Xylem IM182 User Manual [en, es, fr]

CentriPro

IM182

ITT

Residential & Commercial Water Systems

CentriPro

BALANCED FLOW® SUBMERSIBLE PUMP CONTROLLER

Installation, Operation and Troubleshooting Manual

CentriPro is a brand of ITT Corporation.

www.goulds.com

Engineered for life

Owner’s Information

Table of Contents

Controller Model Number: Controller Serial Number: Pump Model Number: Pump Serial Number: Motor Model Number: Motor SFA: Tank Serial Number: Dealer:

Dealer Telephone Number: Installation Date: Wire Lengths (Feet)

Service Entrance to Controller: Controller to Well: Top of Well to Motor:

Incoming Voltage:

NOTICE: RECORD THE MODEL NUMBERS

AND SERIAL NUMBERS FROM THE PUMP AND CONTROLLER IN THIS INSTRUCTION MANUAL FOR FUTURE REFERENCE. GIVE IT TO THE OWNER OR AFFIX IT TO THE CONTROLLER WHEN FINISHED WITH THE INSTALLATION.

SUBJECT PAGE

1. Safety Instructions ..................................................... 3

Typical Installation ..................................................... 3

Ratings ...................................................................... 4

Required Materials .................................................... 4

2. Installation ................................................................ 4

Controller .................................................................. 4

Pump and Piping ........................................................ 4

Splicing Drop Cable to Motor Leads .......................... 4

Wiring Pressure Transducer ........................................ 5

Motor Wires .............................................................. 5

Input Power ............................................................... 5

User Interface Board .................................................. 8

3. Installer Pre-Start Selections ...................................... 6

Maximum Frequency (Speed) Switch ......................... 6

Dry Well Sensitivity ................................................... 6

Broken Pipe Protection .............................................. 6

Pressure Drop ............................................................ 6

Motor Overload Setting Dial ..................................... 6

Pressure Adjustment Pushbuttons ............................... 6

Controller Status Indicator ........................................ 6

Purging System .......................................................... 6

Checking Rotation ..................................................... 6

Checking for Leaks .................................................... 7

Switch Input .............................................................. 7

Table 4: Wire Sizing ................................................... 9

4. Troubleshooting ................................................. 10-12

Limited Warranty ........................................................ 12

Water Ends and CentriPro Motors include these extra data labels. Please attach them to the inside cover of the Balanced Flow Controller for future pump and motor identiﬁcation.

Submersible Pump 33GS15

www.goulds.com

CentriPro

Motor: M30432/300C313

3.00 HP FLA: 9.2 SFA: 10.1 LRA: 59 SF: 1.15 Hz: 60 Volts: 230 PH: 3

PLEASE USE THIS CONTROLLER INSTALLATION, OPERATION AND TROUBLESHOOTING MANUAL (IOM) IN CONJUNCTION WITH THE PUMP IOM. THE CONTROLLER IOM COVERS THE CONTROLLER ELECTRICAL INSTALLATION AND ANY SPECIAL INSTALLATION PROCEDURES REQUIRED WITH VARIABLE SPEED CONTROLLERS.

ITT WILL NOT BE RESPONSIBLE FOR ANY DAMAGES TO AN INSTALLATION WHERE THE PRESSURE RELIEF VALVE IS ALLOWED TO DISCHARGE INTO A FINISHED LIVING SPACE OR TO OTHERWISE DAMAGE A CUSTOMERS PROPERTY. PLUMBING SAFETY DEVICES SUCH AS PRESSURE RELIEF VALVES TO AN APPROPRIATE DRAIN IS THE RESPONSIBILITY OF THE INSTALLER AND IS OUT OF OUR CONTROL.

DANGER

WARNING

CAUTION

WARNING

1: SAFETY INSTRUCTIONS

WARNING

1: SAFETY INSTRUCTIONS

TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN MANUAL AND ON EQUIPMENT.

THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH THE UNIT.

This is a SAFETY ALERT SYMBOL. When you see this symbol on the pump, the controller or in the manual, look for one of the following signal words and be alert to the potential for personal injury or property damage.

Warns of hazards that WILL cause serious personal injury, death or major property damage.

Warns of hazards that CAN cause serious personal injury, death or major property damage.

Warns of hazards that CAN cause personal injury or property damage.

NOTICE: INDICATES SPECIAL INSTRUCTIONS WHICH ARE VERY IMPORTANT AND MUST BE FOLLOWED.

THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS PRIOR TO PERFORMING ANY WORK ON THIS CONTROLLER.

MAINTAIN ALL SAFETY DECALS.

TYPICAL INSTALLATION

This controller is not designed for use around swimming pools, open bodies of

water, hazardous liquids, or where ﬂammable gases exist.

Do not use GFCI input power. This will cause nuisance faults.

Disconnect and lockout electrical power before installing or servicing any electrical equipment.

ELECTROCUTION HAZARD.

