Pentair 4 160 manual

IntelliFlo ® 4 160 and 100 V ar iab le Speed Programmab le Pump (Compatib le with IntelliT ouch ™ , EasyT ouch ™ and IntelliComm) Installation and User’ s Guide IMPOR T ANT SAFETY INSTR UCTIONS READ AND FOLLO W ALL INSTR UCTIONS SA VE THESE INSTR UCTIONS[...]

© 2006 P entair Water P ool and Spa, Inc. All rights reserved This document is subject to change without notice 1620 Hawkins A v e., Sanf ord, NC 27330 • (919) 566-8000 10951 W est Los Angeles A ve., Moorpar k, CA 93021 • (805) 553-5000 T rademarks and disclaimers : EasyT ouch, IntelliChlor , IntelliFlo , Quick T ouch and the P entair W ater P[...]

i IntelliFlo 4 Installation and User ’ s Guide Important Safety Precautions ........................................................................................... ii Section 1: IntelliFlo Overview ........................................................................................... 1 IntelliFlo 4 V ariable Speed Pump ..................[...]

ii IntelliFlo 4 Installation and User ’ s Guide Important Notice: Attention Installer: This manual contains impor tant inf or mation about the installation, operation and safe use of this product. This inf or mation should be given to the o wner and/or operator of this equipment. W ARNING — Before installing this product, read and follow all wa[...]

iii IntelliFlo 4 Installation and User ’ s Guide IMPORTANT SAFETY PRECAUTIONS (continued) W ARNING — W ater temperature in e xcess of 100° F ahrenheit may be hazardous to y our health. Prolonged immersion in hot water ma y induce h yper ther mia. Hyperther mia occurs when the internal temperature of the body reaches a level several degrees abo[...]

iv IntelliFlo 4 Installation and User ’ s Guide General Installation Information W ARNING — Pumps improperly sized or installed or used in applications other than for which the pump was intended can result in se v ere personal injur y or death. These r isks may include but not be limited to electric shock, fire, flooding, suction entrapment or [...]

1 IntelliFlo 4 Installation and User ’ s Guide Section 1 Overview IntelliFlo 4 V ariable 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 t[...]

2 IntelliFlo 4 Installation and User ’ s Guide 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 IntelliT ouch, EasyT ouch and IntelliComm system via a two-wire connection • Easy to use oper[...]

3 IntelliFlo 4 Installation and User ’ s Guide IntelliFlo 4 Drive Assembl y and Control P anel 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 [...]

4 IntelliFlo 4 Installation and User ’ s Guide Controls and LEDs 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 (31 10 RPM). The speed button LED is on when the selected but[...]

5 IntelliFlo 4 Installation and User ’ s Guide Section 2 Operating IntelliFlo 4 This section describes how to use the IntelliFlo 4 pump control panel. Setting the pump preset speed IntelliFlo 4 operates using one of the preset speeds. Use the speed buttons to select the preset speeds. T o set the pump speed 1. Ensure that the pump is powered on a[...]

6 IntelliFlo 4 Installation and User ’ s Guide Starting the pump T o start the pump 1. Ensure that the pump is powered on and the green power LED is on. 2. Press the S tart button (LED on) to start the pump. Note: When the pump is using a modified speed and is power ed down, the next time the pump is power ed up, the pump will use that same speed[...]

7 IntelliFlo 4 Installation and User ’ s Guide Priming the pump for the first time or after service Before the IntelliFlo 4 pump is started for the first time it must be primed. T o prime a pump means filling the pump and suction pipe with water . This process evacuates the air from all the suction lines and the pump. It may take several minutes [...]

8 IntelliFlo 4 Installation and User ’ s Guide Priming the pump for the first time or after service (Continued) Priming the Pump • Release all pressure from filter , pump, and piping system; see the filter owner ’ s manual. • In a flooded suction system (water source higher than pump), the IntelliFlo 4 pump will prime itself when suction an[...]

9 IntelliFlo 4 Installation and User ’ s Guide External Control with IntelliComm Communication Center The IntelliFlo 4 can be remotely controlled by the Pentair IntelliComm Communication Center using an optional communications cable (P/N 350122). The IntelliComm provides four pairs of input terminal connections. These inputs are actuated by eithe[...]

10 IntelliFlo 4 Installation and User ’ s Guide Connecting IntelliFlo 4 to an EasyT ouc h System The IntelliFlo 4 can be controlled by an IntelliT ouch system via the RS-485 communication cable (PN 350122). In this configuration, IntelliT ouch starts, stops and controls the speed of the IntelliFlo pump. When the IntelliT ouch does this, it rewrit[...]

11 IntelliFlo 4 Installation and User ’ s Guide 4. Lower down the hinged control panel to access the EasyT ouch motherboard. 5. Route the communication cable into the lower plastic grommet, up through the low voltage raceway to the EasyT ouch load center motherboard. 6. Strip back the cable conductors ¼ inch. Insert the two wires into the screw [...]

12 IntelliFlo 4 Installation and User ’ s Guide EasyT ouch Load Center (front view) Control panel access screw Control panel access screw High voltage cover panel Retaining screw 9. Close the control panel into its original position and secure it with the two access screws. 10. Install the high voltage cover panel and secure it with the two retai[...]

