Amtrol DC2 User Guide

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GUARDIAN CP® DIGITAL CONTROL

FOR WELL PUMP & BOOSTER SYSTEMS

INSTALLATION & OPERATION INSTRUCTIONS

Model DC2

INSTALLER: LEAVE THIS MANUAL WITH HOMEOWNER.

Your Guardian CP DIGITAL CONTROL has been carefully assembled and factory tested. To enjoy the full service this unit can provide, you should read and follow all of the instructions in this manual. When all installation steps have been completed, make sure you also follow the startup, adjustment and operation instructions before using your AMTROL product. You should also read carefully the section describing proper product maintenance and follow the required procedures as you use your Guardian CP DIGITAL CONTROL. Keep this manual with the product. This manual may become out-of-date by later amendments. Check our web site, www.amtrol.com or ask your AMTROL supplier for any updates relating to your product.

NOTE: Inspect for shipping damage. Notify freight carrier or store where purchased immediately if damage is present. To avoid risk of personal injury and property damage, if the product appears to be malfunctioning or shows signs of corrosion, call a qualified professional immediately. Current copies of the product manual can be viewed at www.amtrol.com. Use proper safety equipment when installing.

THIS IS THE SAFETY ALERT SYMBOL. IT IS USED TO ALERT YOU TO POTENTIAL PERSONAL INJURY AND OTHER HAZARDS. OBEY ALL SAFETY MESSAGES THAT FOLLOW THIS

SYMBOL TO REDUCE THE RISK OF PERSONAL INJURY AS WELL AS PROPERTY DAMAGE

READ CAREFULLY THE

OPERATION INSTRUCTIONS. FAILURE TO FOLLOW THE INSTRUCTIONS AND WARNINGS IN THE MANUAL MAY RESULT IN SERIOUS OR FATAL INJURY AND/OR PROPERTY DAMAGE, AND WILL VOID THE PRODUCT WARRANTY. THIS PRODUCT MUST BE INSTALLED BY A QUALIFIED PROFESSIONAL. FOLLOW ALL APPLICABLE LOCAL AND STATE CODES AND REGULATIONS. IN THE ABSENCE OF SUCH CODES, FOLLOW THE CURRENT EDITIONS OF THE NATIONAL PLUMBING CODE AND NATIONAL ELECTRIC CODE, AS APPLICABLE.

under pressure, which may over time corrode, weaken and burst or explode, causing serious or fatal personal injury, leaking or flooding and/or property damage. To minimize risk, a licensed professional must install and periodically inspect and service the product and system. A drip pan connected to an adequate drain must be installed if leaking or flooding could cause property damage. Do not locate system in an area where leaking could cause property damage.

exceed the limitations of system components. Never set the operating pressure higher than that of the safe system capacity.

PRODUCT INSTALLATION &

This product is used in conjunction

with a system containing a tank

This control is capable of running

pumps to pressures that may

This control can be adjusted to a

narrow pressure differential. An

improperly sized tank can cause the pump to cycle and lead to pump damage. This may require a larger pressure tank than is normally used.

ELECTROCUTION HAZARD. Must

First disconnect all electrical power before attempting service. For your safety, the installation and operation instructions must be followed to minimize the risk of electric shock, property damage or personal injury.

equipment. The water quality can significantly influence the life of your system. You should test for corrosive elements, acidity, total solids and other relevant contaminants, including chlorine and treat your water appropriately to insure satisfactory performance and prevent premature failure.

required by state and federal codes.

installed to prevent pressure in excess of local code requirement or maximum working pressure designated in the product manual, whichever is less. Do not expose system to freezing temperatures or temperatures in excess of 120°. Failure to properly size the system or follow instructions in the manual may result in excessive strain on the system and may lead to product failure, leakage, flooding and/or property damage.

be installed by a qualified professional.

A water test must be taken before

installation of any water treatment

Use only lead-free solder and flux for

all sweat-solder connections, as

EXPLOSION OR RUPTURE

HAZARD! A relief valve must be

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PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY FOR IMPORTANT

GENERAL SAFETY INFORMATION AND ADDITIONAL SPECIFIC SAFETY ALERTS.

UNIT MUST BE INSTALLED BY A QUALIFIED PROFESSIONAL.

Pre-Installation

DANGER! EXPLOSION HAZARD.

When the well tank has been in service and a change to a higher pre-charge pressure is necessary due to a required change in the pressure switch setting, failure to follow instructions below can cause a rupture or explosion, possibly causing serious or fatal personal injury and/or property damage.

•

Do not adjust or add pressure if there has been a loss of air.

•Donot adjust the pre-charge pressureifthereis visible

exterior corrosion.

