Xylem LOWARA SMB /SVE Series User manual

SMB Booster set
SMB../SVE, SMB../VME, SMB../HME
Installation, Operation and Maintenance Manual
Cod.001086038EN rev.C ed.03/2018

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Table of Contents
1Introduction and Safety ............................................................................................................................................5
1.1 Introduction........................................................................................................................................................5
1.2 Safety ................................................................................................................................................................5
1.2.1 Danger levels and safety symbols ................................................................................................................5
1.2.2 User safety....................................................................................................................................................6
1.2.3 General safety rules......................................................................................................................................7
1.2.4 Protection of the environment .......................................................................................................................8
1.2.5 Sites exposed to ionizing radiations..............................................................................................................8
1.3 Spare parts........................................................................................................................................................8
1.4 Product warranty...............................................................................................................................................8
2Transportation and Storage .....................................................................................................................................9
2.1 Handling the booster set ...................................................................................................................................9
2.2 Storage............................................................................................................................................................10
3Technical Description .............................................................................................................................................11
3.1 Designation .....................................................................................................................................................11
3.2 Data plates......................................................................................................................................................11
3.2.1 Booster set ..................................................................................................................................................11
3.2.2 Distribution panel.........................................................................................................................................12
3.3 Design and layout............................................................................................................................................13
3.4 Intended use....................................................................................................................................................14
3.4.1 Application alternatives ...............................................................................................................................14
3.5 Improper use...................................................................................................................................................14
4Installation ...............................................................................................................................................................15
4.1 Mechanical installation....................................................................................................................................15
4.1.1 Installation area...........................................................................................................................................15
4.1.2Guidelines for mechanical installation.........................................................................................................16
4.2 Hydraulic installation .......................................................................................................................................16
4.2.1 Guidelines for hydraulic installation.............................................................................................................17
4.3 Electrical Installation .......................................................................................................................................18
4.3.1 Electrical requirements................................................................................................................................18
4.3.2 Electrical connection checklist ....................................................................................................................18
4.3.3 Electrical control panel check-list................................................................................................................18
4.3.4 Wire types and ratings.................................................................................................................................19
4.3.5 Protection against dry running ....................................................................................................................20
5Use and operation ..................................................................................................................................................21
5.1 Wait times........................................................................................................................................................21
5.2 Starting and stopping ......................................................................................................................................21
5.2.1 Adjusting the frequency converter...............................................................................................................22
5.2.2 Pre-charging the diaphragm pressure tank.................................................................................................22

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5.2.3 Starting the booster set...............................................................................................................................22
6Maintenance ...........................................................................................................................................................24
6.1 Maintenance of the control panel and frequency converters..........................................................................24
6.2 Maintenance of the diaphragm pressure tank.................................................................................................24
7Troubleshooting ......................................................................................................................................................25
7.1 The booster set is off.......................................................................................................................................25
7.2 Motor does not start ........................................................................................................................................25
7.3 Frequent start-ups and stops ..........................................................................................................................25
7.4 The speed of the pump unit increases and decreases without stopping and without consumption of water
(utility closed)...............................................................................................................................................................25
7.5 The motor runs but no water is delivered........................................................................................................26
7.6 Loss of water from the pump unit....................................................................................................................26
7.7 Too noisy.........................................................................................................................................................26
7.8 The booster set does not generate the required pressure..............................................................................26
7.9 Tripping of the main protection system (fuses)...............................................................................................26
7.10 Tripping of the differential protection...............................................................................................................27
7.11 The pump unit runs at maximum speed without stopping ..............................................................................27
7.12 Only one pump unit is running ........................................................................................................................27
7.13 There is demand for water but the pump unit does not start ..........................................................................27
8Technical Data .......................................................................................................................................................28
8.1 Dimensions and weights .................................................................................................................................29
9Declarations.............................................................................................................................................................29
9.1 EC Declaration of Conformity (Original)..........................................................................................................29
9.2 EU Declaration of Conformity (No EMCD23)..................................................................................................29

