Xylem Goulds AquaBoost VS User manual

INSTRUCTION MANUAL
10-001-251 Rev 7
Variable Speed
AquaBoost VS Pumping
Packages

Table of Contents
1 Introduction and Safety..............................................................................................................3
1.1 Introduction.......................................................................................................................... 3
1.2 Safety..................................................................................................................................... 3
1.2.1 Safety terminology and symbols.................................................................................3
1.2.2 Protecting the environment.........................................................................................4
1.3 User safety.............................................................................................................................4
1.3.1 Wash the skin and eyes................................................................................................5
2 Transportation and Storage...................................................................................................... 6
2.1 Examine the delivery........................................................................................................... 6
2.1.1 Examine the package................................................................................................... 6
2.1.2 Examine the unit............................................................................................................6
2.2 Transportation guidelines...................................................................................................6
2.2.1 Lifting methods............................................................................................................. 6
2.3 Storage guidelines...............................................................................................................6
2.3.1 Long-term storage........................................................................................................ 6
3 Product Description....................................................................................................................8
3.1 General description............................................................................................................. 8
3.1.1 Operational limits......................................................................................................... 8
3.1.2 Package information.....................................................................................................8
3.2 Nameplate information....................................................................................................... 9
4 Installation................................................................................................................................. 12
4.1 Field connections...............................................................................................................12
4.1.1 Field piping diagrams................................................................................................ 13
4.1.2 Wiring diagrams......................................................................................................... 15
4.2 ground (earth) connections..............................................................................................16
4.3 Pump package location guidelines................................................................................. 17
4.4 Foundation requirements.................................................................................................17
4.5 Level the base on a concrete foundation ...................................................................... 17
4.6 Connect the optional storage tank..................................................................................18
4.7 Connect the optional low-suction pressure switch....................................................... 18
4.8 Piping checklist.................................................................................................................. 19
5 Commissioning, Startup, Operation, and Shutdown.......................................................... 21
5.1 Preparation for startup...................................................................................................... 21
5.1.1 Final installation checks............................................................................................. 21
5.1.2 Final adjustments........................................................................................................22
5.2 Pump package operation description............................................................................ 23
5.2.1 Variable speed operation.......................................................................................... 23
6 Maintenance..............................................................................................................................25
6.1 Precautions......................................................................................................................... 25
6.2 Monthly maintenance........................................................................................................25
7 Troubleshooting....................................................................................................................... 26
7.1 Pump station troubleshooting......................................................................................... 26
7.1.1 The pump station does not power up..................................................................... 26
7.1.2 The station powers up, but the pumps do not run.................................................26
Table of Contents
AquaBoost VS Pumping Packages INSTRUCTION MANUAL 1

7.1.3 The pumps run but do not build desired pressure................................................ 27
7.1.4 The pump station experiences excessive vibration............................................... 28
7.1.5 The pump station does not shut down and no water is used...............................28
7.1.6 The pump station cycles or hunts erratically...........................................................29
8 Other Relevant Documentation or Manuals......................................................................... 30
8.1 Manuals for AquaBoost components..............................................................................30
9 Product warranty...................................................................................................................... 31
Table of Contents
2 AquaBoost VS Pumping Packages INSTRUCTION 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 injury 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
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Operating, installing, or maintaining the unit in any way that is not covered in this
manual could cause death, serious personal injury, or damage to the equipment. This
includes any modification to the equipment or use of parts not provided by Xylem. If
there is a question regarding the intended use of the equipment, please contact a
Xylem representative before proceeding.
• Do not change the service application without the approval of an authorized Xylem
representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result
in physical injury, damage, or delays.
1.2.1 Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent
these hazards:
• Personal accidents and health problems
• Damage to the product and its surroundings
• Product malfunction
Hazard levels
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will result in
death or serious injury
1 Introduction and Safety
AquaBoost VS Pumping Packages INSTRUCTION MANUAL 3

Hazard level Indication
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:
Notices are used when there is a risk of equipment
damage or decreased performance, but not personal
injury.
Special symbols
Some hazard categories have specific symbols, as shown in the following table.
Electrical hazard Magnetic fields hazard
Electrical Hazard: CAUTION:
1.2.2 Protecting the environment
Emissions and waste disposal
Observe the local regulations and codes regarding:
• Reporting of emissions to the appropriate authorities
• Sorting, recycling and disposal of solid or liquid waste
• Clean-up of spills
Exceptional sites
CAUTION: Radiation Hazard
Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless
Xylem has been informed and appropriate actions have been agreed upon.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
1.3 User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash
hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment
within the work area:
1 Introduction and Safety
4 AquaBoost VS Pumping Packages INSTRUCTION MANUAL

• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.
Electrical connections
Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local regulations. For more information about
requirements, see sections dealing specifically with electrical connections.
Precautions during work
Observe these safety precautions when you work with the product or are in connection
with the product:
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• 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.
• Do not exceed the maximum working pressure of the pump.
• Do not open any vent or drain valve or remove any plugs while the system is
pressurized. Make sure that the pump is isolated from the system and that pressure is
relieved before you disassemble the pump, remove plugs, or disconnect piping.
• Never operate a pump without a properly installed coupling guard.
1.3.1 Wash the skin and eyes
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 minutes.
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 minute.
3. Seek medical attention, if necessary.
1 Introduction and Safety
AquaBoost VS Pumping Packages INSTRUCTION MANUAL 5

2 Transportation and Storage
2.1 Examine the delivery
2.1.1 Examine the package
1. Examine the package for damaged or missing items upon delivery.
2. Record any damaged or missing items on the receipt and freight bill.
3. If anything is out of order, then file a claim with the shipping company.
If the product has been picked up at a distributor, make a claim directly to the
distributor.
2.1.2 Examine the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. To determine whether any parts have been damaged or are missing, examine the
product.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
Use care around nails and straps.
4. If there is any issue, then contact a sales representative.
2.2 Transportation guidelines
2.2.1 Lifting methods
WARNING:
• Assembled units and their components are heavy. Failure to properly lift and support
this equipment can result in serious physical injury and/or equipment damage. Lift
equipment only at the specifically identified lifting points. Lifting devices such as
eyebolts, slings, and spreaders must be rated, selected, and used for the entire load
being lifted.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods
and wear steel-toed shoes at all times.
2.3 Storage guidelines
Storage location
The product must be stored in a covered and dry location free from heat, dirt, and
vibrations.
NOTICE:
Protect the product against humidity, heat sources, and mechanical damage.
NOTICE:
Do not place heavy weights on the packed product.
2.3.1 Long-term storage
If the unit is stored for more than 6 months, these requirements apply:
• Store in a covered and dry location.
• Store the unit free from heat, dirt, and vibrations.
• Rotate the pump shaft by hand several times at least every three months.
2 Transportation and Storage
6 AquaBoost VS Pumping Packages INSTRUCTION MANUAL

Treat bearings and machined surfaces so that they are well preserved. Refer to the drive
unit and coupling manufacturers for their long-term storage procedures.
For questions about possible long-term storage treatment services, please contact your
local sales and service representative.
2 Transportation and Storage
AquaBoost VS Pumping Packages INSTRUCTION MANUAL 7

3 Product Description
3.1 General description
AquaBoost VS pumping package
The AquaBoost Variable Speed pumping package can precisely match the pump
discharge pressure to the system pressure by varying the speed of the pump. This is
accomplished by using the variable-speed controllers such as the AquaBoost II and
Aquavar CPC.
The pressure transducer monitors the system pressure, allowing the controller to start and
regulate the pump speed. AquaBoost VS is available in simplex and duplex
configurations.
WARNING:
This product can expose you to chemicals including Lead, which is known to the State of
California to cause cancer and birth defects or other reproductive harm. For more
information go to: www.P65Warnings.ca.gov.
3.1.1 Operational limits
Ambient temperature and humidity
All electrical equipment is susceptible to failure if operated in ambient temperatures
outside of its rating. Do not operate the unit outside these extremes.
Characteristic Specification
Operating temperature range 32°F to 105°F (0°C to 40°C)
Maximum relative humidity 95% non-condensing
3.1.2 Package information
AquaBoost VS simplex
53
24
1
6
7
RS000004
This variable-speed configuration uses the AquaBoost II controller model 1151AB2 or 2AB2 (for single-phase
power supply: 115V – 0.75 hp; 230V – 1.5 to 2 hp range).
1. Pump: NPE with TEFC motor
2. AquaBoost II controller
3. Transducer assembly
4. Safety switch
5. Temperature relief valve
6. To drain
7. To controller
3 Product Description
8 AquaBoost VS Pumping Packages INSTRUCTION MANUAL

5
3
1
6
7
24
RS000006
This variable-speed configuration uses the Aquavar CPC controller (for 3 & 5 HP 208-230/1, and 1.5-to-5 HP 3
PH power supply).
1. Pump: NPE with TEFC motor
2. Aquavar CPC controller
3. Transducer assembly
4. Safety Switch
5. Temperature relief valve
6. To drain
7. To controller
AquaBoost VS duplex
2
3
5
6
7
7
4
1
8
9
RS000007
This variable-speed duplex configuration uses the Aquavar CPC controller (for 3–phase
power supply: 1.5 to 5 hp range).
1. Pump: NPE with TEFC motor
2. Safety switch single-point power panel
3. Aquavar CPC controller
4. Temperature relief valve
5. Discharge header: copper L-type
6. Suction header: copper L-type
7. Pressure transducer assembly
8. To controller
9. To drain
3.2 Nameplate information
Nameplate
Every pump station has a nameplate that provides information about the pump station.
The pump station nameplate is located on the outside of the control enclosure door.
When ordering spare parts, please be prepared to identify the nameplate information
when contacting the factory.
3 Product Description
AquaBoost VS Pumping Packages INSTRUCTION MANUAL 9

