Pentair CGL-21DW, CGL-21SW, CGL-01DW, CGL-23DW, CGL-23SW Installation And Service Manual
...
MODELS CGL-01SW, CGL-01DW (2HP, 208V, 1PH)
CGL-21SW, CGL-21DW (2HP, 230V, 1PH)
CGL(LD)-21SW, CGL(LD)-21DW (2HP, 230V, 1PH)
CGL-23SW, CGL-23DW (2HP, 208-230V, 3PH)
CGL-43SW, CGL-43DW (2HP, 460V, 3PH)
CGL CONTROL PANELS
INSTALLATION AND SERVICE MANUAL
For Simplex and Duplex.
NOTE! To the installer: Please make sure you provide this manual to the owner of the equip ment or to the responsible
party who maintains the system.
Part # 23833A150 | © 2012 Pentair Pump Group, Inc. | 11/08/12
LOCATION AND MOUNTING
CALIFORNIA PROPOSITION 65 WARNING:
This product and related
accessories contain chemicals known to the
State of California to cause cancer, birth
defects or other reproductive harm.
INDOOR USE
Locate the control box in a convenient location,
preferably close to the pump installation. The box
may be secured to a wall or other stable vertical
support by use of the four mounting holes located
in the mounting feet on the top and bottom of the
box.
The box should be mounted approximately 5 feet
from the floor to the circuit breaker handle. Care
should be taken to avoid mounting the control
box under sweating pipes, faucets or other damp
locations.
POWER SUPPLY
OUTDOOR USE
The control box may be mounted at the location of
the pump and basin or may be mounted in a remote
location. The box should be secured to a stable
vertical support which in turn should be secured to
a concrete basin or footer. The box could also be
mounted to the side of the house or other stationary
support if available within a reasonable distance.
When selecting a location, you should consider the
visibility of the alarm light.
The box may be secured by the use of four mounting
holes located in the mounting feet on the top and
bottom of the box. The box should be mounted
approximately 5 feet from the ground to the circuit
breaker handle.
WARNING
Do not attempt to wire this control box unless you
have a good working knowledge of electricity and
are familiar with state and local codes. If you are in
doubt about anything, contact an electrician.
The power supply for the control box will vary
depending upon which particular model you have
purchased. Do not attempt to operate this unit on
any other voltage or power distribution other than
what it was originally designed. Failure to comply
with this will result in the immediate cancellation
of all warranties and claims.
It is advisable to put the pump on its own circuit
using a circuit breaker adequately sized to protect
the pump. Check state and local codes for the
correct wire size and circuit protection to use. The
wire should be sized large enough to handle the
full load current of both pumps you are operating,
and any voltage drop that might occur due to long
service runs.
Run power supply lines to the control box and
secure (knockouts are not supplied in this box).
Select a convenient location on the bottom to enter
the box with the power supply. Cut a hole with a
chassis punch, caution should be taken not to get
fiberglass chips in the components while cutting
hole. After the hole is cut, any fiberglass particles
must be removed from box. Failure to do so may
result in premature component failure.
Connect incoming power to the circuit breaker top
lugs and all necessary ground wires to the ground
lug at the bottom of the box. The ground lug should
be fastened to a good driven earth ground by one
of the methods described in the National Electric
Code.
NOTE: On single phase panels, the neutral terminal
block (labeled “N” and located next to the circuit
breaker) must be connected to the incoming power
neutral line. If the incoming power does not have a
neutral line, then the neutral terminal block should
be jumpered to the ground lug.
23833A150 11/08/12
2
CONNECTING PUMPS AND FLOATS TO CONTROL BOX
PUMP CORD
Run the wires from both pumps to the bottom of
the control box by means of one of the methods
described in your pump or basin installation
instructions. A hole must be cut into the control
box (use the same procedure as that described for
incoming power supply lines).
Connect red, white and black wires to terminals
marked M1, M2 and M3 (for 3 phase applications),
or connect the red, white and black wires to
terminals marked R, W and B (for 1 phase
applications). Fasten green wire to ground lug.
WGL pumps may have an additional brown wire in
the pump cord. This is for the seal leak probe and it
OPERATING PUMPS
1. Make sure that all wires are inside the control box
and not in a position to be pinched or shorted
when the door is closed.
