Pentair 4-100, 4-160 User Manual

IntelliFlo® 4/160 and 4/100

Variable Speed Programmable Pump

(Compatible with IntelliTouch

™

, EasyTouch™ and IntelliComm)

AUTO HEATER
SPA 100°F / 95°F
AIR 70°F
MON 09:30 AM

Installation and

User’s Guide

IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS

Customer Support

Sanford, North Carolina (8 A.M. to 5 P.M.)

Phone: [phone]

Moorpark, California (8 A.M. to 5 P.M.)

Phone: [phone] (Ext. 6312)

Fax [phone]

Web sites: visit www.pentairpool.com and staritepool.com

© 2006 Pentair Water Pool and Spa, Inc. All rights reserved

This document is subject to change without notice

1620 Hawkins Ave., Sanford, NC 27330 • [phone]
10951 West Los Angeles Ave., Moorpark, CA 93021 • [phone]

Trademarks and disclaimers: EasyTouch, IntelliChlor, IntelliFlo, QuickTouch and the Pentair Water Pool and Spa
logo are trademarks of Pentair Water Pool and Spa, Inc. Other trademarks and trade names may be used in this
document to refer to either the entities claiming the marks and names or their products. Pentair Water Pool and Spa,
Inc. disclaims proprietary interest in marks and names of others.

P/N 357269 Rev B - 02/15/2006

Contents

Important Safety Precautions ........................................................................................... ii

Section 1: IntelliFlo Overview ........................................................................................... 1

IntelliFlo 4 Variable Speed Pump .......................................................................................... 1

IntelliFlo 4 models ................................................................................................................. 1

External Control.................................................................................................................... 1

Features ............................................................................................................................... 2

IntelliFlo 4 Motor Assembly .................................................................................................. 2

IntelliFlo 4 Drive Assembly and Control Panel ...................................................................... 3

IntelliFlo 4 Operator Control Panel........................................................................................ 4

Controls and LEDs ..........................................................................................................4

Section 2: Operating IntelliFlo 4........................................................................................ 5

Setting the pump preset speed ............................................................................................. 5

Adjusting the pump speed .................................................................................................... 5

Starting the pump ................................................................................................................. 6

Stopping the pump ................................................................................................................ 6

Resetting the pump to factory defaults ................................................................................. 6

Assigning a pump address for remote control ...................................................................... 6

Priming the pump for the first time or after service ............................................................... 7

Priming the Pump ............................................................................................................. 8

External Control with IntelliComm Communication Center ................................................... 9

External Control Connection ............................................................................................ 9

Connecting IntelliFlo 4 to an EasyTouch System ................................................................ 10

Connecting IntelliFlo 4 to an IntelliTouch System ................................................................ 13

Section 3: User Maintenance ............................................................................................ 15

Pump Strainer Basket ......................................................................................................... 15

Pump Strainer Basket Service ............................................................................................ 15

Motor Service ...................................................................................................................... 16

Winterizing ........................................................................................................................... 17

Priming the pump after service ............................................................................................ 17

Section 4: Installation and Removal ................................................................................ 19

IntelliFlo 4 Kit Contents ........................................................................................................ 19

Installing IntelliFlo 4 ............................................................................................................. 19

Location ............................................................................................................................... 19

Piping ................................................................................................................................. 19

Check Valve ........................................................................................................................ 19

Wiring the IntelliFlo 4 ........................................................................................................... 20

Pump Disassembly ............................................................................................................. 21

Pump Reassembly/Seal Replacement ................................................................................ 22

Shaft Seal Replacement ...................................................................................................... 22

Drive Assembly Removal and Installation ........................................................................... 23

Illustrated Parts List ............................................................................................................. 24

IntelliFlo Pump Dimensions ................................................................................................. 25

IntelliFlo Flow and Power vs Flow Pump Curve .................................................................. 25

IntelliFlo 4 Electrical Specifications ..................................................................................... 25

Section 5: Troubleshooting .............................................................................................. 27

Warning and Alarm LED conditions ..................................................................................... 27

Alarm and warning LED sequence ...................................................................................... 27

General IntelliFlo 4 Troubleshooting Problems ..................................................................... 28

i

IntelliFlo 4 Installation and User’s Guide

ii

IMPORTANT SAFETY PRECAUTIONS

Important Notice:

Attention Installer: This manual contains important information about the installation, operation and safe use

of this product. This information should be given to the owner and/or operator of this equipment.

