SymCom PumpSaver Plus 111P, PumpSaver Plus 233P-1.5, PumpSaver Plus 233P Installation Instructions Manual

INSTALLATION
INSTRUCTIONS

MODEL 233P/111P/233P-1.5

Revision B1

Rapid City, SD, USA, 07/2009

II-111-233-15P-B

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BE SURE POWER IS DISCONNECTED PRIOR TO INSTALLATION!

FOLLOW NATIONAL, STATE AND LOCAL CODES.

READ THESE INSTRUCTIONS ENTIREL Y BE FORE INSTALLATION.

SymCom’s PumpSaver

®

Plus is a pum p monitor designed to protect single-phase pumps from dry­well, dead-head, jammed impeller, rapid-cycling, overvoltage and undervoltage conditions. The
PumpSaver

®

Plus Model 233P protects 230V, 2 or 3-wire, 1/3 to 3 hp pumps. The Pum pSaver®Plus

Model 233P-1.5 protects 230V, 2 or 3-wire, 1/ 3 to 1.5 hp pumps. The PumpSaver

®

Plus Model 111P
protects 115V, 2 or 3-wire, 1/3 to 1 hp pumps. Typical applications include submersible pumps,
centrifugal pumps, circulating pum ps, cooling pumps, environmental pumps , residential waterwells,
commercial waterwells, irrigation wells, and golf course and other sprinkler systems.

CONNECTIONS

NOTE: Use with UL/CSA listed over load or impe danc e pr ote ct e d pumps or motors only.

1. Mount the PumpSaver

®

Plus in a convenient location in or near the pump control box. If the

location is wet or dusty a NEMA 3R, 4, or 12 enc losure s hould be u sed. The PumpSaver

®

Plus

must be protected by a fuse or circuit breaker (30A RK5 fuse or 30A inverse time breaker max).

2. Connect one line from the fused disconnec t to the L1 I N terminal of the PumpSaver

®

Plus. Run

a wire from the L1 OUT terminal to the other in-line controls such as pressure or float switches.

3. Connect the other line from the fused disconnect (ungrounded fused conductor) t o the L2 IN

terminal of the PumpSaver

®

Plus. Run a wire from the L2 OUT terminal to the other in-line

controls such as pressure or float switches (see Figure 1).

4. Refer to the appropriate wiring diagram for your specific application:

• Typical wiring diagram – Figure 1

• Standard 3-wire control box – Figure 2

• Deluxe control box – Figure 3

• 2-Wire pump direct feed – Figure 4

*** WARNING ***

PROPER OPERATION REQUIRES FIELD CALIBRATION

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FIGURE 1: Typical Wiring Diagram

FIGURE 2: Standard Control Box Wiring Diagram

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FIGURE 3: Deluxe Control Box Wiring Diagram

FIGURE 4: 2-Wire P ump Direct-Feed Wiring Diagram

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OPERATION

The PumpSaver®Plus monitors pump load i n amps and ki lowatts. When the c urrent (am ps) exceeds
approximately 125% of calibrated current, or power (kW) drops below the adjustable underload t rip
point, the PumpSaver

®

Plus—after the trip delay—will turn off the pump. The PumpSaver®Plus will
time through the restart delay, and then restart the pump. The calibration is stored in permanent
memory—it does not need to be recalibrated if power is lost.

CALIBRATION

NOTE: Th e PumpSaver®Plus should be cal ibrated
during normal pumping conditions.

1. T urn the RESTART DELAY/ CALIBRATION knob

fully counter-clockwise to th e CAL. position.

2. A pply power—the pump will run for approximately

10 seconds then shut off.

3. Set the RESTART DELAY/ CALIBRATION knob

to the desired restart delay (dry-well recovery
time)—the pump will turn on.

CALIBRATING WHILE PUMPING

The PumpSaver

®

Plus can also be calibrated while the pump is running. Turn the R ESTART DELAY/
CALIBRATION knob to CAL. while pumping. Wait for the pump to turn off (approximately 10
seconds), then adjust the RESTART DELAY/ CALIBRATION knob to the desired setting.

SENSITIVITY

The PumpSaver®Plus has an adjustment knob to set the underload trip sensitivity. Setting
SENSITIVITY to the m iddle pos ition (straight up) is equivalent t o Sym Com’s st andard underload tri p
level. Adjust the SENSITIVITY knob to increase/dec rease underload sensitivity up to appro ximately
10% of the standard trip. It may be necessary to increase the sensitivity if the PumpSaver

®

Plus does
not trip on dry-run or dead-head or it is k nown that the water level i n the well is ver y low relative to
the pump’s capabilities.

WARNING: Decreasing the SENSITIVITY may compromise the PumpSaver

®

Plus’ ability to

detect dry-run and/or dead-head conditions.

