Pentair IntelliComm manual

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

© 2005 P entair W ater 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 ., Moor park, CA 93021 • (805) 553-5000 T rademarks and disc laimers : IntelliFlo , IntelliT ouch and the P entair W ater P ool and Spa logo are t[...]

i IntelliFlo Installation and User ’ s Guide Important Safety Precautions ........................................................................................... ii Section 1: Introduction ...................................................................................................... 1 IntelliFlo Overview ..............................[...]

ii IntelliFlo Installation and User ’ s Guide Contents (Continued) External Control with IntelliComm Communication Center ....................................... 2 9 External Control ..................................................................................................... 2 9 Setting up External Control using IntelliComm .............[...]

iii IntelliFlo Installation and User ’ s Guide 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 o wner and/or operator of this equipment. W ARNING — Before installing this product, read and follow all warning [...]

iv IntelliFlo Installation and User ’ s Guide IMPORTANT SAFETY PRECAUTIONS (continued) W ARNING — W ater temperature in e xcess of 100° F ahrenheit ma y be hazardous to your health. Prolonged immersion in hot water ma y induce h yper ther mia. Hyper thermia occurs when the inter nal temperature of the body reaches a level several degrees above[...]

1 IntelliFlo Installation and User ’ s Guide Section 1 Intr oduction IntelliFlo Overview The IntelliFlo variable-speed pump control system offers pool and spa filter automation and advanced features that include energy conservation and programmable scheduled water features for your pool, spa, cleaner , waterfall, and other applications. The Intel[...]

2 IntelliFlo Installation and User ’ s Guide IntelliFlo Features • Sizes itself to any pool • Reduces energy cost by as much as 90% • Protects against loss of prime or flow blockage • Prevents thermal overload • Detects and prevents damage from under and over voltage conditions • Protects against freezing • Can communicate with an I[...]

3 IntelliFlo Installation and User ’ s Guide IntelliFlo Motor Features • Permanent Magnet Synchronous Motor (PMSM) • High efficiency (3450 RPM 92% and 400 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 e[...]

4 IntelliFlo Installation and User ’ s Guide IntelliFlo Drive Assembl y and Control P anel The IntelliFlo drive assembly consists of an operator control panel and the system electronics that drive the 230 V AC single phase (260 V AC~170 V AC) motor . The drive microprocessor controls the motor by changing the frequency of the current it receives [...]

5 IntelliFlo Installation and User ’ s Guide Section 2 Operator Contr ol P anel This section describes the operator control panel controls and LEDs. IntelliFlo Operator Control Panel Controls and LEDs Filter b utton/LED: Star ts Filter mode. The LED is on when Filter mode is active . V acuum button/LED: Star ts V acuum mode. The LED is on when V [...]

6 IntelliFlo Installation and User ’ s Guide Controls and LEDs (Continued) Arrow buttons: • Up arrow: Move one level up in the menu tree or increase a digit when editing a setting. • Down arrow: Move one level down in the menu tree or decrease a digit when editing a setting. • Left arrow: Move cursor left one digit when editing a setting. ?[...]

7 IntelliFlo Installation and User ’ s Guide Navigating the Menu Structure Before navigating the control panel menu structure, first familiarize yourself with the menu buttons. T o change a parameter setting, use the Left and Right arrow buttons to select the digit, then the Up and Down arrow buttons to edit the digit. The following example shows[...]

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9 IntelliFlo Installation and User ’ s Guide Section 3 Operating IntelliFlo This section describes how to use the IntelliFlo pump control panel. Metering the System The first step to operating and programming IntelliFlo is to know what is being used in the pool system. After the devices are selected you can then set valves for the appropriate fea[...]

10 IntelliFlo Installation and User ’ s Guide Manual Mode (Continued) T o change the Set Flow and Set Speed features: 1. Ensure that the green power LED is on. 2. Press the Manual button (LED is on). 3. Set Flow: Use the Up and Down arrow buttons to select Set Flow , then press the Select button to edit the setting. 4. T o change the setting, pre[...]

11 IntelliFlo Installation and User ’ s Guide 9. Press the S tart/S top button (LED is on) to run IntelliFlo in “Manual” mode (LED is on). The pump will start and control the flow or speed using the last settings made. After the button is pressed, the display shows “Running.” T o stop IntelliFlo, press the S tart/S top button (LED is off)[...]