CONTROLLER INPUT GROUND TERMINAL (GND) AND ALL EXPOSED METAL PIPING, INCLUDING PRESSURE TRANSDUCER CASE, MUST BE CONNECTED TO THE SERVICE ENTRANCE GROUND TERMINAL.

All electrical work must be performed

by a qualiﬁed technician. Always follow the National Electrical Code (NEC), or the Canadian Electrical Code, as well as all local, state and provincial codes. Code questions should be directed to your local electrical inspector. Failure to follow electrical codes and OSHA safety standards may result in personal injury or equipment damage. Failure to follow manufacturer’s installation instructions may result in electrical shock, ﬁre hazard, personal injury or death, damaged equipment, unsatisfactory performance, and may void manufacturer’s warranty.

NOTICE: Some installations pull a vacuum on the transducer when the system is drained. The new controller is designed to protect against up to 17” Hg. of vacuum on the transducer. An optional Gauge Guard, order no. 6K210, will protect the transducer from a vacuum condition.

PARTS DESCRIPTION:

1) Pump and Motor 10) Power Supply Cable

2) Check Valve (built-in 11) Service Entrance on some models) 12) Pressure Sensor Cable

3) Torque Arrestor (optional) with drip loop

4) Pump Power Cable 13) Diaphragm Tank with Splice Kit 14) Pressure Transducer

5) Electrical Tape 15) Pressure Gauge (Cable to Pipe) 16) Relief Valve

6) Safety Rope (optional) 17) Shut-Off Valve

7) Well Cap / Seal 18) Drop Pipe

8) Pitless Adapter 19) Lateral Pipe

9) Controller 20) Electrical Disconnect

Ratings

WARNING

CAUTION

WARNING

CAUTION

Refer to serial number label on enclosure.

Required Materials

• BF Pump Controller with Transducer and Transducer Wire

• Pump (water end) (see Speed Selector Switch for 60 Hz or 80 Hz Operation)

• Motor: 230 V, three phase (3Ø), 3450 RPM

• Pressure Relief Valve – piped to a drain for safety

• Pressure Gauge – for setting system pressure

• Heat Shrink Kit – one required for each underwater or underground splice (mandatory)

• Tank Tee or (2) ¼" NPT Female pipe ﬁttings for pressure sensor and pressure gauge connections

• Pipe and ﬁttings – as necessary per each system

• Disconnect Switch: 230 V, 2 pole, properly sized

(see Controller, Breaker, Generator Sizing Table)

• Copper Wire: Minimum 75ºC rated wire, double jacketed is recommended but not mandatory (see Wire Sizing table)

• Tank: diaphragm style tank

(see Tank Sizing Section and Chart)

2: INSTALLATION

Determine where the Controller, Pressure Tank and Transducer will be located before starting the installation.

Controller

The controller is rated NEMA 3R (Raintight) so it may be located outdoors. It must be mounted vertically. Locate the enclosure in a shaded area where the temperature stays within 0ºF to +122ºF (-18ºC to +50ºC). Since the controller is designed for outdoor mounting it may be located at the wellhead.

Opening Controller Cover

Lay the controller on a ﬂat surface or hang

on wall before removing the cover screw. Failure to do so may result in dropping and damaging the unit. Once screw is removed, lift the cover up and out to

remove. There is a locking tab on the bottom of the unit to accommodate a padlock if so desired.

Mounting Controller

Three screws are provided for mounting the enclosure. Using the enclosure as a guide, select a mounting location.

First install the top screw in the mounting surface leaving the head of the screw approximately 1⁄8" from the surface. Hang the enclosure on this screw. Finish by installing the two bottom screws and tightening the top screw. Be sure

to leave a minimum of 6" of clearance on each side of the controller to ensure proper cooling.

EXPLODING TANK CAN INJURE OR KILL.

Always protect the tank from over pressure by installing a pressure relief valve large enough to limit the system pressure below the maximum working pressure of the tank. Install the tank at a point in the system where the maximum possible system pressure cannot exceed the maximum working pressure of the tank. Install the pressure relief valve at the tank.

Avoid property damage caused by pressure

relief valve opening. Pipe the pressure relief valve discharge to a drain or other location so that property damage and ﬂooding will not occur.

Locate the tank and transducer where they

will not freeze. Ensure the system pressure setting does not exceed the

maximum working pressure of the tank. For optimum performance, as a minimum, we recommend

using the same size pipe as the pump discharge between the pump and the tank. Smaller diameter pipe may severely limit the maximum capacity of the system. On long runs, larger pipe may be beneﬁcial for optimum performance and ﬂow.

If using a torque arrestor, install it on the

discharge pipe before connecting pipe to the discharge head.

Diaphragm Tank Sizing and Pre-Set Pressure Recommendations:

Diaphragm type (captive air) tanks are required on these systems.

Table 1: Tank Sizing Selection

Maximum

Pump GPM

10 2 V6P TP6P 23 4.5 V15P TP15P 41 8.2 V25P TP25P 70 13.9 V45 TP45 100 19.9 V60 TP60

Use Total Tank Volume, not drawdown volume, to select the proper tank size. The total tank volume should be approximately 20% of the pump’s maximum ﬂow. For example, when using a 10 gpm pump the system requires a 2 gallon (total volume) tank.