RESET MODE / RESTART DELAY

Any restart delay can be by-passed by rotat ing the RESTART DELAY/ CALIBRATION knob to the
RESET position and back to the desired restart delay setting.

NOTE: The restart delay setting can be changed at any time. The current and subsequent
trips will follow the new restart delay setting.

The RESTART DELAY/ CALIBRATION knob can be placed in the RESET position for manual
reset. If the PumpSaver

®

Plus trips off in this m ode due to a voltage or load probl em, the RESTART

DELAY/ CALIBRATION knob must be rotated out of the RESET position to restart the pump.

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RUN HOURS / FAULT HISTORY

The PumpSaver®Plus records pump run hours. Run hours can be displayed by a PumpSaver®
Informer (see USING AN INFORMER

at the bottom of this page). Run hours and fault history can be

cleared on the PumpSaver

®

Plus. Read the following instructions fully before performing the

procedure.

NOTE: Turn the S ENSITIVITY knob completely to the left (counter-clockwise) o r completely to
the right (clockwise) when directed.

To Reset Run Hours and Clear Fault History:

1. Remove power to the PumpSaver

®

Plus.

2. Set the RESTART DELAY/ CALIBRATION knob to RESET and the SENSITIVITY knob to t he

middle (12:00) position.

3. Apply power to the PumpSaver

®

Plus—the CAL. LIGHT will turn on.

4. Turn the SENSITIVITY knob to the right—the CAL. LIGHT will turn off and the RUN LI GHT will

turn on.

5. Turn the SENSITIVITY knob to the left—both lights will turn on.

6. Turn the SENSITIVITY knob to the right.

7. After 10 seconds, t he CAL. and RUN LI GHTS will blink twice indicat ing the run hours and fault

history have successfully been cleared.

RAPID CYCLING

Rapid cycling is defined as more than 4 restarts in a 60-second period. The PumpSaver®Plus is
capable of detecting a rapid-cycle c ondition whether a control device, s uch as a pressure switch, i s
installed before* or after it . Upon detecting either f orm of rapid cyc ling, the PumpSaver

®

Plus will

lock-out, preventing damage to the pump. To reset the PumpSaver

®

Plus, remove and re-apply

power.

RAPID CYCLING (Line Side / Upstream)

Rapid cycling of the line side of the PumpSaver

®

Plus may be caused by several naturally occurring
conditions which are indistinguishable from true rapid cycling. For this reason, once tripped, the
PumpSaver

®

Plus will wait 30 minutes and restart. If the restart is successful (the pump runs for

more than one minute), the rapid cycle counter will res et t o zero. If the PumpS aver

®

Plus encounters
rapid cycle 4 times without a successful restart, it will lock-out and require a manual reset. To res et
the PumpSaver

®

Plus, remove and re-apply power.

*Protection against rapid cycling of a control device installed before the PumpSaver

®

Plus is
disabled by default. Read the f ollowing instructions fully bef ore performing the procedure t o enable
this feature.

NOTE: Turn the S ENSITIVITY knob completely to the left (counter-clockwise) o r completely to
the right (clockwise) when directed.

To Enable Rapid-Cycle Protection when a Control Device is Installed BEFORE the
PumpSaver®Plus: (to disabl e, f ollow the sam e procedure)

1. Remove power to the PumpSaver

®

Plus.

2. Set the RESTART DELAY/ CALIBRATION knob to RESET and the SENSITIVITY knob to the

middle (12:00) position.

3. Apply power to the PumpSaver

®

Plus —the CAL. LIGHT will turn on.

4. Turn the SENSITIVITY knob to the right—the CAL. LIGHT will turn off, RUN LIGHT will turn on.

5. Turn the SENSITIVITY knob to the left—both lights will turn on.

6. Turn the SENSITIVITY knob right—left—right—left—right.

7. After 2 seconds, the CAL. and RUN LIGHTS will blink once indicating line side rapid-cycle

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protection has been enabled.

RAPID CYCLING (Load Side / Downstream)

Load side rapid cycling of the pump will immediately result in a manual lock-out. The pump will not
restart automatically. To reset the PumpSaver

®

Plus, remove and re-apply power.

Note: P

rotection against rapid cycling of a control device installed after the PumpSaver

®

Plus is

always enabled. Disabling line side detection will not disable load side detecti on.

USING AN INFORMER

PumpSaver®Plus products are equipped with an infrared LE D that will communicate to a SymCom
Informer—a handheld, battery-operated, diagnostic tool. The Informer—when directed at the
PumpSaver

®

Plus—will display real-time voltage, current and power; dry-well and overcurrent trip
points; calibration voltage; last 20 faults; voltage, current and power at the last fault; highest/lowest
voltage and current since c alibrat ion; the m odel num ber; and the CT s ize if applic able. The Inf ormer
can be used on any single-phase PumpSaver®Plus equipped with an infrared LED transmitter.
Contact SymCom for more information at 800-894-0412 or visit our website.

