Franklin 5870206300 User Manual

Constant Pressure Water System

SubDrive300

Installation Manual

Contents

Description and Features ................................................................................4

Included Items ..................................................................................................5

How It Works .....................................................................................................6

Pump Sizing and Drive Confi guration ............................................................8

Underload Sensitivity for Shallow Wells ........................................................9

Before Getting Started ...................................................................................10

Controller Location Selection ................................................................. 11-12

Circuit Breaker and Wire Sizing ....................................................................13

Quick Reference Guide ............................................................................ 14-15

Pressure Tank .................................................................................................16

Installation Procedure ....................................................................................17

Wiring Connections .................................................................................. 18-20

Start-Up and Operation .................................................................................21

Specifi cations .................................................................................................22

Mounting Dimensions ....................................................................................23

Diagnostic Fault Codes ..................................................................................24

System Troubleshooting Guide .....................................................................25

Underload Smart Reset .................................................................................26

Over Temperature Foldback ..........................................................................26

Tables

1. SubDrive Models .......................................................................................3

2. Breaker Size and Maximum Cable Length ...........................................13

3. Minimum Pressure Tank Size .................................................................16

4. Pressure Tank Precharge .......................................................................16

2

Figures

1. Shipping and Mounting Screws .............................................................17

2. Motor Lead Connections .......................................................................18

3. Power and Pressure Sensor Connections ............................................19

4. Pressure Sensor ......................................................................................20

5. Underload “Smart Reset” Well Recovery Time ....................................26

Table 1: SubDrive Models

Model Name Part Number Use with Motor Series

SubDrive300 5870206300 (NEMA 4) 234 317 xxxx (5.0 Hp)

3

Description and Features

The Franklin Electric SubDrive300 is a dependable residential and light
commercial water system controller that uses advanced electronics to
enhance the performance of standard submersible pumps. When used with
the specifi ed Franklin Electric motor (see Table 1), the SubDrive eliminates
pressure cycling associated with conventional water well systems and
owners of private water well systems can enjoy “city-like” water pressure.

In addition, the reduced tank size (see Table 3) allows installation in small
spaces. Key features of the SubDrive include:

4

• Constant water pressure with a wide range of settings (25-80 psi)

• Smaller pressure tank can be used

• Fits the pump to the application – pump speed is controlled to
provide the optimum performance without overloading the motor

• Flexibility – you can use this unit with standard off-the-shelf pumps

• No in-rush (power-on transient) current

• Low motor start-up current (soft-starting)

• Active Power Factor Correction minimizes input RMS current

• Protection features

- Dry well conditions – using smart pump monitoring (see Page 26)

- Bound pump – with auto-reversing torque

- High voltage / lightning surge

- Low line voltage

- Open motor circuit

- Short circuit

Included Items

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A. Controller Unit
B. Strain Relief Fittings
C. Pressure Shut-off
Sensor and Boot
D. Pressure Sensor and Boot

G

E. Sensor Adjustment Tool
F. Sensor Cable
G. Installation Manual
H. Installation Guide
I. Warranty Card

H

5

How It Works

The Franklin Electric SubDrive300 is designed to be part of a system that
consists of only four components:

A. Standard Pump and Franklin Electric Motor.
B. SubDrive Controller.
C. Small Pressure Tank (for tank size, see Table 3).
D. Franklin Electric Pressure Sensor (provided).
E. Franklin Electric Pressure Shut-Off Sensor (provided).

B

Pressure

C

Sensor
Leads

Pressure
Shut-o
Sensor
Leads

DE

Pressure
Relief Valve

PUMP

Power Supply
From Circuit Breaker

Constant Pressure

The Franklin Electric SubDrive300 provides consistent pressure regulation
using advanced electronics to drive a standard motor and pump according
to the pressure demands indicated by a highly accurate, heavy-duty,
long-life pressure sensor. By adjusting the motor/pump speed, the
SubDrive300 can deliver constant pressure dependably, even as water
demand changes. For example, a small demand on the system, such as
a bathroom faucet, results in the motor/pump running at a relatively low
speed. As greater demands are placed on the system, such as opening
additional faucets or using appliances, the speed increases accordingly to
maintain the desired system pressure.