2. Turn on power to the control box.
3. Turn hand-off-auto switches to the “HAND”
position. The pumps should start and the pump
run lights should come on. (On duplex panels,
this should be done for both pumps).
4. To put into service, put the hand-off-auto switch
in the “AUTO” position. (On duplex panels, this
should be connected to the terminal strip in the
control box. See wiring diagram for the proper
terminal connections.
NOTE: On 3 phase installations check for proper
pump rotation. See the “ROTATION OF 3
PHASE PUMPS” section in this manual.
FLOAT CORDS
See basin instructions for the proper depth at which
to set the floats. Strip the float cord wires 3/8", twist
strands together, and connect black and white
wires to terminal strip in the control box. See wiring
diagram for proper terminal connections.
should be done fore both pumps). See basin
instructions.
5. If unit does not operate as described, see
troubleshooting chart.
NOTE: Addition of electrical components and
circuitry to this unit is expressly forbidden
unless written factory authorization is
obtained. Failure to do so will result in
warranty cancellation.
ROTATION OF THREE PHASE PUMPS
IMPORTANT
Rotation of three phase pumps must be established
by one of the two methods described below.
CAUTION
Keep hands and feet clear of impeller when
checking rotation. Be sure to disconnect power to
the control box while handling pumps. Make sure
pump is wired and readied for rotation test before
the control box is energized.
1. Before positioning pump in basin, run wires to
control box. Lay the pump unit on its side and
secure so that the starting torque of the motor
will not cause the pump to roll. Energize the
pump by turning the circuit breaker on and the
hand-off-auto to “HAND”. The rotation should be
counterclockwise as observed facing the bottom
of the pump.
If you do not get the proper rotation, disconnect
the power to the control box and change the
position of any two of the black motor leads in
the terminal blocks.
2. Install the pump in the basin and run in some
water so the pump can operate. Energize the
pump by turning the circuit breaker on and the
hand-of-auto switch to “HAND”. Let the pump
pull the water down in the basin, and when the
water reaches the bottom of the pump the
rotation of the water can be observed. The water
should rotate in a clockwise direction if the
pump rotation is correct.
If you do not get the proper rotation, disconnect
the power to the control box and change the
position of any two of the black motor leads in
the terminal blocks.
3
23833A150 11/08/12
CHECKING PUMP CURRENT DRAW
1 PHASE PUMPS
1. Use an amprobe to check the amperage of the
pump.
2. Turn the hand-off-auto switch to the “HAND”
position and compare the amperage reading to
the values shown on the chart. (See page 9).
3. If you get a reading of 0, make sure there
is voltage to the motor leads. Push the Klixon
overload reset button in the control panel. the on
winding overload may be tripped. Wait 15 minutes
and try again. If you still do not get a reading,
either the motor has failed or there might be a
wiring problem between the control panel and
pump (improper connection in the junction box).
3 PHASE PUMPS
1. Use an amprobe to check the amperage of any of
the power leads going to the pump.
2. Turn the hand-off-auto switch to the “HAND”
position and compare the amperage reading to
the values shown on the chart.
3. If you get a reading of 0, make sure there is
voltage to the motor leads. Push the overload
reset button on the overload relay in the control
panel. If you still do not get a reading either the
motor has failed or there might be a wiring
problem between the control panel and pump
(improper connection in the junction box).
4. If you get high amperage readings on 2 wires and
a zero reading on the third, you have a single
phase condition which could be caused by one
of the following:
A. One motor lead is not connected properly.
B. You have lost 1 phase of the 3 phase power
coming into the panel.
C. One winding in the motor is open.
CHECKING PUMP AND FLOAT RESISTANCE
TO CHECK PUMP OR FLOAT, DISCONNECT INCOMING POWER AND REMOVE WIRES
FROM THE TERMINAL BLOCK AND WITH AN OHMMETER CHECK THE MEASUREMENTS PER CHART.
CORD ITEM CORRECT OHMMETER IF YOU GET ANY OTHER READING
MEASURED MEASURED READING SETTING CHECK FOR THE FOLLOWING:
Power Motor Winding
(See Chart) R x 1 Damaged winding or cord
Cord (1 Phase)
Power Motor Winding
(See Chart) R x 1 Damaged winding or cord
Cord (3 Phase)
Power Ground to Motor Winding
Infinity to 200 R x 100K
Cord (Green to Red, Black or White)
Power Ground to Seal Probe (Opt.)
