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Pentair 4/100 User's Manual

1. Be sure to release all air from filter and piping system The IntelliFlo 4 pump is a variable speed pump Typically the lower speeds are used for filtration and heating The higher speeds can be used for spa jets water features and priming Accaution Before starting this procedure first read the following Lid Before removing the pump lid Press the Stop button if the pump is running before proceeding Disconnect the communication cable from the pump Close the gate valves in suction and discharge pipes Volute Release all pressure from pump and piping system Never tighten or loosen the clamp while the pump is operating ee Be E Awarnine If the pump is being pressure tested release all pressure before removing the trap cover Do not block the pump suction while the pump is running If a body part blocks the pump suction it may cause severe or fatal injury Small children using the pool must ALWAYS have close adult supervision Awaarnina FIRE and BURN HAZARD The pump motor may run at a high temperatures To reduce the risk of fire do not allow leaves debris or foreign matter to collect around the pump motor To avoid burns when handling the motor shut off the motor and allow it to cool for 20 minutes before trying to work on it The IntelliFlg 4 provides an automatic internal cutoff switch to protect the motor from heat damage during operation IntelliFlo 4 Installation and User s Guide 8 Priming the pump for
2. and 1000 RPM at 90 The motor assembly is continually cooled by an external fan Dual seals on the motor shaft and at the fan assembly seal the entire motor from any moisture from entering the motor assembly For added protection a slinger located in front of the main shaft seal assists in slinging water away from the shaft opening in the flange Motor fan cover Motor assembly Drive assembly and electronics enclosure Control panel cover Communication port for connection to IntelliTouch EasyTouch or IntelliComm system via two wire RS 485 cable IntelliFlo 4 Motor Assembly IntelliFlo 4 Installation and User s Guide 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 Operator Control Panel buttons and LEDs NPT male threaded PVC nipple Three Wire Harness Red hot Red hot Green Ground 20 of 230 Volt IntelliFlo 4 Drive Assembly IntelliFlo 4 Motor Features e Permanent Magnet Synchronous Motor PMSM e High efficiency 3400 RPM 92 and 1000 RPM 90 e Superior speed control e Operates at lower temperatures due to high efficiency e Same technology as deployed in hybrid electric vehicles e Designed to withstand out
3. are not adequately supported pump assembly will be strained Do not mount pump ona wooden platform Securely mount on concrete platform for quietest performance Foreign matter gravel metal etc in pump impeller Disassemble pump clean impeller follow pump service instructions for reassembly Improve suction conditions Increase pipe size Decrease number of fittings Increase discharge pressure 1 Ensure that the communication cable is connected at both ends 2 Check that the IntelliFlo local address matches with the address used in the IntelliTouch 3 Check that the IntelliFlo has been assigned a circuit name on the EasyTouch IntelliTouch system 4 Ensure that the IntelliFlo display says DISPLAY NOT ACTIVE A defective device on the network can inhibit the proper operation of other network device Devices should be disconnected sequentially until the network starts working IntelliFlo 4 Installation and User s Guide 30 Notes IntelliFlo 4 Installation and User s Guide 31 Notes IntelliFlo 4 Installation and User s Guide 32 Notes IntelliFlo 4 Installation and User s Guide gt Pentair Water Pool and Spa P N 357269 RevB
4. a minimum of three 3 meters from pool water A CAUTION ANo 8 AWG or larger conductor must be wired to the motor bonding lug A CAUTION This pump is for use with permanently installed pools and may also be used with hot tubs and spas if so marked Do not use with storable pools A permanently installed pool is constructed in or on the ground or in a building such that it cannot be readily disassembled for storage A storable pool is constructed so that it may be readily disassembled for storage and reassembled to its original integrity and has a maximum dimension of 18 feet 5 49m and a maximum wall height of 42 inches 1 07m A CAUTION For hot tubs and spa pumps do not install within an outer enclosure or beneath the skirt of a hot tub or spa unless so marked A CAUTION IntelliFlo is capable of generating systems pressures up to 50 psi Installers must ensure that all system components are rated to withstand at least 50 psi Over pressurizing the system can result in catastrophic component failure or property damage General Installation Information All work must be performed by a licensed electrician and must conform to all national state and local codes e Install to provide drainage of compartment for electrical components IntelliFlo 4 Installation and User s Guide iv IMPORTANT SAFETY PRECAUTIONS continued General Installation Information A WARNING Pumps improperly sized or installed or
5. equipment e The IntelliFlo 4 100 pump is capable of 100 GPM or 85 feet of head use caution when installing and programming to limit pumps performance potential with old or questionable equipment e Code requirements for the electrical connection differ from state to state Install equipment in accordance with the National Electrical Code and all applicable local codes and ordinances e Always Press the Stop button and disconnect the communication cable before performing maintenance IntelliFlo 4 Installation and User s Guide 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 IntelliFlo 4 models There are two IntelliFlo 4 models which operate identically with the exception of the maximum flow rate e JntelliFlo 4 160 operates at a maximum system flow of 160 gallons per minute GPM e JntelliFlo 4 100 operates at a maximum system flow of 100 gallons per minute GPM The IntelliFlo 4 variable speed pump can operate from 400 RPM to 3450 RPM with preset speeds of 750 1500 2350 and 3110 RPM The