• Model
• Size
• Serial number
• Item numbers of the required parts
Model number
Serial number
Voltage
Phase
Hz
SCCR
FLA
Max. HP
RS000033
Nameplate field Explanation
Model number The model number of the pump station
Serial number The serial number of the pump station
Voltage Input voltage required for the pump station
Phase Single-phase or 3–phase
Hz Frequency
SCCR Short circuit current rating
FLA Full load amps
Max. HP Maximum horsepower
Model number designation
Number of
pumps
Pump model / rpm HP Voltage / Phase Impeller diameter
(inches)
Control
1 A (1x1-1/4, 3600) 05 =
1/2
1 = 115/1/60 A = 4-5/8
2 B (1-1/4x1-1/2,
3600)
07 =
3/4
2 = 208/3/60 B = 5-1/16 –VS = variable speed
10 = 1 3 = 380/3/50 C = 5-3/16
15 =
1.5
4 = 460/3/60 D = 5-3/4
20 = 2 5 = 575/3/60 E = 5-15/16
30 = 3 6 = 230/1/60 F = 6-1/8
50 = 5 7 = other Z = other
8 = 230/3/60
A = 208–230/3/60*
B = 208–230/1/60*
Owner's information
Fill in the right-hand column with the information specific to your pump station.
AquaBoost CS/VS model number
Pump model number
Pump serial number
Control panel model number
Dealer
Dealer phone number
Date of purchase
Date of installation
3 Product Description
10 AquaBoost VS Pumping Packages INSTRUCTION MANUAL

Electrical ratings at startup Current
Voltage
Phase
3 Product Description
AquaBoost VS Pumping Packages INSTRUCTION MANUAL 11

4 Installation
4.1 Field connections
Review the field piping diagrams and wiring diagrams before you install and operate the
unit.
Electrical precautions
WARNING:
Electrical shock hazard. The electrical supply must match the control panel nameplate
specification. Incorrect voltage can cause a fire, which damages the electrical components
and voids the warranty. Failure to follow these instructions could result in serious personal
injury or death, or property damage.
NOTICE:
Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local rules.
Power wiring
Select power wire types and sizes based upon conformance with the National Electrical
Code and all local codes and restrictions. In addition, only copper (Cu) wire rated for at
least 167°F (75°C) can be used for the power connections. Refer to the input current as
listed on the motor nameplate when sizing wire.
Power supply requirements
The power supply required for the AquaBoost VS unit depends on its model number. It
can be one of the following with a dedicated ground wire:
• 115/1/60
• 230/1/60
• 208, 230, 460, 575/3/60
• 380/3/50
WARNING:
Electrical shock hazard. Conduit grounds are not adequate. You must attach a separate
ground (earth) wire to the ground (earth) lug provided in the enclosure in order to avoid
potential safety hazards. Failure to follow these instructions can result in serious personal
injury, death, or property damage.
Input voltage tolerance
The input voltage tolerance is ±10% of the voltage indicated on the nameplate.
Overload protection for constant-speed units
Motor type Overload protection Description
Single-phase Internal • Disconnecting means
• Fuses for short-circuit protection
Three-phase External in the control panel • Disconnecting means
• GV2Ps / manual starters with
thermal overload for short-circuit
protection in the control panel
4 Installation
12 AquaBoost VS Pumping Packages INSTRUCTION MANUAL

Overload protection for variable-speed units
Variable-speed units have a single-point power panel with fuses for protection against
voltage spikes. In addition, the controllers have inherent features that protect the unit
against:
• short circuit
• undervoltage
• overload
• motor temperature
• dead heading
• run out
• suction loss
• sensor fault
• bound pump
• overvoltage
• static discharge
4.1.1 Field piping diagrams
AquaBoost VS simplex
1
2
3
4
5 6
7
8
10
9
RS000011
Typical field piping arrangement for the AquaBoost Variable Speed simplex pumping
package.
1. Anchor the pipe securely if vibration eliminators are used.
2. If a bypass line is installed, then this valve must be kept closed during normal operation. Do not install a
check valve.
3. Suction gauge, recommended
4. Optional tank
5. Discharge gauge
6. Vibration eliminator
7. 1/4 in. inlet tap on the check valve for low-suction pressure switch
8. Controller: AquaBoost II or Aquavar CPC
9. City supply
10.To system
_ _ _ _ Dashed lines indicate field installation.
4 Installation
AquaBoost VS Pumping Packages INSTRUCTION MANUAL 13

