INSTALLATION, OPERATING AND SERVICE MANUAL CITY BOSS
Contents
1. OPTIONAL PRESSURE TANK Not supplied with CITY BOSS Install pressure tank in line after the pressure booster system if reducing the amount of pump start ups is desired Use of a small pressure tank a k a expansion tank can SUBSTANTIALLY DELAY the pump start up For suggested tank size and air pre charge see page 4 Figure 2 Note Many local plumbing codes mandate backflow prevention The MASCONTROL pump controller has a built in check valve also Thermal expansion can cause pressure buildup in the closed hot water system causing relief valves to open Follow all local plumbing codes regarding use of an expansion tank PAGE 3 INSTALLATION ATTENTION Apply all safety rules dictated by professional standards Figure 1 WARNING Disconnect power before installing system FR Conduit Connections BEFORE MOUNTING THE MASCONTROL pump controller on the booster pump open the MASCONTROL s electronic box cover by removing the six screws refer to the MASCONTROL 4 LEVEL manual packaged with the pump controller Press the two rubber Flow arrows MASCONTROL pump controller grommets supplied into the 1 2 conduit connection holes located Electronic box on the side of MASCONTROL s electronic box A flat blade screw n i driver may be needed to help insert the grommets Liquid tight non metallic conduit fittings rated NEMA 12 or UL type 12 can be used not supplied to achieve NEMA type 12 enclosure rating Booster Pump 4 Use of met2. A Loess cos i Oon n Power on Fron on OFallure O Failure C Restart C Restart ower on n On OFallure OFallure B C POWER ON and PUMP ON lights on POWER ON light on FAILURE light off POWER ON light on FAILURE light off FAILURE light is off All taps closed and PUMP ON light short cycles on and PUMP ON light turns on and off several off Tap closed pump cycles on off times then turns off definitively and The top flow valve is obstructed by metal The bottom check valve is obstructed from FAILURE light comes on Tap closed sediment from pipe threads etc attaching closing properly by a small stone filament pump cycles a few times and then stops to the magnetic surface of the valve assem etc In this case the cycles are very fast definitively bly or by natural sediment such as small Disconnect the unit tap on stones lodging in the valve seat Open and MASCONTROL near the bottom check The diaphragm is compromised If a small close the tap quickly several times to re valve to free object and allow valve to seat drop of water appears at MASCONTROL move the sediment If problem still exist properly If this does not clear the obstruc safety valve on the end of the unit the dia the unit tap on tion rinse inner cavity with water dumping phragm has broken and unit must be re MASCONTROL near the top flow valve to out any sediment that may be present placed This condition is very r
3. Tap opened no no flow or no pressure boost pressure boost pump off Fig 13 el pump off Fig 17 The tap is open and the pump is not The column of water between Mascontrol operating Check the wiring in the electronic and the highest tap exceeds 70 feet therefore the column of water has created a pressure higher than the cut in pressure of Mascontrol 32 psi This prevents the box to make sure all wires are securely fastened to the proper terminals Also recheck voltage for correct application i 115V or 230V Press the restart button unit from working properly Reposition If all lights remain on and the pump still Mascontrol higher so the water column does not operate the electronic box has Figure 17 height is less than 70 feet failed and should be replaced PAGE 7 ower on n O Failure restart A pump runs continuously TOP FLOW VALVE DIAPHRAM aon K SETTERS SAFETY VALVE a M77 Mw ZY fee fli Z Le R Z y h o lh l Nnnn NN say Qoasseseene eos a A eo X f 3 JAN S ERAEN MONU X yi EH f J ee AALRREEERA RET ES EZEL Pr Se ae AJ Y A Pana WWW SITS SL ILLES OS PERERRRCECEN entail Tu Fe nt Se y oN e HF A A Vil Kc lt S annann A aa 7 aes S i ANS y a s aani N aS AN rig Ya SEE
4. The pump increases water pressure using an impeller located inside the pump body The impeller rotates with the motor shaft drawing water into its center opening Water exiting the impeller goes to discharge entering the pump controller This pump is NOT intended to lift water from a well Well pumps require a nozzle venturi device known as an injector or jet The booster pump included in the CITY BOSS system is not fitted with an injector The pump is only meant to boost incoming city water pressure MASCONTROL The MASCONTROL pump controller operates the pump within the pressure range of city supply pressure or 32 psi whichever is greater to the maximum operating pressure of the CITY BOSS system city supply pressure PLUS pump pressure boost The MASCONTROL pump controller allows the booster pump to provide constant boosted water pressure during operation to the service piping unlike the 20 psi differential cyclic pressure provided by a conventional pressure tank and switch system The MASCONTROL pump controller is equipped with an internal check valve spring loaded diaphragm pressure switch and a stainless steel flow switch After the CITY BOSS pressure booster system is installed and the start up procedure is completed the service piping will be pressurized to the maximum operating pressure When a service tap is opened service pressure will drop very quickly MASCONTROL has a factory calibrated non adjustable 32 psi re star
