 PSI

30 PSI 9 - 10

Temperature sensor KTY83 13 - 14

Pressure sensor setup

1. Install pressure sensor on the pipe

2. Connect wires at terminals 9 and 10. See Figure 4 on page 8.

3. Power the pump on.

4. Upon startup, the pump detects the sensor and displays the setup

menu.

5. Select the right sensor model and conﬁrm the selection using the

parameter button (3). See User interface (page 8).

6. The pump will run through the startup sequence and automatical-

ly start working in constant pressure mode.

7. The setpoint can be changed using the settings button (5). See

User interface (page 8).

External temperature sensor setup

The external temperature sensor setup and related control modes are

available only through RS-485 or wireless module connection.

For details refer to the electronic drive manual on www.bellgos-

sett.com

Wireless module

The wireless module is an optional module, to be coupled with the

ecocircXL circulators. When correctly conﬁgured, it generates a wire-

less network accessible by a mobile device, tablet or a personal com-

puter. See wireless module instructions manual for details.

5.2.10 Communication bus

The pump has a built-in RS-485 communication channel (terminals

15-16-17). See Figure 4 on page 8.

The pump can communicate with external BMS systems via Modbus or

BACnet protocol. For a complete description of the protocols, refer to

the electronic drive manual at www.bellgossett.com.

NOTICE:

When remote control is active, the set points and control modes are

managed only through communication channels and cannot be

changed via the user interface. The displayed quantity and unit of

measurement remain active on the user interface.

5.2.11 Automatic two-pump operation

Backup operation (bcup)

Only the lead pump runs. The second pump starts in case of failure of

the lead pump.

Alternate operation (alte)

Only one pump runs at a time. The working time is switched every 24

hours so that workload is balanced between both pumps. The second

pump is started immediately in case of failure of the lead pump.

Automatic parallel operation (para)

Both pumps run simultaneously at the same set point. The lead pump

determines the behavior of the full system and is able to optimize the

performance. To guarantee the required performance with the mini-

mum power consumption, the lead pump starts or stops the lag (sec-

ond) pump to satisfy system requirement of ﬂow and head.

Forced parallel operation (forc)

Both pumps run simultaneously with the same set point. The master

pump determines the behavior of the full system.

6 System Setup and Operation

Precaution

CAUTION:

Always wear protective gloves when handling the pumps and

motor. When pumping hot liquids, the pump and its parts

may exceed 40°C (104°F).

NOTICE:

The pump must not run dry as this can result in the destruction of the

bearings. Fill the system correctly with liquid and vent the air before

ﬁrst start-up.

6 System Setup and Operation

ecocirc®XL Installation, Operation, and Maintenance manual 9

NOTICE:

• Never operate the pump with discharge valve closed for longer

than a few seconds.

• Do not expose an idle pump to freezing conditions. Drain all liq-

uid that is inside the pump. Failure to do so can cause liquid to

freeze and damage the pump.

• The suction plus shut-off discharge pressure must not exceed the

pump pressure rating.

• Do not use the pump if cavitation occurs. Cavitation can damage

the internal components.

6.1 Configure the pump settings

Change the pump settings using one of the following methods:

• User interface

• Bus communication

• Wireless communication

6.1.1 Change the communication parameters

Change pump communication parameters. See User interface (page 8).

1. Switch off the pump.

Wait until the power indicator light turns off.

2. Switch on the pump.

3. When the display shows COMM, press the parameter button (3) to

access the communication menu.

4. Select one of the four below parameters using the settings button

(5).

•BAUD = baud rate setup (available values 4.8 - 9.6 - 14.4 -

19.2 - 38.4 - 56.0 - 57.6 kbps)

•PROT = communication protocol (available protocols “mod”

= Modbus; “bac” = BACnet

•ADDR = address setup (available address 1-247 for Modbus

0–127 for BACnet)

•MODU = optional module setup (“none” = no module; “wiﬁ”

= Wireless module; “485” = RS-485 module)

5. Press the parameter button to enter the submenu

6. Edit the values using setting buttons.

7. Press the parameter button to conﬁrm and store the new values.

8. Press mode button to exit the submenu.

9. Repeat above procedure for each of the three parameters.

If no buttons are pressed for 10 seconds, then the pump exits the cur-

rent menu and continues start-up procedure. All the parameters that

are changed but not conﬁrmed restore back to previous state.