AquaBoost VS duplex
1
2
3 4 5
6
7
8
9
10
RS000012
Typical field piping arrangement for the AquaBoost Variable Speed duplex pumping
package.
1. 1/4 in. tap on the suction manifold for low-suction pressure switch
2. Optional tank
3. Discharge gauge
4. Vibration eliminator
5. Anchor the pipe securely if vibration eliminators are used.
6. If a bypass line is installed, then this valve must be kept closed during normal operation. Do not install a
check valve.
7. Suction gauge, recommended
8. Controller: Aquavar CPC
9. City supply
10.To system
_ _ _ _ Dashed lines indicate field installation.
4 Installation
14 AquaBoost VS Pumping Packages INSTRUCTION MANUAL

4.1.2 Wiring diagrams
AquaBoost VS – Aquavar CPC controls
208V-230V/3ɸ
HP GROUND
WIRE - C
VFD/MOTOR
WIRE - J
VFD/MOTOR
CONDUIT
VFD FUSES FUSE
WIRE
VFD GND
WIRE
FPSI MODEL FRAME MODEL P/N
1 1/2
14 AWG 14 AWG 1/2"
FG-CPC20071
1
HJS10 43-011-010
14 AWG 14 AWG
2 FG-CPC20071 3 FG-CPC20121 HJS15 43-011-015 5 12 AWG 12 AWG FG-CPC20171 HJS25 43-011-025 12 AWG
460V/3ɸ
HP GROUND
WIRE - C
VFD/MOTOR
WIRE - J
VFD/MOTOR
CONDUIT
VFD FUSES FUSE
WIRE
VFD GND
WIRE
FPSI MODEL FRAME MODEL P/N
1 1/2
14 AWG 14 AWG 1/2"
FG-CPC40041
1HJS10 43-011-010 14 AWG 14 AWG
2 FG-CPC40041
3 FG-CPC40061 5FG-CPC40081 HJS15 43-011-015
575V/3ɸ
HP GROUND
WIRE
VFD/MOTOR
WIRE
VFD/MOTOR
CONDUIT
VFD FUSES FUSE
WIRE
VFD GND
WIRE
FPSI MODEL FRAME MODEL P/N
1 1/2
14 AWG 14 AWG 1/2"
FG-CPC50031
1HJS10 43-011-010 14 AWG 14 AWG
2 FG-CPC50031 3 FG-CPC50041 5FG-CPC50061 HJS15 43-011-015
380V/3ɸ
HP GROUND
WIRE - C
VFD/MOTOR
WIRE - J
VFD/MOTOR
CONDUIT
VFD FUSES FUSE
WIRE
VFD GND
WIRE
FPSI MODEL FRAME MODEL P/N
1 1/2
14 AWG 14 AWG 1/2"
FG-CPC40041
1
HJS10 43-011-010
14 AWG 14 AWG
2 FG-CPC40061 3 FG-CPC40081 HJS15 43-011-015 5 FG-CPC40121
STATION POWER REQUIREMENTS (A)
VOLTAGE HP SIMPLEX DUPLEX
SIMPLEX DISCONNECT DUPLEX DISCONNECT
208V-230V
1ɸ/60Hz
1.5 11/10
30A
22/20 30A
213.2/12 26.4/24
3 18.7/17 37.4/34 60A 530.8/28 60A 61.6/56 100A
208V-230V
3ɸ/60Hz
1.5 6.6/6
30A
13.2/12
30A
27.5/6.8 15/13.6
3 10.6/9.6 21.2/19.2
5 16.7/15.2 33.4/30.4 60A
380V/3ɸ/50
Hz
1.5 3.3
30A
6.6
30A
24.3 8.6
36.1 12.2
59.7 19.4
460V/3ɸ/60
Hz
1.5 3
30A
6
30A
23.4 6.8
3 4.8 9.6 5 7.6 15.2
575V/3ɸ/60
Hz
1.5 2.4
30A
4.8
30A
22.7 5.4
3 3.9 7.8 56.1 12.2
BELDEN
8770
TRANSDUCER
(MOUNTED ON DISCHARGE MANIFOLD)
DRIVE SUPPLIED WITH 0-20mA
TRANSDUCER
DIGITAL INPUT 4, PROGRAMMABLE. DEFAULT = SET POINT SELECTION
DIGITAL INPUT 3, PROGRAMMABLE. DEFAULT = E-STOP OR JUMPER
ANALOG OUTPUT, COMMON. (CONNECTED INTERNALLY TO CHASSIS
THROUGH 1MΩ)