Infinity to 200 R x 100K
Cord (Green to Brown)
Float Ground to Float Contacts
Infinity to 200 R x 100K Water in float or damaged cord
Cord (Green to Black or White)
Float Float Contacts
R x 1 Switch has failed or damaged cord
Cord (Black to White)
NOTE: Readings may vary slightly depending on length of wire running to the motor and the accuracy of the measurement instrument.
0 - Float On
Infinity-Float Off
Damaged winding or cord
moisture in motor
Water in seal chamber or
damaged cord
23833A150 11/08/12
4
TESTING COMPONENTS IN CONTROL BOX
WARNING
To prevent electrical shock, disconnect power entering
the control box and turn the circuit breaker in the
control box to the “OFF” position.
CONTRACTOR
1. Physically examine the contractor for badly burnt
or sticking contacts. The contractor arm should
move in and out freely.
2. Remove the wires on the coil to the contactor and
measure the resistance. Zero the ohmmeter, and on
the R x 1 scale you should read approximately 138
ohms.
3. Often a burnt coil can be spotted by merely looking
to see if it is badly discolored or has a dark spot on it.
TRANSFORMER (3 PHASE PANELS ONLY)
208 VOLT
1. Remove the wires from the primary side (H3-H4)
and also from the secondary side (X2-XF-X1).
2. With an ohmmeter on the R x 1 scale touch
terminals H3 and H4 (primary), you should get a
reading of approximately 15.6 ohms for Simplex
panels, and 5.8 ohms for Duplex panels.
3. With an ohmmeter on the R x 1 scale touch
terminals X2 and X1 (secondary), you should get
a reading of approximately 3.6 ohms for Simplex
panels and 1.6 ohms for Duplex panels.
4. With an ohmmeter on the R x 1 scale touch
terminals XF and X1, you should get a reading of
0. If you do not, replace the fuse.
230 VOLT
1. Remove the wires from the primary side (H2-H4)
and also from the secondary side (X2-XF-X1).
2. With an ohmmeter on the R x 1 scale touch
terminals H2 and H4 (primary), you should get a
reading of approximately 14 ohms for Simplex
panels, and 6.5 ohms for Duplex panels.
3. With an ohmmeter on the R x 1 scale touch
terminals X2 and X1 (secondary), you should get
a reading of approximately 3.6 ohms for Simplex
panels and 1.6 ohms for Duplex panels.
4. With an ohmmeter on the R x 1 scale touch
terminals XF and X1, you should get a reading of
0. If you do not, replace the fuse.
460 VOLT
1. Remove the wires from the primary side (H1-H4)
and also from the secondary side (X2-XF-X1).
2. With an ohmmeter on the R x 1 scale touch
terminals H1 and H4 (primary), you should get a
reading of approximately 49.7 ohms for Simplex
panels, and 21.5 ohms for Duplex panels.
3. With an ohmmeter on the R x 1 scale touch
terminals X2 and X1 (secondary), you should get
a reading of approximately 3.6 ohms for Simplex
panels and 1.6 ohms for Duplex panels.
4. With an ohmmeter on the R x 1 scale touch
terminals XF and X1, you should get a reading of
0. If you do not, replace the fuse.
OVERLOAD BLOCK (3 PHASE PANELS ONLY)
1. Remove the wires from the terminals on the side of
the overload block.
2. With an ohmmeter on the R x 1 scale touch the two
terminals, you should get a reading of 0. If you do
not get this reading, push the large black reset
button on the front of the overload block.
3. You may test the inner switching mechanism by
pushing the small black button on the front of the
overload block to trip the switch and pushing the
large black button to reset it. If the inner switch
does not work properly replace the overload block.
OVERLOAD HEATERS (3 PHASE PANELS ONLY)
1. Remove the heaters from the overload block and
examine them for physical damage. A slight
discoloration is normal, but if they are melted or
warped they should be replaced.
FUSES
1. Pull the fuse out of the fuse block and check for
continuity with an ohmmeter.
2. With an ohmmeter on the R x 1 scale, you should
get a reading of 0. If you do not, replace it with the
same type and rating that is shown on the decal
located next to the fuse block.
OVERRIDE RELAY (DUPLEX PANELS ONLY)
1. Physically examine the relay for burnt or stuck
contacts and for a burnt or discolored coil.
