Xylem Lowara Genyo plus Manual

Additional Installation, Operation and
Maintenance Instructions
Genyo plus
Electronic pressure switch

en - Original instructions
2 Genyo plus, Additional Installation, Operation and Maintenance Instructions
Table of Contents
1Introduction and Safety ............................................................................................................................................4
1.1 Introduction ......................................................................................................................................................4
1.2 Safety ................................................................................................................................................................4
1.2.1 Danger levels and safety symbols ...............................................................................................................4
1.2.2 User safety ....................................................................................................................................................5
1.2.3 Protection of the environment.....................................................................................................................6
1.2.4 Sites exposed to ionizing radiations............................................................................................................6
2Handling and Storage...............................................................................................................................................7
2.1 Handling of the packed unit ............................................................................................................................7
2.2 Unit inspection upon delivery..........................................................................................................................7
2.2.1 Inspect the package .....................................................................................................................................7
2.2.2 Unpacking and inspection of the unit .........................................................................................................7
2.3 Storage .............................................................................................................................................................7
3Technical Description ...............................................................................................................................................9
3.1 Designation ......................................................................................................................................................9
3.2 Data plate .........................................................................................................................................................9
3.3 Identification code .........................................................................................................................................10
3.4 Names of the main components ...................................................................................................................10
3.4.1 Control panel..............................................................................................................................................11
3.4.2 LEDs description ........................................................................................................................................12
3.5 Intended use...................................................................................................................................................12
3.6 Improper use ..................................................................................................................................................13
4Installation ...............................................................................................................................................................14
4.1 Precautions .....................................................................................................................................................14
4.2 Installation area ..............................................................................................................................................14
4.3 Hydraulic connection .....................................................................................................................................14
4.3.1 Guidelines for hydraulic connection .........................................................................................................15
4.3.2 Assembly ....................................................................................................................................................16
4.4 Electrical connection......................................................................................................................................16
4.4.1 Ground........................................................................................................................................................17
4.4.2 Guidelines for the electrical control panel................................................................................................17
4.4.3 Guidelines for electrical connection..........................................................................................................17
5Use and operation ..................................................................................................................................................19
5.1 Precautions .....................................................................................................................................................19
5.2 Initial start-up and basic settings ...................................................................................................................19
5.2.1 OFF mode...................................................................................................................................................19
5.2.2 AUT mode...................................................................................................................................................20

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Genyo plus, Additional Installation, Operation and Maintenance Instructions 3
5.2.3 Setting the current......................................................................................................................................20
5.2.4 Setting the P START and P STOP pressure values ....................................................................................21
5.2.5 Visualization and setting of the parameter menu......................................................................................23
6Programming ..........................................................................................................................................................24
6.1 Precautions .....................................................................................................................................................24
6.2 Functional parameters ...................................................................................................................................24
6.3 Operating parameters ...................................................................................................................................25
6.4 Parameters for lack of water ..........................................................................................................................26
6.5 Other parameters...........................................................................................................................................26
6.6 The ART function ............................................................................................................................................26
6.7 The function of the booster set......................................................................................................................27
7Maintenance............................................................................................................................................................28
7.1 Precautions .....................................................................................................................................................28
7.2 Maintenance every 3 months of operation ...................................................................................................28
7.3 Spare parts ordering ......................................................................................................................................28
8Troubleshooting......................................................................................................................................................29
8.1 Precautions .....................................................................................................................................................29
8.1.1 Alarms.........................................................................................................................................................29
8.2 Alarm A01, lack of water via the software.....................................................................................................29
8.3 Alarm A02, overcurrent..................................................................................................................................29
8.4 Alarm A04, start-ups too frequent.................................................................................................................30
8.5 Alarm A05, pressure sensor faulty.................................................................................................................30
8.6 Alarm A11, minimum pressure......................................................................................................................30
8.7 Low pressure, booster set mode ...................................................................................................................30
9Technical Information .............................................................................................................................................31
9.1 Operating data and conditions .....................................................................................................................31
9.2 Dimensions .....................................................................................................................................................31
10 Disposal ..............................................................................................................................................................32
10.1 Precautions .....................................................................................................................................................32
10.2 WEEE 2012/19/EU (50 Hz) ............................................................................................................................32
11 Declarations........................................................................................................................................................33
11.1 EU Declaration of Conformity (n. 38) ............................................................................................................33
12 Warranty .............................................................................................................................................................34
12.1 Information .....................................................................................................................................................34