12 IntelliFlo Installation and User ’ s Guide Main Structure POOL DATA PRIMING FILTER TIME / CONTR FEATURES Clock (hr:min - AM/PM) Set Flow (15 - 130 gpm) Features 1 Features 2 Features 3 Features 4 Features 5 Set Duration (0:01 - 10:00) Set Flow (15 - 130 gpm) Set Duration (0:01 - 10:00) Set Flow (15 - 130 gpm) Set Start Time (hr:mm AM/PM) Set S[...]

13 IntelliFlo Installation and User ’ s Guide P ool Data Mode Use the Pool Data menu to configure IntelliFlo for the pool and spa system. From this menu you can set an address for the IntelliFlo pump when connected to an IntelliT ouch system, set the volume of pool water , in 1000’ s of gallons (kgal) and estimated pool water temperature. T o a[...]

14 IntelliFlo Installation and User ’ s Guide Priming Mode 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 to prime depending on the depth of water , pipe size and length. It is easier to prime a pump if you allow all th[...]

15 IntelliFlo Installation and User ’ s Guide Priming Mode (Continued) 6. T o set the System Priming Time: Press the Select button to access the “System Priming T ime” setting. After the pump is primed it will take sometime before the system is primed. This time is called “System Priming T ime” T o enter the maximum system priming time, s[...]

16 IntelliFlo Installation and User ’ s Guide Filter Mode IntelliFlo will calculate the required flow rate based on pool size, clean filter pressure, pool turns per day and cycles per day , and will control the motor speed to keep a constant flow . The filter mode can run cycles, power save or features. The IntelliFlo internal scheduler will keep[...]

17 IntelliFlo Installation and User ’ s Guide Filter Mode (Continued) 5. T o set the Cycles P er Day: Press the Select button to access the “Cycles Per Day” setting. T o edit this setting, see step 6. IntelliFlo uses the Cycles Per Day parameter to calculate how much time it has to complete its filter job. Y ou can program up to four start an[...]

18 IntelliFlo Installation and User ’ s Guide Based on “Pool V olume”, “Turnovers per day” and the total number of hours for Cycle 1 + 2 + 3 + 4 the flow must be calculated: 4 3 2 1 " " " " Cycle Cycle Cycle Cycle day pr Turnovers PoolVolume Flow + + + × = Note: Only enabled cycles are included in the calculation E M [...]

19 IntelliFlo Installation and User ’ s Guide Filter Mode (Continued) Clean Filter Pressure Example The following example shows the “Clean Filter Pressure” set to 14 PSI. Pump newly installed and system run for the first time Aler t Status Once the “Alert” is triggered the yellow warning LED is lit and “Alert” is displayed on the scre[...]

20 IntelliFlo Installation and User ’ s Guide Filter Mode (Continued) Using Filter mode with Features mode IntelliFlo will start and stop at programmed filter cycles 1-4. The filter cycles can be overridden by “Feature” (3-9 only) as shown in the example below . This may cause the required filter volume to be achieved earlier . The “Feature[...]

21 IntelliFlo Installation and User ’ s Guide Filter Mode (Continued) Flow Control and Filter Mode The Filter Mode feature provides the ability of overcoming head pressure loss to provide the required flow through the plumbing. The flow that the unit can provide is limited by the installed plumbing. If more flow is demanded than the IntelliFlo ca[...]

22 IntelliFlo Installation and User ’ s Guide Time and Contrast Menu Use the “T ime and Contr” menu settings to set the IntelliFlo system clock and to adjust the control panel display contrast. The IntelliFlo system clock controls all scheduled start and stop times, functions, and programmed cycles. The system clock can store the correct time[...]

23 IntelliFlo Installation and User ’ s Guide Features Mode The Feature mode can be used with water features such as spa, cleaner , waterfalls, etc. Y ou can schedule start and stop times for each feature. All Features are operated using Flow control. The Feature mode and Filter mode are run simultaneously . The three types of features are; Featu[...]

24 IntelliFlo Installation and User ’ s Guide Features Mode (Continued) Feature Settings e m a Ne u l a Vn o i t p i r c s e D o l F . O . M d n a 9 - 1 F w o l F t e S M P G 0 3 1 - 5 1 ) M P G 0 5 t l u a f e D ( 0 1 - 1 e r u t a e f r o f w o l f t e s - e r P e t a v i t c A : 0 1 - 3 F e r u t a e F d e l b a s i D / d e l b a n E ) d e l b[...]