6. gt Pentair Water Pool and Spa IntelliFlo 4 160 and 4 100 Variable Speed Programmable Pump Compatible with IntelliTouch EasyTouch and IntelliComm tellin poolispa control system 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 PM 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 e 919 566 8000 10951 West Los Angeles Ave Moorpark CA 93021 e 805 553 5000 Trademarks and disclaimers EasyTouch IntelliChlor IntelliFlo QuickTouch and the Pentair Water Pool and Spa logo are trademarks of Pentair Water Pool and Spa Inc Other trademarks and trade names may be used in this document to refer to either the entities claiming the marks and names or their products Pentair Water Pool and Spa Inc disclaims proprietary interest in marks and names of others P N 357269 Rev B 02 15 2006 Contents Important Safety Precautions crass ctcce cesses edna cdecdeteeenccenebaceensasseehieics earthen stants leeriaadenass ji Section 1 IntelliFlo Overview ecsccccccncdacscccecsecetenicdssceeeccduccrantetecdexsces
7. hold both the Start and Stop buttons until the red LED will starts flashing then press one of the four speed buttons to select which address to assign the pump 4 Press and hold both the Start and Stop buttons to save the address Repeat the process for the other pumps 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 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 Pumps do not hold prime the pool piping system has that task A CAUTION To avoid permanent damage to the IntelliFlo 4 pump before starting the pump fill the IntelliFlo housing strainer with water so that the pump will prime correctly If there is no water in the stainer the pump will not prime NEVER run the pump dry Running the pump dry may damage the seals causing leakage and flooding Do not add chemicals to the system directly in front of pump suction Adding undiluted chemicals may damage the pump and will void the warranty Open gate valves before starting system Pump will prime itself when used in flooded suction system
8. of the four speed buttons for three seconds to assign the speed to the selected button the LED be on Four adjusted pump speeds can be assigned to the speed buttons When the pump is using an adjusted speed and the pump is powered down the next time the pump is powered up the pump will use the same speed For more about using the Up Down button see page 5 3 Start button LED Starts the pump using a selected or adjusted speed This LED is on when the pump is running 4 Stop button Press this button to stop the pump 5 On LED This green power LED is on when IntelliFlo 4 is powered up 6 Alarm LED This LED is on when an error condition occurs This green LED will flash a certain number of times indicating a specific error condition For the alarm LED flash sequence refer to Alarm and Warning LED Sequence on page 27 IntelliFlo 4 Installation and User s Guide 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 o li om oO Speed Speed Speed Speed 1 2 3 4 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
9. the motor assembly oe ee oS Make sure all electrical breakers and switches are turned off before removing the drive Disconnect the RS 485 communication cable from the pump Open the control panel cover 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 Lift up the drive assembly and remove it from the motor adapter located on top of the motor assembly Note Be careful not to remove the gasket between the drive and motor it is critical in keeping moisture out of the drive and motor Replace the gasket if damaged Do not reassemble with a damaged or missing gasket To install the IntelliFlo drive assembly onto the motor assembly Make sure all electrical breakers and switches are turned off before installing the drive Be sure that the gasket between the drive and motor is in place It is critical in keeping moisture out of the drive and motor Replace the gasket if damaged Do not reassemble with a damaged or missing gasket Verify that the three 3 orange motor post caps are in position before placing the drive on the motor assembly Align the drive assembly with the motor adapter and seat the drive on the motor assembly Secure and tighten the drive assembly with the three Phillips head screws Phillips head screw Phillips head screws Do not remove Adapter connector these screw
10. when the air temperature drops below 40 F This feature is not intended to protect the system plumbing from freezing 1 Ifthe airtemperature drops below 40 F the water in the pump can freeze and cause damage Freeze damage is not warrantable 2 Topreventfreeze damage follow the procedures listed below Note Shut off electrical power for the pump at the circuit breaker Drain the water out of the pump by removing the two thumb twist drain plugs located at the bottom of the volute Store the plugs in the pump basket Cover the motor to protect it from severe rain snow and ice Do not wrap the motor in plastic It will cause condensation and rust on the inside of the motor In mild climate areas when temporary freezing conditions may occur run your filtering equipment all night to prevent freezing 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 To prime IntelliFlo 4 the strainer pot must be filled with water A CAUTION DO NOT run the pump dry If the pump is run dry the mechanical seal will be damaged and the pump will start leaking If this occurs the damaged seal must be replaced ALWAYS maintain proper water level in your pool Continued operation in this manner could cause a loss of pressure resulting in damage to the pump case impeller and seal For instructions about how to prime the IntelliFlo 4 pump refe
11. which are included Failure to follow safety warnings and instructions can result in severe injury death or property damage Call 800 831 7133 for additional free copies of these instructions A WARNING Entrapment Avoidance Notice The suction outlet connected to a swimming pool or spa pump can pull a high vacuum if it is blocked Therefore if only one suction outlet smaller than 18 x 23 is used anyone blocking the suction outlet with their body can be trapped and held against the suction outlet Disembowelment or drowning can result Therefore if small suction outlets are used with this pump to prevent this entrapment and possible death install at least two suction outlets in the body of water Separate these suction outlets as described in the International Residential Code IRC the International Business Code IBC the Consumer Products Safety Council CPSC Guidelines for Entrapment Hazards Making Pools and Spas Safer or ANSI IAF 7 Standard for Suction Entrapment Avoidance in Swimming Pools Wading Pools Spas Hot Tubs and Catch Basins If suction outlets are not used additional entrapment avoidance measures as described in the CPSC Guidelines or ANSI IAF 7 should be employed The covers used on suction outlets should be approved and listed as conforming to the currently published edition of ANSI ASME A112 19 8 Standard covering Suction Fittings for Use in Swimming Pools Wading Pools Spas and Hot Tubs These covers should b