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1Introduction and Safety
1.1 Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
Installation
Operation
Maintenance
CAUTION:
Before installing and using the product, make sure that you read and fully understand this manual
in all its parts. Improper use of the product can cause personal injuries and damage to property,
as well as making the warranty null and void.
NOTICE:
This manual is an integral part of the product. It must always be made available to the user,
stored in the proximity of the product, and well kept.
1.2 Safety
1.2.1 Danger levels and safety symbols
Before using the product, and in order to avoid the following risks, make sure that you carefully
read, understand and comply with the following danger warnings:
Injuries and health hazards
Damage to the product
Product malfunction.
Hazard levels
Hazard level
Indication
DANGER:
It identifies a dangerous situation which, if not avoided, causes serious
injury, or even death.
WARNING:
It identifies a dangerous situation which, if not avoided, may cause
serious injury, or even death.
CAUTION:
It identifies a dangerous situation which, if not avoided, may cause small
or medium level injuries.
NOTICE:
It identifies a situation which, if not avoided, may cause damage to
property but not to people.

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Special symbols
Some hazard categories have specific symbols, as shown in the following table:
Symbol
Description
Electrical hazard
Magnetic hazard
Hot surface hazard
Ionizing radiation hazard
Potentially explosive atmosphere hazard (ATEX EU
Directive)
Cut and abrasion hazard
Crushing hazard (limbs)
Other symbols
Symbol
Description
User
Specific information for the users of the product.
Installer / Maintenance technician
Specific information for personnel responsible for the
installation of the product within the system (hydraulic
and/or electric system), and for maintenance operations.
1.2.2 User safety
Strictly comply with current health and safety regulations.
WARNING:
This product must be used only by qualified users.
For the purposes of this manual, in addition to the provisions of any local regulations, qualified
personnel means any individuals who, due to their experience or training, are capable of
recognising any existing hazards and to avoiding dangers during the installation, the use and the
maintenance of the product.

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Inexperienced users
WARNING:
FOR THE EUROPEAN UNION
This appliance can be used by children aged from 8 years and above and persons with
reduced physical, sensory or mental capabilities or lack of experience and knowledge if they
have been given supervision or instruction concerning use of the appliance in a safe way and
understand the hazards involved.
Children shall not play with the appliance.
Cleaning and user maintenance shall not be made by children without supervision.
FOR OTHER COUNTRIES
This appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have been
given supervision or instruction concerning use of the appliance by a person responsible for
their safety.
Children should be supervised to ensure that they do not play with the appliance.
1.2.3 General safety rules
WARNING:
Always keep the work area clean.
Pay attention to the risks presented by gas and vapors in the work area.
Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
DANGER: Electrical hazard
Avoid all electric dangers; pay attention to the risk of electric shock or electric arcs
Unintended rotation of motors creates voltage and can charge the unit, resulting in death,
serious injury, or equipment damage. Ensure that motors are blocked to prevent unintended
rotation.
Magnetic fields
The removal or installation of the rotor in the motor casing generates a strong magnetic field.
DANGER: Magnetic hazard
The magnetic field may be dangerous for anyone wearing peacemakers, or any other medical
devices sensitive to magnetic fields.
NOTE
The magnetic field may attract metal debris on the rotor surface, causing damage to the same.
Electrical connections
DANGER: Electrical hazard
The connection to the electric power supply must be completed by an electrician possessing
the technical-professional requirements outlined in the current regulations
Precautions before work
WARNING:
Install a suitable barrier around the working area, for example a guard rail
Make sure that all safety guards are in place and secure.
Make sure that you have a clear path of retreat.
Make sure that the product cannot roll or fall over and injure people or damage property.
Make sure that the lifting equipment is in good condition.
Use a lifting harness, a safety line, and a breathing device as required.

