®
IntelliFlo 4/160 and 4/100
Variable Speed Programmable Pump
(Compatible with IntelliTouch™, EasyTouch™ and IntelliComm)
AUTO
SPA
AIR
HEATER
100°F / 95°F
70°F
MON 09:30 AM
Installation and
User’s Guide
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
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i
Contents
Important Safety Precautions ........................................................................................... ii
Section 1: IntelliFlo Overview ........................................................................................... 1
IntelliFlo 4 Variable Speed Pump .......................................................................................... 1
IntelliFlo 4 models ................................................................................................................. 1
External Control.................................................................................................................... 1
Features ............................................................................................................................... 2
IntelliFlo 4 Motor Assembly .................................................................................................. 2
IntelliFlo 4 Drive Assembly and Control Panel...................................................................... 3
IntelliFlo 4 Operator Control Panel........................................................................................ 4
Controls and LEDs .......................................................................................................... 4
Section 2: Operating IntelliFlo 4........................................................................................ 5
Setting the pump preset speed............................................................................................. 5
Adjusting the pump speed .................................................................................................... 5
Starting the pump ................................................................................................................. 6
Stopping the pump................................................................................................................ 6
Resetting the pump to factory defaults ................................................................................. 6
Assigning a pump address for remote control ...................................................................... 6
Priming the pump for the first time or after service ............................................................... 7
Priming the Pump ............................................................................................................. 8
External Control with IntelliComm Communication Center ................................................... 9
External Control Connection ............................................................................................ 9
Connecting IntelliFlo 4 to an EasyTouch System ................................................................ 10
Connecting IntelliFlo 4 to an IntelliTouch System ................................................................ 13
Section 3: User Maintenance............................................................................................ 15
Pump Strainer Basket ......................................................................................................... 15
Pump Strainer Basket Service ............................................................................................ 15
Motor Service ...................................................................................................................... 16
Winterizing........................................................................................................................... 17
Priming the pump after service............................................................................................ 17
Section 4: Installation and Removal ................................................................................ 19
IntelliFlo 4 Kit Contents........................................................................................................ 19
Installing IntelliFlo 4 ............................................................................................................. 19
Location ............................................................................................................................... 19
Piping ................................................................................................................................. 19
Check Valve ........................................................................................................................ 19
Wiring the IntelliFlo 4 ........................................................................................................... 20
Pump Disassembly ............................................................................................................. 21
Pump Reassembly/Seal Replacement................................................................................ 22
Shaft Seal Replacement ...................................................................................................... 22
Drive Assembly Removal and Installation........................................................................... 23
Illustrated Parts List............................................................................................................. 24
IntelliFlo Pump Dimensions ................................................................................................. 25
IntelliFlo Flow and Power vs Flow Pump Curve .................................................................. 25
IntelliFlo 4 Electrical Specifications ..................................................................................... 25
Section 5: Troubleshooting .............................................................................................. 27
Warning and Alarm LED conditions ..................................................................................... 27
Alarm and warning LED sequence ...................................................................................... 27
General IntelliFlo 4 Troubleshooting Problems..................................................................... 28
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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. Call (800) 831-7133 for additional free copies of these
instructions.
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, HotTubs 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 be
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 ENTANGLEMENTWHICH CAN RESULT IN DEATH.
WARNING — Risk of electrical shock or electrocution.
This pool pump must be installed by a licensed or certified electrician or a qualified pool
servicemaninaccordancewiththeNationalElectricalCodeandallapplicablelocalcodes
andordinances.Improperinstallationwillcreateanelectricalhazardwhichcouldresultin
death or serious injury to pool users, installers, or others due to electrical shock, and may
also cause damage to property.
Alwaysdisconnectpowertothepoolpumpatthecircuitbreakerbeforeservicingthe
pump. Failure to do so could result in death or serious injury to serviceman, pool users
or others due to electric shock.
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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.
The effects of hyperthermia include: 1) Unawareness of impending danger. 2) Failure to
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.
WARNING — The use of alcohol, drugs, or medication can greatly increase the risk of fatal
hyperthermia in hot tubs and spas.
WARNING — To reduce the risk of injury, do not permit children to use this product unless they are closely
supervised at all times.
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.
WARNING — When setting up pool water turnovers or flow rates the operator must consider local codes
governing turnover as well as disinfectant feed ratios.