The tank sizing recommendations are ﬁeld proven to prevent objectionable pressure drops on start-up and provide smooth operation for the majority of variable speed pump systems.

Recommended Tanks

Total Volume Order No. or Order No.

For a 5 PSI Pressure Drop Set-up:

Set the tank pressure, while tank is empty of water, to 20 psi below the desired system pressure setting. Ex. for a 50 psi system pressure, charge the tank to 30 psi.

Pump and Piping

Do not install any valves, ﬂow control

devices or ﬁlters between the pressure transducer and the pump. It is allowable to run branches off the pipe between the pump and transducer as long as no ﬂow restricting devices are between the pump and transducer.

NOTICE: The terms Transducer and Pressure Sensor are

equal and interchangeable.

For a 20 PSI Pressure Drop Set-up:

Start with the tank pre-charge set 30 psi below the set point, this setting may need minor adjustment for optimum performance as all systems and piping are slightly different.

Splicing Drop Cable To Motor Leads

The underwater connection where the drop cable connects to the motor wires must be done using a waterproof heat shrink kit. To make the connection, ﬁrst strip the wires ½" and place the heat shrink tubes over the wires. Then,

CAUTION

connect the wires using the crimps. Finish by shrinking the

CAUTION

WARNING

CAUTION

tubes over the crimps heating from the center outward. The sealant in the tube will ﬂow out the ends making a watertight seal. If a heat shrink tube is burnt or split, the connection will need to be remade.

Vinyl electrical tape is not acceptable for

underwater splices when using variable speed drives due to the high potential for leakage to ground through taped joints. Failure to use a waterproof heat shrink kit will void the warranty.

Before installing the motor in the well, the drop cable must be connected to the motor wires. Refer to the wire size chart when selecting wire size for the drop cable. See Wire Sizing Table.

Figure 1: Transducer Grounding

Wiring Pressure Transducer

Transducer wires must never be in same

conduit with power wires. There should always be a minimum of 12" between transducer wires and power wires. Failure to separate these wires can cause controller malfunctions.

The pressure transducer cable is pre-wired at the factory. If desired, the length of the cable can be changed. The cable can also be put in conduit to protect against damage.

To change the length of the transducer cable:

• Cable length cannot exceed 200'.

• Disconnect transducer wires from terminal block by pushing

down on tabs at rear of block one at a time and pulling the wires out of the terminal.

• Splice additional cable to transducer wire, cut off excess as

required.

• Reconnect wires to terminal block. Be sure wire colors match

labels on circuit board (B = Black, R = Red, W = White).

To put the transducer cable in conduit, do the following: Disconnect the cable from the terminal block and remove the cable strain relief in the bottom of the enclosure. Starting at the enclosure, run ﬂexible or rigid ½" conduit to where the transducer is located. The last few feet of conduit adjacent to the transducer will need to be ﬂexible. The conduit must be well supported – NO stress can be placed on the pressure transducer connector. Use a strain relief bushing to seal around the pressure transducer connector.

After reconnecting the transducer wires to

the terminal block and ground terminal, tug on each wire individually to ensure they are tight.

Any exposed metal in the system piping,

including transducer case, must be grounded to the service entrance per NFPA 70: National Electrical Code, Article 250.

The transducer cable has a Green ground wire and a ground clamp supplied to facilitate grounding the transducer. See Figure 1.

Motor Wires – See Table 4

NOTE: A MINIMUM OF 75ºC COPPER WIRE IS MANDATORY.

Refer to the Table 4 for wire sizing and maximum wire lengths. Charts are designed to limit voltage drop to 5%.

Figure 2 shows the terminal block where the motor and input wires connect. The protective cover on the terminal block snaps off and on. Attach the motor wires to the terminals according to colors marked on circuit board: GND = Green, RED = Red, BLK = Black, YEL = Yellow. Reversing any two leads on RED/BLK/YEL will change the direction of motor rotation. Later during start-up you may need to change motor rotation.

Input Power

SHOCK OR ELECTROCUTION HAZARD

Connect a ground wire from the service panel to the terminal marked GND. Controller has high leakage to ground. Controller ground terminal must be connected to the service entrance ground terminal. Failure to do so will result in high voltage being present on the controller chassis. Connect two “hot” wires from the 2 pole circuit breaker to the terminals marked L1 and L2.

The input power system used must be a grounded power system. The voltage measured from L1 to L2 must be in the range of 196Vac to 265Vac. The voltage measured from L1 to GND must be equal to the voltage measured from L2 to GND. These voltages must be within the range of 120Vac +/- 10%. Reduced input voltage will reduce system performance.

Do not use a Ground Fault Circuit Interruptor (GFCI) with this product or nuisance tripping will result.