en - Original instructions
4 Genyo plus, Additional Installation, Operation and Maintenance Instructions
1Introduction and Safety
1.1 Introduction
Purpose of this manual
This manual provides information on how to do the following in the correct manner:
•Installation
•Operation
•Maintenance.
CAUTION:
This manual is an integral part of the unit. Make sur
e to have read and understood the manual
before installing the unit and putting it to use. The manual must always be made available to
the user, stored in the proximity of the unit, and well kept.
Supplementary instructions
The instructions and warnings of this manual apply to the standard unit as described in the sale
documentation. Special version pumps may be supplied with supplementary instruction
manuals. For situations not considered in the manual or in the sales document, contact Xylem
or the Authorised Distributor.
1.2 Safety
1.2.1 Danger levels and safety symbols
Before using the unit, the user must read, understand and comply with the indications of the
danger warnings in order to avoid the following risks:
•Injuries and health hazards
•Damage to the product
•Unit malfunction.
Danger 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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Genyo plus, Additional Installation, Operation and Maintenance Instructions 5
Complementary symbols
Symbol
Description
Electrical hazard
Hot surface hazard
Danger, system pressurized
Do not use flammable liquids
Do not use corrosive liquids
Read the instruction manual
1.2.2 User safety
Strictly comply with current health and safety regulations.
WARNING:
This unit must be used only by qualified users. Qualified users are people able to recognise
the risks and avoid hazards during installation, use and maintenance of the unit.
Inexperienced users
WARNING:
•
For EU countries: this product may be used by children aged 8 years and above and
persons with reduced physical, sensory or mental capabilities, or who lack experience and
knowledge, provided that they are being supervised and have been instructed on how to
use it sa
fely, and understand the hazards involved. Children must not play with the product.
Cleaning and maintenance must not be carried out by children without supervision.
•
For countries outside the EU: this product is not intended for use by persons (including
children) with reduced physical, sensory or mental capabilities, or who lack experience and
knowledge, unless they are being supervised and have been instructed on how to use it by
a person responsible for their safety. Children should be supervised to ensure that they do
not play with the product.

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6 Genyo plus, Additional Installation, Operation and Maintenance Instructions
1.2.3 Protection of the environment
Disposal of packaging and product
Comply with the current regulations on sorted waste disposal.
1.2.4 Sites exposed to ionizing radiations
WARNING: Ionizing radiation hazard
If the uni
t has been exposed to ionizing radiations, implement the necessary safety measures
for the protection of people. If the unit needs to be despatched, inform the carrier and the
recipient accordingly, so that appropriate safety measures can be put in place.

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Genyo plus, Additional Installation, Operation and Maintenance Instructions 7
2Handling and Storage
2.1 Handling of the packed unit
WARNING:
Take appropriate measures during transport, installation and storage to prevent contamination
from external substances.
The Manufacturer delivers the unit and its components in a cardboard box.
2.2 Unit inspection upon delivery
2.2.1 Inspect the package
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.
2.2.2 Unpacking and inspection of the unit
1. Remove packing materials from the product.
2. Check the unit for integrity and to make sure that there are no missing components.
3. In case of damage or missing components, promptly contact Xylem or the Authorised
Distributor.
Content of the package
•Unit
•Two M20x2.5 cable glands
•Instructions manual.
2.3 Storage
Storage of the packed unit
The unit 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 +65°C (-13°F and 149°F), and humidity
between 5% and 95%.
NOTICE:
Do not place heavy loads on top of the unit.
NOTICE:
Protect the unit from collisions.

en - Original instructions
8 Genyo plus, Additional Installation, Operation and Maintenance Instructions
Long-term storage of the unit
Follow the same instructions for the storage of the packed unit.
For further information about preparation for long-term storage, please contact Xylem or the
Authorised Distributor.

