Xylem GOULDS AQUAFORCE e-HVX Mechanical Installation, Operation, And Maintenance Manual
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Xylem GOULDS AQUAFORCE e-HVX Mechanical Installation, Operation, And Maintenance Manual

Xylem GOULDS AQUAFORCE e-HVX Mechanical Installation, Operation, And Maintenance Manual

Packaged booster systems
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Mechanical Installation, Operation,
and Maintenance Manual
IM416_1.0
AQUAFORCE e-HVX & e-HVXR
Packaged Booster Systems

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Summary of Contents for Xylem GOULDS AQUAFORCE e-HVX

  • Page 1 Mechanical Installation, Operation, and Maintenance Manual IM416_1.0 AQUAFORCE e-HVX & e-HVXR Packaged Booster Systems...
  • Page 2 Page intentionally left blank...

  • Page 3: Table Of Contents

    4.5 Foundation requirements.....................14 4.6 Level the base on a concrete foundation ..............14 4.7 Grout the baseplate..................... 15 4.8 Piping checklist......................15 4.9 Xylem App setup......................15 5 Commissioning, Startup, Operation, and Shutdown............17 5.1 Preparation for startup....................17 5.1.1 Prestartup checklist....................17 5.1.2 Final installation checks..................17 5.1.3 Final adjustments....................18...
  • Page 4 Table of Contents 6 Maintenance........................22 6.1 Precautions........................22 6.2 Maintenance........................ 22 6.2.1 Monthly maintenance....................22 6.2.2 Maintenance every 3 months................22 6.2.3 Maintenance every year, or 4000 hours of operation........... 22 6.2.4 Maintenance every 2 years, or 10,000 hours of operation........23 6.2.5 Maintenance every 5 years, or 17,500 hours of operation........23 7 Troubleshooting.........................

  • Page 5: Introduction And Safety

    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.

  • Page 6: Protecting The Environment

    • 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.

  • Page 7: Wash The Skin And Eyes

    1 Introduction and Safety • 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.
  • Page 8 1 Introduction and Safety WARNING: • Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical injury. The main station panel is equipped with a main station disconnect for completely powering down the system.

  • Page 9: Transportation And Storage

    2 Transportation and Storage 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.

  • Page 10: Long Term Storage

    – Storage location should also provide minimal exposure to vibration and other damage potentially transmitted from adjacent operating equipment. – Product supplied in factory cartons, pallets or similar Xylem packaging should be kept in ‘as-shipped’ condition where possible. – Inspect suction and discharge manifold flange covers.
  • Page 11 2 Transportation and Storage – Every 30 days, the pump and motor shaft should be rotated by hand (10-15 turns) to prevent bearing damage and potential for binding. Be sure shaft comes to rest in different positions. – Close-coupled pumps may have minimal access to exposed shaft areas. In those cases, care must be taken to avoid damage to the shaft though use of channel-lock pliers or similar tools.

  • Page 12: Product Description

    3 Product Description 3 Product Description 3.1 General description Description A pump station is a pre-engineered and fabricated line of packaged booster systems that provides: • Energy efficiency • System protection • Hydraulic capability up to 2200 GPM • Boost pressures up to 400 PSI Intended applications WARNING: This product can expose you to chemicals including Lead, which is known to the State of...
  • Page 13 3 Product Description www.xylem.com/goulds MODEL NUMBER SERIAL NUMBER VOLTS/PH/HZ ENCL TYPE UL/NEMA MAX HP SCCR STATION FLOW PUMP BOOST DATE CODE Assembled in Auburn, NY, U.S.A. Part Number A01276C Nameplate field Explanation Model number The manufacturer's number to indicate the particular type of product which has been acquired.

  • Page 14: Installation

    Tools section of the e-SVX product web page: For information on hydrovar X programming and operation, use the following IOM: • hydrovar X Programming IOM For additional information on optimyze programming and operation please visit www.xylem.com/optimyze https://www.xylem.com/avensor For additional information on Avensor please visit 4.2 Field connections Diagrams Actual equipment manufacturers/models installed are system specific.

  • Page 15: Ground (Earth) And Power Connections

    4 Installation 4.3 Ground (earth) and Power 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.

  • Page 16: Foundation Requirements

    4 Installation WS016115A Figure 1: e-HVX Lifting Points 1. Lifting slots for slings, hooks, chains, etc. 2. Lifting slots for forklifts WS016116A Figure 2: Rigging examples 4.5 Foundation requirements Requirements • The foundation must be able to absorb any type of vibration and form a permanent, rigid support for the unit.