Incoming Power

Figure 2: Wiring Connections

NOTE: IT MAY BE NECESSARY TO PLACE A DISCONNECT SWITCH IN FRONT OF AND WITHIN SIGHT OF THE CONTROLLER – CONSULT LOCAL CODES.

Wires to Motor

Size wire for worst case scenarios (low voltage) and stay within the charts recommendations. Insure that the wire is rated for direct burial and/or submergence.

3. INSTALLER PRE-START SELECTIONS

WARNING

3: INSTALLER PRE-START SELECTIONS DRIVE SETTINGS AND PROTECTION

Maximum Frequency (Speed) Switch

The Maximum Frequency switch sets the maximum frequency (motor speed) the controller uses to energize the motor to either 60 or 80 Hz.

• 60 Hz - Use for matched pump-motor combinations

where the motor HP and pump HP are the same. Example: 2 HP WE and 2 HP Motor

• 80 Hz - Use for mis-matched pump-motor combinations

where motor HP is larger than the pump HP (typically 2x larger). Example: 1 HP WE and 2 HP Motor

• The unit is factory pre-set at 60 Hz.

Dry Well Sensitivity

Selections are High or Low. This function protects the system from running dry. The selection depends on several conditions and pump size.

Start with the sensitivity on high and test by running pump at various ﬂows. If a dry well fault is triggered, switch to low setting. The unit is factory pre-set at high.

Restart times in minutes are: 1, 10, 20, 30, 60, 60 and repeating every 60 minutes thereafter.

Example: 1st fault shuts down for 1 minute, next fault shuts down for 10 minutes, then 20, etc.

• See Table 3 or the motor nameplate for Motor Amperage ratings. The controller limits the output current to the value selected by this dial. It does this by lowering the frequency and voltage. If the current does not come within the selected value by the time the frequency is at 40Hz, the controller will shut down and indicate Bound Pump error (4 red blinks).

PRESSURE ADJUSTMENT Pressure Adjustment Pushbuttons

The INCREASE and DECREASE pushbuttons are used to set the desired pressure. To adjust pressure, press and hold (do not tap) the button until the desired pressure is obtained. It may take a full minute to adjust the pressure from maximum to minimum, please be patient. Pressure can only be changed when the pump-motor is running.

Controller Status Indicator (Light Visible Through

Window in Cover)

The controller status indicator light has 3 possible modes:

• Solid green = Standby, pump not running. There is no water ﬂow or the SWITCH INPUT is open.

• Blinking green = Pump running. There is ﬂow (possibly a leak) and the SWITCH INPUT terminals are connected to each other (closed).

• Red = Error/Fault. Light will blink to indicate a particular fault. See Troubleshooting Section for Fault Codes.

Broken Pipe Protection

ON Position - Used for constant pressure systems. The drive will turn off if the system pressure drops 20 PSI below the system set point pressure for a minimum of 30 seconds. This fault must be manually reset, it will not

clear automatically, this may prevent property damage if a pipe breaks.

OFF Position - Use for open discharge situations such as ﬂushing a tank, ﬁlling a pond or tank, or whenever the system pressure will be 20 psi or more below the system set point pressure.

Pressure Drop – 5 PSI or 20 PSI

The pressure drop before the pump restarts can be set to the standard 5 PSI or to 20 PSI.

The 20 PSI setting results in fewer starts for systems with leaks. It is recommended for irrigation systems. It will require a tank pre-charge adjustment. See Tank Sizing.

CURRENT LIMIT PROTECTION Motor Overload Setting Dial

Failure to properly adjust the Motor Overload Setting before applying power may

damage the motor or wire and void the warranty.

• Use Table 2 to determine which controller and setting to use. Note that some 200V motors require upsizing to the next larger controller.

• Set the Motor Overload - Turn the dial pointer to align with the motor’s service factor amps (SFA) as listed on the Motor Overload / Current Limit chart. Choose the amperage value from the Current Limit Settings chart on UIB that is closest to the SFA listed on the motor nameplate but not higher.

Purging System

Open a valve and turn power on to the controller. If the system pressure is below the factory preset pressure setting (50 psi), the status light will begin blinking green indicating that pump is running. The controller hums when it is running. This is normal.

It is common for the pump to be air bound at ﬁrst, especially with shallow wells. In this case, the controller will begin testing for a dry well (refer to the troubleshooting section for a description of Dry Well Detection).

Once the water is ﬂowing, be sure to open all valves to purge air from the system.

Checking Rotation

It is possible that the motor is rotating in

the wrong direction. The pump will work but will have greatly reduced performance if rotating backwards.

To check rotation, perform the following test: Connect an amp probe to one of the power supply wires. Run the system with several valves open and note the pressure and amps. Leave the valves open, turn the power off, and wait 5 minutes for the hazardous voltages to discharge.

Swap red and black motor leads where they connect to the controller terminal block (NOT L1 and L2).

Turn power back on and let the system pressure stabilize. Again note the pressure and amps. Whichever wire position provided the most pressure/ﬂow is the correct wire position. If there was little difference in the pressure/ﬂow, then whichever had the lower amp reading is the correct wire position.