12. 0 60 Hz 15 240 VAC Program 1 or 1 mA 1 Input 50 60 Hz 15 100 VDC 15 240 VAC Program 2 or 1 mA 1 Input 50 60 Hz 15 100 VDC 15 240 VAC Program 3 or 1 mA 1 Input 50 60 Hz 15 100 VDC 15 240 VAC Program 4 or 1 mA 1 Input 50 60 Hz 15 100 VDC RS 485 Data Yellow See VDG 5mA 1 Output N A Data Green 1 2 3 4 5 6 7 8 9 10 11 12 IntelliFlo 4 Installation and User s Guide 10 Connecting IntelliFlo 4 to an EasyTouch System The IntelliFlo 4 can be controlled by an EasyTouch system via the RS 485 communication cable P N 350122 In this configuration EasyTouch starts stops and controls the speed of the IntelliFlo pump When the EasyTouch does this it rewrites the IntelliFlo 4 memory which can take several seconds This causes a delay after a command is given on the EasyTouch control panel until the Intelliflo 4 physically responds The IntelliFlo 4 control panel is disabled when communicating with the EasyTouch system Note that IntelliTouch will not start communicating with the IntelliFlo 4 until the pump is assigned to a circuit The IntelliFlo 4 default pump address is one which is the only address that works with EasyTouch See page 6 for details about how to check the address and change if necessary For more information refer to the EasyTouch User s Guide P N 520584 To connect the IntelliFlo 4 communication cable to EasyTouch load center 1 A CAUTION Switch the main power off to the EasyTouc
13. FE ALMOND 28 350521 INTELLIFLO 4 SPEED DRIVE 30 357102 GASKET SANTOPRENE MOLDED 31 357151 LID SEE THRU WF 32 357199 CLAMP CAM amp RAMP WF Almond Note Not serviceable parts 25 IntelliFlo Pump Dimensions 3X lf AOI C4 ee sz Sy SS e 23 41 gt lt 10 78 gt PUMP PERFORMANCE CURVE 60 HZ SINGLE PHASE TEST VOLTAGE 230V i 5 speed 1 750 rpm TDH in Feet T ll nis lit Hip RPM a speed 3 2350 rpm iN DIR je q speed 4 3110 rpm aa o der H Wi Intelliflo at 3450 V5 A FLOW RATE IN U S GPM IntelliFlo 4 Electrical Specifications Circuit Protection Two pole 20 AMP device at the Electrical Panel Input 230 VAC 50 60 Hz 3200 Watts IntelliFlo 4 Installation and User s Guide 26 Blank Page IntelliFlo 4 Installation and User s Guide 27 Section 5 Troubleshooting A 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
14. Stopping the pump To stop the pump e Press the Stop button to stop the pump Note The pump can automatically restart if the communication cable is connected Resetting the pump to factory defaults The IntelliFlo 4 pump can be reset to the factory default settings All previously adjusted pump speeds that were saved will be erased To reset the pump to the factory default settings 1 Ensure that the pump is powered on and the green power LED is on 2 Press the Stop button to stop the pump 3 Press and hold all of the four Speed buttons simultaneously for three seconds Power off the drive and reenergize The default settings will be in effect oO oO Oo oO Speed Speed Speed Speed 1 2 3 4 Control Panel Speed Buttons Assigning a pump address for remote control The default communications address for the IntelliFlo 4is 1 This is the only IntelliFlo address that the EasyTouch and IntelliComm systems will communicate with Therefore these devices can only communicate with one IntelliFlo 4 The IntelliTouch is able to communicate with four Intelliflo 4 pumps If more than one IntelliFlo 4 is being used with an IntelliTouch the 2nd 3rd and 4th pumps will have to be readdressed as described below To assign a pump an address 1 Be sure that the pump is powered on and the green power LED is on 2 Press the Stop buttons to stop the pump 3 Press and
15. ainer pot volute to the rear subassembly GENTLY pull the two pump halves apart removing the rear subassembly Use a3 32 inch Allen head wrench to loosen the two holding screws located on the diffuser Hold the impeller securely in place and remove the impeller lock screw by using a Phillips head screwdriver The screw is a left handed thread and loosens in aclockwise direction Use a flat blade screwdriver to hold the motor shaft The motor shaft has a slot on the end whichis accessible through the center of the fan cover IntelliFlo 4 Installation and User s Guide 22 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 down on a flat surface and tap out the carbon spring seat 13 Clean the seal plate seal housing and the motor shaft Pump Reassembly Seal Replacement GASKET MOTOR BOLT 4x SEAL O RING SET SCREW BOLT 2x SEAL PLATE IMPELLER LOCK SCREW LOCK SCREW SEAL 1 When installing the replacement shaft seal use silicone sealant on the metal portion before pressing into the seal plate as shown 2 Before installing the rotating portion of the seal into the impeller be sure the impeller is clean Use a light density soap an
16. bly Seal Replacement ccccccessseeeeeeseceeeeenaeeeesenneeeeteeaaeeesssaeeeneeseeees 22 Shaft Seal Replac mMent cyiscraicanscertcabaicehaasasecerse suis bas codemwbaa E EE EE NE EEN 22 Drive Assembly Removal and Installation sisi cccceccesesecdinsacaverrsicssneeerectteeieccerbensrieededee 23 lllustrated Parts ISt minenisrisisisssiaaaa aaa ee ee ee ee aes 24 I ntelliFlo Pump DIMENSIONS siisii ener ier aaiae a aai RS 25 IntelliFlo Flow and Power vs Flow Pump Curve xccisccsssvaclarscnctevecsstecussucstewesbesaeloscecetseunctiae 25 intelliFlo 4 Electrical Specifications sirrcna a a 25 Section 5 Troubleshooting nssssnnseunnnenennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn mnnn na 27 Warning and Alarm LED COnditionS sesissscrisss aroi itre tests rcrenrecebatastintdnmetemceaaedenels 27 Alarm and warning LED sequence 2 cccceeeeeceeceeeeeeeeeeeeeeeeeeeeeeeeeeeneeseeeeeeeneeseeseeneeeenneaes 27 General IntelliFlo 4 Troubleshooting Problems ccceccceeeeeseeeeeeeeeeeeeesaeeeeeseeeeeeeeaaeeeeeas 28 IntelliFlo 4 Installation and User s Guide IMPORTANT SAFETY PRECAUTIONS RA 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 A WARNING Before installing this product read and follow all warning notices and instructions