25 IntelliFlo Installation and User ’ s Guide Features Mode (Continued) The functions of the Features groups are shown below: How to set up the Feature 1 or 2 (Flow and Duration) mode T o access the Features menu: 1. Ensure that the green power LED is on and the pump is stopped. 2. Press the Menu button. Press the Up or Down arrows to select the [...]

26 IntelliFlo Installation and User ’ s Guide Features 1 – 2 (Flow and Duration) T o run Feature 1 or 2 (Flo w and Duration) 1. Press the Feature 1 or Feature 2 button, then press the S tart/S top button. The active feature LED will be on until the process is finished. 2. The Features screen will then start to subtract time in minutes from your[...]

27 IntelliFlo Installation and User ’ s Guide 3. T o enable Feature 3: Press the Select button then the Down arrow button to select Enabled if not already selected. Press the Enter button to save the setting. 4. T o set the flow rate for Feature 3: Press the Down arr ow button to select “Set Flow” setting. Press the Select button to access th[...]

28 IntelliFlo Installation and User ’ s Guide Mo Flo (Modulation Output Flow) M.O. Flo (Modulated Output Flow) is specifically designed for Pentair branded heaters with an IntelliComm, although it can be used for other functions, such as water effects. This feature allows you to have flexibility in flow control if the filter cycle flow is less th[...]

29 IntelliFlo Installation and User ’ s Guide External Control with IntelliComm Communication Center The IntelliFlo 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 either 1[...]

30 IntelliFlo Installation and User ’ s Guide Setting up External Control using IntelliComm The IntelliComm communication center is activated by the device voltage when it switches on and off which in turn enables any one of the IntelliFlo Programs 1-4. When the signal stops, the IntelliFlo will default back to it’ s cycle programming. The Inte[...]

31 IntelliFlo Installation and User ’ s Guide Contr olling IntelliFlo with the IntelliT ouch The IntelliFlo pump can be controlled by an IntelliT ouch system via the RS-485 communication cable. In this configuration IntelliT ouch starts and stops the IntelliFlo. IntelliT ouch also rewrites many of the parameters in the IntelliFlo drive's mem[...]

32 IntelliFlo Installation and User ’ s Guide Connecting IntelliFlo to IntelliT ouch (Continued) 6. Strip back the cable conductors ¼”. Insert the wires into the either of the COM POR TS (J7 and J8) screw terminals located on the left side of the Personality board. Secure the wires with the screws. For wiring details, refer to the pin configur[...]

33 IntelliFlo Installation and User ’ s Guide Backwash Mode When the Filter mode has detected that the differential pressure is at the “Clean Filter Pressure” the filter must be cleaned. Y ou need to stop IntelliFlo either by pressing the Backwash button or “Start/Stop” button. IntelliFlo must now be run for a preset cycle time with a pre[...]

34 IntelliFlo Installation and User ’ s Guide Running Backwash mode T o start Backwash mode: 1. Press the Backwash button. 2. When running in Backwash mode IntelliFlo will run at the preset backwash flow for the preset backwash time. 3. When the Backwash mode is stopped, manually or after the preset Backwash cycle time, the IntelliFlo will stop a[...]

35 IntelliFlo Installation and User ’ s Guide V acuum Mode Use V acuum mode to clean the pool manually . V acuum mode only operates in flow control. V acuum mode shuts off all sensors. This mode is identical to Feature 1 and 2 except that you can manually start this mode using the V acuum button. Safety considerations should be made when setting [...]

36 IntelliFlo Installation and User ’ s Guide Blank Page[...]

37 IntelliFlo Installation and User ’ s Guide Section 4 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 debr[...]

38 IntelliFlo Installation and User ’ s Guide Pump Strainer Basket Service (Continued) 10. Ensure that the lid o-ring is properly placed. Seat the clamp and lid then turn clockwise until the handles are horizontal as shown. 11 . Reconnect the communication cable to the pump if required. 12. Switch the power ON at the circuit breaker . Reset the p[...]

39 IntelliFlo Installation and User ’ s Guide Manual Priming and Initial Start-up 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, the strainer pot must be filled with water . CA UTION — DO NO T run the pump dr y . If the pump is r un dr y , t[...]