Turn the power off, wait 5 minutes and swap the wires back if necessary.

Replace the plastic protective covers on the terminal

DANGER

block.

Checking for leaks

Constant pressure systems utilizing small tanks run whenever there is demand. Even small leaks can prevent a pump from turning off. To check for leaks, close all valves, turn power off to the controller, and note the pressure displayed on the pressure gauge. Tap the gauge to ensure you get an accurate reading.

Wait ten minutes and check the gauge again tapping to prevent the needle from sticking. If the pressure dropped then the system may have a leak*.

*If a system is pressurized after having been unpressurized, it will continue to expand for several minutes. This expansion causes the pressure to drop and can be misinterpreted as a leak. Allow a system to stabilize for 10 minutes under pressure before performing the aforementioned leak test.

A spring check valve placed on the pump side of the tank and transducer will often improve the ability of the system to shut down.

SWITCH INPUT Optional Switch Input and Switch Input

Status Light

Log onto www.centripro.com, click on Goulds Pumps or Red Jacket, click on Electrical Controls Water, click on Balanced Flow for more detailed examples on using the Switch Input.

Electrocution Hazard. Opening SWITCH

INPUT does not de-energize controller or any of its outputs. Always treat wire terminals of this controller as energized until power supply to the controller has been removed for 5 minutes.

SWITCH INPUT - for connection of an external switch or control device used to start and stop the pump. Devices such as an over-pressure switch, level (ﬂoat) switch or any other non-powered switch (time delay, ﬂow, etc.) can be connected to this input.

The Switch Input terminals have a Jumper Wire installed at the factory (do not confuse the jumper wire on the Switch Input with the Transducer Jumper next to the Transducer Connection Terminals, see Transducer Jumper below). The Switch Input terminals must be connected (closed) for the pump to operate. If they are not connected the Switch Input Status Light (visible inside the enclosure) will be Solid RED and the Controller Status Light will be Solid GREEN indicating that the pump-motor is off. Remove the Jumper Wire when connecting a ﬂoat or over-pressure switch:

CONSTANT PRESSURE SYSTEM - with an Over-Pressure

Switch:

• Connect two wires from the Load and Lead connections

of a pressure switch to provide over-pressure protection. In the event the pressure transducer fails, this will prevent high pressure from damaging piping.

• The over-pressure switch cut-out setting must be a mini-

mum of 10 PSI higher than the system set point pressure.

• Set the over-pressure switch cut-out 5 - 10 PSI lower than

the pressure relief valve (PRV) pop-off pressure. This will turn the system off before the pressure relief valve opens.

• Ex. On a system with a 50 PSI set point, set the over-pressure switch cut-out at 60 PSI with a typical PRV setting of 75 PSI. In the event the transducer fails at high pressure the switch will turn the system off before the PRV pops.

• Typical UIB Settings For This Type System:

• 60 or 80 Hertz (depends on pump/motor)

• Dry Well - High (switch to low if it trips while pumping water)

• Broken Pipe - On

• Pressure Drop - 5 PSI

• Transducer - Connected

• Transducer Jumper - Bottom Position (Factory Setting)

• Pressure Switch Connected to Switch Input

FLOAT SWITCH OPERATION - Filling a Pond or Tank

(Non-Constant Pressure System):

• Connect two wires from a ﬂoat (level) switch to ﬁll or empty a tank, pond, etc. The pump will run when the level switch contacts close. The maximum switch wire length tested is 200’. The pump will run at maximum speed when the ﬂoat switch is closed.

• Typical UIB Settings For This Type System:

• 60 or 80 Hertz (depends on pump/motor)

• Dry Well - High (switch to low if it trips while pumping water)

• Broken Pipe - Off

• Pressure Drop - 5 or 20 PSI

• Transducer - Not Connected

• Transducer Jumper - Top Position (Installer Must Move)

• Float Switch Connected to Switch Input

FLOAT SWITCH OPERATION - Filling a Pond or Tank

and Constant Pressure System:

• Connect two wires from a ﬂoat (level) switch to ﬁll or empty a tank or pond and a pressurized system. The maximum switch wire length tested is 200’. The pump will operate at various speeds and try to maintain the set point pressure. If piping is large and it cannot maintain set point pressure it will operate at maximum speed.

• Typical UIB Settings:

• 60 or 80 Hertz (depends on pump/motor)

• Dry Well - High (switch to low if it trips while pumping)

• Broken Pipe - On (switch to off if pressure drops by 20 PSI or more)

• Pressure Drop - 5 PSI

• Transducer - Connected

• Transducer Jumper - Bottom Position (Factory Setting)

• Float Switch Connected to Switch Input

Transducer Jumper

Explosion Hazard. Keep jumper in bottom

position whenever a pressure transducer is used. Failure to do so may cause a pressure transducer error to be ignored and an over-pressure hazard to result.