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Allow all booster set components to cool before handling them
Make sure that the product has been thoroughly cleaned
Disconnect and lock out power before you service the pump unit.
Check the explosion risk before you weld or use electric hand tools.
Precautions during work
WARNING:
Never work alone.
Always wear personal protective equipment
Always use suitable working tools
Always lift the product by its lifting device.
Stay clear of suspended loads.
Beware of the risk of a sudden start if the product is used with an automatic level control.
Beware of the starting jerk, which can be powerful.
Rinse the components in water after you disassemble the pump unit.
Do not exceed the maximum working pressure of the pump unit.
Do not open any vent or drain valve or remove any plugs while the booster set is pressurized.
Make sure that the pump unit is isolated from the system and that all pressure is released
before disassembling the pump, removing plugs, or disconnecting the piping.
Never operate the pump unit without a properly installed coupling guard.
In case of contact with chemical substances or dangerous liquids
Follow these procedures for chemicals or hazardous fluids that have come into contact with your
eyes or your skin:
Condition
Action
Chemicals or hazardous fluids
in eyes
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 min.
3. Seek medical attention.
Chemicals or hazardous fluids
on skin
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 min.
3. Seek medical attention, if necessary.
1.2.4 Protection of the environment
Disposal of packaging and product
Comply with the current regulations on sorted waste disposal.
1.2.5 Sites exposed to ionizing radiations
WARNING: Ionizing radiation hazard
If the product has been exposed to ionizing radiations, implement the necessary safety measures
for the protection of people. If the product needs to be despatched, inform the carrier and the
recipient accordingly, so that appropriate safety measures can be put in place.
1.3 Spare parts
When contacting Xylem or the Authorised Distributor to request technical information or spare
parts, always indicate the product type and code.
1.4 Product warranty
For information on the warranty refer to the documentation of the sale contract.

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2Transportation and Storage
Packaging inspection
1. Check that quantity, descriptions and product codes match the order.
2. Check the packaging for any damage or missing components.
3. In case of immediately detectable damage or missing parts:
Accept the goods with reserve, indicating any findings on the transport document, or
Reject the goods, indicating the reason on the transport document.
In both cases, promptly contact Xylem or the Authorised Distributor from whom the product was
purchased.
Unpacking and inspection of the product
1. Remove the packaging material from the product.
2. Release the product by removing the screws and/or cutting the straps, if fitted.
CAUTION: Cut and abrasion hazard
Always wear personal protective equipment.
3. Check the product for integrity and to make sure that there are no missing components.
4. In case of damage or missing components, promptly contact Xylem or the Authorised
Distributor.
2.1 Handling the booster set
The booster set must be harnessed and lifted as shown in Figure 1.
WARNING: Crushing hazard (limbs)
The product and its components may be heavy: risk of crushing
Always wear personal protective equipment
Manual handling of the product and its components must be in compliance with the current
regulations on "manual load handling", to avoid unfavourable ergonomic conditions causing
risks of back-spine injury.
Use cranes, ropes, lifting straps, hooks and clasps that comply with current regulations and
that are suitable for the specific use
Make sure that the harnessing does not damage the booster set
During the lifting operations, always avoid sudden movements that could compromise the
stability of the load
During handling, make sure to avoid injury to people and animals, and/or damage to property.

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Figure 1: Lifting
2.2 Storage The product must be stored:
In a covered and dry place
Away from heat sources
Protected from dirt
Protected from vibrations
At an ambient temperature between -25°C and +55°C (-13°F and 131°F), and relative
humidity between 5% and 95%.
NOTICE:
Do not place heavy loads on top of the product
Protect the product from collisions.
SMB_M0001_B_sc

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3Technical Description
3.1 Designation
Booster set consisting of one (SMB10) or more identical variable speed vertical or horizontal
multistage non-self priming pump units (SMB20, SMB30) connected in parallel.
The pump units are mounted on a shared base with suction and delivery manifolds, on-off valves,
non-return valves, pressure gauge, pressure transmitters and a single-phase or three-phase
control panel. A booster set with one pump unit (SMB10) does not come with a control panel and
it may not have a base.
There are 1" couplings on the delivery manifold for installing diaphragm pressure tanks with an
on-off valve. The manifold, like the tanks, requires appropriate support.
Additional diaphragm pressure tanks can be installed and connected to the manifold.
3.2 Data plates
The data plate is a label showing:
The main product details
Identification code
Approval and certifications
For the approvals see the booster set data plate:
only
3.2.1 Booster set
Data plate of the booster set
Figure 2: Data plate of the booster set
1. Code of the booster set
2. Booster set definition code
3. Electric service pump
4. Jockey pump
5. Serial number (date+progressive number)
Booster set definition code
Figure 3: Booster set definition code