13 IntelliFlo 4 Installation and User ’ s Guide Section 3 User Maintenance The following information describes how to service and maintain the IntelliFlo pump. Pump Strainer Basket The strainer , sometimes referred to as the “Hair and Lint Pot,” is in front of the of the pump. Inside there is a basket which must be kept clean of leaves and de[...]

14 IntelliFlo 4 Installation and User ’ s Guide Motor Service 1. Protect from heat: • Shade the motor and controller from the sun. • Any enclosure must be well ventilated to prevent overheating. Particular attention should be paid to the motor fan cover and the cooling fins between the drive and the motor. • Provide ample cross ventilation.[...]

15 IntelliFlo 4 Installation and User ’ s Guide Priming the pump after service Before a system start-up, the pump and system must be manually primed. Make sure to reopen valves before operating. T o prime IntelliFlo 4, the strainer pot must be filled with water . CA UTION — DO NO T r un the pump dr y . If the pump is run dr y , the mechanical s[...]

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17 IntelliFlo 4 Installation and User ’ s Guide Section 4 Installation and Remo v al The following information describes how to install the IntelliFlo 4 pump. Note: Before installing this product, read and follow all warning notices and instructions on page ii. IntelliFlo 4 Kit Contents • IntelliFlo 4 160 (or IntelliFlo 4 100) pump Installing t[...]

18 IntelliFlo 4 Installation and User ’ s Guide GROUND WIR E (GREEN) BONDING LUG Wiring the IntelliFlo 4 T o connect the IntelliFlo 4 to an AC power source: 1. Make sure all electrical breakers and switches are turned off before wiring motor. 2. Make sure that the wiring voltage is 230 VAC. 3. Use #12 AWG for wire runs up to 100 feet and #10 AWG [...]

19 IntelliFlo 4 Installation and User ’ s Guide Pump Disassembly W ARNING — Always disconnect power to the pool pump at the circuit breaker and disconnect the communication cab le before servicing the pump. F ailure to do so could result in death or serious injury to serviceman, pool users or others due to electric shock. Read all servicing ins[...]

20 IntelliFlo 4 Installation and User ’ s Guide Pump Disassembly (Continued) 9 . T o unscrew the impeller from the shaft, twist the impeller counterclockwise. 10. Remove the rotating portion of the mechanical seal from the impeller . 1 1. Remove the four bolts from the seal plate to the motor , using a 9/16 inch wrench. 12. Place the seal plate f[...]

21 IntelliFlo 4 Installation and User ’ s Guide Drive Assembly Removal and Installation T o remove the IntelliFlo 4 drive and control panel from the motor assembly: 1. Make sure all electrical breakers and switches are turned off before removing the drive. 2. Disconnect the RS-485 communication cable from the pump. 3. Open the control panel cover[...]

22 IntelliFlo 4 Installation and User ’ s Guide Replacement Parts Item Part Description No. No. 1 070387 BASKET AQ & WF 2 070429 B OL T HEX HD , 2-56x0.875 s/s, (QTY 4) 3 070430 B OL T 3/8 - 16 X 1¼ HEX CAP 18-8 s/s, (QTY 4) 4 070431 B OL T 3/8 -16 X 2 HEX CAP 18-8 s/s, (QTY 2) 5 070927 FOOT WF - PUMP MOTOR SUPPORT 6 070929 FOOT INSERT WF PU[...]

23 IntelliFlo 4 Installation and User ’ s Guide IntelliFlo Pump Dimensions 10.78 12.50 23.41 IntelliFlo 4 Electrical Specifications Circuit Protection: T wo-pole 20 AMP device at the Electrical Panel. Input: 230 V AC, 50/60 Hz, 3200 W atts Intelliflo Flow and P ower vs Flow Pump Curve[...]

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25 IntelliFlo 4 Installation and User ’ s Guide W arning and Alarm conditions The IntelliFlo 4 alarms and warnings are indicated by flashing LEDs on the control panel. For example, if a “Drive T emperature” warning occurs, the LED will blink two times, then Of f, then blink two times. This sequence is repeated until the condition is cleared. [...]

26 IntelliFlo 4 Installation and User ’ s Guide General IntelliFlo 4 T roubleshooting Pr oblems Use the following general troubleshooting information to resolve possible problems with your IntelliFlo 4 pump. Note: Switch the main power off to the pump before attempting service or repair . m e l b o r Pe s u a C e l b i s s o P n o i t c A e v i t[...]

27 IntelliFlo 4 Installation and User ’ s Guide Problems and Corrective Action (Continued) m e l b o r Pe s u a C e l b i s s o P n o i t c A e v i t c e r r o C s p i r t r e k a e r b t i u c r i C . y l d e t a e p e r d n a m r a l A o t r e f e R e c n e u q e s D E L g n i n r a w . 5 2 e g a p n o . t n e r r u c r o t o m e v i s s e c x [...]

28 IntelliFlo 4 Installation and User ’ s Guide Notes[...]

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P/N 357269 - Rev B[...]