For applications not requiring a pressure transducer such as level control, the transducer can be removed. When the transducer is not used, the Transducer Jumper must be placed in the top position to prevent a sensor error. Never place the jumper in the top position when using a pressure transducer.

USER INTERFACE BOARD

Drive

Settings /

Protection

Pressure

Adjustment

Current Limit Dial

(Motor Overload

Protection)

Pressure

Transducer

Connection

TRANSDUCER JUMPER

Switch Input (Over

Figure 3: UIB (User Interface Board)

Pressure Protec-

tion, Level Control)

Table 2: Controller, Breaker, Generator Sizing Table 3: Service Factor Amps 3 Phase Motors

3 Phase Motor Controller Model ②  Circuit Generator ④ HP Voltage ① BF20 BF30 BF50 Breaker ③ (VA)

¾ 230 200 1 230 200

230

1½

200 2 230 200 230 3 40 5 230 200

8100

200

2900

3500

4400

6100

13300

230 Volt, 3Ø 200 Volt, 3Ø

CentriPro Franklin CentriPro Franklin

SFA SFA SFA SFA

¾ 4.0 3.8 4.5 4.4 1 4.7 4.7 5.5 5.4 1½ 6.1 5.9 7.2 6.8 2 7.6 8.1 8.8 9.3 3 10.1 10.9 12 12.5 5 17.5 17.8 20.2 20.5

NOTES:

① Motor Nameplate must be the same as supply voltage. ② Shaded areas indicate which controller models can be used with which

motors. Lighter shading indicates combinations where controller will limit peak performance to 85% of catalog value for pump/motor.

③ Circuit Breaker or Dual Element Time Delay Fuse Size (Amps) protecting

branch circuit supplying controller.

④ Minimum size of single phase 240 V generator required.

Table 4: Wire Sizing

Maximum Cable Lengths in Feet to Limit Voltage Drop to 5% for 230 V Systems ①

Service Entrance to Controller

Controller Motor

Input

½ 366 583 925 1336 2107 3345 4175 5267 6637 8364 ¾ 279 445 706 1020 1608 2552 3186 4019 5065 6383 8055 1 226 360 571 824 1300 2064 2576 3250 4095 5161 6513 8201

230V

1½ * 286 455 657 1036 1644 2052 2589 3262 4111 5188 6533 8236 9710

1 PH

2 * * 331 478 754 1197 1495 1886 2376 2995 3779 4759 5999 7073 8455 9852 3 * * 246 355 561 890 1111 1401 1766 2225 2808 3536 4458 5256 6283 7321 8343

5 * * * 218 343 545 680 858 1081 1363 1720 2165 2730 3219 3847 4483 5109 6348

Controller to Motor

Controller Motor

Input

½ 905 1442 2290 3306 5213 8276 ¾ 690 1100 1748 2523 3978 6316 7884 9945 1 558 890 1413 2040 3216 5106 6375 8041

230V

1½ 445 709 1126 1625 2562 4068 5078 6406 8072

3 PH

2 324 516 820 1184 1866 2963 3699 4666 5879 7410 9351 3 241 384 609 880 1387 2202 2749 3467 4369 5506 6949 8750 5 * 235 373 539 849 1348 1683 2123 2675 3372 4255 5358 6755 7964 9520

① Reduce lengths by 13% for 200 V systems. * Wire does not meet the N.E.C. ampacity requirement. ② Lengths in bold require 90º C wire. Shading indicates 40º C maximum ambient.

Copper Wire Size 75ºC Insulation Exposed to a Maximum of 50ºC (122ºF) Ambient Temperature ②

14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500

Copper Wire Size 75ºC Insulation Exposed to a Maximum of 50ºC (122ºF) Ambient Temperature ②

14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500

The lengths in each of the Wire Sizing tables represent 100% of the allowable voltage drop when motor is running at full load. When sizing wire, the voltage drop of each wire segment must be included. The total must not exceed 100% of the allowable drop. Take for example a 1.5 HP motor with a distance from Service Entrance to Controller of 100' and 500' between the Controller and Motor.

• Service Entrance to Controller = 100' of 10 AWG (100/455) = 22 % (455' is from the S.E. to Controller chart)

• Controller to Motor = 500' of 12 AWG (500/709) = 71 % (709' is from the Controller to Motor chart)

Total Drop (must be ≤ 100%) 93 % If the distance from the Controller to Motor was 600' (600/709) = 85% + 22% = 107%, we would need to

use #10 wire for that segment, ex. 600/1126 = 53% + 22% (for 100' of #10) = 75% which is acceptable. It is also acceptable to use different wire sizes for the Buried and Well sections of wire.

Table 5: Possible Combinations for TRANSDUCER, JUMPER AND SWITCH INPUT

Scenario

Transducer Position Input Status Indicator Indicator

Bottom Open Disabled Solid Green Solid Red

Constant

pressure operation

else solid green

Level or pressure

switch control

* See description of Maximum Speed Switch and Motor Overload Setting Switch for their effect on Full Speed value.