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1. Series
SMB
2. Number of pump units
[10] = 1 pump unit
[20] = 2 pump units
[30] = 3 pump units
3. Non-return valve
[_] = Delivery side
[RA] = Suction side
4. Certificate of drinking water
unit
A = WRAS, ACS, M.D.174
B = ACS, M.D.174
Z = not certified by a third party
5. e-SM pump unit
SVE
VME
HME
6. Control panel power supply
[M2] = Single-phase, 1 x 230 V
[T3] = Three-phase, 3 x 230 V
[T4] = Three-phase, 3 x 400 V
7. Version of material
[__] = Standard component
[A304] = Special AISI 304 version
[B304] = Special AISI 304 version
[C304] = Special AISI 304 version
[A316] = Special AISI 316 version
[B316] = Special AISI 316 version
[C316] = Special AISI 316 version
8. Option
[PA] = Minimum pressure pressure switch on the suction manifold, for protection
against dry running.
[WM] = Wall-mounted control panel; cables L= 5 m
NOTE: Refer to the B/W catalogue for further details
3.2.2 Distribution panel
Data plate of the control panel
Figure 4: Data plate of the control panel
1. Control panel definition code
2. Code of the control panel
3. Rated voltage
4. Rated current
5. Serial number (date+progressive number)
6. Protection grade
7. Rated frequency
8. Short circuit current

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3.3 Design and layout
Booster set in standard configuration
Figure 5: Booster set
Position
number
Description
Q.ty
1.
Distribution panel
1
2.
E series pump units (e-SM units)
n
3.
Base
1
4.
Priming connection
1
5.
Anti-vibration foot
2 x n
6.
Suction manifold
1
7.
On-off valve on suction line
n
8.
Non-return valve
n
9.
On-off valve on delivery line
n
10.
Pressure sensor
n
11.
Pressure gauge
1
12.
Diaphragm pressure tank connection
1/2/3
13.
Delivery manifold
1
14.
Mounting bracket
1
Frequency converter
Refer to the Installation, Operation and Maintenance Manual of the pump units in the Smart Pump Range.

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3.4 Intended use
The product can be used to pump:
Cold water
Hot water
Always observe the limits indicated in the Technical Data chapter.
The variable speed pump units installed in the SMB booster sets are suitable for the following
applications:
Pressure, level, and flow regulation (open loop systems)
Single or multi pump unit irrigation systems.
3.4.1 Application alternatives
Actuator (constant speed)
The unit operates as an actuator according to speed set point; this is done through user
interface, the corresponding analog input or the communication bus.
Controller (constant pressure)
This mode is set as the default operating mode, and is used for units that run with a single pump
unit.
Cascade serial / Cascade synchronous
The units are connected via the RS485 interface and communicate via the provided protocol.
The combination of the different units which are used in a multi-pump system depends on the
system requirements.
It is possible to run all the pump units in cascade serial mode (default mode for multi pump
systems) and synchronous mode as well. If one unit fails, then each pump unit of the booster set
can become the lead pump unit and can take control.
3.5 Improper use
The product must not be used in closed circuit systems where the difference in pressure between
two points of the system, generally the delivery and suction of the booster set, is controlled by
two sensors for the purpose of keeping it constant.