WARNING — Before servicing the system, switch the main power OFF and remove the communication
cable from the pump.
CAUTION — Install the pump a minimum of five (5) feet from the inside wall of the pool and spa. Canadian
installations require a minimum of three (3) meters from pool water.
CAUTION — A No. 8 AWG or larger conductor must be wired to the motor bonding lug.
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).
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.
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.
•
Install to provide drainage of compartment for electrical components.
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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.
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.
•
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
•
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.
•
•
The IntelliFlo 4 pump is not submersible
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
equipment
•
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
•
•
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.
Always Press the Stop button and disconnect the communication cable before performing
maintenance
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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:
•
•
IntelliFlo 4 160 operates at a maximum system flow of 160 gallons per minute (GPM)
IntelliFlo 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 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
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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) 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
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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
¾” 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
•
•
•
•
•
•
•
•
•
•
•
Permanent Magnet Synchronous Motor (PMSM)
High efficiency (3400 RPM 92% and 1000 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 environment
Totally enclosed fan cooled
Three-phase motor
56 Square Flange
Six-Pole
Low noise
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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 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 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.
Stop button: Press this button to stop the pump.
4
On LED: This green power LED is on when IntelliFlo 4 is powered up.
5
Alarm LED: This LED is on when an error condition occurs. This green LED will flash a certain number of
6
times indicating a specific error condition. For the alarm LED flash sequence, refer to “Alarm and Warning
LED Sequence,” on page 27.
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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. 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.
2. Press the Start button to start the pump if the pump is not running.
3. Press the UP/Down button to increase or decrease the pump speed.
•
10 RPM increments: Press and quickly release the Up/Down button to
increase or decrease the speed in 10 RPM increments.
•
20 RPM increments: Press and hold the Up/Down button to continuously
increase or decrease the pump speed.
4. 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).
Up/Down button
5. Press the Speed button that is assigned to the adjusted speed.
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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.
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.
Control Panel Speed Buttons
Assigning a pump address for remote control
The default communications address for the IntelliFlo 4 is 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 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.
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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.
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.
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.
CAUTION - Before starting this procedure, first read the following
Before removing the pump lid:
1. Press the Stop button if the pump is running before proceeding.
1. Disconnect the communication cable from the pump.
2. Close the gate valves in suction and discharge pipes.
3. Release all pressure from pump and piping system.
4. Never tighten or loosen the clamp while the pump is operating.
WARNING! 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.
WARNING! 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 IntelliFlo
4 provides an automatic internal cutoff switch to protect the motor from heat damage during operation.
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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. 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.
•
•
Clean and inspect o-ring; reinstall on trap cover.
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. Turnthepumpclampandlidinacounterclockwisedirectionuntilitstops
andremovethem.
2. Fillthepumpstrainerpotwithwater.
3. Reinstallthepumpclampandlidontothestrainerpot.Thepumpisnow
readytoprime.
4. Makesureallelectricalconnectionsarecleanandtight.
5. Opentheairreleasevalveonthefilter,andstandclearofthefilter.
6. Switch the IntelliFlo pump on at the circuit breaker. Ensure that the
Top view
green power light is on.
7. Press the Speed 1 button to select the pump speed of 750 RPM.
8. PresstheStartbuttontostartthepump.UsetheUp/Downbuttontoincreasethespeedasnecessary
toprimethepump.
9. Whenwatercomesoutoftheairreleasevalve,closethevalve.Thesystemshouldnowbecirculatingwater
backtothepoolwithoutairbubblesshowingineitherthehairandlintpotoratthepoolreturnfittings.
10. UsetheUp/Downbuttontoadjusttheoperatingspeedasdesired.
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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.
If more 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
Maximum
current
Terminal number Terminal name
Voltage
Phase type
Frequency
1-2
3-4
Power supply
Program 1
100 - 240 VAC
100 mA
1 Input
50/60 Hz
15 -240 VAC
or
15 - 100 VDC
1 mA*
1 mA*
1 mA*
1 mA*
1 Input
1 Input
1 Input
1 Input
50/60 Hz
50/60 Hz
50/60 Hz
50/60 Hz
15 -240 VAC
or
15 - 100 VDC
5-6
7-8
Program 2
Program 3
15 -240 VAC
or
15 - 100 VDC
15 -240 VAC
or
15 - 100 VDC
9-10
Program 4
RS-485
-5 to +5 VDC
11
12
+ Data: Yellow
- Data: Green
5 mA
1 Output
N/A
Ground
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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.