•Donotadjust thepre-charge pressureif therehas been

a reduction of the pump cycle time or the pre-charge pressure compared to its initial setting. This is because a reduction in pump cycle time can result from loss of tank air pressure which can mean there may be internal corrosion. Any re-pressurization or additional pressure could result in rupture or explosion.

•Do not use with components or materials that are

incompatible with the Guardian CP.

Plumbing Connection

1. The Guardian CP should be mounted as close as

possible to the pressure tank.

LOCATE THE GUARDIAN CP

CODES. DO NOT LOCATE THE UNIT WHERE IT CAN BE AFFECTED BY FLOODING.

2. You may assemble the Guardian CP to a “Tank Tee” or

“Tank Cross” (Figure 1) or adapt the unit to an in-line pipe fitting (Figure 2). Use pipe sealing tape or pipe sealant. Tighten the Guardian CP using the wrench flats provided on the bottom connection. DO NOT EXCEED 15 LB./FT. of torque.

NOTE: Do not allow pipe sealant or other contaminants to enter the small port in the Guardian CP connection.

NOTE: A mechanical pressure gauge is not required. Use the appropriate plug to block any unused ports.

FOLLOWING ALL LOCAL

Electrical Connection

ELECTRICAL POWER BEFORE SERVICING.

ELECTRICALLY GROUNDED.

NOTE:

The Guardian CP will operate on 115 VAC & 230 VAC

systems. Its ambient air temperature rating is 122°F / 50°C.

NOTE: The Guardian CP has openings to accept standard conduit terminations. Outdoor installations must use watertight connections.

1. Disconnect power and verify with a volt meter.

2. Determine the pump electrical requirements. If unknown, contact the pump manufacturer.

3. Select the appropriate wire gauge per local codes and the pump manufacturer’s recommendation.

4. Loosen the screw on the cover of the controller and remove the plastic cover, exposing the wiring leads. (When reassembling cover, do not over-tighten screw.)

5. The wire conduit hub is to be connected to the conduit before the hub is connected to the enclosure. The maximum hub diameter cannot exceed 1.15" (1 Larger hub will interfere with cover closure.

6. The opening of the enclosure shall be closed with hubs rated 3, 3S, 3SX, 3X, 4, 4X, 6 or 6P.

NOTE:

Steps 5 and 6 are required for outdoor installations only.

7. Following all electrical codes, wire the Guardian CP using the appropriate wiring diagram (Figure 3).

ELECTRICAL CONDUIT.

USED WHEN EXPOSED TO DIRECT WEATHER, MOISTURE OR HIGH HUMIDITY.

CONDUCTOR (EMT, RMC, IMC, ETC): BONDING BETWEEN AUTOMATIC AND MUST BE PROVIDED AS PART OF THE INSTALLATION. A BONDING KIT CAN BE ORDERED SEPARATELY.

Figure 2. In-Line InstallationFigure 1. Typical Tank Tee Installation

ELECTROCUTION HAZARD. FIRST DISCONNECT ALL

ELECTROCUTION HAZARD.

THE Guardian CP MUST BE

UNIT MUST NOT BE

SUPPORTED SOLELY BY THE

WATERTIGHT CONDUIT CONNECTIONS MUST BE

SYSTEMS WITH METALLIC CONDUIT AS GROUNDING

CONDUIT CONNECTIONS IS NOT

ELECTRICAL

/20").

1/4˝

NPTF

Drain Valve

Pipe

Nipple

Guardian CP

Relief Valve

Plug

1/4˝

NPTF

Tee

Relief Valve

Guardian CP

Pipe Nipple Adapt as necessary

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Figure 3. Basic Wiring

L1 L2 L3

GUARDIAN CP

TO MOTOR

CONTACTS

FUSES

BLACK

BLUE

WHITE

WHITE/STRIPE

COIL

3-PHASE CONTROL BOX

LINE

LOAD

LINE

LOAD

BLACK

BLUE

WHITE

WHITE /STRIPE

TYPICAL WIRING

CONNECTIONS

115/230 VAC

BLUE

WHITE

WHITE/STRIPE

PUMP MOTOR OR

CONTROL BOX

BLACK

Startup

BEFORE CONTINUING, CHECK

FOR OPEN DRAIN VALVES OR

OTHER SOURCES OF FLOODING BEFORE STARTING UNIT.

1. Prime pump if necessary and adjust tank precharge to manufacturer’s recommendation for intended pressure range. The factory Guardian CP® setting is 40 psi cut-in and 60 psi cut-out.

2. Turn on power and ensure Guardian CP display illuminates, “88” will appear, then code revision number, then “00”. Display will blank momentarily and the pump will start. If not, check installation.