NOTE: The communication setup menu is available only on display and

not through communication bus.

6.1.2 Change the control mode

The pump can be controlled by a BMS (Building management system)

or other devices through the RS-485 communication port via Modbus

or BACnet protocol.

The following instructions are used when making the change on the

user interface. See User interface (page 8).

•Press the operating mode button (1).

• The operating modes are cyclically changed by the pressed but-

ton.

mode

mode mode

mode

6.1.3 Change the set point

See User interface (page 8).

1. Press one of the arrow setting buttons (5).

The display starts to blink.

2. Change the value using the buttons (5).

3. Wait 3 seconds to store and activate the new set point.

The display will stop blinking to conﬁrm the change.

NOTICE:

If a check valve is installed on the system, ensure that the pump head is

sufﬁcient to allow ﬂow through the system.

6.1.4 Change the displayed unit of measurement

Power, Flow, Head and Speed parameters cyclically change by press-

ing the parameter button (3). In order to change the unit of measure-

ment, follow these steps:

1. Press the button (3) to change the unit of measurement. See User

interface (page 8).

Power

Speed

Head

Flow

Parameter

button

Parameter

button

Parameter

button

Parameter

button

2. When ﬂow and head are displayed, by pressing the button (3) for

more than one second at each of these parameters, the unit of

measurement automatically changes as below:

• Flow: m3/h ↔ gpm (US)

• Head: m ↔ ft

6.2 Start or stop the pump

CAUTION:

• The pump must not run dry as this can result in prema-

ture failure of the bearings in a very short time. Fill and

vent the system correctly before ﬁrst start-up. The pump

rotor chamber will be vented after the pump is powered

on with an automatic air venting procedure. "deg" will

be displayed indicating degassing process.

NOTICE:

The system cannot be vented through the pump.

• Start the pump in one of the following ways:

• Switch on power to supply the pump.

• Close the start/stop contact by jumpering terminals 11 and

12 or through a remote dry contact..

• Send start command through the communication bus.

The pump starts pumping in constant pressure mode with the fol-

lowing default set points:

7.5 ft 15–XX (Max head 15 ft)

10 ft 20–XX (Max head 20 ft)

18 ft 36–XX (Max head 36 ft)

20 ft 40–XX (Max head 40 ft)

27.5 ft 55–XX (Max head 55 ft)

32.5 ft 65–XX (Max head 65 ft)

For more information about how to change setting, see Conﬁgure

the pump settings (page 10).

• Stop the pump in one of the following ways:

6 System Setup and Operation

10 ecocirc®XL Installation, Operation, and Maintenance manual

• Switch off power supply to the pump.

• Open the start/stop contact.

• Send stop command through the communication bus.

6.2.1 Automatic air venting procedure

At each power-on of the pump unit, an automatic air venting proce-

dure is executed. During this phase, the user interface displays "deg"

(degassing) and a count-down begins until the completion of the pro-

cedure.

The air venting procedure can be recalled or skipped:

• Manually by pressing simultaneously the two buttons (5). See User

interface (page 8). The feature will remain disabled until power to

pump is disconnected.

The procedure can be permanently enabled or disabled by:

• Manually by pressing simultaneously the two buttons (5) for at

least 10 seconds. See User interface (page 8). Or

• Via communication bus. See the electronic drive manual on

www.bellgossett.com.

6.2.2 Twin pump configuration setup

The circulators are conﬁgured as single units by factory default. To acti-

vate the 2–pump functions, follow the procedure below only on one of

the two units. The other unit will be auto conﬁgured. The working

modes are described in Automatic two-pump operation (page 9) and

Activate automatic two-pump operation (page 11).