WARNING — Before installing this product, read and follow all warning notices and instructions which

are included. Failure to follow safety warnings and instructions can result in severe injury,
death, or property damage. Call [phone] for additional free copies of these
instructions.

WARNING — Entrapment Avoidance Notice:

The suction outlet connected to a swimming pool or spa pump can pull a high vacuum
if it is blocked. Therefore, if only one suction outlet smaller than 18" x 23" is used,
anyone blocking the suction outlet with their body can be trapped and held against the
suction outlet. Disembowelment or drowning can result. Therefore, if small suction
outlets are used with this pump, to prevent this entrapment and possible death, install
at least two suction outlets in the body of water. Separate these suction outlets as
described in the International Residential Code (IRC), the International Business Code
(IBC), the Consumer Products Safety Council (CPSC) Guidelines for Entrapment Hazards:
Making Pools and Spas Safer or ANSI/IAF-7 Standard for Suction Entrapment Avoidance
in Swimming Pools, Wading Pools, Spas, Hot Tubs and Catch Basins. If suction outlets
are not used, additional entrapment avoidance measures as described in the CPSC
Guidelines or ANSI/IAF-7 should be employed.

The covers used on suction outlets should be approved and listed as conforming to the
currently published edition of ANSI/ASME A112.19.8 Standard covering Suction Fittings
for Use in Swimming Pools, Wading Pools, Spas and Hot Tubs. These covers should be
inspected regularly and replaced if cracked, broken or older than the design lifetime
indicated on them by the manufacturer. The maximum possible flow rate of this pump
should be less than or equal to the maximum approved flow rate indicated on the suction
outlet cover by the manufacturer. THE USE OF UNAPPROVED COVERS OR ALLOWING
USE OF THE POOL OR SPA WHEN COVERS ARE CRACKED OR BROKEN CAN
RESULT IN HAIR ENTANGLEMENT WHICH CAN RESULT IN DEATH.

WARNING — Risk of electrical shock or electrocution.

This pool pump must be installed by a licensed or certified electrician or a qualified pool
serviceman in accordance with the National Electrical Code and all applicable local codes
and ordinances. Improper installation will create an electrical hazard which could result in
death or serious injury to pool users, installers, or others due to electrical shock, and may
also cause damage to property.

Always disconnect power to the pool pump at the circuit breaker before servicing the
pump. Failure to do so could result in death or serious injury to serviceman, pool users

or others due to electric shock.

IntelliFlo 4 Installation and User’s Guide

IMPORTANT SAFETY PRECAUTIONS (continued)

WARNING — Water temperature in excess of 100° Fahrenheit may be hazardous to your health. Prolonged

immersion in hot water may induce hyperthermia. Hyperthermia occurs when the internal
temperature of the body reaches a level several degrees above normal body temperature of

98.6° F. (37° C.). The symptoms of hyperthermia include: drowsiness, lethargy, dizziness,
fainting, and an increase in the internal temperature of the body.

The effects of hyperthermia include: 1) Unawareness of impending danger. 2) Failure to
perceive heat. 3) Failure to recognize the need to leave the spa. 4) Physical inability to exit
the spa. 5) Fetal damage in pregnant women. 6) Unconsciousness resulting in danger of
drowning.

WARNING — The use of alcohol, drugs, or medication can greatly increase the risk of fatal

hyperthermia in hot tubs and spas.

WARNING — To reduce the risk of injury, do not permit children to use this product unless they are closely

supervised at all times.

WARNING — For units intended for use in other than single-family dwellings, a clearly labeled emergency

switch shall be provided as part of the installation. The switch shall be readily accessible to
the occupants and shall be installed at least 5 feet (1.52 m) away, adjacent to, and within
sight of, the unit.

iii

WARNING — When setting up pool water turnovers or flow rates the operator must consider local codes

governing turnover as well as disinfectant feed ratios.

