Xylem IM183 R09 3AB2 & 5AB2 Aquavar ABII Variable Speed Pump Controller - Manual (Page 8)

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The Switch Input terminals have a Jumper Wire installed at
the factory (do not confuse the jumper wire on the Switch
Input with the Transducer Jumper next to the Transducer
Connection Terminals, see Transducer Jumper below).
The Switch Input terminals must be connected (closed) for
the pump to operate. If they are not connected the Switch
Input Status Light (visible inside the enclosure) will be Solid
RED and the Controller Status Light will be Solid GREEN
indicating that the pump-motor is off. Remove the Jumper
Wire when connecting a float or over-pressure switch.
CONSTANT PRESSURE SYSTEM - with an Over-Pressure
Switch:
• Connect two wires from the Load and Lead connections
of a pressure switch to provide over-pressure protection.
In the event the pressure transducer fails, this will prevent
high pressure from damaging piping.
• The over-pressure switch cut-out setting must be a mini-
mum of 10 PSI higher than the system set point pressure.
• Set the over-pressure switch cut-out 5 - 10 PSI lower than
the pressure relief valve (PRV) pop-off pressure. This will
turn the system off before the pressure relief valve opens.
• Ex. On a system with a 50 PSI set point, set the over-pres-
sure switch cut-out at 60 PSI with a typical PRV setting of
75 PSI. In the event the transducer fails at high pressure
the switch will turn the system off before the PRV pops.
• Typical UIB Settings For This Type System:
• For AB controllers, 30 or 10 Hertz (depends on pump/
motor)
• Dry Run Restart - 5X
• Low Pressure Cut-Off - On
• Pressure Drop - 5 PSI
• Transducer - Connected
• Transducer Jumper - Bottom Position (Factory Setting)
• Pressure Switch Connected to Switch Input
FLOAT SWITCH OPERATION - Filling a Pond or Tank
(Non-Constant Pressure System):
• Connect two wires from a float (level) switch to fill or
empty a tank, pond, etc. The pump will run when the
level switch contacts close. The maximum switch wire
length tested is 200’. The pump will run at maximum
speed when the float switch is closed.
• Typical UIB Settings For This Type System:
• 30 or 10 Hertz (depends on pump/motor)
• Dry Run Restart - 5X or continuous
• Low Pressure Cut-Off - Off
• Pressure Drop - 5 or 20 PSI
• Transducer - Not Connected
• Transducer Jumper - Top Position (Installer Must Move)
• Float Switch Connected to Switch Input
FLOAT SWITCH OPERATION - Filling a Pond or Tank
and Constant Pressure System:
• Connect two wires from a float (level) switch to fill or
empty a tank or pond and a pressurized system. The
maximum switch wire length tested is 200’. The pump
will operate at various speeds and try to maintain the set
point pressure. If piping is large and it cannot maintain
set point pressure it will operate at maximum speed.
Checking for leaks
Constant pressure systems utilizing small tanks run
whenever there is demand. Even small leaks can prevent
a pump from turning off. To check for leaks, close all
valves, turn power off to the controller, and note the
pressure displayed on the pressure gauge. Tap the gauge
to ensure you get an accurate reading.
Wait ten minutes and check the gauge again tapping to
prevent the needle from sticking. If the pressure dropped
then the system may have a leak*.
A spring check valve placed on the pump side of the
tank and transducer will often improve the ability of the
system to shut down.
* If a system is pressurized after having been un-pressurized, it
will continue to expand for several minutes. This expansion
causes the pressure to drop and can be misinterpreted as
a leak. Allow a system to stabilize for 10 minutes under
pressure before performing the aforementioned leak test.
Checking Rotation
For three phase motors, it is possible for the motor to
rotate in the wrong direction. If running backwards,
the pump will work but it will have greatly reduced
performance.
To check rotation, perform the following tests:
Connect an amp probe to one of the power supply
wires. Run the system with several valves open and note
the pressure and amps. Leave the valves open, turn the
power off.
Electrocution Hazard. After turning off
power, wait 5 minutes for hazardous
voltages to discharge before proceeding to swap wires.
Swap red and black motor leads where they connect to
the controller terminal block (NOT L1 and L2).
Turn power back on and let the system pressure
stabilize. Again note the pressure and amps. Whichever
wire position provided the most pressure/flow is the
correct wire position. If there was little difference in the
pressure/flow, then whichever had the lower amp reading
is the correct wire position.
Turn the power off, wait 5 minutes and swap the wires
back if necessary.
Replace the plastic protective covers on the terminal
block.
4. SWITCH INPUT OPTIONS
Optional Switch Input and Switch Input
Status Light
Electrocution Hazard. Opening SWITCH
INPUT does not de-energize controller
or any of its outputs. Always treat wire terminals of this
controller as energized until power supply to the controller
has been removed for 5 minutes.
SWITCH INPUT - for connection of an external switch
or control device used to start and stop the pump. Devices
such as an over-pressure switch, level (float) switch or any
other non-powered switch (time delay, flow, etc.) can be
connected to this input.
DANGER
DANGER
4. SWITCH INPUT OPTIONS