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4Installation
4.1 Mechanical installation
4.1.1 Installation area
DANGER: Potentially explosive atmosphere hazard
The operation of the booster set in environments with potentially explosive atmospheres or with
combustible dusts (e.g.: wood dust, flour, sugars and grains) is strictly forbidden.
WARNING:
Always wear personal protective equipment
Always use suitable working tools
When selecting the place of installation and connecting the unit to the hydraulic and electric
power supplies, strictly comply with current regulations.
Ensure that the ingress protection rating of the unit (IP 55, type 1) is suitable for the installation
environment.
CAUTION:
Input protection: to ensure the IP55 (type 1) protection index make sure that the unit is closed
correctly.
Before opening the terminal box cover, make sure that there is no water in the unit
Make sure that all unused cable glands and cable holes are correctly sealed
Make sure that the plastic cover is correctly closed
Do not leave the terminal box without cover: risk of damage due to contamination
Make sure that the electric panel is correctly closed.
Outdoor installation of the booster set
In case of outdoor installation of the booster set, ensure appropriate cover (see example in
Figure 6). The size of the cover must be such as to ensure protection of the booster set against
snow, rain and direct sunlight.
Figure 6: Outdoor installation of the booster set

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4.1.2 Guidelines for mechanical installation
The arrows on the pump unit body indicate the flow and the rotation direction of the motor
The standard rotation direction of the motor is clockwise (looking at the fan cover)
Install the booster set in a well ventilated room, leaving sufficient clearance (at least 0.5 m) on
each side and at the front for the purpose of maintenance; there should also be a clearance of
0.5 m above the highest part of the booster set
Place the booster set on a flat and solid surface, without fixing it down
Mount expansion joints and suitable supports for the pipes to protect these against stress, see
Figure 7. The weight of the pipes and pressure tanks increases when they are filled with
water. Before starting the set, make sure you have closed and tightened all the unused
couplings.
Figure 7: Mechanical installation of the booster set
4.2 Hydraulic installation
Figure 8 and 9 show a single pump system and a multi-pump system respectively.
Figure 8: Single pump unit system

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Figure 9: Multi-pump system
1. e-SM pump unit with motor
2. Diaphragm pressure tank
3. Distribution panel
4. On-off valve
5. Non-return valve
6. Low water control
7. Pressure gauge
8. Pressure sensor
9. Drain tap
4.2.1 Guidelines for hydraulic installation
Install the booster set according to the water flow rate of the system
The arrows on the body of the pump unit indicate the flow and the rotation direction
Install a foot check valve in case of a suction lift system
Install an on-off valve immediately downstream of the booster set
Install a drain valve for the tests if there is no valve next to the booster set
The pipes connected to the booster set must be adequately sized (if possible, according to
manifold diameter). You can use either end of the manifold, but don't forget to plug the
unused end.
The size of the suction pipe and foot check valve must be such as to avoid excessive load
loss and the cavitation phenomena that can be caused as a result
Diaphragm pressure tank
On the delivery side of the pump unit there is a membrane expansion vessel, which gives the
possibility of maintaining the pressure inside the piping when the booster set is not being used.
The diaphragm pressure tank stops the pump unit from continuing to run at zero demand and
reduces the size of the tank that is required for supply purposes.
Choose a diaphragm pressure tank suited to the pressure of the system.
Variable speed booster sets can operate with diaphragm pressure tanks of smaller sizes than
traditional systems. A diaphragm pressure tank with a capacity in litres equivalent to about 10%
the flow rate of a single pump unit, expressed in litres per minute. The volume of water required
can be distributed between several tanks.

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4.3 Electrical Installation
DANGER: Electrical hazard
The connection to the electric power supply must be completed by an electrician possessing the
technical-professional requirements outlined in the current regulations.
For the electrical connections, refer to the wiring diagram in the control panel.
4.3.1 Electrical requirements
Local directives prevail on the specific requirements indicated below.
4.3.2 Electrical connection checklist
Check that the following requirements are met:
The electrical leads are protected from high temperature, vibrations, and collisions.
The current and voltage of the mains power supply must be compatible with the data on the
plate of the control panel, or the data on the plate of the pump unit in the case of booster sets
without control panel.
Check that the power supply cable is capable of carrying the nominal current of the booster
set, and connect it to the relevant terminals of the control panel. The wiring diagram and the
labels on the panel provide the necessary information for connection and the required power
supply values. For booster sets without control panel, refer to the Installation, Operation and
Maintenance Manual of the pump units in the Smart Pump Range.
If there is a control panel, connect the power cable:
- Single-phase version to the L-N terminals, PE to the ground terminal
- Single-phase version to the L1, L2 and L3 terminals, PE to the ground terminal
Any exposed cables must be protected in an appropriate way
The power supply line is provided with:
- A high-sensitivity differential switch (30 mA) [residual current device RCD] suitable for
earth fault currents with DC or pulsating DC content (a Type B RCD is suggested).
- A mains isolator switch with a contact gap of at least 3 mm.
4.3.3 Electrical control panel check-list
NOTICE:
The standard version of the booster set has a control panel.
If the booster set is supplied without a control panel, install a control panel that is compatible with
the ratings of the pump unit.
Inappropriate combinations do not guarantee the protection of the booster set.
Check that the following requirements are met:
The control panel must protect the pump unit against short-circuit. A time lag fuse or a circuit
breaker (Type C model is suggested) can be used to protect the pump unit.
The pump unit has built in overload and thermal protection. No additional overload protection
is required.
DANGER: Electrical hazard
Before starting the pressure booster, make sure that the booster set and the control panel are
isolated from the power supply and cannot be energized.