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Genyo plus, Additional Installation, Operation and Maintenance Instructions 9
3Technical Description
3.1 Designation
Electronic pressure switch for the supply, control and protection of single-phase pump units.
3.2 Data plate
Position
number
Description
Position
number
Description
1
Power Supply Voltage
12
Hardware version
2
Frequency
13
Maximum liquid pressure
3
Maximum current of the pump unit
14
Maximum differential
4
Maximum motor power
15
Minimum differential
5
Protection degree
16
STOP pressure range
6
Weight
17
START pressure range
7
Model
18
Maximum liquid operating temperature
8
Product code
19
Maximum ambient temperature
9
Manufacturing date
20
QR code (if present)
10
Serial number
21
Minimum cosØ of the motor
11
Software version
-
-

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10 Genyo plus, Additional Installation, Operation and Maintenance Instructions
3.3 Identification code
Position
number
Description
Position
number
Description
1
Series name
3
Pressure adjustment range, bar
2
Maximum current of the pump unit, A
4
Voltage supply range 50/60Hz, V
3.4 Names of the main components
Position
number
Description
Position
number
Description
1
Cable gland of the U
in
power supply cord
6
Screws of the cover
2
Electronic circuit boards
7
Cable gland of the U
OUT
motor power supply cord
3
Fastening screws of the power supply cords
8
Base
4
Cover
9
Fastening screw of the ground cable
5
Control panel
-
-
Genyop_M0004_A_ds
6
12
4
78
9
3
5

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Genyo plus, Additional Installation, Operation and Maintenance Instructions 11
3.4.1 Control panel
Position
number
Description
1
Display
2
LED indicator of the pressure (bar) measurement unit, see also LEDs description
3
LED indicator of the pressure (psi) measurement unit, see also LEDs description
4
LED indicator of the current (A) measurement unit, see also LEDs description
5
Button for viewing on the display:
• pressure in bar, or
• pressure in psi, or
• absorbed current in Ampere
6
Button for:
• selecting the operating mode (automatic or OFF), or
• confirming a change, or
•
accessing the menu
7
Button for:
• increasing a value, or
• selecting the stop pressure
8
Button for:
• decreasing a value, or
• selecting the start pressure
9
Start pressure LED, see also LEDs description
10
Stop pressure LED, see also LEDs description
11
Alarm LED, see also LEDs description

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12 Genyo plus, Additional Installation, Operation and Maintenance Instructions
3.4.2 LEDs description
Illustration
LED
Unit status
Notes
Off
Unit powered
Operating mode upon initial
start-up: OFF.
The operating mode then
reverts to the one before the
energy was disconnected
Off
OFF mode, pump unit stopped
Slow flashing
AUT mode, pump unit running
The pressure is shown on the
display
Steady
AUT mode, pump unit stopped
Off
OFF mode, pump unit stopped
Slow flashing
AUT mode, pump unit running
The absorbed current of the
motor is shown on the
display
Fast flashing
OFF mode, change of the nominal Ampere value
Steady
AUT mode, pump unit stopped
Slow flashing
STOP pressure being modified
The display flashes and shows
the pressure
Steady
STOP pressure set
Slow flashing
START pressure being modified
Steady
START pressure set
Off
No alarm; pump unit running, stopped or in OFF mode
Slow flashing
Alarm triggered and automatic reset procedure in progress
Fast flashing
Start cycles alarm
Steady
Alarm triggered, pump unit locked
Alarm switched off: the pump unit can now be started, if it is
not already running
3.5 Intended use
•Residential water boosting systems
•Irrigation systems for gardens
•Boosting systems for small commercial buildings.
Pumped liquids
•Chemically and mechanically non aggressive
•Non flammable and/or explosive.
•With solid particles a maximum of 1.5 mm (0.06 inches) in diameter
•Clean water.
Observe the operating limits in Technical Information on page 31.