5. panel are off see Figure 5 NOW turn the power supply ON to the MASCONTROL Indicator lights will illuminate and pump will run see Figure 6 Re open faucet If the faucet is not open within approximately 8 seconds the MASCONTROL will simply shut off the pump Re open faucet in any case The green POWER ON light indicates the presence of power in the MASCONTROL the yellow PUMP ON light indicates that the pump is running see Figure 7 After the faucet is closed the pump will shut off after approximately 8 seconds and the MASCONTROL will go to the stand by mode with POWER ON light illuminated see Figure 8 The CITY BOSS water pressure booster system is correctly installed and ready to operate automatically Using the RESTART Button If water does not enter the pump and MASCONTROL the red FAILURE light will illuminate and the MASCONTROL will shut off the pump within 20 30 seconds This is the run dry protection feature preventing damage to the pumps internal components See Figure 9 After the water supply problem is corrected is a check valve installed backwards did you open valve to allow city water into booster system the RESTART button must be depressed and held in for a suitable length of time to allow pump to pressurize system thus overriding the run dry protection feature Do not override the circuit and run the pump until water supply is confirmed and no pump inlet line obstructions exist O Failure O Restart Figure
6. the pressure boost developed by the pump is a SAFE psi for the application s piping and fixtures If required a pressure reducing valve can be installed in line after the booster system to reduce water pressure to a safe level A pressure relief valve piped to a suitable drain is recommended for overall system protection Never install or service the pump or system without relieving the internal pressure 2 WARNING HAZARDOUS VOLTAGE Voltage can shock burn or cause death Install ground and wire pump and controller according to local and national electrical code requirements that apply The pump s single phase motor is equipped with automatic resetting thermal protection The motor may re start unexpectedly causing the leads to energize or pump to turn DISCONNECT ELECTRICAL POWER SUPPLY BEFORE INSTALLING OR SERVICING THE PUMP Capacitor voltage may be hazardous To discharge motor capacitor hold insulated handle screwdriver BY THE HANDLE and short the capacitor terminals together Do not touch metal screwdriver blade or capacitor terminals 3 Install the water pressure booster system according to all plumbing code requirements 4 Pump only water with this system Pump can be severely damaged if run dry The pump controller will detect a run dry condition and shut off the pump Do not pump water above 120 F due to internal pump components temperature limitations Do not allow pump pump controller piping or any other system componen
7. 5 Figure 6 Figure 7 Figure 8 Figure 9 TROUBLE SHOOTING NOTE The pump s single phase motor is equipped with automatic resetting thermal protection Constant cutting out of this overload device indicates a problem such as low voltage at the motor excessive temperature in a pump house etc This protection is separate and independent of the MASCONTROL pump controller The motor may re start unexpectedly causing the leads to energize or pump to turn WARNING DISCONNECT ELECTRICAL POWER SUPPLY BEFORE SERVICING THE SYSTEM WARNING RELIEVE INTERNAL WATER PRESSURE BEFORE SERVICING THE SYSTEM Although the MASCONTROL pump controller can be used with jet pumps on well systems the CITY BOSS pressure booster system pump provided is NOT intended to be used for wells The booster pump provided is meant to boost city water pressure PAGE 6 O Power On O Pump On O Failure O Restart Figure 10 Figure 11 Figure 13 TROUBLESHOOTING POWER ON PUMP ON and FAILURE POWER ON PUMP ON and FAILURE lights all off Tap opened no lights are all on Tap closed pump pressure boost pump off Fig 10 Failure on Fig 14 Power supply is on but no lights are lit O Restart The pump is operating and all taps are Turn off power supply to the Mascontrol and closed the electronic box has failed and remove the electronic box cover Check all must be replaced electrical connections to be certain they are tightly fastened t