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Grounding (earthing)
DANGER: Electrical hazard
Always connect the external protection conductor to the ground terminal before attempting to
make any other electrical connections
All the electrical equipment must be grounded (earthed); this includes the booster set and its
equipment. Check that the ground terminal is connected properly.
Check that the protection conductor (ground) is longer than the phase conductors; in case of
accidental disconnection of the power supply conductor, the protection conductor (ground)
must be the last one to detach itself from the terminal.
Keep the connections to the ground cable as short as possible.
Use a cable with several strands to reduce electric noise.
4.3.4 Wire types and ratings
For the standard version with control panel, the booster set is supplied with the power cables of
the pump unit and the control cables. The booster set without control panel is supplied with the
cable for connecting the pressure sensor but without the power cables of the pump unit.
If the power cable of the pump unit and/or the control cables need to be replaced or added, refer
to the Installation, Operation and Maintenance Manual of the pump units in the Smart Pump
Range.
All cables must comply with local and national standards in terms of section and ambient
temperature
Use cables with a minimum heat resistance of +70°C (158°F)
Cables must never enter into contact with the motor body, the pump unit and the piping.
The wires connected to the power supply terminals and the fault signal relay (NO, C) must be
separated from the others by means of reinforced insulation.
Power supply connection
WARNING:
Do not make any connection to the terminal board box of the pump unit without first
disconnecting the power supply and waiting for the minimum time in Table 1.
The standard version of the booster set is supplied with the power cables of the motor.
Replace the power cable of the motor, if necessary, with a cable of a cross-section suited to
the maximum consumption of the electric motor.
Control cables
External volt free contacts must be suitable for switching < 10 VDC.
NOTICE:
Install the control cables separate from the power supply cables and the fault signal relay
cable
If the control cables are installed in parallel with the power supply cable or the fault signal
relay, the distance between the cables must exceed 200 mm
Do not intersect the power supply cables; should this be necessary, a 90°intersection angle is
permitted.
Connecting the control panel
Refer to the wiring diagram in the control panel.
Connecting the frequency converter
Refer to the Installation, Operation and Maintenance Manual of the pump units in the Smart
Pump Range.

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4.3.5 Protection against dry running
The standard control panel can be connected to a common float for the open tanks, or to a
minimum pressure pressure switch on the suction side (recommended value: 0.2-0.4 bar). When
the minimum pressure conditions are restored, the pump units start automatically. If the dry
running protection is considered to be superfluous, do not remove the jumper on the terminal in
the control panel. The correct numbers of the terminals are given in the connection diagram that
can be found in the control panel.
NOTICE:
The booster set is supplied with the jumper installed and, therefore, without the dry running
protection enabled.
The optional electronic level control kit permits control with electrode probes.
Install the three probes supplied with the kit in the collection tank and connect them to the
terminals in the control panel.
The correct numbers of the terminals are given in the wiring diagram that can be found in the
panel:
Max probe (A) determines the level at which to activate the booster set during filling of the
collection tank.
Min probe (B) determines the level at which to deactivate the booster set.
Probe (C) must be at a level below that of the Min probe (B).