17. cure the wires with the screws For wiring details refer to the pin configuration shown below Note Multiple wires may be inserted into a single screw terminal AL mkaa hoe EA VALVE ACTUATORS IntelliTouch Personality board COM PORT T i7 AND i9 ori cnp INDOOR CONTROL AND OR vey alee RF TRANSCEIVER REDS D 15 voc aay ANDOR 0 i810 SPA SIDE REM Pin Configuration for IntelliFlo 4 to IntelliTouch e IntelliFlo 4 Connect pin 6 green to IntelliTouch screw terminal pin 2 green e IntelliFlo 4 Connect pin 7 yellow to IntelliTouch screw terminal pin 3 yellow IntelliTouch COM PORT J7 J8 screw terminal 0099 _ Pin 6 Green IntelliTouch inne Pin 7 Yellow screw terminal gt wire cable connector i 2 GRN GREEN Pin 6 IntelliFlo 4 cable pin configuration 3 YEL YELLOW Pin 7 Pin configuration 7 Close the IntelliTouch control panel and secure it with the two access screws 8 Install the high voltage panel cover and secure it with the two retaining screws 9 Close the load center front door and secure with the two latches 10 Switch power on to the IntelliTouch load center IntelliFlo 4 Installation and User s Guide 15 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 f
18. d water to lubricate the inside of the seal Press the seal into the impeller with your thumbs and wipe off the ceramic and carbon faces with a clean cloth Oy ae A aligned oo x Remount the seal plate to the motor Grease the motor shaft thread and screw impeller onto the motor shaft Screw in the impeller lock screw counterclockwise to tighten Remount the diffuser onto the seal plate Make sure the plastic pins and holding screw inserts are Grease the diffuser o ring and seal plate gasket prior to reassembly Grease the bolt threads assemble the motor subassembly to the strainer pot pump body by using the two 2 through bolts for proper alignment Do not tighten the through bolts until all six 6 bolts are in place and finger tightened 9 Reconnect the RS 485 communication cable to the pump 10 Fill the pump with water 11 Reinstall the pump lid and plastic clamp see page 15 for details 12 Prime the pump see page 7 Shaft Seal Replacement The Shaft Seal consists primarily of two parts a rotating member and a ceramic seal The pump requires little or no service other than reasonable care however a shaft seal may occasionally become damaged and must be replaced Note The polished and lapped faces of the seal could be damaged if not handled with care IntelliFlo 4 Installation and User s Guide 23 Drive Assembly Removal and Installation To remove the IntelliFlo 4 drive and control panel from
19. door environment e Totally enclosed fan cooled e Three phase motor e 56 Square Flange e Six Pole e Low noise IntelliFlo 4 Installation and User s Guide 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 IntelliFlo 4 160 Select Preset Speed Press Speed 1 4 to select speed Press On to start Change Preset Speed Press or W to adjust the speed Press Speed 1 4 for 3 sec to save speed O oO o O Speed Speed Speed Speed 1 2 3 4 Controls and LEDs 1 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 3110 RPM The speed button LED is on when the selected button is pressed If the pump is running and the Up Down button is used to adjust the speed the selected speed LEDs will go off For more about using the speed buttons see page 5 2 Up Down button While the pump is running press the Up or Down button to increase or decrease the pump speed To save the new pump speed press any one
20. e inspected regularly and replaced if cracked broken or older than the design lifetime indicated on them by the manufacturer The maximum possible flow rate of this pump should be less than or equal to the maximum approved flow rate indicated on the suction outlet cover by the manufacturer THE USE OF UNAPPROVED COVERS OR ALLOWING USE OF THE POOL OR SPA WHEN COVERS ARE CRACKED OR BROKEN CAN RESULT IN HAIR ENTANGLEMENT WHICH CAN RESULT IN DEATH A WARNING Risk of electrical shock or electrocution This pool pump must be installed by a licensed or certified electrician or a qualified pool A serviceman in accordance with the National Electrical Code and all applicable local codes S and ordinances Improper installation will create an electrical hazard which could result in death or serious injury to pool users installers or others due to electrical shock and may also cause damage to property Always disconnect power tothe pool pump atthe circuit breaker 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 IntelliFlo 4 Installation and User s Guide IMPORTANT SAFETY PRECAUTIONS continued A 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 no
21. elief valve 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 2 Protectagainstdirt Protect from any foreign matter or splashing water Do notstore or spill pool chemicals near the motor Avoid sweeping or stirring up dust near the motor while itis operating Ifa motor has been damaged by dirt it voids the motor warranty 3 Protectagainst moisture Protect from splashing pool water Protect from the weather Protect from lawn sprinklers Ifa motor has become wet let it dry before operating Do not allow the pump to operate if it has been flooded Ifamotor has been damaged by water it voids the motor warranty Note DO NOT wrap motor and controller with plastic or other air tight materials The motor and controller may be covered but not wrapped in plastic during a storm for winter storage etc but never when operating or expecting operation When replacing the motor be certain that the motor support is correctly positioned to support the size of motor being installed IntelliFlo 4 Installation and User s Guide 17 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
22. en the airrelease valve on the filter and stand clear of the filter 6 Switch the IntelliFlo pump on at the circuit breaker Ensure that the green power light is on Top view 7 Press the Speed 1 button to select the pump speed of 750 RPM 8 Press the Start button to start the pump Use the Up Down button to increase the speed as necessary to prime the pump 9 When watercomes out of the air release valve close the valve The system should now be circulating water back to the pool without air bubbles showing in either the hair and lint pot or at the pool return fittings 10 Use the Up Down button to adjust the operating speed as desired 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 either 15 240 VAC or 15 100 VDC Using the device s inputs the programmed IntelliFlo 4 pump speeds can be controlled Ifmore than one input is active the highest number will be communicated to the IntelliFlo pump The IntelliComm will always communicate to pump address 1 The following table shows the wiring terminal descriptions for IntelliComm External Control Terminals IntelliComm Communication Center pte Power supply 100 240 VAC 100 mA 5