2. Remove the relay from the socket and with an
ohmmeter on R x 1000 scale, you should read
approximately 7.68 ohms on pins 13 and 14.
Often a burnt coil can be spotted by merely
looking to see if it is badly discolored or has a dark
spot on it.
ALARM LIGHT
1. The light should activate when the alarm float con nections are jumpered, if not replace the light bulb.
ALTERNATOR RELAY (DUPLEX PANELS ONLY)
1. When power is on and the relay is functioning
properly, one of the two lights on top of the relay
should be on.
2. With circuit breaker turned “off”, remove relay from
socket. With an ohmmeter on the R x 1000 scale,
touch the alternator coil terminals. The “black” lead
5
23833A150 11/08/12
TESTING COMPONENTS IN CONTROL BOX
should be on pin 3, and the “red” lead should be on
pin 5. You should have a reading of approximately
920-1020 ohms.
3. If alternator shows physical damage or does not test
properly, replace it.
KLIXON OVERLOAD (1 PHASE PANELS ONLY)
1. Remove black wire from the bottom of contactor
and the white wire from the “B” terminal for the pump.
Clip ohmmeter leads to the black and white wires
and with the ohmmeter on R x 1, you should have a
reading of 0. If you do not, push in on the reset button
and check again. If you still do not read 0, replace
overload.
START AND RUN CAPACITOR
NOTE: A good sign of a failed capacitor is a bulged or
swollen enclosure, leaking oil or a burnt smell. This is
true on both types of capacitors.
1. With power shut off, short the terminals of the
capacitors together with a screwdriver or jumper
cables. This will discharge any voltage stored in the
capacitor.
2. Remove the wires from the ends of the capacitor.
3. Set the ohmmeter on R x 10,000 (10K) and adjust
needle to zero, after clipping the ohmmeter leads
together.
4. Clip one lead to one side of the capacitor terminal
and touch the other lead to the other capacitor
terminal. If the capacitor is good, the needle will go
towards zero and then drift slowly towards infinity.
If the ohmmeter does not read as described, the
capacitor is bad and must be replaced.
5. If the capacity is checked a second time, be sure to
reverse the ohmmeter leads to get a correct reading.
START RELAY
1. With the power shut off, disconnect the wires going
to the relay.
2. Set the ohmmeter to R x 1,000 and adjust the
needle to zero, after clipping the ohmmeter leads
together.
3. Check the resistance between terminals 1 and 2 on
the relay. If the relay is good, the ohmmeter will
read 0.
4. Check the resistance between terminals 2 and 5.
The ohmmeter should read approximately 6,000
ohms. If it reads 0 or infinity, the relay is bad.
NOTE: The relay can check good according to the
above test and still not work properly. The contacts
between terminals 1 and 2, that disconnect the start
winding, may be stuck or burnt together, keeping the
winding in the circuit until the overload trips. If this
happens, replace the relay.
23833A150 11/08/12
6
TROUBLESHOOTING CHART
(SIMPLEX PANELS)
Motor overload tripped. (1 PHASE ONLY) Reset by pushing Klixon overload reset button. If overload
CAUSE REMEDY
A
trips again, check power supply voltage. Check motor winding resistance, make
sure pump shaft is not locked.
Position
Hand-
Auto Run
Problem Switch Light Check Pump
Tripped circuit breaker or Reset breakers or replace fuses. If they continue to blow, check amp capacity of
(3 PHASE ONLY) Reset by pushing overload reset button. If overload does not
trip again problem may be fixed. If overload trips again, check power supply
voltage. Check motor winding resistance, make sure pump shaft is not locked.
B
fuse at power supply wire and breakers. Make sure it is wired properly and that you have the correct
Does Not Auto On H-I
Turn Off
Tripped circuit breaker Reset by pushing handle down to “OFF” position and resetting to “ON” position.
panel. power supply system. (See instructions “Power Supply”).
C
Hand Off A-C-B-
Pump D-F
Control circuit fuse blown. Check fuse per instructions. Replace fuse with same type and rating.
Level in basin may not be Check basin. Run pump manually to see if pump operates properly.
in control panel. Make sure that wires are not shorted and that the box is wired properly.
D
E
high enough to turn
switch on.