Pressure Jumper Switch Controller Status Switch Status

Connected

Top Open Disabled Solid Green Solid Red

Not

Connected

Bottom Closed Constant pressure

Top Closed Run Full Speed* Blinking green Off

Blinking green if ﬂow

Off

4: TROUBLESHOOTING

The status light described in Section 3 Installer Pre-Start Selections is used to indicate system status i.e. running, stopped, or faulted. When faulted, the status light will be red. The error code is the number of quick ﬂashes followed by a 1 second pause. The number of ﬂashes can be any number from 2 to 8. The error code will be repeated until cleared. Some errors will clear themselves with time. Others must be cleared manually by turning the power off for 1 minute. The following table describes the various errors that can occur.

NO LIGHT

Flashes Controller Status Description

None Low/No Input Voltage Check the input voltage to the controller. Measure the voltage between L1 and L2 using an AC Voltmeter. This voltage should be greater than 190Vac.

GREEN LIGHT CODES

Flashes Controller Status Description

Constant Standby/Low Voltage Constant Green Light indicates the pump is off. The system is in Standby mode when there is no ﬂow in the system and the pressure setting has been reached. The system is in a Low Voltage condition when the line input voltage drops below 190VAC.

Blinking Pump Running Flashing Green Light indicates the pump is running.

RED LIGHT CODES

Flashes This information is to be used by professional installers or qualiﬁed

Constant Controller Error Internal controller fault. Replace controller.

2 Blinks Dry Well This fault can be caused by:

• Water supply level in well falls below suction inlet of pump.

• Plugged suction screen.

• Restriction in pipe between pump and pressure sensor.

• Air bound pump – see “Purging System”

• Incorrect setting of “MAXIMUM SPEED” switch. Be sure to set the “MAXIMUM SPEED” switch to 80 Hz when using mismatched pumps (water ends) and motors.

• Incorrect setting of “MOTOR OVERLOAD SETTING (SFA)” switch. Ensure the Motor Overload Setting (SFA) Switch is not set higher than the

Service Factor Amps (SFA) listed on the motor nameplate.

In systems where the motor operates at less than Service Factor Amps the controller may show a false “dry well” fault. See Dry Well Sensitivity Section.

If problems persists, please verify supply capacity. The controller will automatically restart according to the chart below.

Dry Well Fault Reset table: Fault 1 (Start Point) - resets after 1 minute

Fault 2 - resets after 10 minutes Fault 3 - resets after 20 minutes Fault 4 - resets after 30 minutes Fault 5 - resets after 60 minutes

Will repeat every 60 minutes, when the system cycles Off the Dry Well will default back to the start point.

Controller Status

Controller Action

To clear the fault, turn off

power to the controller, wait

1 minute, turn on power to

the controller. If fault persists

contact installer.

The controller will

automatically restart according to the table shown on the right. If fault persists contact installer.

Fault Description

personnel only.

Table 6: Fault Blink Codes (continued on next page)

WARNING

RED LIGHT CODES

Flashes Controller Status Description

3 Blinks Sensor Fault This fault can be caused by:

• Disconnected sensor. Disconnect sensor from sensor cable connector and

The controller will not run

if the signal from the

sensor is disconnected or out

of tolerance. The controller will automatically restart when the signal is within tolerance. If

fault persists contact installer.

reconnect to ensure a good connection.

• Disconnected sensor cable lead inside the controller. Check for loose wires where the sensor cable connects to the circuit board by tugging on each wire.

• Broken wire in the sensor cable.

• Miswired sensor cable. Check that the wires are connected to the correct terminals on the sensor connector. The correct location of the wires is indicated on the circuit board. B=Black, R=Red, W=White.

• Failed sensor. With the sensor cable connected to the circuit board, measure the DC voltage between the black and white wires of the sensor cable at the sensor connector. The voltage measured should be between 0.5Vdc and

4.5Vdc depending on the system pressure, see chart below.

• A vacuum on the sensor (transducer) of 17" Hg or more will cause a sensor fault, eliminate the vacuum.

4.5

3.5

2.5

1.5

Transducer Output (Volts DC)

0.5

0 25 50 75 100 125 150 175 200

Sensor Output vs. Applied Pressure

Pressure (PSI)

100 PSI Sensor 200 PSI Sensor

4 Blinks Pump or Motor Bound This fault can be caused by:

• Installing a 1Ø motor - system requires a 3Ø, 200 or 230 V motor.

• Mechanical binding from debris in pump.

• Electrical failure of the motor.

• Incorrect setting of “MOTOR OVERLOAD SETTING (SFA)” switch. A false “bound pump” error will be displayed if the switch is set too low.

Verify the error by turning power to controller off for 1 minute and then on.

The controller will try to restart the motor three times before displaying

this fault. To clear the fault, turn off power to the controller, wait 1 minute, turn on power to the controller.

If fault persists contact installer.

Pump/Motor must be checked if fault persists. 5 Blinks Short Circuit This fault can be caused by:

• Electrical failure of the motor.