8. Bulletin 1 SK50BOSS1 SK75BOSS125 32 PSI Effective FEB 2014 LANCASTER INSTALLATION OPERATING AND SERVICE MANUAL CITY BOSS RESIDENTIAL CITY WATER PRESSURE BOOSTER SYSTEM CITY BOSS is a city water pressure booster system utilizing the MASCONTROL pump controller and a single stage pressure booster pump The pump controller monitors both flow and pressure controlling the operation of the pump automatically The system maintains constant boosted water pressure during operation No pressure tank or switch required No adjustment or maintenance is needed CAREFULLY READ THE LITERATURE PROVIDED BEFORE INSTALLATION Familiarize yourself with the specific details regarding installation and use Leave this manual with the system for future reference LANCASTER PUMP RECOMMENDS A QUALIFIED PROFESSIONAL TO INSTALL THIS SYSTEM INSPECT THE SYSTEM COMPONENTS Occasionally products are damaged during shipment If a component is damaged contact the transportation company or your dealer Save the product s packing materials until the claim is settled The system package includes pump pump controller and rubber grommets For systems utilizing 174 MNPT pump controller pipe fittings are included to connect pump to pump controller SAFETY INSTRUCTIONS 1 WARNING HIGH PRESSURE The pump can boost to high pressure Verify the incoming water pressure BEFORE installing the booster system Make sure the incoming water pressure plus
9. allic conduit is not recommended Mounting MASCONTROL pump controller see Figure 1 The MASCONTROL may be mounted directly on the booster pump s outlet MASCONTROL must be mounted on a vertical column with the electronic box level and the flow direction arrows pointing upward Use only Teflon tape for threaded connections Do not install any tap between the pump and the MASCONTROL Detailed system installation diagram see Figure 2 Ball valve for system maintenance Figure 2 CITY BOSS Installation Diagram City Water Pressure Booster System Isolation Bypass Shown OPTIONAL Pressure Reducing Valve Install a PRV if incoming city pressure PLUS pump s maximum pressure boost exceeds SAFE service pressure If city pressure OPTIONAL flucuates use highest pressure reading and add pump s maximum Pressure pressure boost see chart below to arrive at total service pressure Tank Follow all local codes on maximum in house water pressure and OPTIONAL Pressure Gauge Relief Pressure Reducing a Total Service yae Isolating Ball Valve OPTIONAL Pressure Tank and Relief Valve To CITY BOSS provides on demand pump control Service Pressure Ball valve To prevent the pump from starting for small water Gauge for system uses such as ice makers glasses of water etc City maintenance install a 2 0 gallon gross volume pressure tank Union Gi AFTER the MASCONTROL and pressure reduci
10. are free object and allow valve to seat properly Reconnect the unit restore power and If this does not clear the obstruction rinse monitor for correct operation Although this inner cavity with water dumping out any condition is rare service persons and or sediment that may be present Reconnect installers should note the possibility of sedi the unit restore power and monitor for ment obstructions correct operation Although this condition is service persons and or should note the possibility of sediment ob installers LANCASTER PUMP A DIVISION OF C B TOOL 1340 Manheim Pike Lancaster PA 17601 3196 Tel 717 397 3521 Fax 717 392 0266 www lancasterpump com PAGE 8
11. ectronic box cover using the six screws upon completion of wiring the system If cover is not securely fastened RESTART button will not operate 115Vac NEUTRAL GROUND CIRCUIT BREAKER pod 7 GREEN OR FUSED DISCONNECT pee SWITCH C M N I MN Ka MN Pgs awe oO a a TO HOUSE spate MOTOR GROUND GREEN MASCONTROL NURON 66 MOTOR VOLTAGE SELECTOR SWITCH SET FOR 115V Figure 3 115VAC Single Phase Wiring Diagram 115Vac 115Vac GROUND GREEN TO HOUSE CIRCUIT BREAKER OR o FUSED DISCONNECT 0O SWITCH j lt GEcer MASCONTROL S NWAUOODNO s s s s s9 s 8 MOTOR VOLTAGE SELECTOR SWITCH SET FOR 230V Figure 4 230VAC Single Phase Wiring Diagram PAGE 5 START UP AND OPERATION After the booster system has been installed by following this manual s installation instructions and diagrams the city water supply can be released into the booster system filling the pump and MASCONTROL pump controller etc with water If a bypass line was also installed around the booster system the isolation valve should now be closed refer to Figure 2 BEFORE turning the power supply ON to the MASCONTROL pump controller open the faucet closest to the booster system so air can escape from the system After air has escaped the system and a steady flow of water occurs close faucet When the booster system is first installed all indicator lights on the MASCONTROL
