SymCom PumpSaver Plus 235P Manuel utilisateur

2880 North Plaza Drive, Rapid City, South Dakota 57702

(800) 843-8848 ·(605) 348-5580 ·fax (605) 348-5685

INSTALLATION

INSTRUCTIONS

MODEL 235P

Revision A1

Rapid City, SD, USA, 02/2009

II_235P_A1

BE SURE POWER IS DISCONNECTED PRIOR TO INSTALLATION!

FOLLOW NATIONAL, STATE AND LOCAL CODES.

READ THESE INSTRUCTIONS ENTIRELY BEFORE INSTALLATION.

The Model 235P Single-phase PumpSaver®Plus is a pump monitor designed to protect single-

phase pumps from dry-well, dead-head, rapid-cycle, jammed impeller, and over/under voltage

conditions. The PumpSaver®Plus Model 235P protects 5 to 15 HP, 230VAC pumps. Typical

applications include submersible pumps, centrifugal pumps, cooling pumps, environmental pumps,

residential water wells, commercial water wells, irrigation wells, and golf course or other sprinkler

equipment.

CONNECTIONS

NOTE: Use with UL/CSA listed overload or impedance protected pumps or motors only.

1. Mount the PumpSaver®Plus Model 235P in a convenient location in or near the pump control

box. If the location is wet or dusty, a NEMA 3R, 4, or 12 enclosure should be used. The

PumpSaver®Plus must be protected by a fuse or circuit breaker.

2. Connect a current transformer (CT) to the PumpSaver’s terminals marked CT1 and CT2. (see

Table 1 for proper CT sizing).

3. Connect the PumpSaver’s terminals marked ‘L1’, ‘L2 IN’ and ‘L2 OUT’.

4. Refer to the appropriate wiring diagram for your specific application.

•Typical wiring diagram – Figure 1

•Standard 3-wire control box – Figure 2

•Deluxe control box – Figure 3

NOTE: One line from the fused disconnect must pass through the current transformer.

The Model 235P will not function without an external current transformer.

NOTE: The PumpSaver®Plus may not detect a dead-head (blocked pipe) condition on

applications where the pump is undersized for a given motor or flow restrictors are used on

high stage pumps or low yield wells.

*** WARNING ***

NO WARRANTY IF DEVICE IS NOT FIELD CALIBRATED

TABLE 1: Current Transformer Selection

Size Current CT

5-7 ½ HP 27.5 – 42.1 50:5

10 HP 51 75:5

15 HP 75 100:5

FIGURE NO.1: Typical Wiring Diagram

OPERATION

The PumpSaver®Plus monitors pump load in amps and kilowatts. When the current (amps) exceeds

approximately 125% of calibrated current, or power (kW) drops below the adjustable underload trip

point, the PumpSaver®Plus—after the trip delay—will turn off the pump. The PumpSaver®Plus will

time through the restart delay, and then restart the pump. The calibration is stored in permanent

memory—it does not need to be recalibrated if power is lost.

CALIBRATION

NOTE: The PumpSaver®Plus should be calibrated

during normal pumping conditions.

1. Turn the RESTART DELAY/ CALIBRATION knob

fully counter-clockwise to the CAL. position.

2. Apply power—the pump will run for approximately

10 seconds then shut off.

3. Set the RESTART DELAY/ CALIBRATION knob

to the desired restart delay (dry-well recovery

time)—the pump will turn on.

NOTE: If the PumpSaver®Plus immediately trips out upon completion of the calibration

process, the current transformer may be installed incorrectly. Switch the CT1 and CT2

connections at the unit, the repeat the calibration process beginning with Step #1.

CALIBRATING WHILE PUMPING

The PumpSaver®Plus can also be calibrated while the pump is running. Turn the RESTART

DELAY/ CALIBRATION knob to CAL. while pumping. Wait for the pump to turn off (approximately

10 seconds), then adjust the RESTART DELAY/ CALIBRATION knob to the desired setting.

SENSITIVITY

The PumpSaver®Plus has an adjustment knob to set the underload trip sensitivity. Setting

SENSITIVITY to the middle position (straight up) is equivalent to SymCom’s standard underload trip

level. Adjust the SENSITIVITY knob to increase/decrease underload sensitivity up to approximately

10% of the standard trip. It may be necessary to increase the sensitivity if the PumpSaver®Plus

does not trip on dry-run or dead-head or it is known that the water level in the well is very low

relative to the pumps capabilities.