ANALOG OUTPUT, PROGRAMMABLE. DEFAULT = NOT USED. CURRENT
0-20mA (LOAD<500Ω)
DIGITAL INPUT COMMON. TO ACTIVATE A DIGITAL INPUT, THERE MUST BE
>= +10V (OR =< -10V) BETWEEN THE INPUT AND DCOM. THE 24V MAY BE
PROVIDED BY THE AQUAVAR (X1-10 OR BY AN EXTERNAL 12-24V SOURCE
OF EITHER POLARITY.
AUXILIARY VOLTAGE OUPUT COMMON (CONNECTED INTERNALLY AS
FLOATING)
AUXILIARY VOLTAGE OUTPUT 24VDC/250mA (REFERNCE TO GND). SHORT
CIRCUIT PROTECTED. TRANSDUCER/DIGITAL INPUT POWER SUPPLY.
ANALOG OUTPUT, PROGRAMMABLE. DEFAULT = NOT USED. CURRENT
0-20mA (LOAD<500Ω)
ANALOG INPUT CHANNEL 2. RESOLUTION 0.1%, ACCURACY ± 1%.
10V/1mA REFERENCE VOLTAGE OUTPUT FOR ANALOG INPUT
POTENTIOMETER, ACCURACY ±2%. (NOT USED.)
ANALOG INPUT CIRCUIT COMMON. (CONNECTED INTERNALLY TO
CHASSIS GROUND THROUGH 1MW. JUMPER WIRE TO X1-11.)
ANALOG INPUT CHANNEL 1, 2ND TRANSDUCER. DEFAULT2=FREQUENCY
REFERENCE. RELAY OUTPUT 1, PROGRAMMABLE. DEFAULT = RUN
POWER TO DRIVE MAXIMUM: 250VAC / 30VDC, 2A MINIMUM: 500mW (12V, 10mA)
RELAY OUTPUT 3, PROGRAMMABLE. DEFAULT = RUN
POWER TO DRIVE MAXIMUM: 250VAC / 30VDC, 2A MINIMUM: 500mW (12V, 10mA)
RELAY OUTPUT 2, PROGRAMMABLE. DEFAULT = RUN
POWER TO DRIVE MAXIMUM: 250VAC / 30VDC, 2A MINIMUM: 500mW (12V, 10mA)
RELAY OUTPUTS
ON
J1:AI1 ON: 0...20mA (Ri=100K Ω)
DIGITAL INPUT 6, PROGRAMMABLE. DEFAULT = NOT USED DIGITAL INPUT 5, PROGRAMMABLE. DEFAULT = HOA (GROUP 12)
DIGITAL INPUT 2, PROGRAMMABLE. DEFAULT = LOW WATER
DIGITAL INPUT 1, PROGRAMMABLE. DEFAULT = RUN ENABLE
ANALOG INPUT CIRCUIT COMMON. (CONNECTED
INTERNALLY TO CHASSIS GND. THROUGH 1 M Ω.
J1:AI1 OFF: 0...10V (Ri=312K Ω) J1:AI1 ON: 0...20mA (Ri=100K Ω)
DIGITAL OUTPUTS ANALOG I/O
ON
ON
J1:AI1 OFF: 0...10V (Ri=312K Ω)
TERMINAL FOR TRANSDUCER SHIELD. (CONNECTED
INTERNALLY TO CHASSIS GROUND)
ON
RO1A RO3C RO3B RO3A RO2C RO2A RO2B RO1B
29
ONON
28
25
27
26
3130 32
ON
J2
ON
26 25 27
323028 29 31
GROUND
(SHIELD)
GND + 24V
DCOM RO1C DI1 DI2 DI3 DI5 DI6 DI4
AGND
+ 10V
AGND
AO1 AO2
AGND AI2
14
22 24 23 21
20
19
15 16 17 18
WHITE
[OR BLACK]
10 11 12 13
9 8 7
6
5
4
3
BROWN
[OR RED]
SCR
AI1
ON
AI2 AI1
ON
2
1
VFD 1
GROUND
(SHIELD)
14
21 20 23 24 22
15 17 16 18
19
TRANSDUCER
(MOUNTED ON
DISCHARGE
MANIFOLD)
9
10 12 11
13
3
4
5
7
8 6
BROWN
[OR RED]
WHITE
[OR BLACK]
AI1 AI2
2
1
ON
ON
VFD 2
J5
J4
J3
J2
J1
J5
J4
J3
J2
J1
CUSTOMER SUPPLIED SERVICE RATED
SERVICE DISCONNECT
(CUSTOMER RESPONSIBLE FOR WIRE
AND CONDUIT SIZES BETWEEN
CUSTOMER DISCONNECT, AND CONTROL
PANEL, BASED ON STATION FULL LOAD
AMPS AND NEC CODE)
A
PE PE
U2
"C"
V2 W2 U2 W2
V2
U1
PE
"F"
PE
"E"
V1 W1
"F"
U1 W1V1
"C"
"K" "K"
NOTES:
1. CONDUIT AND WIRE SIZES SHOWN ARE MINIMUM REQUIRED;