6.2.3 Activate automatic two-pump operation

Once the communication cable is connected, conﬁgure only the “lead”

pump. The twin pump submenu for this conﬁguration is available at

each power-on, when the drive is displaying SING (which stands for

“Single Pump).

The following procedure must be executed during the start-up phase

of the pump.

1. Enter the two-pump sub menu when the display is showing

TWMA (two-pump master) or TWSL (two-pump slave).

2. Select the applicable two-pump operation.

•bcup = backup operation

•alte = alternative operation

•para = automatic parallel operation

•forc = forced parallel operation

3. Push the parameter button to activate the new setting.

The second pump is conﬁgured by the lead pump.

7 Maintenance

Precaution

Electrical Hazard:

Disconnect and lock out electrical power before installing or

servicing the unit.

Wait 2 minutes before opening the conduit box.

WARNING:

• Always wear protective gloves when handling the

pumps and motor. When pumping hot liquids, the

pump and its parts may exceed 40°C (104°F).

• Maintenance and service must be performed by skilled

and qualiﬁed personnel only.

•Observe accident prevention regulations in force.

• Use suitable equipment and apply personal protection.

• Risk of property damage, serious personal injury or

death. You must repair or replace the pump if corrosion

or leakage is found.

8 Troubleshooting

Introduction

See User interface (page 8).

• In case of any alarm that allows the pump to continue running, the

display shows a blinking alarm code and the last quantity select-

ed, while the status indicator (8) becomes orange.

• In case of a failure that stops the pump, the display shows the er-

ror code permanently and the status indicator (8) becomes red

8.1 Periodic inspection

Bell & Gossett ecocircXL circulators are designed to provide years of

trouble-free service. It is recommended that periodic inspections be

made to check for potential problems with the pump. If any leakage or

evidence of leakage is present, repair or replace the unit.

8.2 Display messages

Table 1: Default

Operating LEDs / Display Cause

Power On Pump powered

All LEDs and display On Start-up of the pump

Status Green light Pump is working properly

Remote On Remote communication is activated

Table 2: Fault messages

Operating LEDs / Dis-

play Cause Solution

Power Off Pump is not connected

or is incorrectly con-

nected

Check connection

Power failure Check power supply

and circuit breaker

Status light Orange Alarm for system prob-

lem Check the displayed

alarm code and ﬁnd

cause from table 8.4.

Status light Red Pump failure Check the displayed

error code and ﬁnd the

cause from table 8.3.

Remote Off Remote communica-

tion is deactivated If the communication

does not work, check

the connection and the

conﬁguration parame-

ters for communication

on the external con-

troller.

8.3 Fault and error codes (Red LED)

Error code Cause Solution

E01 Internal communication lost Restart the pump2

E02 High motor current Restart the pump2

E03 DC Bus overvoltage Indicates excessive

power through the

pump. Conﬁrm system

setup, verify correct

position and opera-

tion of check valves.

E04 Motor stall Restart the pump2

E05 Data memory corrupted Restart the pump2

E06 Voltage supply out of operating

range Check the electrical

system voltage and

wiring connection.

2Switch off the pump for 5 minutes and then power on. If the problem persists, contact service.

7 Maintenance

ecocirc®XL Installation, Operation, and Maintenance manual 11

Error code Cause Solution

E07 Motor thermal protection trip Check the presence of

foreign material

around impeller and

rotor that cause over-

load. Check installa-

tion conditions and

temperature of the

water and ambient air.

Wait until the motor is

cooled. If the error

persists try to restart

the pump2.

E08 Inverter thermal protection trip Check installation con-

ditions and ambient

air temperature.

E09 Hardware error Restart the pump.

E10 Dry run Check for system leak-

age or ﬁll the system.

8.4 Alarm codes (Orange LED)

Alarm code Cause Solution

A01 Fluid sensor malfunction Switch off the pump for 5

minutes and then power

on. If the problem persists,

contact local B&G repre-

sentative.