WARNING: Decreasing the SENSITIVITY may compromise the PumpSaver®Plus’ ability to

detect dry-run and/or dead-head conditions.

RESET MODE / RESTART DELAY

Any restart delay can be by-passed by rotating the RESTART DELAY/ CALIBRATION knob to the

RESET position and back to the desired restart delay setting.

NOTE: The restart delay can be changed at any time. The next trip will follow the new restart

delay setting.

For test purposes, the RESTART DELAY/ CALIBRATION knob can be placed in the RESET

IND.CON T. E Q.

784X

LINK

L1 CT1 CT2

PILOT DUTY

RATING 480VA

@240VAC

position for manual reset. If the PumpSaver®Plus trips off in this mode due to a voltage or load

problem, the RESTART DELAY/ CALIBRATION knob must be rotated out of the RESET position

to restart the pump.

NOTE: Any restart delay can be by-passed by rotating the RESTART DELAY/CALIBRATION

adjustment to the “RESET” position and back to the desired Restart Delay setting.

RUN HOURS / FAULT HISTORY

The PumpSaver®Plus records pump run hours. Run hours can be displayed by a PumpSaver®

Informer (see USING AN INFORMER on the next page). Run hours and fault history can be cleared

on the PumpSaver®Plus. Read the following instructions fully before performing the procedure.

NOTE: Turn the SENSITIVITY knob completely to the left (counter-clockwise) or completely

to the right (clockwise) when directed.

To Reset Run Hours and Clear Fault History:

1. Remove power to the PumpSaver®Plus.

2. Set the RESTART DELAY/ CALIBRATION knob to RESET and the SENSITIVITY knob to the

middle (12:00) position.

3. Apply power to the PumpSaver®Plus—the CAL. LIGHT will turn on.

4. Turn the SENSITIVITY knob to the right—the CAL. LIGHT will turn off and the RUN LIGHT will

turn on.

5. Turn the SENSITIVITY knob to the left—both lights will turn on.

6. Turn the SENSITIVITY knob to the right.

7. After 10 seconds, the CAL. and RUN LIGHTS will blink twice indicating the run hours and fault

history have successfully been cleared.

RAPID CYCLING

Rapid cycling is defined as more than 4 restarts in a 60-second period. The PumpSaver®Plus is

capable of detecting a rapid-cycle condition whether a control device, such as a pressure switch, is

installed before or after it. Upon detecting either form of rapid cycling, the PumpSaver®Plus will

lock-out until power is removed and re-applied to the L1 IN and L2 IN terminals.

NOTE: Turn the SENSITIVITY knob completely to the left (counter-clockwise) or completely

to the right (clockwise) when directed.

To Disable Rapid-Cycle Protection: (to re-enable, follow the same procedure)

1. Remove power to the PumpSaver®Plus.

2. Set the RESTART DELAY/ CALIBRATION knob to RESET and the SENSITIVITY knob to the

middle (12:00) position.

3. Apply power to the PumpSaver®Plus —the CAL. LIGHT will turn on.

4. Turn the SENSITIVITY knob to the right—the CAL. LIGHT will turn off, RUN LIGHT will turn on.

5. Turn the SENSITIVITY knob to the left—both lights will turn on.

6. Turn the SENSITIVITY knob right—left—right—left—right.

7. After 2 seconds, the CAL. and RUN LIGHTS will blink once.

USING AN INFORMER

PumpSaver®Plus products are equipped with an infrared LED that will communicate to a SymCom

Informer—a handheld, battery-operated, diagnostic tool. The Informer—when directed at the

PumpSaver®Plus—will display real-time voltage, current and power; dry-well and overcurrent trip

points; calibration voltage; last 20 faults; voltage, current and power at the last fault; highest/lowest

voltage and current since calibration; the model number; and the CT size if applicable. The Informer

can be used on any single-phase PumpSaver®Plus equipped with an infrared LED transmitter.

Contact SymCom for more information at 800-843-8848 or visit our website: www.symcom.com.