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Genyo plus, Additional Installation, Operation and Maintenance Instructions 13
3.6 Improper use
WARNING:
The unit was designed and built for the use described in
Intended use on page 12. Any other
uses are prohibited, as they could compromise the safety of the user and the efficiency of the
unit itself.
DANGER:
It is prohibited to use this unit to pump flammable and/or explosive liquids.
DANGER: Potentially explosive atmosphere hazard
It is prohibited to start the unit in environments with potentially explosive atmospheres or with
combustible dusts.
Examples of improper use
•Use with liquids not compatible with the construction materials of the unit
•Use with liquids with temperatures higher than those shown in Technical Information on
page 31
•Use with liquids that are hazardous, toxic, explosive, flammable or corrosive
•Use with sea water
•Use with liquids containing solid particles more than 1.5 mm (0.06 inches) in diameter.

en - Original instructions
14 Genyo plus, Additional Installation, Operation and Maintenance Instructions
4Installation
4.1 Precautions
Before starting, make sure that the safety instructions shown in Introduction and Safety on
page 4 have been fully read and understood.
DANGER:
All the hydraulic and electrical connections must be completed by a technician possessing the
technical
-professional requirements outlined in the current regulations.
DANGER: Potentially explosive atmosphere hazard
It is prohibited to start the unit in environments with potentially explosive atmospheres or with
combustible dusts.
WARNING:
Always wear personal protective equipment.
WARNING:
Always use suitable working tools.
WARNING:
When sele
cting the place of installation and connecting the unit to the hydraulic and electric
power supplies, strictly comply with current regulations.
4.2 Installation area
•Follow the provisions in Technical Information on page 31
•Install the unit in a dry and well ventilated area
•Place the unit in a raised position in relation to the floor
•Make sure that any leaks will not cause flooding to the installation area or submerge the
unit
•In case of installation of the unit outdoors, ensure appropriate protection against snow, rain
and direct sunlight.
4.3 Hydraulic connection
WARNING:
Piping must be sized to ensure safety at the maximum operating pressure.
WARNING:
Install appropriate seals between the connections o
f the unit and the piping.

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Genyo plus, Additional Installation, Operation and Maintenance Instructions 15
4.3.1 Guidelines for hydraulic connection
Refer to the representative hydraulic diagrams; see the figures below.
Figure 1: Installation with single pump unit
Figure 2: Installation of the booster set
Position
number
Description
Position
number
Description
1
Pump unit
5
Check valve
2
Diaphragm pressure tank ≥ 24 l (6.3 US gal)
6
Genyo plus unit
3
Electric panel
7
Pressure gauge
4
On-off valve
8
Drain tap
1. Remove any welding residues, deposits and impurities in the pipes that could damage the
unit.
2. Install an on-off valve between the piping and the unit.
3. Install an on-off valve on the suction side and another on the delivery side of the pump unit.
4. Install a check valve between the unit and the pump unit.
5. Install a pressure gauge for the unit.
6. Install one or more diaphragm expansion tanks to limit the number of starts of the pump
unit.
Genyop_M0025_A_sc
4
1
5 4
4
8
2
76
7
4
3
Genyop_M0026_A_sc
4
1
54
4
1
544
8
2
3
4
OUT
IN IN
OUT
7
7
66

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16 Genyo plus, Additional Installation, Operation and Maintenance Instructions
4.3.2 Assembly
CAUTION: Danger, system pressurized
Before starting work, close the
on-off valves on the suction and delivery sides or empty the
system.
Screw the unit on the piping, putting sealant on the thread.
Mounting positions
4.4 Electrical connection
DANGER:
All the hydraulic and electrical connections must be completed by a technician possessing the
technical
-professional requirements outlined in the current regulations.
DANGER: Electrical hazard
Before starting work, check that the unit is unplugged and that the
pump unit, the control
panel and the auxiliary control circuit cannot restart, even unintentionally.