LARGER SIZES MAY BE SUBSTITUTED IF CONDUIT SIZE PERMITS.
2. USE 90° C WIRE FOR MOTOR WIRE RUNS; INCLUDE TAG READING
"MOTOR WIRE TO BE NO LESS THAN 90° C RATED".
3. INCLUDE TAG READING "TORQUE SCREWS TO 6-14 LB-IN, USE
COPPER WIRE ONLY" ON CONTROL INTERFACE WIRING.
4. CUSTOMER RESPONSIBLE FOR WIRE AND CONDUIT SIZES
BETWEEN CUSTOMER DISCONNECT, AND CONTROL PANEL,
BASED ON STATION FULL LOAD AMPS AND NEC CODE.
5. STATION MEETS 5kA SCCR RATING ONLY IF CUSTOMER SUPPLY
THE FOLLOW SUPPLY FUSES OR EQUIVALENT CIRCUIT BREAKER
CLASS RK1, J, T - 400 A MAX.
CLASS RK5 - 200 A MAX CLASS G - 60 A MAX CLASS CC - 30 A MAX
"J
"E"
"J"
"E"
"D"
"E"
"D"
BC
JUMPER POSITION
IF MIDDLE DRIVE(S)
J2 JUMPER MAY BE
SHOWN AS SEPERATE J2, J5 OR AS A SINGLE
LARGE J2
JUMPER POSITION IF FIRST OR
LAST (TERMINATING) DRIVES
J2
ON ON
ON ON
J2J2 J5
OR
ON ON ON
J2
A
SCREEN
AGND
SCREEN
B
RS485 MULTIPLE DRIVE
CONNECTIONS
J2
10 (+24)
VFD 1
VFD TERMINALS
14 (DI2)
14 (DI2)
VFD 2
VFD 1
VFD TERMINALS
UE H5425 (SUCTION PRESS.-10PSI)
CUSTOMER INSTALLED PRESSURE SWITCH
P/N: 77-001-135
N.O. N.C.
COM.
3ɸ ONLY
"H"
"H"
SIMPLEX
DUPLEX
SIMPLEX
DUPLEX
"I"
REVISION HISTORY
REV DESCRIPTION REV BY DATE
1UPDATED DISCONNCET SIZES, WIRE SIZES AND FUSE SIZES. M. MARTINEZ FEB-08-2011
2UPDATED FUSES MODEL NUMBERS & P/N'S (SEE COLUMN H). LNT FEB-15-2011
3UPDATED NOTES AND CHARTS. M. MARTINEZ MAR-08-2011
4UPDATE POWER REQUIREMENTS CHART PER UL508A M. REYES 1/19/2012
5CHANGE BORDER TO XYLEM MP 10/12/2012
6CORRECT DUPLEX STATION FLA 21.2/19.2 FOR 3HP,208V/3Ø/60HZ DTT 1/5/2014
7UPDATED LIP INFORMATION DTT 4/27/2015 8ECN2017-0006, ADD 5HP, 208V/1 Ø/60HZ; UPDATED VFD 1.5HP,208-230V/3 Ø/60HZ DTT 1/26/2017
10661 NEWKIRK STREET
DALLAS, TX 75220
800.786.7480
SHEET:
DATE:
DRN: DATE:
CHK:
DRAWING #:
REV
DRAWING NAME:
SIZE
THIS DRAWING AND THE INFORMATION DEPICTED THEREIN IS THE
PROPERTY OF XYLEM. COPIES ARE ISSUED IN STRICT CONFIDENCE
AND SHALL NOT BE REPRODUCED OR COPIED, OR USED AS THE
BASIS FOR THE MANUFACTURE OR SALE OF PRODUCTS WITHOUT
PRIOR WRITTEN PERMISSION OF XYLEM. OF
PROJECT #:
M MARTINEZ 02/02/2011
VN 02/07/0211
11033-01
VALUE BOOSTER
CPC DRIVES
B8 1 1
BOOSTER
208V-230V/1ɸ
ACD E FHJK
HP GROUND
WIRE
VFD/MOTOR
WIRE
VFD/MOTOR
CONDUIT
VFD FUSES FUSE
WIRE
VFD GND
WIRE
FPSI MODEL FRAME MODEL P/N
1 1/2 14 AWG
14 AWG 1/2"
FG-CPC20121
R1
HJS15 43-011-015 12 AWG 14 AWG
2
10 AWG
FG-CPC20171 HJS25 43-011-025 10 AWG
3FG-CPC20241 HJS30 43-011-030 10 AWG 510 AWG FG-CPC20311 R2 HJS40 43-011-040 8 AWG 10 AWG
4 Installation
AquaBoost VS Pumping Packages INSTRUCTION MANUAL 15