  • Page 17: Grout The Baseplate

    Check that fittings for absorbing expansion are This helps to avoid strain on the pump. installed in the system when considerable temperature changes are expected. 4.9 Xylem App setup Introduction Available for mobile devices with wireless technology operating system. Use the App to: •...
  • Page 18 • Generate a work report • Contact the assistance service. Download the App and connect the mobile device with the unit 1. Download the Xylem X App to the mobile device from App Store or Google Play scanning the QR code: 2.

  • Page 19: Commissioning, Startup, Operation, And Shutdown

    5 Commissioning, Startup, Operation, and Shutdown 5 Commissioning, Startup, Operation, and Shutdown 5.1 Preparation for startup WARNING: • Failure to follow these precautions before you start the unit will lead to serious personal injury and equipment failure. • DO NOT operate the pump below the minimum rated flows or with the discharge valves closed.

  • Page 20: Final Adjustments

    5 Commissioning, Startup, Operation, and Shutdown 5.1.3 Final adjustments Make the final adjustments on these adjustable devices in order to match the exact system requirements. Thermal relief valve An optional thermal relief valve is installed on the pump discharge in order to prevent potentially dangerous thermal pressure buildup.

  • Page 21: Filling And Priming

    5 Commissioning, Startup, Operation, and Shutdown 5.2.3 Filling and priming WS016295A 1. On-off valve on discharge line 2. Filler cap and vent plug 3. On-off valve on suction line 4. Fill plug 5. Drain plug A. Positive suction head installation 1.

  • Page 22: Startup

    5 Commissioning, Startup, Operation, and Shutdown Note: a) If the Genie is accidentally bypassed, use the multifunction button located on the lower left of the hydrovar X keypad to enter settings menu. b) If prompted, enter the default password (066). c) Navigate to the "General Settings"...

  • Page 23: Final Checks

    5 Commissioning, Startup, Operation, and Shutdown 5.2.8 Final checks Once the pump system has been tested and in operation, check the following: 1. No liquid is leaking from the pump set or pipes. 2. The maximum pressure of the pump set at the discharge, determined by the available suction pressure, is lower than the maximum pressure rating of the individual pump unit as indicated on the pump nameplate.

  • Page 24: Maintenance

    6 Maintenance 6 Maintenance 6.1 Precautions DANGER: Electrical hazard sufficient to kill. Always disconnect and lock out the power before you service the unit. WARNING: • This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury.

  • Page 25: Maintenance Every 2 Years, Or 10,000 Hours Of Operation

    6 Maintenance 6. Check the status/operation of any fuses or switches. 7. Check the status of the main and local suction/discharge valves. 8. Ensure all valves are able to fully close and open. 9. Clean ventilation openings of the control panel if present. 10.

  • Page 26: Troubleshooting

    7 Troubleshooting 7 Troubleshooting 7.1 Pump station troubleshooting DANGER: • Personal injury hazard. Troubleshooting a live control panel exposes personnel to hazardous voltages. Electrical troubleshooting must be done by a qualified electrician. Failure to follow these instructions will result in serious personal injury, death, and/or property damage.

  • Page 27: The Pumps Run But Do Not Build Desired Pressure

    Make sure that all fasteners and components are properly tightened. Foreign bodies inside the pump system Contact Xylem or an authorized distributor, or send the pump system to an authorized workshop. AQUAFORCE e-HVX & e-HVXR Packaged Booster Systems Mechanical Installation, Operation, and...

  • Page 28: The Pump Station Does Not Shut Down And No Water Is Used

    Pump tie rods are loose Tighten tie rod nuts Pump set faulty Contact Xylem or an authorized distributor. Alternatively, send pump system to an authorized repair facility. 7.1.5 The pump station does not shut down and no water is used...

  • Page 29: The Pump System Does Not Stop When The Setpoint Is Reached

    7.1.8 The pump is leaking at the mechanical seal Cause Remedy Mechanical seal is damaged or worn Contact Xylem or an authorized distributor, or send the pump system to an authorized repair facility. 7.1.9 The drive display does not turn on Cause...

  • Page 30: The Pump Does Not Start When There Is Liquid Demand

    7 Troubleshooting 7.1.12 The pump does not start when there is liquid demand Cause Remedy The setpoint is set to zero. Check the drive settings and adjust the setpoint to the system requirement. The float switch is open. The float switch is faulty and should be replaced or check the level of liquid in the tank.