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Genyo plus, Additional Installation, Operation and Maintenance Instructions 17
4.4.1 Ground
DANGER: Electrical hazard
Always connect the external protection conductor (ground) to the ground terminal before
attempting to make any other electrical connections.
DANGER: Electrical hazard
Connect the unit and any electric accessories to a socket with
protection conductor (ground).
DANGER: Electrical hazard
Check that the external protection conductor (ground) is longer than the phase conductors; In
case of accidental disconnection of the unit from the phase conductors, the protection
conductor must be the last one to detach itself from the terminal.
DANGER: Electrical hazard
Install suitable systems for protection against indirect contact, in order to prevent lethal electric
shocks.
4.4.2 Guidelines for the electrical control panel
NOTICE:
The elec
tric panel must match the ratings on the unit data plate. Improper combinations could
damage the motor.
Install an overload circuit breaker with C-type curve and Icn ≥ 4.5 kA, or other equivalent
device, to protect the system against overloads and short circuits.
The unit has software that protects the pump unit against overloads and short circuits, see also
Programming on page 24.
4.4.3 Guidelines for electrical connection
1. Use a 3G1-1.5 multi-core power supply cord.
2. Check that:
•The mains voltage and frequency match the specifications on the data plate
•The power supply cord is protected from high temperatures, vibrations, collisions and
abrasions.
3. Check that the power supply line is provided with:
•A short circuit protection device of appropriate size
•A mains disconnection device with contact opening distance ensuring complete
disconnection for overvoltage III category conditions
•An RCCB earth leakage switch with tripping current ≤ 30 mA.

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18 Genyo plus, Additional Installation, Operation and Maintenance Instructions
Power supply connection of the unit
Phase
Action
Illustration
1
Undo the screws to remove the cover.
2
Unsheathe the conductors.
3
Insert the Uin power supply cord in cable gland 1.
4
Insert the Uout motor power supply cord in cable gland 2.
5
Insert the cores of the conductors in the respective holes and tighten the
screws.
Tightening torque: 1.2 Nm (10.6 lbf·in).
6
Put the cover back in place, refastening the screws.
Tightening torque: 1.5 Nm (13.3 lbf·in).
7
Connect the unit to the mains power supply referring to the diagram.
8
Tighten cable glands 1 and 2.
Tightening torque: 4 Nm (35.4 lbf·in).
Genyop_M0031_A_ph
L
N
U
V
IN
OUT
L1
N
PE
GENYO PLUS
M
1~
1X110/230 V
50/60 Hz, PE

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Genyo plus, Additional Installation, Operation and Maintenance Instructions 19
5Use and operation
5.1 Precautions
WARNING:
Make sure that the drained l
iquid cannot cause damage or injuries.
WARNING: Electrical hazard
Check that the unit is properly connected to the mains power supply.
WARNING:
It is prohibited to put combustible materials near the unit.
5.2 Initial start-up and basic settings
Upon initial start-up:
•Set the nominal absorbed current of the motor, see Setting the current on page 20
•Set the P START and P STOP pressure values, see Setting the P START and P STOP pressure
values on page 21
•Open the on-off valve on the delivery line
•Start the pump unit in AUT mode
•Close the valve: the P STOP pressure is reached and the pump unit stops.
NOTICE:
A correctly loaded diaphra
gm pressure tank must be installed, see Hydraulic connection on
page
14.
NOTICE:
If the current is not set:
•
The unit remains in OFF mode
•
It is not possible to activate AUT mode
•The overcurrent, short circuit and lack of water protection devices are deactivated.
5.2.1 OFF mode
OFF mode, pump unit stopped.
Action
Illustration
Press once to stop the pump unit

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20 Genyo plus, Additional Installation, Operation and Maintenance Instructions
5.2.2 AUT mode
AUT mode, starting of the pump unit and instant visualization of the pressure and current.
Phase
Action
Illustration
1
To view the pressure with
the unit OFF:
press once and Aut
appears, followed by the
instantaneous pressure
value (bar or psi)
2
Press several times to
view, in alternation, the
pressure (bar or psi) or the
instantaneous current (A)
5.2.3 Setting the current
Set the nominal absorbed current of the motor upon initial start-up or when the default
parameters are loaded or the unit is replaced.
Phase
Action
Illustration
1
With the unit in OFF
mode, press several times
to view the instantaneous
current (A)
2
Press once: the display
flashes and shows the
current value
3
Edit the value