Pentair INTELLIFLO 100, INTELLIFLO 4 160 User Manual 2

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Pentair INTELLIFLO 100, INTELLIFLO 4 160 User Manual 2

IntelliFlo® 4 160 and 100

Variable Speed Programmable Pump

(Compatible with IntelliTouch, EasyTouchand IntelliComm)

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: (800) 831-7133

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

Phone: (800) 831-7133 (Ext. 6312)

Fax (800) 284-4151

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 • (919) 566-8000

10951 West Los Angeles Ave., Moorpark, CA 93021 • (805) 553-5000

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

i

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

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

13

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

13

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

13

Motor Service ......................................................................................................................

14

Winterizing ...........................................................................................................................

15

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

15

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

17

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

17

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

17

Location ...............................................................................................................................

17

Piping .................................................................................................................................

17

Check Valve ........................................................................................................................

17

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

18

Pump Disassembly .............................................................................................................

19

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

20

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

20

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

21

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

22

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

23

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

23

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

23

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

25

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

25

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

25

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

26

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 (800) 831-7133 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.

Alwaysdisconnectpowertothepoolpumpatthecircuitbreakerbeforeservicingthe 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

iii

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.

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

1

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)

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 cable0

IntelliFlo 4 Motor Assembly

IntelliFlo 4 Installation and User’s Guide

3

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

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

3 4

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.

4Stop button: Press this button to stop the pump.

5On LED: This green power LED is on when IntelliFlo 4 is powered up.

6Alarm LED: This LED is on when an error condition occurs. This green LED will flash a certain number of

times indicating a specific error condition. For the alarm LED flash sequence, refer to “Alarm and Warning LED Sequence,” on page 25.

IntelliFlo 4 Installation and User’s Guide

5

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

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).

Up/Down button

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

IntelliFlo 4 Installation and User’s Guide

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