CAUTION - Switch the main power off to the EasyTouch 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
Control panel
access screw
access screw
Retaining screw
High voltage
cover panel
EasyTouch Load Center (front view)
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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. EasyTouch to IntelliFlo 4 pin configuration:
• IntelliFlo: Connect pin 6 (green) to EasyTouch screw terminal pin 2 (green)
• IntelliFlo: Connect pin 7 (yellow) to EasyTouch screw terminal pin 3 (yellow)
EasyTouch (J20)
screw terminal
EasyTouch
IntelliFlo
Pin 6
screw terminal
(2-wire cable)
connector
(Green)
2 (GRN)
3 (YEL)
GREEN (Pin 6)
YELLO (Pin 7)
Pin 7 (Yellow)
IntelliFlo connector pin configuration
Pin configuration
8. Insert the screw terminal onto the EasyTouch 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
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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)
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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 is 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.
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 raceway
Cover-panel
screw
(Cover-panel not
shown)
Plastic grommet
IntelliTouch Load Center
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Connecting IntelliFlo to IntelliTouch (Continued)
6. Strip back the cable conductors ¼”. Insert the wires into the either of the COM PORTS (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 configuration shown below. Note: Multiple wires may be
inserted into a single screw terminal.
IntelliTouch Personality
board COM PORT
(J7/J8)
BLK
GRN
YEL
RED
Pin Configuration for IntelliFlo 4 to IntelliTouch:
• IntelliFlo 4: Connect pin 6 (green) to IntelliTouch screw terminal pin 2 (green)
• IntelliFlo 4: Connect pin 7 (yellow) to IntelliTouch screw terminal pin 3 (yellow)
IntelliTouch
COM PORT (J7/J8)
screw terminal
Pin 6
(Green)
IntelliTouch
screw terminal
connector
2 (GRN)
3 (YEL)
IntelliFlo
(2-wire cable)
Pin 7 (Yellow)
GREEN (Pin 6)
YELLOW (Pin 7)
IntelliFlo 4 cable pin configuration
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.
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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.
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.Adirty basket will reduce the efficiency of the filter and possibly the heater.
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.
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
IftheIntelliFlopumpisinstalledbelowthewaterlevelofthepool,
closethereturnandsuctionlinesbeforeopeningthehairandlintpot
onthepump.
1. PresstheStopbuttontostopthepumpandswitchoffthepump
atthecircuitbreaker.
2. DisconnectthecommunicationcablefromtheIntelliFlo4pump.
3. Relievepressureinthesystem.
4. Turntheclampandlidinacounterclockwisedirectionuntilit
stops.
5. Removetheclampandlid.
6. Removethebasketandputthedebrisintothetrashandrinseout
the basket. If the basket is cracked, replace the basket.
7. Replacethebasketandfillthepumppotandvolutewithwater
uptotheinletport.
8. Cleanthecover,o-ring,andsealingsurfaceofthepumppot.Grease
theo-ringwithTeflonorsiliconelubricant.
9. Reinstallthelidbyplacingtheclampandthelidonthepot.
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Pump Strainer Basket Service (Continued)
10. Ensurethatthelido-ringisproperlyplaced.Seattheclampandlidthen
turnclockwiseuntilthehandlesarehorizontalasshown.
11. Reconnectthecommunicationcabletothepumpifrequired.
12. SwitchthepowerONatthecircuitbreaker.Resetthepooltimeclock
tothecorrecttime.
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, FOLLOWTHESE INSTRUCTIONS.
13. Openthemanualairreliefvalveontopofthefilter.
14. Standclearofthefilter.PresstheStartbuttononthepump.
15. Bleedairfromthefilteruntilasteadystreamofwatercomesout.
16. Closethemanualairreliefvalve.
Motor Service
1. Protectfromheat:
•
•
Shadethemotorandcontrollerfromthesun.
Anyenclosuremustbewellventilatedtopreventoverheating.Particularattentionshouldbepaidtothe
motorfancoverandthecoolingfinsbetweenthedriveandthemotor.