12. ng Pressure valve if one is installed Adjust the pressure tank air pre charge to minimum 28 PSI slightly below the MASCONTROL 32 PSI calibrated re start pressure MASCONTROL do not exceed 20 PSI below total service pressure Pump Controller as set by the pressure reducing valve if installed The tank will feed small demands When the tank is emptied the MASCONTROL will start the pump Ea aw H and continue to supply constant pressure and flow E EHNA until the demand is stopped The small tank will NOT Minimum 3 4 pipe size cause pump cycling On larger homes 3 or more city main to pump inlet Valve bathrooms a 4 6 gallon gross volume tank may be Booster Pump used Pre charge as described above A pressure relief valve may be added as dictated by local code Minimum incoming city pressure CITY BOSS _ Booster MASCONTROL CITY BOSS Maximum Pressure Boost REQUIRED for CITY BOSS System Pump Pump Controller at 0 GPM flow Note 16 PSI 1 SK50BOSS1 1 SK50 1 BOSS1 39 PSI Remember that incoming city pressure plus CITY BOSS pressure boost 12 PSI 1 SK75BOSS125 1 SK75 1 BOSS125 43 PSI equals service pressure PAGE 4 Wiring the system Make sure you have read and understand the SAFETY INSTRUCTIONS concerning HAZARDOUS VOLTAGE and the ELECTRICAL CONNECTIONS portion of the PRE INSTALLATION section in this manual before proceeding Refer to Figures 3 amp 4 for wiring diagrams Replace MASCONTROL s el
13. o the proper terminals for the voltage needed 115V or 230V Refer to the schematic in the electronic box If all electrical connections are secure and correct test electrical terminals with meter O Failure to ensure power is present at all terminals If power is at the terminals the on and off Fig 15 electronic box has failed and must be 1 Leakage less than 0 21 gpm may be replaced power must be on to unit to test O Failure present in piping The higher the leakage terminals O Restart rate but less than 0 21 gpm the faster the pump cycles Make sure all taps are closed and all toilet valves are functioning properly After tap inspection check all piping and Figure 15 valves connected to the system for leakage POWER ON light on FAILURE light off and PUMP ON light short cycles on and off Tap closed pump cycles POWER ON and FAILURE light on PUMP ON light is off Tap opened no pressure boost pump off Fig 11 To help determine leak location close the The unit has detected one of the following shut off valve after the Mascontrol If pump 1 Loss of suction check water supply cycling stops leak is located after the Mas 2 Blockage in pipe from water supply to control in the water supply Shut off power to pump and Mascontrol remove blockage Mascontrol and locate and fix leak Restore 3 If a pump has a thermal protection power to Mascontrol Mascontrol will start switch check to make sure the switch has the p
14. r is lost MASCONTROL will reset and restart automatically when power is restored MASCONTROL is not adjustable and does not require maintenance Note Maximum operating pressure city supply pressure PLUS pump pressure boost at close off service taps closed cannot be less than 55 psi Note The column of water between MASCONTROL and the highest service tap must NOT EXCEED 70 feet If the column of water above MASCONTROL exceeds 70 feet reposition MASCONTROL higher so the water column is less than 70 feet MOTOR The booster pump s motor is a single phase capacitor start open drip proof type with a 14 3 SJTW cord set attached for connection to the pump controller The motor bearings are permanently lubricated therefore no maintenance is required The motor is a dual voltage design utilizing a voltage selector switch in its rear housing Use this switch to match the motor voltage setting with the power supply line voltage OPTIONAL PRESSURE REDUCING VALVE PRV Not supplied with CITY BOSS Install PRV in line after the pressure booster system if city supply pressure PLUS pump pressure boost exceeds SAFE service pressure Follow PRV manufacturer s instructions regarding installation and adjustment If PRV adjustment is necessary Lancaster Pump suggests this is done accurately with the use of a pressure gauge while the booster pump is running with only the closest service tap open allowing only 2 to 3 GPM flow See page 4 Figure 2
15. t below the freeze line Remember the pump controller has an internal check valve and will not drain through Lancaster Pump recommends installing unions or slip couplings on the inlet side of pump and discharge side of pump controller for ease of disconnecting booster system for service or to protect from freezing ELECTRICAL CONNECTIONS Wiring to this booster system must be installed and maintained in accordance with both the National Electrical Code and state local codes Make sure motor voltage rating matches available power supply See the motor nameplate Dual voltage motors have a label on them that identifies the factory pre wired voltage If needed the motor voltage is changed inside the motor cover See the motor nameplate for instruction Make sure the breaker or disconnect is OFF before entering the motor cover VOLTAGE CHANGE SWITCH LOCATED INSIDE REAR END OF MOTOR REMOVE MOTOR COVER TO ACCESS SWITCH VOLTAGE CONNECTION MUST MATCH POWER SUPPLY VOLTAGE 0 CONNECTION SHOWN FOR 230 V TO CHANGE TO 115 V SLIDE SWITCH UP TO SHOW 115 aa aa Properly sized copper wire from service to pump controller will avoid over heating wire and excessive voltage drop at the motor Pump controller should be connected to a separate branch circuit with no other appliances on it Consult dealer or electrician PAGE 2 HOW IT WORKS UNDERSTAND THE SYSTEMS MAJOR COMPONENTS AND THEIR FUNCTIONS BOOSTER PUMP