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TROUBLESHOOTING

RUN LIGHT CAL. LIGHT PROBLEM or FUNCTION CORRECTIVE ACTION

On Steady Off

RUN:

Pump is running—or ready to
run—no problems in operation

If pump is not running, check for
loose wiring and ensure proper
function of pressure or float

switches.

On Steady On Steady

CAL:

The PumpSaver®Plus is in the

calibration process.

None

Off On Steady

CAL COMPLETE:
The PumpSaver®Plus has
calibrated, the RESTART
DELAY/ CALIBRATION knob
was left in the CAL. position.

Pump is off.

Pump will restart as soon as the

RESTART DELAY/
CALIBRATION k nob i s rotated

out of the CAL. position.

Off Off

OFF / MANUAL RESTART:

The pump is not running. Either
the PumpSaver

®

Plus has t ri pped
on dry-run, dead-head, or
overcurrent while the RESTART
DELAY/ CALIBRATION knob
was in the RESET position or
source power is not present.

If knob is in the RESET position,
rotate out of RESET—If the CAL.
light blinks, check for an
overcurrent condition. If the RUN
light blinks, look for a dry-run or
dead-head condition. If no lights
come on, check incoming power
for adequate voltage.

Blinking Off

DRY RUN / DEAD HEAD:
The PumpSaver

®

Plus has shut
the pump off due to a dry run or
dead head condition. The unit is
timing through the restart delay
and will try to restart.

Check for restricted flow or
inadequate supply of liquid.

Off Blinking

OVERCURRENT:
The PumpSaver

®

Plus has shut
the pump off due to an
overcurrent condition. The unit is
timing through the restart delay
and will try to restart if line voltage
is at an acceptable level.

Check for low or high voltage or
jammed pump impellers. If these
conditions do not exist,
recalibrate the unit while it is
drawing higher current (amps
should not exceed SFA).

Blinking

alternately

with the

CAL. LIGHT

Blinking

alternately

with the

RUN LIGHT

VOLTAGE FAULT:

The PumpSaver®Plus is
preventing the pump from starting
due to voltage problems. The
voltage is being interrogated and
the unit will remain in this mode
until the voltage is at an

acceptable level.

If the unit remains in this state for
more than 5 seconds, check for
high or low voltage.

Blinking in

unison with

the CAL.

LIGHT

Blinking in

unison with

the RUN

LIGHT

RAPID CYCLE:

The PumpSaver®Plus has shut
down on rapid cycling. Power
must be removed and reapplied

to reset the unit.

Check for a broken bladder in the
pressure tank (if used), or check
for a defective pressure or float
switch.

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PHYSICAL DIMENSIONS

4.05" (102.87)

5.26" (133.60)

4.50" (114.30)

.375"

(9.53)

2.93"

(74.42)

2.17"

(55.12)

2.90"

(73.66)

FRONT VIEW

BOTTOM VIEW

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SPECIFICATIONS

Functional Specifications

Adjustments/Settings

Overcurrent

125% of calibration point

Underload (dry-well)

Adjustable (70-90% of calibrated run power)

Overvoltage

233P, 233P-1.5

265VAC

111P

132.5VAC

Undervoltage

233P, 233P-1.5

190VAC

111P

95VAC

Number of restarts allowed in 60

second period (rapid-cycling)

4

Trip Delay Times

Overcurrent

5 seconds

Dry-well

4 seconds

Dry-well Optional*

8 seconds

Restart Delay Times

Over/undervoltage

2 seconds

All other faults

Manual, 2-225 minutes

Input Characteristics

Supply Voltage

233P, 233P-1.5

230VAC

111P

115VAC

Load Range

233P

1/3 – 3 hp

233P-1.5

1/3 – 1.5 hp

111P

1/3 – 1 hp

Frequency 50/60Hz

(NOTE: 50Hz will increase all delay timers by 20%)

Output Characteristics

Output Contact Rating-SPST

233P

3hp @ 240VAC (17 Amps max.)

233P-1.5

1.5hp @ 240VAC (10 Amps max.)

111P

1hp @ 120VAC (16 Amps max.)

General Characteristics

Operating Temperature

-40° to 55°C (-40° to 131°F)

Maximum Input Power

5 W

Wire Gauge

Solid or stranded 10 – 22 AWG

Terminal Torque

13 in.-lbs.

Standards Passed

Electrostatic Discharge (ESD)
Surge Immunity

IEC 61000-4-2, Level 2, 4kV contact, 6kV air
IEC 61000-4-5, Level 4, 4kV line-to-line and line-to-

ground

Safety Marks

cUL Listed

UL508 & C22.2 No. 14

Dimensions

2.90” H x 5.26” W x 2.93” D

Weight

14 oz.

Mounting Methods

#8 screws

*use part number 233P-UCTD8

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