DIAGNOSTIC INDICATOR TABLE

RUN LIGHT CAL. LIGHT PROBLEM or FUNCTION CORRECTIVE ACTION

On Steady Off RUN:

Pump is running—or ready to run—

no problems in operation None

On Steady On Steady CAL:

The PumpSaver®Plus is in the

calibration process. None

Off On Steady

CAL COMPLETE:

The PumpSaver®Plus is calibrated,

the RESTART DELAY/

CALIBRATION knob was left in the

CAL. position. Pump is off.

Pump will restart as soon as

the RESTART DELAY/

CALIBRATION knob is rotated

out of the CAL. position.

Off Off

OFF / MANUAL RESTART:

The pump is not running. Either the

PumpSaver®Plus has tripped on

dry-run, dead-head, or overcurrent

while the RESTART DELAY/

CALIBRATION knob was in the

RESET position or source power is

not present.

If knob is in the RESET

position, rotate out of RESET—

If the CAL. light blinks, check

for an overcurrent condition. If

the RUN light blinks, look for a

dry-run or dead-head condition.

If no lights come on, check

incoming power for adequate

voltage.

Blinking Off

DRY RUN / DEAD HEAD:

The PumpSaver®Plus has shut the

pump off due to a dry-run or dead-

head condition. The unit is timing

through the restart delay and will

try to restart.

Check for restricted flow or

inadequate supply of liquid.

Off Blinking

OVERCURRENT:

The PumpSaver®Plus has shut the

pump off due to an overcurrent

condition. The unit is timing

through the restart delay and will

try to restart if line voltage is at an

acceptable level.

Check for low or high voltage

or jammed pump impellers. If

these conditions do not exist,

recalibrate the unit while it is

drawing higher current (amps

should not exceed SFA).

Blinking

alternately

with the

CAL. LIGHT

Blinking

alternately

with the

RUN LIGHT

VOLTAGE FAULT:

The PumpSaver®Plus is preventing

the pump from starting due to

voltage problems. The voltage is

being interrogated and the unit will

remain in this mode until the

voltage is at an acceptable level.

If the unit remains in this state

for more than 5 seconds, check

for high or low voltage.

Blinking in

unison with

the CAL.

LIGHT

Blinking in

unison with

the RUN

LIGHT

RAPID CYCLE:

The PumpSaver®Plus has shut

down on rapid cycling. Power must

be removed and reapplied to reset

the unit.

Check for a broken bladder in

the pressure tank (if used), or

check for a defective pressure

or float switch.

PHYSICAL DIMENSIONS

4.05" (102.87)

5.26" (133.60)

4.50" (114.30)

.375"

(9.53)

2.93"

(74.42)

2.17"

(55.12)

2.90"

(73.66

)

FRONT VIEW

BOTTOM VIEW

SPECIFICATIONS

Functional Specifications

Adjustments/Settings

Overcurrent 125% of calibration point

Underload (dry-well) Adjustable (70-90% of calibrated run power)

Overvoltage 265VAC

Undervoltage 190VAC

Number of restarts allowed in 60

second period (rapid-cycling) 4

Trip Delay Times

Overcurrent 5 seconds

Dry-well 4 seconds

Restart Delay Times

Over/undervoltage 2 seconds

All other faults Manual, 2-225 minutes

Input Characteristics

Supply Voltage 230VAC

Load Range 5 to 15hp (external current transformer required)

Frequency 50/60 Hz (note: 50Hz will increase all delay timers by

20%)

Output Characteristics

Output Contact Rating-SPST 720VA @ 240VAC

General Characteristics

Operating Temperature -40° to 55°C (-40° to 131°F)

Power Consumption 5 Watts (max.)

Wire Gauge Solid or stranded 10 - 22AWG

Terminal Torque 13 in.-lbs.

Standards Passed

Electrostatic Discharge (ESD)

Surge Immunity IEC 61000-4-2, Level 2, 4kV contact, 6kV air

IEC 61000-4-5, Level 4, 4kV line-to-line and line-to-

ground

Safety Marks

cUL Listed UL508, C22.2 No. 14

Dimensions 2.90” H x 5.26” W x 2.93” D

Weight 14 oz.

Mounting Methods #8 screws

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