Xylem IM183 R09 3AB2 & 5AB2 Aquavar ABII Variable Speed Pump Controller - Manual (Page 4)

4
Mounting Controller
Three screws are provided for mounting the enclosure.
Using the enclosure as a guide, select a mounting location.
First install the top screw in the mounting surface leaving
the head of the screw approximately 1 ⁄
8
" from the surface.
Hang the enclosure on this screw. Finish by installing the
two bottom screws and tightening the top screw. Be sure
to leave a minimum of 6" of clearance on each side of the
controller to ensure proper cooling.
Pump and Piping
Do not install any valves (except check
valves), flow control devices or filters
between the pressure transducer and the pump. It is
allowable to run branches off the pipe between the pump
and transducer as long as no flow restricting devices are
between the pump and transducer.
NOTICE: The terms Transducer and Pressure Sensor are
equal and interchangeable.
EXPLODING TANK CAN INJURE OR
KILL.
Always protect the tank from over pressure by installing
a pressure relief valve large enough to limit the system
pressure below the maximum working pressure of the tank.
Install the tank at a point in the system where the maximum
possible system pressure cannot exceed the maximum
working pressure of the tank. Install the pressure relief valve
at the tank.
Avoid property damage caused by pressure
relief valve opening. Pipe the pressure relief
valve discharge to a drain or other location so that property
damage and flooding will not occur.
Locate the tank and transducer where they
will not freeze.
Ensure the system pressure setting does not exceed the
maximum working pressure of the tank.
For optimum performance, as a minimum, we recommend
using the same size pipe as the pump discharge between the
pump and the tank. Smaller diameter pipe may severely limit
the maximum capacity of the system. On long runs, larger
pipe may be beneficial for optimum performance and flow.
Check Valve
Use a spring check valve between pump and tank for
reliable turn-off when flow stops.
TANK SIZING AND TANK PRESSURE SETTING -
Refer to Table 1 for recommended tank size. On pre-existing
systems, larger tanks may be used.
Table 1: Systems with Small Tanks
Pump Size Minimum Tank
GPM Total Volume
5 - 6 2
7 - 8 2
10 -12 2
13 -15 4
18 - 20 4
25 - 28 5
33 - 35 7
40 - 45 9
55 - 60 12
75 - 80 15
For a 5 PSI Pressure Drop Set-up:
Set the tank pressure, while tank is empty of water, to 20 psi
below the desired system pressure setting. Ex. for a 50 psi
system pressure, charge the tank to 30 psi. *
For a 20 PSI Pressure Drop Set-up:
Set the tank pre-charge to 30 psi below the desired system
pressure setting. Ex. for a 50 psi system pressure, charge the
tank to 20 psi. *
* The tank pre-charge is always checked with the tank empty of water.
Wiring Pressure Transducer
Transducer wires must never be in same
conduit with power wires. There should
always be a minimum of 12" between transducer wires
and power wires. Failure to separate these wires can cause
controller malfunctions.
The pressure transducer cable is pre-wired at the factory. If
desired, the length of the cable can be changed. The cable
can also be put in conduit to protect against damage.
To change the length of the transducer cable:
• Cable length cannot exceed 200'.
• Disconnect transducer wires from terminal block by
pushing down on tabs at rear of block one at a time and
pulling the wires out of the terminal.
• Splice additional cable to transducer wire, cut off excess as
required.
• Reconnect wires to terminal block. Be sure wire colors
match labels on circuit board (B = Black, R = Red, W =
White).
To put the transducer cable in conduit, do the following:
Disconnect the cable from the terminal block and remove
the cable strain relief in the bottom of the enclosure.
Starting at the enclosure, run flexible or rigid ½" conduit to
where the transducer is located. The last few feet of conduit
adjacent to the transducer will need to be flexible. The
conduit must be well supported – NO stress can be placed
on the pressure transducer connector. Use a strain relief
bushing to seal around the pressure transducer connector.
After reconnecting the transducer wires to
the terminal block and ground terminal, tug
on each wire individually to ensure they are tight.
Any exposed metal in the system piping,
including transducer case, must be grounded
to the service entrance per NFPA 70: National Electrical
Code, Article 250.
The transducer cable has a Green ground wire and a ground
clamp supplied to facilitate grounding the transducer. See
Figure 1.
WARNING
WARNING
CAUTION
CAUTION
Figure 1: Transducer Grounding
CAUTION
CAUTION
CAUTION