3. The display will now read the current line pressure.

4. Allow the pump to reach the factory cut-off setting of 60 psi. IF THE PUMP CANNOT REACH THIS SETTING, DISCONNECT POWER AND SEE THE TROUBLESHOOTING SECTION.

5. Check for leaks and repair as necessary before proceeding.

6. Proceed to the ADJUSTMENT section.

NOTE: During the first 30 seconds after start up, the pump can be made to operate manually by depressing the 5 arrow for 6 seconds. This is useful for priming jet pumps.

Adjustment

NOTE: Differential pressure cannot exceed 55 psi or be

less than 10 psi. If display will not change, alter cut-in or cut-out to within 55 psi.

1. Press and hold  until “LO” appears, then release.

2. When number appears, tap 5 or 6 to change

3. Press  again. When “HI” appears, tap 5 or 6 to

This will determine the pressure at which the pump activates.

cut-in setting.

change cut-out setting. This will determine the pressure at which the pump shuts off.

L2 YBR

TO MOTOR

GUARDIAN CP

BLACK

BLUE

WHITE

LINE IN

WHITE/STRIPE

NOTE: Press  a third time to display the last Error Code in memory (see Error Code table). If no errors have occurred, the display will show “- -”.

4. After approx. 10 seconds “Pr” will appear, indicating the settings are programmed. Display will then revert to line pressure.

NOTE: Settings will be stored until changed manually, even if there is a power failure. NOTE: If pump cannot reach cut-out setting within 5 minutes with no water running, lower the pressure settings to fall within the pump’s pressure capabilities. NOTE: Pressing 5 6 together for 3 seconds will rotate the screen 180 degrees for easier viewing.

Operation

The Guardian CP incorporates built-in diagnostic functions to protect the system and alert the user or installer to potential problems. If a fault is found, an error code will be displayed, indicating that service may be necessary. Error codes are listed in the Error Codes section.

Maintenance

A professional plumber should check the complete system, including the Guardian CP, yearly and more frequently as the system ages.

Warranty

Guardian CP Model DC2: Two (2) Year Limited Warranty Unit contains no serviceable parts. Removal of main circuit board cover will void warranty.

Visit www.amtrol.com for complete warranty details.

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Troubleshooting

Problem Cause Solution

Display will not illuminate.

HI or LO setting will not change.

Pump will not reach cut-out (HI).

Pump rapid cycles.

Pump will not start.

Water flow stops before cut-in.

Display reads upside-down. Mounting position may vary.

No power.

Improper wiring.

Improper voltage. Differential attempted is below 10 psi

or above 55 psi.

Minimum cut-in reached.

Maximum cut-out reached. HI setting greater than pump rating.

Insufficient prime (above ground pumps).

No water to pump.

Pump or line blockage.

Fixture open or leak in plumbing. Pressure tank too small.

Differential too narrow.

Waterlogged pressure tank.

Improper tank air charge.

Improper wiring. No power.

Guardian CP error encountered.

Faulty pump.

Improper wiring

Tank precharge too high. Adjust precharge per manufacturer’s instruction.

(Guardian CP or pump).

Check circuit breaker and wiring connection.

Check polarity and wiring.

Ensure voltage is 115V or 230V. Differential cannot be less than 10 psi or greater

than 55 psi. Adjust as necessary.

LO cannot be set below 10 psi.

HI cannot be set above 80 psi. Reduce HI setting to within pump capability.

Prime pump as directed by manufacturer - use manual operation mode.

Check shutoff valves.

Remove obstructions.

Determine cause of water flow and remedy. Size tank per manufacturer’s literature.

Spread range via HI or LO setting.

Replace tank.

Charge as instructed by manufacturer.

Check proper wiring to “line in”, L1 & L2. Check circuit breaker and wiring connections.

See error chart below.

Contact pump manufacturer.

Check wiring per manufacturer’s instructions.

Press 5 6 together for 3 seconds and screen will rotate 180 degrees.

Error Codes

Code

To reset switch at any time: Press 5  6 buttons simultaneously for 5 seconds.

Reason Action Solution

See

Rapid cycle.

Excessive amp draw.

Low water cut-off.

Running pressure below 10 PSI.

Improper voltage.

Electrical disturbance. Pump shuts off.

1400 Division Road, West Warwick, RI USA 02893

T: 800.426.8765 F: 800.293.1519

Pump continues to operate.

Pump shuts off.

Auto restart after 60 min.

Pump shuts off. Auto restart when voltage

connected.

www.amtrol.com

“Pump Rapid Cycles” above.

Have pump checked for proper operation.

(A) Determine cause of low-suction

(B) Check Wiring

(C) Inspect pump Restore voltage to proper range. Unit will monitor voltage until it returns to normal. Pump will restart automatically. Disconnect power for one

minute to reset. If error persists, contact Amtrol Technical Support.