WARNING — Before servicing the system, switch the main power OFF and remove the communication

cable from the pump.

CAUTION — Install the pump a minimum of five (5) feet from the inside wall of the pool and spa. Canadian

installations require a minimum of three (3) meters from pool water.

CAUTION — A No. 8 AWG or larger conductor must be wired to the motor bonding lug.

CAUTION — This pump is for use with permanently installed pools and may also be used with hot tubs and

spas if so marked. Do not use with storable pools. A permanently installed pool is constructed
in or on the ground or in a building such that it cannot be readily disassembled for storage. A
storable pool is constructed so that it may be readily disassembled for storage and reassembled
to its original integrity and has a maximum dimension of 18 feet (5.49m) and a maximum wall
height of 42 inches (1.07m).

CAUTION — For hot tubs and spa pumps, do not install within an outer enclosure or beneath the skirt of a

hot tub or spa unless so marked.

CAUTION — IntelliFlo is capable of generating systems pressures up to 50 psi. Installers must ensure

that all system components are rated to withstand at least 50 psi. Over pressurizing the
system can result in catastrophic component failure or property damage.

General Installation Information

• All work must be performed by a licensed electrician, and must conform to all national, state,
and local codes.

• Install to provide drainage of compartment for electrical components.

IntelliFlo 4 Installation and User’s Guide

iv

IMPORTANT SAFETY PRECAUTIONS (continued)

General Installation Information

WARNING —Pumps improperly sized or installed or used in applications other than for which

the pump was intended can result in severe personal injury or death. These risks
may include but not be limited to electric shock, fire, flooding, suction entrapment
or severe injury or property damage caused by a structural failure of the pump or
other system component.

WARNING —The pump can produce high levels of suction within the suction side of the

plumbing system. These high levels of suction can pose a risk if a person comes
within the close proximity of the suction openings. A person can be seriously
injured by this high level of vacuum or may become trapped and drown. It is
absolutely critical that the suction plumbing be installed in accordance with the
latest national and local codes for swimming pools.

• These instructions contain information for a variety of pump models and therefore some instructions
may not apply to a specific model. All models are intended for use in swimming pool applications. The
pump will function correctly only if it is properly sized to the specific application and properly installed.

General Warnings

• Never open the inside or the drive motor enclosure. There is a capacitor bank that holds a
230 VAC charge even when there is no power to the unit.

• The IntelliFlo 4 pump is not submersible

• The IntelliFlo 4 160 pump is capable of 174 GPM or 104 feet of head; use caution when
installing and programming to limit pumps performance potential with old or questionable
equipment

• The IntelliFlo 4 100 pump is capable of 100 GPM or 85 feet of head; use caution when
installing and programming to limit pumps performance potential with old or questionable
equipment

• Code requirements for the electrical connection differ from state to state. Install equipment in
accordance with the National Electrical Code and all applicable local codes and ordinances.

• Always Press the Stop button and disconnect the communication cable before performing
maintenance

IntelliFlo 4 Installation and User’s Guide

Section 1

Overview

IntelliFlo 4 Variable Speed Pump

The IntelliFlo 4 variable speed pump is well suited for all of your pool, spa, cleaner, waterfall and other
water application. Using the control panel, IntelliFlo can use one of the four selectable preset speeds or the
pump speed can be adjusted to run at a specific speed. IntelliFlo out performs all conventional pumps in its
class. Advanced energy conservation features ensure that your filtration system is operating at peak
efficiency.

IntelliFlo 4 models

There are two IntelliFlo 4 models which operate identically with the exception of the maximum flow rate:

• IntelliFlo 4 160 operates at a maximum system flow of 160 gallons per minute (GPM)

• IntelliFlo 4 100 operates at a maximum system flow of 100 gallons per minute (GPM)

1

The IntelliFlo 4 variable speed pump can operate from 400 RPM to 3450 RPM with preset speeds of 750,
1500, 2350, and 3110 RPM. The pump can be adjusted from the control panel to run at any speed
between 400 RPM to 3450 RPM for different applications. The IntelliFlo pump control panel alarm LED
warns the user against under and over voltage, high temperature, over current and freeze protection.