•
Provideamplecrossventilation.
2. Protectagainstdirt:
•
•
•
•
Protectfromanyforeignmatterorsplashingwater.
Donotstore(orspill)poolchemicalsnearthemotor.
Avoidsweepingorstirringupdustnearthemotorwhileitisoperating.
Ifamotorhasbeendamagedbydirtitvoidsthemotorwarranty.
3. Protectagainstmoisture:
•
•
•
•
Protectfromsplashingpoolwater.
Protectfromtheweather.
Protectfromlawnsprinklers.
Ifamotorhasbecomewet-letitdrybeforeoperating. Donotallowthepumptooperateifithasbeen
flooded.
•
Ifamotorhasbeendamagedbywateritvoidsthemotorwarranty.
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.
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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. Iftheairtemperaturedropsbelow40°Fthewaterinthepumpcanfreezeandcausedamage.
Freezedamageisnotwarrantable.
2. Topreventfreezedamagefollowtheprocedureslistedbelow.
•
•
Shutoffelectricalpowerforthepumpatthecircuitbreaker.
Drainthewateroutofthepumpbyremovingthetwothumb-twistdrainplugslocatedatthebottomof
thevolute.Storetheplugsinthepumpbasket.
•
•
Coverthemotortoprotectitfromsevererain,snowandice.
Donotwrapthemotorinplastic.Itwillcausecondensationandrustontheinsideofthemotor.
Note: 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.
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, refer to “Priming the pump for the first time or
after servicing,” on page 7.
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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. Installthepumpasclosetothepoolorspaaspossible.Toreducefrictionlossandimproveefficiency,
useshortanddirectsuctionandpipingreturns.
2. Installaminimumoffive(5)feetfromtheinsidewallofthepoolandspa.Canadianinstallationsrequire
aminimumofthree(3)metersfrompoolwater.
3. Installthepumpaminimumoftwo(2)feetfromtheheateroutlet.
4. Donotinstallthepumpmorethan(8)feetabovethewaterlevel.
5. Installthepumpinashelteredwellventilatedlocationprotectedfromexcessivemoisture,(i.e.,rain,
sprinklers,etc.).
6. Forhottubsandspas,donotinstallwithinanouterenclosureorbeneaththeskirtofahottuborspa.
7. Installthepumpwitharearclearanceofatleast6inchessothatthemotorcanberemovedeasilyfor
maintenanceandrepair.
Piping
For improved pool plumbing, it is recommended 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.Avalve, 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.
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Wiring the IntelliFlo 4
To connect the IntelliFlo 4 to an AC power source:
1. Makesureallelectricalbreakersandswitchesareturnedoffbeforewiringmotor.
2. Makesurethatthewiringvoltageis230VAC.
3. Use#12AWGforwirerunsupto100feetand#10AWGforlengthslongerthan100feet. Whenin
doubtuseaheaviergauge(largerdiameter)wire.Heaviergaugewillallowthemotortoruncoolerand
moreefficient.
4. Makesureallelectricalconnectionsarecleanandtight.
5. Cutthewirestotheappropriatelengthsotheydonotoverlaportouchwhenconnected.
6. Permanentlygroundthemotorusingthegreengroundwire,asshownbelow.Usethecorrectwiresize
andtypespecifiedbyNationalElectricalCode.Makesurethegroundwireisconnectedtoanelectrical
serviceground.
7. BondthemotortothepoolstructureinaccordancewiththeNationalElectricalCode.Useasolid
No.8AWGorlargercopperconductor.Runawirefromtheexternalbondinglugtothepoolbonding
structure,asshownbelow.
8. TheIntelliFlopumpisdesignedtobepermanentlyconnectedtoitspowersource.Typicallythepump
receivespowerdirectlyfromthecircuitbreaker. Nocontactorormotorstarterisrequired. Thedrive
controlsthestartingandstoppingofthepump. IftheIntelliFloisconnectedtoanautomationsystem,such
asEasyTouchorIntelliComm,thedrivemustbepowereduptoreceiveandrespondtotheRS-485serial
communicationfromtheautomationsystem. However,thepumpcanbeoperatedin“stand-alone”mode,
startingandstoppingwhenpowerisappliedorremoved. Whenthedrivepowersupitwillreturntothe
modeandrunstatusthatitwasinwhenpowerwasremoved.Thissetupmaybeappropriateifyouneedto
useexistingrelaysortimers.