A02 High temperature of the

ﬂuid Check water temperature

value

A03 Automatic speed reduction

to prevent inverter over-

heating

Check installation condi-

tions and rectify status of

the system

A05 Data memory corrupted Switch off the pump for 5

minutes and then power

on. If the problem persists,

contact local B&G repre-

sentative.

A06 External temperature

probe malfunction Check the probe and the

connection to the pump

A07 External pressure sensor

malfunction Check the sensor and the

connection to the pump

A08 Cooling fan failure (Only

on 2 HP and larger models) Check for the presence of

foreign bodies which could

lock the fan rotation.

Switch off the pump for 5

minutes and then power

on. If the problem persists,

contact service.

A12 2–pump communication

lost If both pumps show the

A12 alarm, check the con-

nection between the

pumps. If one of the pump

is switched off or shows an-

other error code, check the

section 8.1 and 8.2 to ﬁnd

the problem

A20 Internal alarm Switch off the pump for 5

minutes and then power

on. If the problem persists,

contact local B&G repre-

sentative.

8.5 Faults, causes, and remedies

The pump does not start

Cause Remedy

No power. Check the power supply and ensure that

it is properly terminated to the pump

power.

Tripped circuit breaker or

ground-fault protection de-

vice or the circuit breaker.

Reset power supply circuit breaker and

determine cause for overload.

The pump starts but the thermal protection is triggered after a short

time

Cause Remedy

Incorrect wiring size or circuit break-

er rating not suitable for motor cur-

rent.

Check and replace the compo-

nents as necessary.

Thermal overload protection due to

excessive input. Check the pump working con-

ditions.

Missing a phase in the power supply. Verify continuity and ensure

proper wiring connections.

The pump is noisy

Cause Remedy

Not thoroughly vented. Switch off the pump and after 30 sec-

onds switch on again to restart the auto-

matic air-venting procedure.

Cavitation due to insufﬁcient

suction pressure. Increase the system suction pressure

within the admissible range.

Foreign objects in pump. Clean the system.

Worn out bearing Replace pump.

9 Other Relevant Documentation or

Manuals

9.1 Embedded Software and Driver Software

License Agreement

With the purchase of the product, the terms and conditions of the li-

cense for the software embedded on the product are considered ac-

cepted. For more information see license condition on www.bellgos-

sett.com

FCC Statement — USA only (Federal Communications Commission)

This device complies with Part 15 of the FCC Rules. Operation is sub-

ject to the following two conditions:

1. this device may not cause harmful interference and

2. this device must accept any interference received, including inter-

ference that may cause undesirable operation.

This equipment has been tested and found to comply with the limits for

a Class B digital device, pursuant to Part 15 of the FCC Rules. These

limits are designed to provide reasonable protection against harmful

interference in a residential installation. This equipment generates,

uses and can radiate radio frequency energy and, if not installed and

used in accordance with the instructions, may cause harmful interfer-

ence to radio communications. However, there is no guarantee that in-

terference will not occur in a particular installation. If this equipment

does cause harmful interference to radio or television reception, which

can be determined by turning the equipment off and on, the user is en-

couraged to try to correct the interference by one or more of the fol-

lowing measures:

9 Other Relevant Documentation or Manuals

12 ecocirc®XL Installation, Operation, and Maintenance manual

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Consult the dealer or an experienced radio/TV technician for help.

Changes or modiﬁcations not expressly approved by the manufacturer

responsible for compliance could void the user’s authority to operate

the equipment.

10 Product warranty

Commercial warranty

Warranty. For goods sold to commercial buyers, Seller warrants the

goods sold to Buyer hereunder (with the exception of membranes,

seals, gaskets, elastomer materials, coatings and other "wear parts" or

consumables all of which are not warranted except as otherwise pro-

vided in the quotation or sales form) will be (i) be built in accordance

with the speciﬁcations referred to in the quotation or sales form, if such

speciﬁcations are expressly made a part of this Agreement, and (ii) free

from defects in material and workmanship for a period of eighteen (18)

months from the date of installation or thirty-six (36) months from the

date of shipment (which date of shipment shall not be greater than af-

ter receipt of notice that the goods are ready to ship), whichever shall

occur ﬁrst, unless a longer period is speciﬁed in the product documen-

tation (the “Warranty”).