23. eseeeeneeeeneees 7 Primngthe el 19 Ree eee eee ee re ne meee E ER en eee ee ee ee eres 8 External Control with IntelliComm Communication Center c ccccecceeeeeeseeeeeeeeeeeeeeenneeees 9 External Contro ConneGtioN tsescsscnsese nn tid Mug doerdicatd Dene teidareadee ct eoee 9 Connecting IntelliFlo 4 to an EasyTouch System cccccceceesseeeeeeeeeeeeesaeeeeeseeeeeeeeaaeeeeees 10 Connecting IntelliFlo 4 to an IntelliTouch System ecceceeeseeeeeeeeeceeeeeneaeeeeeeeeeeeeeeaaeentees 13 Section 3 User MILO IAIN CC isisisi ananuna aeaa Aranana araea KEA AAE AAEE anni 15 P mp Strainer Basket siccin tact cava tore densa niren e annaia E enaar EEn E E aaRS AET na NEEE ES 15 Pump Strainer Basket SOMiCe wcessccncncesaicancns eenen ie e aaa ae aai aei aA EE aE 15 Motor SENICE E E E E E ee eee Te 16 Winterizing taste toate ceased a a A a sae E E ee eee 17 Priming the pump after service sacs es pactees od esd nee aie ena escalation dans ea idoeat catyeeenateca are 17 Section 4 Installation and Removal isiisiaeiicccscesccsscesscticnshccstaceseiceseeaedeccceceeiediediessariecpeccens 19 InteliFlo 4 Kit Contents kesene E E EEEE 19 installing MEF O A rieien a EE 19 LOc IOM ee a E A A 19 PIPINO ceria E E AEE ee Ree ee er rere 19 Check Valve sscocneunroe ar aae aiana aO tenes geen Ee EEE EE DEt 19 Wining thelntelllFlo 4 Reamer etree ee ener rena E akae E EA 20 P mp DisassemDly eae eee nae perenne aa ee ene Ce eee ee ee E 21 Pump Reassem
24. etesiedeseeesseecsdetacsineanccce 1 IntelliFlo 4 Variable Speed Pump cc5cezdesc cheater cend vlc ngecgeracdectelcbienigaiactiesshieliatneeaioontvilieeds 1 Intelli Flo4 VM CS es easrsete ata coneecena ceees a eaneece aaan Eaa Eaa EEEa 1 External 81911 6 epee nearer eee ree ener reer ener Meee ent Meer tere ee AE een an E R E i eais 1 FO AICS wincscussocreccstcavesacsasiewwesai esate nediegeusd a NEA e EE ea AAT ENTON ERE E aN E 2 intelliFlo A Mot r PSS CTO resiervenesieirneiiiua iaae i eae aE iaei 2 IntelliFlo 4 Drive Assembly and Control Panel c ccceceeccceeeeeeeeeeeeeeeeeeeeaaeeeeesaeeeeeenaeeeeee 3 IntelliFlo 4 Operator Control Panel sssseeesnseeessneesserrrssrrrnettnrrrenrntstntrnsstrnssttrnnerennnnrnnn nenene 4 Controls and LEDS scccccscsccecascecicatactadeeucseseves a E EE E EERS 4 Section 2 Operating Intell 4 sscscccscccssccesnencsscasenceecesnestcsnaaccceerecteereeucncecassecweecesuseresecentes 5 Setting the pump preset Speed asseriscono e EEEE TE E 5 Adj sting the pump Speed aged chatted iio e EE EE ETE iE 5 Starting the pump esea ee ni EE i aE ET A EE REEE 6 Stopping the DUMP iraire iaeaea rE ai daar E aae TEA Eaa ved eSa EEan E EIEEE 6 Resetting ihe pump to factory defaults csswsiiissiissiairiissiina a aai 6 Assigning a pump address for remote control is cissccsccccesietsesceeeesstecasteentenewestassderecenerensstiees 6 Priming the pump for the first time or after service cceceeeeeeceeeeeeeeeeeeeeeeneeeeee
25. h load center 2 Unlatch the two enclosure door spring latches and open the door 3 Remove the two retaining screws securing the high voltage cover panel and remove it from the enclosure 3 Loosen the two access screws securing the control panel Control panel access screw Control panel access screw Retaining screw High voltage cover panel EasyTouch Load Center front view IntelliFlo 4 Installation and User s Guide 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 A j 6 Strip back the cable conductors 1 4 inch Insert the two wires into the screw terminals on the board Secure the wires with the screws 7 EasyTouch to IntelliFlo 4 pin configuration e IntelliFlo Connect pin 6 green to EasyTouch screw terminal pin 2 green e IntelliFlo Connect pin 7 yellow to EasyTouch screw terminal pin 3 yellow EasyTouch J20 screw terminal e609 g Easy Touch IntelliFlo Pin 6 Q screw terminal i 2 wire cable connector G reen 2 GRN GREEN Pin 6 Pin 7 Yellow 3 YEL YELLO Pin 7 IntelliFlo connector pin configuration Pin configuration 8 Insert the screw terminal onto the EasyTo
26. is pressed the LED is on The pump preset buttons and speeds are Speed 1 button 750 RPM Speed 2 button 1500 RPM Speed 3 button 2350 RPM Speed 4 button 3110 RPM 3 Press the Start button to start the pump using the selected speed if necessary Adjusting the pump speed IntelliFlo can be adjusted to run at any speed between 400 RPM and 3450 RPM To adjust the pump speed 1 Ensure that the pump is powered on and the green power LED is on Press the Start button to start the pump if the pump is not running Press the UP Down button to increase or decrease the pump speed e 10 RPM increments Press and quickly release the Up Down button to increase or decrease the speed in 10 RPM increments e 20 RPM increments Press and hold the Up Down button to continuously increase or decrease the pump speed Saving an adjusted speed To save the newly adjusted pump speed press and hold the desired speed buttons to assign the current speed Four new pump speeds can be assigned to Speed buttons 1 4 Press the Speed button that is assigned to the adjusted speed Up Down button IntelliFlo 4 Installation and User s Guide 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
27. mbly A WARNING Always disconnect power to the pool pump at the circuit breaker and disconnect the RMA J serious injury to serviceman pool users or others due to electric shock communication cable before servicing the pump Failure to do so could result in death or Read all servicing instructions before working on the pump A WARNING DONOT open the strainer pot if pump fails to prime or if pump has been operating without water in the strainer pot Pumps operated in these circumstances may experience a build up of vapor pressure and may contain scalding hot water Opening the pump may cause serious personal injury In order to avoid the possibility of personal injury make sure the suction and discharge valves are open and strainer pot temperature is cool to touch then open with extreme caution A CAUTION Be sure not to scratch or mar the polished shaft seal faces seal will leak if faces are damaged All moving parts are located in the rear subassembly of the IntelliFlo 4 pump Tools required 3 32 inch Allen head wrench Y2inch open end wrench 9 16 inch openend wrench Flat blade screwdriver To remove and repair the pump mechanical seal perform the following procedures SD Se eM oS Switch off the pump circuit breaker at the main panel Disconnect the RS 485 communication cable from the pump Drain the pump by removing the drain plugs Remove the six bolts that hold the main pump body str