External Control

Using a communication cable, IntelliFlo 4 can communicate with an IntelliTouch, EasyTouch or IntelliComm
via a two-wire RS-485 connection for remote speed control. The EasyTouch and IntelliComm provide the
ability to remotely control the IntelliFlo 4 with four preset speeds. The IntelliTouch can be setup to use eight
speeds with the IntelliFlo 4.

IntelliFlo 4 variable speed pump

IntelliFlo 4 Installation and User’s Guide

2

Features

• Adjusts to various pool sizes

• Prevents thermal overload

• Detects and prevents damage from under and over voltage conditions

• Protects against freezing

• Communicates with a Pentair IntelliTouch, EasyTouch and IntelliComm system via a two-wire
connection

• Easy to use operator control panel

• Operator control panel buttons for speed control

• Built-in strainer pot and volute

• Ultra energy-efficient TEFC Square Flange Motor

• Compatibility with most cleaning systems, filters, and jet action spas

• Driver assembly features permanent magnet synchronous motor

• Heavy-duty, durable construction designed for long life

• UL approval

IntelliFlo 4 Motor Assembly

The IntelliFlo three-phase six-pole motor operates at 3400 RPM (at 92% efficiency) and 1000 RPM (at
90%). The motor assembly is continually cooled by an external fan. Dual seals on the motor shaft and at the
fan assembly seal the entire motor from any moisture from entering the motor assembly. For added
protection, a slinger located in front of the main shaft seal assists in slinging water away from the shaft
opening in the flange.

Motor fan cover

Motor assembly

Drive assembly and
electronics enclosure

Control panel cover

Communication port for
connection to IntelliTouch,
EasyTouch or IntelliComm
system via two-wire RS-485
cable

IntelliFlo 4 Motor Assembly

IntelliFlo 4 Installation and User’s Guide

IntelliFlo 4 Drive Assembly and Control Panel

The IntelliFlo drive assembly consists of an operator control panel and the system electronics that drive the
motor. The drive microprocessor controls the motor by changing the frequency of the current it receives
together with changing the voltage to control the rotational speed.

Operator Control Panel,

buttons and LEDs

¾” NPT male threaded

PVC nipple

3

Three Wire Harness

Red (hot), Red (hot),

Green (Ground)

+/- 20% of 230 Volt

IntelliFlo 4 Drive Assembly

IntelliFlo 4 Motor Features

• Permanent Magnet Synchronous Motor (PMSM)

• High efficiency (3400 RPM 92% and 1000 RPM 90%)

• Superior speed control

• Operates at lower temperatures due to high efficiency

• Same technology as deployed in hybrid electric vehicles

• Designed to withstand outdoor environment

• Totally enclosed fan cooled

• Three-phase motor

• 56 Square Flange

• Six-Pole

• Low noise

IntelliFlo 4 Installation and User’s Guide

4

IntelliFlo 4 Operator Control Panel

The IntelliFlo 4 operator control panel provides manual speed controls for the pump. There are four preset
speed buttons that can be selected. The Up and Down button is used to adjust the pump speed. The selected
speed can be saved and assigned to one of the speed buttons.

1

2

5

6

4

3

Controls and LEDs

1

Speed 1, Speed 2, Speed 3, and Speed 4 button/LED: Press one of the speed buttons to select the desired

preset pump speed. The pump preset speeds are: Speed 1 (750 RPM), Speed 2 (1500 RPM), Speed 3
(2350 RPM), and Speed 4 (3110 RPM). The speed button LED is on when the selected button is
pressed. If the pump is running and the Up/Down button is used to adjust the speed, the selected speed
LEDs will go off. For more about using the speed buttons, see page 5.