Except as otherwise required by law, Seller shall, at its option and at no

cost to Buyer, either repair or replace any product which fails to con-

form with the Warranty provided Buyer gives written notice to Seller of

any defects in material or workmanship within ten (10) days of the date

when any defects or non-conformance are ﬁrst manifest. Under either

repair or replacement option, Seller shall not be obligated to remove

or pay for the removal of the defective product or install or pay for the

installation of the replaced or repaired product and Buyer shall be re-

sponsible for all other costs, including, but not limited to, service costs,

shipping fees and expenses. Seller shall have sole discretion as to the

method or means of repair or replacement. Buyer’s failure to comply

with Seller’s repair or replacement directions shall terminate Seller’s

obligations under this Warranty and render the Warranty void. Any

parts repaired or replaced under the Warranty are warranted only for

the balance of the warranty period on the parts that were repaired or

replaced. Seller shall have no warranty obligations to Buyer with re-

spect to any product or parts of a product that have been: (a) repaired

by third parties other than Seller or without Seller’s written approval;

(b) subject to misuse, misapplication, neglect, alteration, accident, or

physical damage; (c) used in a manner contrary to Seller’s instructions

for installation, operation and maintenance; (d) damaged from ordina-

ry wear and tear, corrosion, or chemical attack; (e) damaged due to ab-

normal conditions, vibration, failure to properly prime, or operation

without ﬂow; (f) damaged due to a defective power supply or improper

electrical protection; or (g) damaged resulting from the use of accesso-

ry equipment not sold or approved by Seller. In any case of products

not manufactured by Seller, there is no warranty from Seller; however,

Seller will extend to Buyer any warranty received from Seller’s supplier

of such products.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY

AND ALL OTHER EXPRESS OR IMPLIED WARRANTIES, GUARANTEES,

CONDITIONS OR TERMS OF WHATEVER NATURE RELATING TO THE

GOODS PROVIDED HEREUNDER, INCLUDING WITHOUT LIMITATION

ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS

FOR A PARTICULAR PURPOSE, WHICH ARE HEREBY EXPRESSLY DIS-

CLAIMED AND EXCLUDED. EXCEPT AS OTHERWISE REQUIRED BY

LAW, BUYER’S EXCLUSIVE REMEDY AND SELLER’S AGGREGATE LIA-

BILITY FOR BREACH OF ANY OF THE FOREGOING WARRANTIES ARE

LIMITED TO REPAIRING OR REPLACING THE PRODUCT AND SHALL

IN ALL CASES BE LIMITED TO THE AMOUNT PAID BY THE BUYER FOR

THE DEFECTIVE PRODUCT. IN NO EVENT SHALL SELLER BE LIABLE

FOR ANY OTHER FORM OF DAMAGES, WHETHER DIRECT, INDIRECT,

LIQUIDATED, INCIDENTAL, CONSEQUENTIAL, PUNITIVE, EXEMPLARY

OR SPECIAL DAMAGES, INCLUDING BUT NOT LIMITED TO LOSS OF

PROFIT, LOSS OF ANTICIPATED SAVINGS OR REVENUE, LOSS OF IN-

COME, LOSS OF BUSINESS, LOSS OF PRODUCTION, LOSS OF OP-

PORTUNITY OR LOSS OF REPUTATION.

Limited consumer warranty

Warranty. For goods sold for personal, family or household purposes,

Seller warrants the goods purchased hereunder (with the exception of

membranes, seals, gaskets, elastomer materials, coatings and other

"wear parts" or consumables all of which are not warranted except as

otherwise provided in the quotation or sales form) will be free from de-

fects in material and workmanship for a period of eighteen (18) months

from the date of installation or thirty-six (36) months from the product

date code, whichever shall occur ﬁrst, unless a longer period is provid-

ed by law or is speciﬁed in the product documentation (the “Warran-

ty”).