28. mmended to use a larger pipe size When installing the inlet and outlet fittings male adaptors use thread sealant Do NOT use Teflon tape Do not install 90 elbows directly into pump inlet or outlet A valve elbow or tee installed in the suction line should be no closer to the front of the pump than five 5 times the suction line pipe diameter i e two 2 inch pipe requires a ten 10 inch straight run in front of the suction inlet of the pump This will help the pump prime faster and last longer Flooded suction systems should have gate valves installed on suction and discharge pipes for maintenance however the suction gate valve should be no closer than five 5 times the suction pipe diameter as described above Check Valve Check valves must be used when the IntelliFlo 4 is used in parallel with other pumps IntelliFlo pumps cannot be used in series with other pumps IntelliFlo 4 Installation and User s Guide 20 Wiring the IntelliFlo 4 To connect the IntelliFlo 4 to an AC power source 1 2 Make sure all electrical breakers and switches are turned off before wiring motor Make sure thatthe wiring voltage is 230 VAC 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 Make sure all electrical connections are clean and tight Cut the wires to the appr
29. olt and o ring 3 Remove clean and reinstall impeller 4 Reinstall anti spin bolt and o ring Reinstall diffuser and o ring Reinstall motor and seal plate into volute Reinstall 6 bolts around seal plate and volute and tighten securely Clean suction trap Problems and Corrective Action Continued 29 Problem Possible Cause Corrective Action Circuit breaker trips Excessive motor current repeatedly Refer to Alarm and GFCI fault warning LED sequence on page 27 Electrical problem Pump may be too hot Refer to Alarm and warning LED sequence on page 27 Mechanical Troubles The pump motor is running but with loud noise and Noise Cavitation IntelliFlo does not Improper EasyTouch IntelliTouch IntelliFlo setup respond to EasyTouch or IntelliTouch commands Communication network inoperative 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 Check line voltage if less than 90 or more than 110 of rated voltage consult a licensed electrician Increase ventilation Reduce ambient temperature Tighten any loose wiring connections Motor internal terminal overload protector is open Motor runs too hot Turn power to motor off Check for proper voltage Check for proper impeller or impeller rubbing If suction and discharge piping
30. opriate length so they do not overlap or touch when connected Permanently ground the motor using the green ground wire as shown below Use the correct wire size and type specified by National Electrical Code Make sure the ground wire is connected to an electrical service ground Bond the motor to the pool structure in accordance with the National Electrical Code Use a solid No 8 AWG or larger copper conductor Runa wire from the external bonding lug to the pool bonding structure as shown below The IntelliFlo pump is designed to be permanently connected to its power source Typically the pump receives power directly from the circuit breaker No contactor or motor starter is required The drive controls the starting and stopping of the pump Ifthe IntelliFlo is connected to an automation system such as EasyTouch or IntelliComm the drive must be powered up to receive and respond to the RS 485 serial communication from the automation system However the pump can be operated in stand alone mode starting and stopping when power is applied or removed When the drive powers up it will return to the mode and run status that it was in when power was removed This setup maybe appropriate if you need to use existing relays or timers For wiring pinouts for the communications port see page 11 IntelliFlo 4 wiring harness Red Hot Red Hot Green yellow stripe Ground IntelliFlo 4 Installation and User s Guide 21 Pump Disasse
31. ounterclockwise direction until it stops Remove the clamp and lid Remove the basket and put the debris into the trash and rinse out the basket If the basket is cracked replace the basket Replace the basket and fill the pump pot and volute with water up to the inlet port Clean the cover o ring and sealing surface of the pump pot Grease the o ring with Teflon or silicone lubricant Reinstall the lid by placing the clamp and the lid on the pot IntelliFlo 4 Installation and User s Guide 16 Pump Strainer Basket Service Continued 10 Ensure that the lid o ring is properly placed Seat the clamp and lid then Clamp turnclockwise 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 A WARNING FILTER OPERATES UNDER HIGH PRESSURE WHEN ANY PART OF THE CIRCULATING SYSTEM e g LOCK RING PUMP FILTER VALVES ETC IS SERVICED AIR CAN ENTER THE SYSTEM AND BECOME PRESSURIZED PRESSURIZED AIR CAN CAUSE THE LID TO BLOW OFF WHICH CAN RESULT IN SEVERE INJURY DEATH OR PROPERTY DAMAGE TO AVOID THIS POTENTIAL HAZARD FOLLOW THESE INSTRUCTIONS 13 Openthe manual air relief valve on top of the filter 14 Standclear of the filter Press the Start button on the pump 15 Bleed air from the filter until a steady stream of water comes out 16 Closethe manualairr
32. pump can be adjusted from the control panel to run at any speed between 400 RPM to 3450 RPM for different applications The IntelliFlo pump control panel alarm LED warns the user against under and over voltage high temperature over current and freeze protection External Control Using a communication cable IntelliFlo 4 can communicate with an IntelliTouch EasyTouch or IntelliComm via a two wire RS 485 connection for remote speed control The EasyTouch and IntelliComm provide the ability to remotely control the IntelliFlo 4 with four preset speeds The IntelliTouch can be setup to use eight speeds with the IntelliFlo 4 IntelliFlo 4 variable speed pump IntelliFlo 4 Installation and User s Guide 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 action spas Driver assembly features permanent magnet synchronous motor Heavy duty durable construction designed for long life UL approval IntelliFlo 4 Motor Assembly The IntelliFlo three phase six pole motor operates at 3400 RPM at 92 efficiency