9. Forwiringpinoutsforthecommunicationsport,seepage11.
GROUND WIRE
(GREEN)
IntelliFlo 4 wiring harness
Red = Hot
Red = Hot
Green/yellow stripe = Ground
BONDING LUG
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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. 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
extremecaution.
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:
•
•
•
•
3/32inchAllenheadwrench.
½inchopenendwrench.
9/16inchopenendwrench.
Flatbladescrewdriver.
To remove and repair the pump mechanical seal, perform the following procedures:
1. Switchoffthepumpcircuitbreakeratthemainpanel.
2. DisconnecttheRS-485communicationcablefromthepump.
3. Drainthepumpbyremovingthedrainplugs.
4. Removethesixboltsthatholdthemainpumpbody(strainerpot/volute)totherearsubassembly.
5. GENTLYpullthetwopumphalvesapart,removingtherearsubassembly.
6. Usea3/32inchAllenheadwrenchtoloosenthetwoholdingscrewslocatedonthediffuser.
7. HoldtheimpellersecurelyinplaceandremovetheimpellerlockscrewbyusingaPhillipshead
screwdriver.Thescrewisaleft-handedthreadandloosensinaclockwisedirection.
8. Useaflatbladescrewdrivertoholdthemotorshaft.Themotorshafthasaslotontheendwhichis
accessiblethroughthecenterofthefancover.
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Pump Disassembly (Continued)
9. To unscrew the impeller from the
shaft, twist the impeller
GASKET
SEAL
MOTOR
BOLT (4x)
counterclockwise.
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)
IMPELLER
SEAL PLATE
LOCK SCREW
LOCK SCREW SEAL
13. Clean the seal plate, seal housing,
and the motor shaft.
Pump Reassembly/Seal Replacement
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 and 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.
3. Remount the seal plate to the motor.
4. Grease the motor shaft thread and screw impeller onto the motor shaft.
5. Screw in the impeller lock screw (counterclockwise to tighten).
6. Remount the diffuser onto the seal plate. Make sure the plastic pins and holding screw inserts are
aligned.
7. Grease the diffuser o-ring and seal plate gasket prior to reassembly.
8. 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.
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Drive Assembly Removal and Installation
To remove the IntelliFlo 4 drive and control panel from the motor assembly:
1. Makesureallelectricalbreakersandswitchesareturnedoffbeforeremovingthedrive.
2. Disconnect the RS-485 communication cable from the pump.
3. Openthecontrolpanelcover.
4. RemovethethreePhillipsheadscrewssecuringthedrivetothemotorassemblyasshown.
CAUTION: TO AVOID ELECTRICAL HAZARD, DO NOT REMOVE THE FOUR TAMPER
PROOF BITS FROM THE MOTOR ASSEMBLY
5. Liftupthedriveassemblyandremoveitfromthemotoradapterlocatedontopofthemotorassembly.
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:
1. Makesureallelectricalbreakersandswitchesareturnedoffbeforeinstallingthedrive.
2. Besurethatthegasketbetweenthedriveandmotorisinplace.Itiscriticalinkeepingmoistureoutof
thedriveandmotor.Replacethegasketifdamaged.Donotreassemblewithadamagedormissing
gasket.
3. Verifythatthethree(3)orangemotorpostcapsareinpositionbeforeplacingthedriveonthemotor
assembly.
4. Alignthedriveassemblywiththemotoradapterandseatthedriveonthemotorassembly.
5. SecureandtightenthedriveassemblywiththethreePhillipsheadscrews.
Phillips head screw
Phillips head screws
Adapter connector
Do not remove
these screws
Orange motor post
caps (QTY. 3)
Gasket
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Illustrated Parts List
22
24
3
15
28
32
31
20
26
25
10
11
1
23
4
21
2
30
27
19
16
14
12
17
13
5
18
28
9 8
Replacement Parts
7
Item
No.
Part
No.
Description
Item
No.
Part
No.