  • Page 31: Product Nomenclature

    8 Product Nomenclature 8 Product Nomenclature 8.1 Pump station numbering system The pump station label located on the inside of the control enclosure door identifies the product code number for the various versions of the pump systems. This number is also the catalog number for the pump station.
  • Page 32 8 Product Nomenclature NOTICE: Please note not all e-SVX configurations are available for e-HVX and e-HVXR booster package systems. Refer to the product technical brochure for a list of valid combinations. AQUAFORCE e-HVX & e-HVXR Packaged Booster Systems Mechanical Installation, Operation, and Maintenance Manual...
  • Page 33 8 Product Nomenclature Nomenclature - 1-22SVX WS016123A Figure 3: 1-22SVX AQUAFORCE e-HVX & e-HVXR Packaged Booster Systems Mechanical Installation, Operation, and Maintenance Manual...
  • Page 34 8 Product Nomenclature Nomenclature - 33-125SVX Example Product Code (33-125 e-SVX)* Special Configurations (1-2 Characters) SV X [P] = Passivization only [S] = Customized configuration [Z] = High Pressure (250/300 psi pump body) Seal Materials (1 Character) [0] = Carbon/SilCar/FKM [1] = Carbon/SilCar/AFLAS (High Temp) [2] = SilCar/SilCar/FKM [4] = SilCar/SilCar/EPR...

  • Page 35: Appendix

    9 Appendix 9 Appendix 9.1 Installation drawings Duplex (200-240/3 and 380-480/3 Volt): 5SVX to 15SVX4 WS016117A Duplex (200-240/3 and 380-480/3 Volt): 15SVX7 to 92SVX WS016118A AQUAFORCE e-HVX & e-HVXR Packaged Booster Systems Mechanical Installation, Operation, and Maintenance Manual...
  • Page 36 9 Appendix Duplex (380-480/3 Volt): 125SVX WS016119A Triplex (200-240/3 and 380-480/3 Volt): 5SVX to 15SVX4 WS016120A Triplex (200-240/3 and 380-480/3 Volt): 15SVX7 to 92SVX WS016121A AQUAFORCE e-HVX & e-HVXR Packaged Booster Systems Mechanical Installation, Operation, and Maintenance Manual...

  • Page 37: Sound Pressure

    9 Appendix Triplex (380-480/3 Volt): 125SVX WS016122A 9.2 Sound pressure Measured in free field at a distance of one meter (3.28 ft) from the pump set operating at 3600 RPM without load. Size Frame LpA, dB +/- 2 143-145 4-7.5 <...
  • Page 38 9 Appendix Voltage Specification Document Motor Type Power (hp) Motor Frame Range Number EXM213-215/3.075CH2 213-215 XY-hyXeXM-SUB-537 EXM254-256/3.150DH2 254-256 XY-hyXeXM-SUB-538 EXM254-256/3.200DH2 254-256 XY-hyXeXM-SUB-539 EXM90HMHB/3.040BH2 XY-hyXeXM-SUB-540 AQUAFORCE e-HVX & e-HVXR Packaged Booster Systems Mechanical Installation, Operation, and Maintenance Manual...

  • Page 39: Product Warranty

    10 Product Warranty 10 Product Warranty Commercial warranty Warranty. For goods sold to commercial buyers, Seller warrants the goods sold to Buyer hereunder (with the exception of membranes, seals, gaskets, elastomer materials, coatings and other "wear parts" or consumables all of which are not warranted except as otherwise provided in the quotation or sales form) will be (i) be built in accordance with the specifications referred to in the quotation or sales form, if such specifications are expressly made a part of this Agreement, and (ii) free from defects in material and workmanship for a...
  • Page 40 To make a warranty claim, check first with the dealer from whom you purchased the product or visit www.xylem.com for the name and location of the nearest dealer providing warranty service. Notice - Industrial Control Protocols Certain Industrial Control Protocols do not offer security protections at protocol level and may be exposed to additional Cybersecurity risk.
  • Page 41 10 Product Warranty physical security measures are an important layer of defense in such cases. The Xylem, e- HVX/e-HVXR systems are designed with the consideration that it would be deployed and operated in a physically secure location. • Xylem suggests that physical access to cabinets and/or enclosures containing and the associated system should be restricted, monitored and logged at all times.
  • Page 42 For more information on how Xylem can help you, go to www.xylem.com Xylem Inc. Visit our Web site for the latest version of this document and more information 2881 East Bayard Street Ext., Suite A...

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