2

Up/Down button: While the pump is running, press the Up or Down button to increase or decrease the

pump speed. To save the new pump speed, press any one of the four speed buttons for three seconds to
assign the speed to the selected button (the LED be on). Four adjusted pump speeds can be assigned to the
speed buttons. When the pump is using an adjusted speed and the pump is powered down, the next time
the pump is powered up the pump will use the same speed. For more about using the Up/Down button, see
page 5.

3

Start button/LED: Starts the pump using a selected or adjusted speed. This LED is on when the pump is

running.

Stop button: Press this button to stop the pump.

4

On LED: This green power LED is on when IntelliFlo 4 is powered up.

5

Alarm LED: This LED is on when an error condition occurs. This green LED will flash a certain number of

6

times indicating a specific error condition. For the alarm LED flash sequence, refer to “Alarm and Warning
LED Sequence,” on page 27.

IntelliFlo 4 Installation and User’s Guide

Section 2

Operating IntelliFlo 4

This section describes how to use the IntelliFlo 4 pump control panel.

Setting the pump preset speed

IntelliFlo 4 operates using one of the preset speeds. Use the speed buttons to select the preset speeds.

To set the pump speed

1. Ensure that the pump is powered on and the green power LED is on.

2. Press the desired speed button (1- 4) for less than three seconds to select the preset pump speed.

When the selected speed button is pressed, the LED is on. The pump preset buttons and speeds are:

Speed 1 button - 750 RPM

Speed 2 button - 1500 RPM

Speed 3 button - 2350 RPM

Speed 4 button - 3110 RPM

5

3. Press the Start button to start the pump using the selected speed if necessary.

Adjusting the pump speed

IntelliFlo can be adjusted to run at any speed between 400 RPM and 3450 RPM.

To adjust the pump speed

1. Ensure that the pump is powered on and the green power LED is on.

2. Press the Start button to start the pump if the pump is not running.

3. Press the UP/Down button to increase or decrease the pump speed.

• 10 RPM increments: Press and quickly release the Up/Down button to

increase or decrease the speed in 10 RPM increments.

• 20 RPM increments: Press and hold the Up/Down button to continuously

increase or decrease the pump speed.

4. Saving an adjusted speed: To save the newly adjusted pump speed, press and

hold the desired speed buttons to assign the current speed. Four new pump
speeds can be assigned to Speed buttons (1-4).

5. Press the Speed button that is assigned to the adjusted speed.

Up/Down button

IntelliFlo 4 Installation and User’s Guide

6

Starting the pump

To start the pump

1. Ensure that the pump is powered on and the green power LED is on.

2. Press the Start button (LED on) to start the pump.

Note: When the pump is using a modified speed and is powered down, the next time the pump is
powered up, the pump will use that same speed.

Stopping the pump

To stop the pump

• Press the Stop button to stop the pump.

Note: The pump can automatically restart if the communication cable is connected.

Resetting the pump to factory defaults

The IntelliFlo 4 pump can be reset to the factory default settings. All previously adjusted pump speeds that were
saved will be erased.

To reset the pump to the factory default settings:

1. Ensure that the pump is powered on and the green power LED is on.

2. Press the Stop button to stop the pump.

3. Press and hold all of the four Speed buttons simultaneously for three seconds. Power off the drive
and reenergize. The default settings will be in effect.

Control Panel Speed Buttons

Assigning a pump address for remote control

The default communications address for the IntelliFlo 4 is 1. This is the only IntelliFlo address that the
EasyTouch and IntelliComm systems will communicate with. Therefore these devices can only communicate
with one IntelliFlo 4. The IntelliTouch is able to communicate with four Intelliflo 4 pumps. If more than one
IntelliFlo 4 is being used with an IntelliTouch the 2nd, 3rd and 4th pumps will have to be readdressed as
described below.

To assign a pump an address:

1. Be sure that the pump is powered on and the green power LED is on.

2. Press the Stop buttons to stop the pump.

3. Press and hold both the Start and Stop buttons until the red LED will starts flashing, then press one
of the four speed buttons to select which address to assign the pump.

4. Press and hold both the Start and Stop buttons to save the address. Repeat the process for the
other pumps.

IntelliFlo 4 Installation and User’s Guide