Does Not
Run
Auto Off A-F-C-B-
E-D-H Auto
Or On G-I
7
May not be wired properly. Check wiring per wiring diagram. Make sure pump is connected to terminal
F
Too much water coming Reduce water flow. Pump may need servicing.
block properly.
G
into basin.
Hand
Alarm
Activates
Auto Off A-H-D-F
Float switch may have Operate manually to see if basin pumps down and alarm goes off. Repair float if
H
failed. necessary.
Circuit Auto-
Pump or discharge line Pull pump and check discharge line and pump inlet. (CAUTION: Never put
I
Breaker Off- Off F-J
may be plugged. hands on grinder impeller unless power is turned off).
Tripped Hand
May be short circuit in Check wiring. (Short will not be located in control cucuit unless control circuit
J
wiring or pump power fuse is blown). Check motor. (See chart for checking pump cables).
Fuse in Auto-
May be failed component Check components per instructions.
supply–Short in motor.
K
Control Circuit Off- Off G-H-K-I
Blown Hand
23833A150 11/08/12
Wrong operating voltage Check voltage and make sure relays and contactors are of proper voltage.
operating coil.
L
or wrong voltage
Control Auto- On
Box Off- Or L
components.
Buzzes Hand Off
TROUBLESHOOTING CHART
(DUPLEX PANELS)
Motor overload tripped. (1 PHASE ONLY) Reset by pushing Klixon overload reset button. If overload
CAUSE REMEDY
A
trips again, check power supply voltage. Check motor winding resistance, make
sure pump shaft is not locked.
(3 PHASE ONLY) Reset by pushing overload reset button. If overload does not
Position
Hand-
Auto Run
Problem Switch Light Check
23833A150 11/08/12
Tripped circuit breaker or Reset breakers or replace fuses. If they continue to blow, check amp capacity of
trip again problem may be fixed. If overload trips again, check power supply
voltage. Check motor winding resistance, make sure pump shaft is not locked.
B
Pump
1 AND 2
Hand On G-A-L-K
Will Not Run
Hand Off C-E-B-G
Auto On A-G-L-K
Tripped circuit breaker Reset by pushing handle down to “OFF” position and resetting to “ON” position.
Override relay not working Try operating both pumps in “HAND” position. If the run light comes on and
Control circuit fuse blown. Check fuse per instructions. Replace fuse with same type and rating.
Level in basin may not be Check basin. Run pump manually to see if pump operates properly.
E
F
1 OR 2
Will Not Run
Auto On A-G-K-L
C
in control panel. Make sure that wires are not shorted and that the box is wired properly.
B-E-G
D
properly pumps operate properly, replace override relay.
fuse at power supply panel. wire and breakers. Make sure it is wired properly and that you have the correct
– wrong supply voltage power supply system. (See instructions “Power Supply”).
F-I-C-
Pump
Auto Off
Hand On A-G-K
Hand Off C-G-L
May not be wired properly. Check wiring per wiring diagram. Make sure pump is connected to terminal
high enough to turn
switch on.
G
block properly.
Auto Off M-F-G
Both
Auto Lights H-I-J
8
Too much water coming Reduce water flow. Pump may need servicing.
Float switch may have Operate manually to see if basin pumps down and alarm goes off. Repair float if
Pump or discharge line Pull pump and check discharge line and pump inlet. (CAUTION: Never put
H
into basin.
I
failed. necessary.
J
No
On
One
Only
Light
Alarm
Activates
On
Auto G-D
May be failed component Check components per instructions.
may be plugged. hands on grinder impeller unless power is turned off).
Run
Auto E-L
K
operating coil.
On
Light
Wrong operating voltage Check voltage and make sure relays and contactors are of proper voltage.
L
Circuit Auto-
May not be lead pump in Let float switches cycle basin to see if alternator is alternating pumps. If not
or wrong voltage
components.
M
Breaker Off- Off G-N
Tripped Hand
Fuse in Auto-
May be short in circuit in Check wiring. (Short will not be located in control circuit unless control circuit
alternating phase — check alternator relay per instructions.
alternator may not be
working properly.
N
wiring or pump power fuse is blown). Check motor. (See chart for checking pump cables).
supply—Short in motor.
Control Circuit Off- Off H-I-J-K
Blown Hand
Control Auto- On
Box Off- or L
Buzzes Hand Off
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