AquaBoost VS – ABII controls
208V-230V/1ɸ
60Hz
AC D E F H I JK
HP GROUND
WIRE
VFD/MOTOR
WIRE
VFD/MOTOR
CONDUIT
VFD FUSES STATION
DISCONNECT
FUSE
WIRE
VFD GND
WIRE
FPSI MODEL P/N MODEL P/N
1 1/2 12 AWG 14 AWG 1/2" 2AB2 200-S100061 HJS15 43-011-015 30A 14 AWG 12 AWG
210 AWG 12 AWG HJS20 43-011-020 12 AWG 10 AWG
NOTES:
1. CONDUIT AND WIRE SIZES SHOWN ARE MINIMUM REQUIRED; LARGER SIZES MAY BE SUBSTITUTED IF CONDUIT SIZE PERMITS.
2. USE 90° C WIRE FOR MOTOR WIRE RUNS; INCLUDE TAG READING "MOTOR WIRE TO BE NO LESS THAN 90° C RATED".
3. INCLUDE TAG READING "TORQUE SCREWS TO 6-14 LB-IN, USE COPPER WIRE ONLY" ON CONTROL INTERFACE WIRING.
4. CUSTOMER RESPONSIBLE FOR WIRE AND CONDUIT SIZES BETWEEN CUSTOMER DISCONNECT, AND CONTROL PANEL, BASED ON
STATION FULL LOAD AMPS AND NEC CODE.
5. STATION MEETS 5kA SCCR RATING ONLY IF CUSTOMER SUPPLY THE FOLLOW SUPPLY FUSES OR EQUIVALENT CIRCUIT BREAKER
CLASS RK1, J, T - 400 A MAX.
CLASS RK5 - 200 A MAX
CLASS G - 60 A MAX
CLASS CC - 30 A MAX
6. CUSTOMER SUPPLIED CIRCUIT BREAKER OR FUSES AND DISCONNECT. CIRCUIT BREAKER MUST BE A 20A
DEDICATED TO PUMP
STATION (CUSTOMER RESPONSIBLE FOR WIRE AND CONDUIT SIZES BETWEEN CUSTOMER DISCONNECT, AND CONTROL PANEL,
BASED ON STATION FULL LOAD AMPS AND NEC CODE).
MOTOR OVERLOAD SETTING
WARNING
Disconnect Power And Wait For LED Indicator To Turn
Off Before Touching Motor Overload Setting Switches.
1 = UP 0 = DOWN
DIP SWITCH
SETTING
MOTOR OVERLOAD
SETTINGS (A)
1 2 3 4 1AB2 2AB2
1 1 1 1 2.5 4.6
1 1 1 0 2.8 5.2
1 1 0 1 3.3 5.3 1 0 1 1 3.5 5.3
0 1 1 1 3.8 6.5
0 0 0 0 4.2 6.9
6
A
115V/1ɸ
(115AB2)
*98V-132V
RANGE
208V-230V/1ɸ
(2AB2)
* 196V-264V
RANGE
"E"
"J"
C
"H"
L1
L2
GND
1234
Applic.
Type
1234
Motor
Overload
INPUT
1 PHASE
SEE MANUAL FOR
SWITCH SETTINGS
T2
T3
T1
OUTPUT TO
MOTOR
GND
RED +5V
WHITE INPUT
BLK COM
PRESSURE
SENSOR
"C"
"E"
"D"
APPLICATION TYPE SWITCH SETTING
WARNING
Disconnect Power And Wait For LED Indicator To Turn
Off Before Touching Application Setting Switches.
1 = UP 0 = DOWN
DIP SWITCH
SETTING 1 = UP 0 = DOWN
1 2 3 4 Minimum
Speed (Hz)
Ramp
Speed
1 1 1 1 10 Slow
1 1 1 0 10 Medium
1 1 0 1 10 Fast 1 0 1 1 30 Slow
0 1 1 1 30 Medium
0 0 0 0 30 Fast
1151AB2 (3/4HP) or 2AB2 (1 1/2 -2 HP)
* LOW SUCTION PRESSURE SWITCH NOT AVAILABLE FOR
THESE MODELS
115V/1ɸ
60Hz
A C D E F H I J K
HP GROUND
WIRE
VFD/MOTOR
WIRE
VFD/MOTOR
CONDUIT
VFD FUSES STATION
DISCONNECT
FUSE
WIRE
VFD GND
WIRE
FPSI MODEL P/N MODEL P/N
3/4 10 AWG 12 AWG 1/2" 115AB2 200-S100064 HJS20 43-011-020 30A 12 AWG 12 AWG
PRT0100SA1P
* SET 0 0 0 0 AS DEFAULT
* SET EQUAL TO SF AMP VALUE
ON MOTOR NAMEPLATE
"E" "E"
REVISION HISTORY
REV DESCRIPTION REV BY DATE
1UPDATED DISCONNCET SIZES, WIRE SIZES AND FUSE SIZES. M. MARTINEZ FEB-10-2011
2UPDATED FUSES MODEL NUMBERS & P/N'S FOR 1151AB2/2AB2 &
3AB2/5AB2 MODELS (SEE COLUMN H IN TABLES).
LNT FEB-15-2011
3UPDATED NOTES. M. MARTINEZ MAR-01-2011
4UPDATED INCOMING POWER CHART. M. MARTINEZ MAR-08-2011
5CHANGE BORDER TO XYLEM MP 10/12/2012
6UPDATED SIMPLEX FLA 208/230V/1ɸ/60HZ TO MATCH UL508A TABLE 50.1 DTT 2/4/2015
7UPDATED LIP INFORMATION, UPGRADE UIB ABII TO ABII+ DTT 4/29/2015 8ECN2017-0006, OBSOLETED 3AB2 (3HP) AND 5AB2 (5HP) CONTROLLER DTT 1/26/2017
10661 NEWKIRK STREET
DALLAS, TX 75220
800.786.7480
SHEET:
DATE:
DRN: DATE:
CHK:
DRAWING #:
REV
DRAWING NAME:
SIZE
THIS DRAWING AND THE INFORMATION DEPICTED THEREIN IS THE
PROPERTY OF XYLEM. COPIES ARE ISSUED IN STRICT CONFIDENCE
AND SHALL NOT BE REPRODUCED OR COPIED, OR USED AS THE
BASIS FOR THE MANUFACTURE OR SALE OF PRODUCTS WITHOUT
PRIOR WRITTEN PERMISSION OF XYLEM. OF
PROJECT #:
M.MARTINEZ 02/08/2011
11033-02
VALUE BOOSTER
AQUABOOST DRIVES
B811
BOOSTER
4.2 ground (earth) connections
WARNING:
Electrical shock hazard. Conduit grounds are not adequate. You must attach a separate
ground (earth) wire to the ground (earth) lug provided in the enclosure in order to avoid
potential safety hazards. Failure to follow these instructions can result in serious personal
injury, death, or property damage.
4 Installation
16 AquaBoost VS Pumping Packages INSTRUCTION MANUAL