MOTOR

6

Motor Soft Start

Normally, when there is a demand for water, the SubDrive300 will
be operating to accurately maintain system pressure. Whenever the
SubDrive300 detects that water is being used, the controller always “ramps
up” the motor speed while gradually increasing voltage, resulting in a cooler
motor and lower start-up current compared to conventional water systems.
In those cases where the demand for water is small, the system may cycle
on and off at low speed. Due to the controller’s soft-start feature and
sensor’s robust design, this will not harm the motor or the pressure sensor.

System Diagnostics

In addition to regulating pump pressure and accurately controlling motor
operation, the SubDrive300 continuously monitors system performance and
can detect a variety of abnormal conditions. In many cases, the controller
will compensate as needed to maintain continuous system operation. But
if there is high risk of equipment damage, the controller will protect the
system and display the fault condition. If possible, the controller will try to
restart itself when the fault condition subsides.

Unique Features

SubDrive controllers provide the ultimate in system performance, utilizing
Franklin Electric’s three-phase motor series for maximum starting torque,
high effi ciency and smooth operation. SubDrives convert residential single-
phase 60Hz power into the variable-frequency three-phase needed by the
motor. In addition, SubDrives can spin a smaller pump slightly faster to
boost output to roughly double its 60Hz horsepower rating. This allows use
of smaller pumps for less system cost. If a smaller pump of the desired fl ow
rating is not available, the controller can be confi gured to use larger pumps
up to the horsepower rating of the motor.

7

Pump Sizing

The SubDrive300 is confi gured at the factory for use with 3 Hp pumps that
are mounted to 5 Hp Franklin Electric three-phase motors. In general, the

SubDrive300 will enhance the performance of a 3 Hp pump to a similar
or better performance than a conventional 5 Hp pump of the same
fl owrating (pump series).

To select the proper 3 Hp
pump, fi rst choose a 5 Hp
curve that meets the
application’s head and fl ow
requirements. Use the 3 Hp
pump in the same pump
series (fl ow rating). The
SubDrive300 will adjust the
speed of this pump to
produce the performance
of the 5 Hp curve. An
example of this is
illustrated in the graph at right.

Typical SubDrive300 Performance

700

600

500

400

300

Total Head (ft)

200

100

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Flow GPM

Drive Confi guration

The SubDrive300 can also be set up to run a 5 Hp pump if desired, but the
larger pump will still produce to the 5 Hp curve and may only be operated
with a 5 Hp motor. To operate a different pump size, a DIP switch must be
positioned to select the correct pump rating. Otherwise, the SubDrive300
may trigger erroneous faults.

To confi gure the SubDrive300
for a 5 Hp pump, locate the DIP
switch marked “SW1” at the
lower right corner of the main
circuit board. Use a small
screwdriver (provided)
to change the DIP switch
setting according to the chart
as shown.

SW1

N

O

Configuration Switch

1 Pump Size

OFF 3.0 Hp
ON 5.0 Hp

8

!

▲ WARNING

Serious or fatal electrical shock may result from contact with internal
electrical components. DO NOT, under any circumstances, attempt
to modify DIP switch settings until power has been removed and 5
minutes have passed for internal voltages to discharge!

Underload Sensitivity for
Shallow Wells

The SubDrive300 controller is confi gured at the factory to ensure detection
of Underload faults in a wide variety of pumping applications. In rare cases
(as with certain pumps in shallow wells) this trip level may result in nuisance
faults. If the pump is installed in a shallow well, activate the controller and
observe system behavior. Once the controller begins to regulate pressure,
check operation at several fl ow rates to make sure the default sensitivity
does not induce nuisance Underload trips.

If it becomes necessary to desensitize the Underload trip level, remove
power and allow the controller to discharge. Once the internal voltages have
dissipated, locate the DIP switch marked “SW1” at the lower right corner
of the main circuit board. Use a small screwdriver (provided) to change
Position 3 to the “ON” position to select the lower Underload sensitivity as
shown in the chart below.

Configuration Switch

POS Underload Sensitivity

SW1

N

O

!

▲ WARNING

Serious or fatal electrical shock may result from contact with internal
electrical components. DO NOT, under any circumstances, attempt
to modify DIP switch settings until power has been removed and 5
minutes have passed for internal voltages to discharge!

3 OFF Normal (default)

ON Low (shallow wells)

9