Description
1
2
070387 BASKET AQ & WF
15
072184 WASHER 3/8 ID X 7/8 OD .05 THICK
18-8 s/s, (QTY 6)
070429 BOLT HEX HD, 2-56x0.875 s/s,
(QTY 4)
16
17
18
072928 DIFFUSER ASSEMBLY WFE 12
073131 IMPELLER WFE 12 1000 SER
3
4
070430 BOLT 3/8 - 16 X 1¼ HEX CAP 18-8 s/s,
(QTY 4)
074629 GASKET FLAT WASHER WFE DRAIN,
(QTY 2)
070431 BOLT 3/8 -16 X 2 HEX CAP 18-8 s/s,
(QTY 2)
19
20
21
22*
23*
24
075713 RUBBER WASHER WFE PUMP
350013 O-RING LID CH/WF 2-436
5
6
7
8
070927 FOOT WF - PUMP MOTOR SUPPORT
070929 FOOT INSERT WF PUMP
350015 VOLUTE CASING WFE (Almond)
350082 CONTROL COVER ASSEMBLY
350105 VFD MOTOR 3.2KW PMSM
071131 PLUG DRAIN WFE (Almond) (QTY 2)
071403 NUT 3/8 - 16 BRASS NICKEL PLATED,
(QTY 2)
9
071406 NUT ¼ - 20 HEX s/s (QTY 2)
350107 SCREW 10-24 X 3¼ in. PH MS 18-8 s/s,
(QTY 3)
10
11
071444 O-RING 238, 3.484x0.139, Buna-N 70
25
26
27
28*
30
31
32
350108 INTELLIFLO DRIVE GASKET
350142 SPACER CAP (QTY 3)
071652 SCREW ¼-20 X 1 LH PHILLIPS PAN
MS 18-8 s/s
12
13
14
071657 SCREW ¼ - 20 X 1 in. HEX CAP 18-8 s/s,
(QTY 3)
350201 SEAL PLATE KIT, WFE ALMOND
350521 INTELLIFLO 4 SPEED DRIVE
357102 GASKET SANTOPRENE MOLDED
357151 LID SEE THRU WF
071660 SCREW SET 4-40 X 1-1/8 WFE SCKT
CAP 18-8 s/s (QTY 2)
072183 WASHER FLAT ¼ X 5/8 20 GA THICK
18-8 s/s (QTY 2)
357199 CLAMP CAM & RAMP WF (Almond)
Note: (*) Not serviceable parts.
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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.
Input: 230 VAC, 50/60 Hz, 3200 Watts
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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.
•
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.
•
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
Alarm
Description
Action
LED will blink
2
Drive Temperature Warning
Excessive drive temperature
1. 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
6
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.
7
8
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.
9
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.
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General IntelliFlo 4Troubleshooting 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 27.
Pump will not prime - Air leak in suction.
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.
Pump will not prime - Not enough water.
Ensure that the suction lines,
pump, strainer, and pump volute
are full of water.
Pump strainer clogged.
Clean pump strainer pot.
Replace gasket.
Pump strainer gasket defective.
Reduced capacity and / Air pocket or leaks in suction line.
or head.
Check suction piping and valve
glands on any suctin gate valves.
Refer to Alarm and
warning LED sequence Clogged impeller.
on page 27.
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 bolt 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.
Pump strainer clogged.
Clean suction trap.
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Problems and Corrective Action (Continued)
Problem
Possible Cause
Excessive motor current.
GFCI fault.
Corrective Action
Circuit breaker trips
repeatedly.
Refer to Alarm and
warning LED sequence
on page 27.
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 27.
Pump may be too hot.
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.
Mechanical Troubles
and Noise.
The pump motor is running but with loud noise.
If suction and discharge piping
are not adequately supported,
pump assembly will be strained.
Do not mount pump on a
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.
Cavitation.
Improve suction conditions.
Increase pipe size. Decrease
number of fittings. Increase
discharge pressure.
IntelliFlo does not
respond to EasyTouch
or IntelliTouch
Improper EasyTouch/IntelliTouch/IntelliFlo setup.
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
commands
4. Ensure that the IntelliFlo
display says ""DISPLAY NOT
ACTIVE"".
Communication network inoperative.
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
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30
Notes
IntelliFlo 4 Installation and User’s Guide
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31
Notes
IntelliFlo 4 Installation and User’s Guide
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32
Notes
IntelliFlo 4 Installation and User’s Guide
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Download from Www.Somanuals.com. All Manuals Search And Download.
P/N 357269 - Rev B
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