A grounding terminal is provided for a dedicated ground (earth) wire connection. You
must follow all provisions of the National Electrical Code and local codes.
4.3 Pump package location guidelines
WARNING:
Assembled units and their components are heavy. Failure to properly lift and support this
equipment can result in serious physical injury and/or equipment damage. Lift equipment
only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and
spreaders must be rated, selected, and used for the entire load being lifted.
Guideline Explanation/comment
Make sure that the space around the pump package is
sufficient.
This facilitates ventilation, inspection, maintenance, and
service.
If you require lifting equipment such as a hoist or tackle,
make sure that there is enough space above the pump
package.
This makes it easier to properly use the lifting equipment
and safely remove and relocate the components to a safe
location.
Use traditional lifting equipment (safety belt, sling, or
chain) to secure assembly. Corner holes in base have
been provided for installation of an approved lifting
eyebolt and nuts (not furnished with package).
Prevention against overturning the package
Protect the unit from weather and water damage due to
rain, flooding, and freezing temperatures.
This is applicable if nothing else is specified.
Do not install and operate the equipment in closed
systems unless the system is constructed with properly-
sized safety and control devices.
Acceptable devices:
• Pressure relief valves
• Compression tanks
• Pressure controls
• Temperature controls
• Flow controls
If the system does not include these devices, consult the
engineer or architect in charge before you operate the
pump.
Take into consideration the occurrence of abnormal noise
and vibration.
The best pump location for noise and vibration
absorption is on a concrete floor with subsoil underneath.
4.4 Foundation requirements
Requirements
• The foundation must be able to absorb any type of vibration and form a permanent,
rigid support for the unit.
• The foundation must weigh at least 2-1/2 times the weight of the pump unit.
• Provide a flat, substantial concrete foundation in order to prevent strain and distortion
when you tighten the foundation bolts.
• Sleeve-type and J-type foundation bolts are most commonly used. Both designs allow
movement for the final bolt adjustment.
• Tie the concrete pad in with the finished floor.
4.5 Level the base on a concrete foundation
1. Place the pump package on its concrete foundation.
2. Place 1.00 in./(25.40 mm) thick steel shims or wedges on both sides of each anchor
bolt in order to support the pump package.
Make sure that you also place the shims or wedges midway between the bolts.
This also provides a means of leveling the base.
4 Installation
AquaBoost VS Pumping Packages INSTRUCTION MANUAL 17

4.6 Connect the optional storage tank
1. If the unit is a simplex configuration, then install the tank to the top connection of the
discharge cross as shown:
1
2
RS000021
1. Storage tank
2. Discharge gauge
2. If the unit is a duplex configuration, then connect the tank to the discharge manifold as
shown:
1
2
RS000022
1. Storage tank
2. Discharge gauge
3. Precharge the tank according to the tank-specific IOM.
4.7 Connect the optional low-suction pressure switch
1. If the unit is a simplex configuration, then install the low-suction pressure switch piped
to the 1/4 in. inlet tap on the check valve as shown:
4 Installation
18 AquaBoost VS Pumping Packages INSTRUCTION MANUAL