16. t pressure as indicated on the rear of the device If city supply pressure is less than 32 psi MASCONTROL s internal pressure switch will start the booster pump when service pressure drops to 32 psi If city supply pressure is greater than 32 psi MASCONTROL s internal flow switch will start the booster pump when service pressure drops to city supply pressure MASCONTROL will keep the booster pump running to provide constant boosted water pressure until all service taps are closed After the service taps are closed MASCONTROL will continue running the booster pump for approximately 8 seconds before shutting off to avoid quick cycling The CITY BOSS booster system is on standby until water is again demanded at the service tap If all service taps are closed and the booster pump does not shut off after approximately 8 seconds the MASCONTROL s internal flow switch may be detecting leakage in the service piping greater than 0 21 GPM the value of the minimum flow below which the flow switch stops the booster pump MASCONTROL will protect the booster pump from damage if the city supply piping to the booster pump inlet is dry or blocked MASCONTROL will detect irregular city water supply conditions and shut off the booster pump The red Failure light will be on After the problem is corrected the user needs only to press and hold the red Restart button for 3 to 5 seconds with a service tap opened to restore normal operation If powe
17. t to freeze Freezing may damage system leading to injury or flood 5 Pipe joint compound can cause cracking in plastics Use only Teflon tape when sealing threaded plastic pipe or connecting pipe to plastic components such as the pump controller PAGE 1 PRE INSTALLATION PREPARATION MAKE SURE YOU HAVE READ THE SAFETY INSTRUCTIONS PRECEEDING THIS SECTION LOCATION The water pressure booster system pump and pump controller should be installed in any convenient location that provides sufficient space for installation and servicing A clean dry basement or utility room to avoid dampness and temperature extremes are excellent choices when allowed by law Check with state and local agencies to determine restrictions in your area A pressure relief valve piped to a suitable drain is recommended for overall system protection PIPE CONNECTIONS Always follow state and local plumbing codes Lancaster Pump does not sell or specify pipe types or materials consult with your pipe supplier to determine the best pipe for your installation Use Teflon tape on male threads of plastic pipe Do not use pipe joint compound on plastic piping because it will damage piping crack over time Use minimum pipe size to the pump inlet Provide a drain cock at a low point in the service line for draining the system If the booster system is inactive for any length of time it is advisable to completely drain the system to prevent freezing Drain all piping to a poin
18. ump automatically and monitor system not been tripped by the pump If pump has to determine that leak has been corrected been switched off due to the thermal switch 2 If pump cycling still occurs after closing check pump for proper operation and the shut off valve behind Mascontrol the condition and reset thermal switch Press bottom check valve is obstructed from restart button on Mascontrol Pump should closing properly start up 4 The pump capacitor has failed or is not adequate POWER ON and PUMP ON light on 5 Electronic box failed replace box rare FAILURE light off All taps closed occurrence O Failure Paes pump runs continuously Fig 16 1 The condition may be similar to condition 1 Fig 15 above but leak flow rate is greater than 0 21 gpm In this case the leak simulates an open tap condition Follow instructions for condition 1 figure 15 above 2 The top flow valve to the Mascontrol is POWER ON and FAILURE light on PUMP ON light is off Tap closed pump off Fig 12 1 Pump cannot attain at least 55 psi incoming psi boost at close off check pump pressure reading with pressure gauge Pump must be able to attain at least Figure 16 Sa MA box has failed and should 55 psi to work properly with Mascontrol unit S 2 Electronic box failure replace box rare be replaced occurrence POWER ON light on PUMP ON and POWER ON PUMP ON and FAILURE qA FAILURE light off Tap open lights are all on
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