33. r to Priming the pump for the first time or after servicing on page 7 IntelliFlo 4 Installation and User s Guide 18 Blank Page IntelliFlo 4 Installation and User s Guide 19 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 e JntelliFlo 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 To reduce friction loss andimprove efficiency use short and direct suction and piping returns 2 Installaminimum of five 5 feet from the inside wall of the pool and spa Canadian installations require aminimum of three 3 meters from pool water 3 Install the pump aminimum of two 2 feet from the heater outlet 4 Donotinstall the pump more than 8 feet above the water level 5 Install the pump ina sheltered well ventilated location protected from excessive moisture i e rain sprinklers etc 6 Forhottubs and spas do not install within an outer enclosure or beneath the skirt of a hot tub or spa 7 Install the pump with arear clearance of at least 6 inches so that the motor can be removed easily for maintenance and repair Piping For improved pool plumbing it is reco
34. rmal 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 AN The effects of hyperthermia include 1 Unawareness of impending danger 2 Failure to POD perceive heat 3 Failure to recognize the need to leave the spa 4 Physical inability to exit the spa 5 Fetal damage in pregnant women 6 Unconsciousness resulting in danger of drowning A warnina The use of alcohol drugs or medication can greatly increase the risk of fatal hyperthermia in hot tubs and spas Awarnine To reduce the risk of injury do not permit children to use this product unless they are closely supervised at all times A WARNING For units intended for use in other than single family dwellings a clearly labeled emergency switch shall be provided as part of the installation The switch shall be readily accessible to the occupants and shall be installed at least 5 feet 1 52 m away adjacent to and within sight of the unit A WARNING When setting up pool water turnovers or flow rates the operator must consider local codes governing turnover as well as disinfectant feed ratios A WARNING Before servicing the system switch the main power OFF and remove the communication cable from the pump A CAUTION _ Install the pump a minimum of five 5 feet from the inside wall of the pool and spa Canadian installations require
35. ront 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 Regardless of the length of time between filter cleaning it is most important to visually inspect the hair and lint pot basket at least once a week A dirty basket will reduce the efficiency of the filter and possibly the heater A WARNING DO NOT open the strainer pot if pump fails to prime or if pump has been operating without water in the strainer pot Pumps operated in these circumstances may experience a build up of vapor pressure and may contain scalding hot water Opening the pump may cause serious personal injury In order to avoid the possibility of personal injury make sure the suction and discharge valves are open and that the strainer pot is cool to the touch then open with extreme caution A CAUTION To prevent damage to the pump and filter and for proper operation of the system clean pump strainer and skimmer baskets regularly Pump Strainer Basket Service Ifthe IntelliFlo pump is installed below the water level of the pool close the return and suction lines before opening the hair and lint pot on the pump 1 Press the Stop button to stop the pump and switch off the pump at the circuit breaker Disconnect the communication cable from the IntelliFlo 4 pump Relieve pressure in the system Turn the clamp and lid in ac
36. s Orange motor post caps QTY 3 Gasket IntelliFlo 4 Installation and User s Guide 24 Illustrated Parts List 2 Replacement Parts 27 304719 BE Item Part Description No No 1 070387 BASKET AQ amp WF 2 070429 BOLT HEX HD 2 56x0 875 s s QTY 4 3 070430 BOLT 3 8 16 X 1 HEX CAP 18 8 s s QTY 4 4 070431 BOLT 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 PUMP 7 071131 PLUG DRAIN WFE Almond QTY 2 8 071403 NUT 3 8 16 BRASS NICKEL PLATED QTY 2 9 071406 NUT 4 20 HEX s s QTY 2 10 071444 O RING 238 3 484x0 139 Buna N 70 11 071652 SCREW 14 20 X 1 LH PHILLIPS PAN MS 18 8 s s 12 071657 SCREW 20 X 1 in HEX CAP 18 8 s s QTY 3 13 071660 SCREW SET 4 40 X 1 1 8 WFE SCKT CAP 18 8 s s QTY 2 14 072183 WASHER FLAT X 5 8 20 GA THICK 18 8 s s QTY 2 IntelliFlo 4 Installation and User s Guide Item Part Description No No 15 072184 WASHER 3 8 ID X 7 8 OD 05 THICK 18 8 s s QTY 6 16 072928 DIFFUSER ASSEMBLY WFE 12 17 073131 IMPELLER WFE 12 1000 SER 18 074629 GASKET FLAT WASHER WFE DRAIN QTY 2 19 075713 RUBBER WASHER WFE PUMP 20 350013 O RING LID CH WF 2 436 21 350015 VOLUTE CASING WFE Almond 22 350082 CONTROL COVER ASSEMBLY 23 350105 VFD MOTOR 3 2KW PMSM 24 350107 SCREW 10 24 X 3 in PH MS 18 8 s s QTY 3 25 350108 INTELLIFLO DRIVE GASKET 26 350142 SPACER CAP QTY 3 27 350201 SEAL PLATE KIT W
37. s assigned to a circuit The IntelliFlo 4 default pump address is one See page 6 for details about how to check the address and change if necessary For more information refer to the IntelliTouch User s Guide P N 520102 To connect the IntelliFlo 4 communication cable to IntelliTouch load center 1 A CAUTION Switch the main power off to the IntelliTouch load center 2 Unlatch the IntelliTouch load center front door spring latches and open the front door 3 Remove the cover panel screws securing the high voltage cover panel and remove it from the enclosure 4 Loosen the two control panel access screws and fold down the outdoor control panel 5 Insert the two wire cable into plastic grommet on the bottom of the enclosure and route the wire up through the low voltage raceway to the Personality board Personality Board Access screw Low voltage covey g Cover panel screw Cover panel not JESS O shown GOO 0000 l ooa EEA Plastic grommet IntelliTouch Load Center IntelliFlo 4 Installation and User s Guide 14 Connecting IntelliFlo to IntelliTouch Continued 6 Strip back the cable conductors 1 4 Insert the wires into the either of the COM PORTS J7 and J8 screw terminals located on the left side of the Personality board Se