40 IntelliFlo Installation and User ’ s Guide 4. Make sure all electrical connections are clean and tight. 5. Open the air release valve on the filter, and stand clear of the filter. 6. Switch the IntelliFlo on at the circuit breaker . Ensure that the green power LED is on. 7. Press the Manual button (LED on) to place IntelliFlo in manual mode. 8[...]

41 IntelliFlo Installation and User ’ s Guide Section 5 Installation and Remo v al The following general information describes how to install the IntelliFlo pump. Attention Installer: Before installing the IntelliFlo pump, read and follow all warning notices, instructions and safety precautions on pages iii and vi. Installing the IntelliFlo Only [...]

42 IntelliFlo Installation and User ’ s Guide GROUND WIR E (GREEN) BONDING LUG Wiring the IntelliFlo T o connect the IntelliFlo to AC power: 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 for lengths long[...]

43 IntelliFlo Installation and User ’ s Guide Pump Disassembly W ARNING — Always disconnect power to the pool pump at the circuit breaker before servicing the pump. F ailure to do so could result in death or serious injur y to serviceman, pool users or others due to electric shock. Read all servicing instructions before working on the pump. WAR[...]

44 IntelliFlo Installation and User ’ s Guide Pump Disassembly (Continued) 9. To unscrew the impeller from the shaft, twist the impeller counterclockwise. 10 . Remove the rotating portion of the mechanical seal from the impeller. 11. Remove the four bolts from the seal plate to the motor, using a 9/16 inch wrench. 12. Place the seal plate face do[...]

45 IntelliFlo Installation and User ’ s Guide Drive Assembly Removal and Installation T o remove the IntelliFlo 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 communication cable from the pump. 3. Open the control panel cover. 4. Remove[...]

46 IntelliFlo Installation and User ’ s Guide Illustrated P ar ts List 23 26 3 4 24 23 2 28 17 18 11 13 16 10 6 8 12 5 9 7 14 19 2 1 3 2 1 3 1 3 0 2 0 22 25 27 15 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 0[...]

47 IntelliFlo Installation and User ’ s Guide IntelliFlo Pump Dimensions IntelliFlo 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 Flo w Pump Curve IntelliFlo ® Flow and P ower vs . Flow 0 20 40 60 80 100 120 0 20 40 60 80 100 120[...]

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49 IntelliFlo Installation and User ’ s Guide Aler ts and W arnings The IntelliFlo displays all alarms and warnings on the control panel display . When an alarm or warning condition exists, the corresponding LED will be lit on the display . All control panel buttons are disabled until the alarm or warning is acknowledged with the Enter button. Pr[...]

50 IntelliFlo Installation and User ’ s Guide General IntelliFlo T roubleshooting Pr oblems Use the following general troubleshooting information to resolve possible problems with your IntelliFlo pump. Note: T urn off power to unit prior to attempting service or r epair . 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 . e [...]

51 IntelliFlo 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 . n o i t a l u c r i c e t a u q e d a n I t r e l a o l F i l l e t n I r o F ( r e f e r , s e g a s s e m y a l p s i d g n i n r a W d n a s t r e l A o t . ) 9 4 e g a p n o . t n e [...]

52 IntelliFlo Installation and User ’ s Guide Electrical Cost Overview T o calculate a system’ s “Continuous W atts” use the following formula: Amps X V olts X Power Factor = Continuous W atts Examples: • 1 HP E+ WhisperFlo = 7.4 amps X (230 V olt) X .90 PF = 1532 watts • 1 HP Max – E – Pro = 8.0 amps X (230 V olt) X .87 PF = 1600 w[...]

53 IntelliFlo Installation and User ’ s Guide Swimming pools are great for relaxing, exercising or just having fun. But they also mean higher than average energy bills. The key to saving energy with your pool is to correctly manage the filter pump time, pool temperature and lighting. Consider the following when operating your swimming pool: Using[...]

54 IntelliFlo Installation and User ’ s Guide Preventive maintenance Follow a regular program of preventive maintenance, including an annual inspection of the heat exchanger to help maintain heating efficiency . Energy Efficient IntelliFlo pump When its time to replace your old motor and pump assembly , consider using the IntelliFlo variable spee[...]

55 IntelliFlo Installation and User ’ s Guide Notes[...]

56 IntelliFlo Installation and User ’ s Guide SA VE THESE INSTR UCTIONS Notes[...]

Notes[...]

P/N 350075 Rev . B[...]