• Electrical failure of wiring between controller and motor. Verify the error by turning power to controller off for 1 minute and then on.

If error persists, motor and wiring between controller and motor must be checked. Turn power off for 5 minutes. Remove the three motor wires from the terminal block. Check wiring and motor for shorting phase to phase and phase to ground. Refer to motor’s manual for information on resistance readings.

If this fault is detected while

the pump is running, the

controller will attempt to restart

three times before displaying this

fault. To clear the fault, turn off power to the controller, wait 1 minute, turn on power to the controller.

If fault persists contact installer.

6 Blinks Ground Fault This device does not provide personnel protection against

shock. This function is intended for equipment protection only.

This fault can be caused by:

• Electrical failure of the motor

• Electrical failure of wiring between controller and motor.

• Miswiring of motor cable.

The controller will not restart if displaying this fault. To clear the fault, turn off power to the

controller, wait 1 minute, turn

on power to the controller. If fault persists contact installer.

Verify the error by turning power to controller off for 1 minute and then on. If error persists, motor and wiring between controller and motor must be checked. Turn power off and wait 5 minutes. Remove the three motor wires and ground wire from the terminal block. Check wiring and motor for shorting phase to ground using a megohmmeter (“megger”). A reading less than 200K Ohms indicates faulty insulation in the motor cable or motor. Test each to determine fault location.

Table 6: Fault Blink Codes (continued on next page)

ITT

CentriPro

Flashes Controller Status Description

7 Blinks Temperature This fault can be caused by:

• High ambient temperature. The maximum ambient temperature rating is 122º F (50º C).

• Low ambient temperature. The minimum ambient temperature rating is -4º F (-20º C).

Check for a fan failure. The fan will turn on when the temperature inside the controller reaches 140º F (60º C). The fan will turn on for 1 second each time the controller starts the motor. If the fan never turns on, check fan connections and replace as needed. Ensure that the external fan intake ﬁlter is not blocked or clogged. It can be removed for cleaning and replacements are available.

8 Blinks Open Lead This fault can be caused by:

• Disconnected or broken wire between the controller and motor. Verify the error by turning power to controller off for 1 minute and

then on. If error persists, motor and wiring between controller and motor must be checked. Turn power off for 5 minutes. Remove the three motor wires from the terminal block. Using an ohmmeter, measure the resistance from phase to phase. A disconnected or broken wire will be indicated by a high resistance reading (20 ohms or higher).

9 Blinks Broken Pipe This fault can be caused by:

• Pressure 20 PSI below set point for 30 seconds. May be a broken pipe or tripped pressure relief valve. If 20 PSI or more pressure drop for 30 seconds is normal for the system, switch the broken pipe protection off or change system to prevent the pressure drop.

The controller will auto-

matically restart when the

temperature reaches an acceptable level. If fault

persists contact installer.

The controller will not restart if displaying this

fault. To clear the fault, turn

off power to the controller,

wait 1 minute, turn on pow-

er to the controller. If fault

persists contact installer.

The controller will not restart if displaying this

fault. To clear the fault, turn

off power to the controller,

wait 1 minute, turn on pow-

er to the controller. If fault

persists contact installer.

Table 6: Fault Blink Codes (continued from previous page)

Residential & Commercial Water Systems

RED LIGHT CODES

This warranty applies to the Balanced Flow Series Controller manufactured by CentriPro. Any part or parts found to be defective within the warranty period shall be replaced at no charge to the dealer during the warranty period. The warranty pe-

riod shall exist for a period of twenty-four (24) months from date of installation or thirty (30) months from date of manufacture, whichever period is shorter. A dealer who believes that a warranty claim exists must contact the authorized CentriPro distributor from whom the equipment was purchased and furnish

complete details regarding the claim. The distributor is authorized to adjust any warranty claims utilizing the CentriPro Customer Service Department.

The warranty excludes:

(a) Labor, transportation and related costs incurred by the dealer; (d) Consequential damages of any kind; and, (b) Reinstallation costs of repaired equipment; (e) Reimbursement for loss caused by interruption of service. (c) Reinstallation costs of replacement equipment;

For purposes of this warranty, the following terms have these deﬁnitions:

(1) “Distributor” means any individual, partnership, corporation, association, or other legal relationship that stands between CentriPro and the dealer in

purchases, consignments or contracts for sale of the subject equipment.

(2) “Dealer” means any individual, partnership, corporation, association, or other legal relationship which engages in the business of selling or leasing equip-

ment to customers.

(3) “Customer” means any entity who buys or leases the subject equipment from a dealer. The “customer” may mean an individual, partnership, corporation,

limited liability company, association or other legal entity which may engage in any type of business.

CentriPro and the ITT Engineered Blocks Symbol are registered trademarks and tradenames of ITT Corporation.

SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

CENTRIPRO LIMITED WARRANTY

THIS WARRANTY EXTENDS TO THE DEALER ONLY.

IM182 Revision 12 February, 2010

Engineered for life

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