38. the first time or after service Continued Priming the Pump e Release all pressure from filter pump and piping system see the filter owner s manual e Ina flooded suction system water source higher than pump the IntelliFlo 4 pump will prime itself when suction and discharge valves are opened e Ifthe IntelliFlo 4 pump is not in a flooded suction system unscrew and remove lid cover fill the and pump with water e Do not lubricate the trap cover o ring The original equipment o ring contains a permanent internal lubricant NOTICE If you replace the o ring with a non internally lubricated o ring you may need to apply a silicone based lubricant e Clean and inspect o ring reinstall on trap cover e Replace trap cover on trap turn clockwise to tighten cover NOTICE Tighten the pump lid by hand only no wrenches Pump should prime now Priming time will depend on vertical length of suction lift and horizontal length of suction piping If pump does not prime make sure that all valves are open suction pipe end is under water pump suction is below water level and that there are no leaks in suction pipe To prime the IntelliFlo 4 pump 1 Turnthe pump clamp and lidinacounterclockwise direction until it stops andremove them 2 Fillthe pump strainer pot with water 3 Reinstall the pump clamp and lid onto the strainer pot The pump is now ready to prime 4 Makesureall electrical connections are clean and tight Op
39. uch COM PORT J20 board connector Note Multiple wires may be inserted into a single screw terminal EasyTouch COM PORT J20 Indoor Control Panel IntelliChlor IntelliFlo RF Transceiver IntelliFlo 4 Installation and User s Guide 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 Control panel access screw Control panel access screw Retaining screw High voltage cover panel EasyTouch Load Center front view IntelliFlo 4 Installation and User s Guide 13 Connecting IntelliFlo 4 to an IntelliTouch System The IntelliFlo 4 can be controlled by an IntelliTouch system via the RS 485 communication cable P N 350122 In this configuration IntelliTouch 4 starts stops and controls the speed of the IntelliFlo 4 pump When the IntelliTouch does this it rewrites the IntelliFlo 4 memory which can take several seconds This causes a delay after a command is given on the IntelliTouch control panel until the Intelliflo 4 physically responds The IntelliFlo 4 control panel is disabled when communicating with the IntelliTouch system Note that IntelliTouch will not start communicating with the IntelliFlo 4 until the appropriate pump address i
40. uide 28 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 Possible Cause Corrective Action Problem Pump failure Refer to Alarm and warning LED sequence on page 27 Reduced capacity and or head Refer to Alarm and warning LED sequence on page 27 Pump will not prime Air leak in suction Pump will not prime Not enough water Pump strainer clogged Pump strainer gasket defective Air pocket or leaks in suction line Clogged impeller Pump strainer clogged IntelliFlo 4 Installation and User s Guide Check suction piping and valve glands on any suction gate valves Secure lid on pump strainer pot and make sure lid gasket is in place Check water level to make sure skimmer is not drawing air Ensure that the suction lines pump strainer and pump volute are full of water Clean pump strainer pot Replace gasket Check suction piping and valve glands on any suctin gate valves Turn off electrical power to the pump Remove the 6 bolts that holds the volute to the seal plate Slide the motor and seal plate away from the volute Clean debris from impeller If debris cannot be removed complete the following steps 1 Remove diffuser and o ring 2 Remove left hand thread anti spin b
41. until the condition is cleared e Warning condition If a warning condition occurs the pump will be continue to run but at a reduced speed The Green LED executes a sequence of blinks to indicate which alarm or warning has occurred e Alarm condition If an alarm condition occurs the pump will drive stop running The red LED flashes continuously to indicate the presence of an alarm The alarm LEDs will reset when the condition clears Alarm and warning LED sequence Number of time the Description LED will blink eee ere Drive Temperature Warning Excessive drive temperature Ensure the motor fan has adequate area for ventilation 2 Stop motor and allow to cool 3 Run motor at a higher speed to improve cooling air flow 5 Unknown alarm Electron failure 1 Cycle power to reset pump 2 Replace drive Drive Temperature Alarm Excessive drive temperature 1 Ensure the motor fan has adequate area for ventilation 2 Run motor at a higher speed to improve cooling air flow Power Out Alarm Supply voltage low Ensure proper supply voltage Over current Alarm Excessive drive current 1 Examine fluid mechanical system for source of overload 2 De energize motor and determine if motor spins freely 3 Replace drive Over voltage Alarm Excessive voltage on drive buss 1 Rapid switching between speeds can cause excessive voltages on the drive s DC buss 2 Ensure proper supply voltage IntelliFlo 4 Installation and User s G
42. 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 A WARNING The pump can produce high levels of suction within the suction side of the plumbing system These high levels of suction can pose a risk if a person comes within the close proximity of the suction openings A person can be seriously injured by this high level of vacuum or may become trapped and drown It is absolutely critical that the suction plumbing be installed in accordance with the latest national and local codes for swimming pools e These instructions contain information for a variety of pump models and therefore some instructions may not apply to a specific model All models are intended for use in swimming pool applications The pump will function correctly only if it is properly sized to the specific application and properly installed General Warnings e Never open the inside or the drive motor enclosure There is a capacitor bank that holds a 230 VAC charge even when there is no power to the unit e The IntelliFlo 4 pump is not submersible e The IntelliFlo 4 160 pump is capable of 174 GPM or 104 feet of head use caution when installing and programming to limit pumps performance potential with old or questionable

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