® IntelliFlo 4 160 and 100 Variable Speed Programmable Pump (Compatible with IntelliTouch™, EasyTouch™ and 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.
i Contents Important Safety Precautions ........................................................................................... ii Section 1: IntelliFlo Overview ........................................................................................... 1 IntelliFlo 4 Variable Speed Pump .......................................................................................... 1 IntelliFlo 4 models .........................................................................................................
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.
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.
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.
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.
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
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.
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 2 3 4 5 6 Press one of the speed buttons to select the desired preset pump speed.
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.
6 Starting the pump To start the pump 1. Ensure that the pump is powered on and the green power LED is on. 2. Press the Start button (LED on) to start the pump. Note: When the pump is using a modified speed and is powered down, the next time the pump is powered up, the pump will use that same speed. Stopping the pump To stop the pump • Press the Stop button to stop the pump. Note: The pump can automatically restart if the communication cable is connected.
7 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. To 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 the air to escape from the pump and pipes. The water cannot enter unless the air can escape.
8 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 and discharge valves are opened. • If the IntelliFlo 4 pump is not in a flooded suction system, unscrew and remove lid cover; fill the and pump with water. • Do not lubricate the trap cover o-ring.
9 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 either 15 - 240 VAC or 15 - 100 VDC. Using the device's inputs, the programmed IntelliFlo 4 pump speeds can be controlled.
10 Connecting IntelliFlo 4 to an EasyTouch System The IntelliFlo 4 can be controlled by an IntelliTouch system via the RS-485 communication cable (PN 350122). In this configuration, IntelliTouch starts, stops and controls the speed of the IntelliFlo pump. When the IntelliTouch does this, it rewrites the IntelliFlo 4 memory, which can take several seconds. This causes a delay from when a command is given on the IntelliTouch control panel until the Intelliflo 4 physically responds.
11 4. Lower down the hinged control panel to access the EasyTouch motherboard. 5. Route the communication cable into the lower plastic grommet, up through the low voltage raceway to the EasyTouch load center motherboard. Control panel motherboard Low voltage Raceway 6. Strip back the cable conductors ¼ inch. Insert the two wires into the screw terminals on the board. Secure the wires with the screws. 7.
12 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 retaining screws. 11. Close the EasyTouch load center front door. Fasten the two spring latches. 12. Switch the power on to the EasyTouch load center.
13 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 debris at all times. View the basket through the top see through lid to inspect for leaves and debris.
14 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 pool time clock to the correct time. WARNING — FILTER OPERATES UNDER HIGH PRESSURE. WHEN ANY PART OF THE CIRCULATING SYSTEM (e.g., LOCK RING, PUMP, FILTER, VALVES, ETC.
15 Winterizing To protect the IntelliFlo 4 pump electronics from damage due to freezing conditions, the pump will switch it self on to generate internal heat when the air temperature drops below 40° F. This feature is not intended to protect the system plumbing from freezing. 1. If the air temperature drops below 40° F the water in the pump can freeze and cause damage. Freeze damage is not warrantable. 2. To prevent freeze damage follow the procedures listed below.
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17 Section 4 Installation and Removal 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 the IntelliFlo 4 Only a qualified service person should install the IntelliFlo 4 pump. Location 1. Install the pump as close to the pool or spa as possible.
18 Wiring the IntelliFlo 4 To 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 for lengths longer than 100 feet. When in doubt use a heavier gauge (larger diameter) wire. Heavier gauge will allow the motor to run cooler and more efficient. 4. Make sure all electrical connections are clean and tight. 5.
19 Pump Disassembly WARNING — Always disconnect power to the pool pump at the circuit breaker and disconnect the communication cable before servicing the pump. Failure to do so could result in death or serious injury to serviceman, pool users or others due to electric shock. Read all servicing instructions before working on the pump. WARNING — DO NOT open the strainer pot if pump fails to prime or if pump has been operating without water in the strainer pot.
20 Pump Disassembly (Continued) 9. To unscrew the impeller from the shaft, twist the impeller counterclockwise. GASKET MOTOR BOLT (4x) SEAL 10. Remove the rotating portion of the mechanical seal from the impeller. O-RING SET SCREW 11. Remove the four bolts from the seal plate to the motor, using a 9/16 inch wrench. 12. Place the seal plate face down on a flat surface and tap out the carbon spring seat. MOTOR BOLT (2x) SEAL PLATE IMPELLER LOCK SCREW 13.
21 Drive Assembly Removal and Installation To 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. 4. Remove the three Phillips head screws securing the drive to the motor assembly as shown. CAUTION: TO AVOID ELECTRICAL HAZARD, DO NOT REMOVE THE FOUR TAMPER PROOF BITS FROM THE MOTOR ASSEMBLY 5.
22 Illustrated Parts List 22 24 3 15 28 32 31 20 26 25 10 11 1 23 4 21 2 Replacement Parts Item Part 27 30 17 19 Description No. No. 1 070387 BASKET AQ & WF 2 070429 BOLT HEX HD, 2-56x0.875 s/s, (QTY 4) 3 070430 BOLT 3/8 - 16 X 1¼ HEX CAP 18-8 s/s, (QTY 4) 13 16 28 12 14 5 9 8 7 18 Item Part No. No. Description 15 072184 WASHER 3/8 ID X 7/8 OD .
23 IntelliFlo Pump Dimensions 23.41 10.78 12.50 Intelliflo Flow and Power vs Flow Pump Curve IntelliFlo 4 Electrical Specifications Circuit Protection: Two-pole 20 AMP device at the Electrical Panel.
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25 Section 5 Troubleshooting CAUTION: Before installing this product, read and follow all warning notices and instructions on page ii. Warning and Alarm conditions The IntelliFlo 4 alarms and warnings are indicated by flashing LEDs on the control panel. For example, if a “Drive Temperature” warning occurs, the LED will blink two times, then Off, then blink two times. This sequence is repeated until the condition is cleared.
26 General IntelliFlo 4 Troubleshooting Problems 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. Problem Possible Cause Corrective Action Pump failure. Refer to Alarm and warning LED sequence on page 25. Pump will not prime - Air leak in suction. Check suction piping and valve glands on any suction gate valves.
27 Problems and Corrective Action (Continued) Problem Possible Cause Corrective Action Circuit breaker trips repeatedly. Refer to Alarm and warning LED sequence on page 25. Excessive motor current. Breaker must be of adequate capacity. For GFCI breaker, test according to GFCI manufacturer’s instructions. Be sure no other lights and appliances are on circuit. Voltage too high or too low. Electrical problem. Refer to Alarm and warning LED sequence on page 25. Pump may be too hot.
28 Notes IntelliFlo 4 Installation and User’s Guide
P/N 357269 - Rev B
