Franklin Electric SubDrive300 User manual

Constant Pressure Water System
SubDrive300
Installation Manual

2
Contents
Description and Features ................................................................................4
Included Items ..................................................................................................5
How It Works.....................................................................................................6
Pump Sizing and Drive Configuration ............................................................8
Underload Sensitivity for Shallow Wells ........................................................9
Before Getting Started...................................................................................10
Controller Location Selection ................................................................. 11-12
Circuit Breaker and Wire Sizing ....................................................................13
Quick Reference Guide............................................................................ 14-15
Pressure Tank .................................................................................................16
Installation Procedure....................................................................................17
Wiring Connections.................................................................................. 18-20
Start-Up and Operation .................................................................................21
Specifications .................................................................................................22
Mounting Dimensions ....................................................................................23
Diagnostic Fault Codes..................................................................................24
System Troubleshooting Guide .....................................................................25
Underload Smart Reset .................................................................................26
Over Temperature Foldback..........................................................................26
Tables
1. SubDrive Models.......................................................................................3
2. Breaker Size and Maximum Cable Length ...........................................13
3. Minimum Pressure Tank Size.................................................................16
4. Pressure Tank Precharge .......................................................................16
Figures
1. Shipping and Mounting Screws.............................................................17
2. Motor Lead Connections .......................................................................18
3. Power and Pressure Sensor Connections............................................19
4. Pressure Sensor......................................................................................20
5. Underload “Smart Reset” Well Recovery Time....................................26

3
Table 1: SubDrive Models
Model Name Part Number Use with Motor Series
SubDrive300 5870206300 (NEMA 4) 234 317 xxxx (5.0 Hp)

4
Description and Features
The Franklin Electric SubDrive300 is a dependable residential and light
commercial water system controller that uses advanced electronics to
enhance the performance of standard submersible pumps. When used with
the specified Franklin Electric motor (see Table 1), the SubDrive eliminates
pressure cycling associated with conventional water well systems and
owners of private water well systems can enjoy “city-like” water pressure.
In addition, the reduced tank size (see Table 3) allows installation in small
spaces. Key features of the SubDrive include:
• Constant water pressure with a wide range of settings (25-80 psi)
• Smaller pressure tank can be used
• Fits the pump to the application – pump speed is controlled to
provide the optimum performance without overloading the motor
• Flexibility – you can use this unit with standard off-the-shelf pumps
• No in-rush (power-on transient) current
• Low motor start-up current (soft-starting)
• Active Power Factor Correction minimizes input RMS current
• Protection features
- Dry well conditions – using smart pump monitoring (see Page 26)
- Bound pump – with auto-reversing torque
- High voltage / lightning surge
- Low line voltage
- Open motor circuit
- Short circuit

5
Included Items
A. Controller Unit
B. Strain Relief Fittings
C. Pressure Shut-off
Sensor and Boot
D. Pressure Sensor and Boot
Franklin Electric is now offering an introductory warranty extension on SubDrive 75,
SubDrive 150 and MonoDrive. The extended warranty is free, but the SubDrive/Mono-
Drive must be registered with Franklin Electric in order to activate the warranty exten-
sion.
SubDrive Extended Warranty Registration
Term of warranty: 3 Years from date of installation, not to exceed 4 years from manufacture date. Warranty
must be registered within 30 days of installation date.
Product Installed (check one): ?SubDrive 75 (5870203380)?SubDrive 150 (5870204150)?MonoDrive
This warranty card must be returned to Franklin Electric, Attn: Inside Sales Coordinator – SubDrive Products, 400 E. Spring
Street, Bluffton, IN 46714 by mail, or faxed to 260-827-5800. All fields in this form must be filled out to validate the extended
warranty.
Installation Name / Owner
Installation Address
Installer
Installer Address
Distributor
Date of Installation SubDrive Date Code
(example: 01A23)
SubDrive/MonoDrive Serial Number
(example: 000451)
Pump Mfg. / Model
Phone Number
State Zip
Phone Number
State Zip
Phone Number
•If a SubDrive is registered, the warranty for that unit covers 3 yearsfrom the date of installation,
not to exceed 4 yearsfrom its manufacture date.
•The registration card must be returned to Franklin Electric no later than 30 days after installation.
•As with our standard warranty, the extended warranty covers defects in material and workman-
ship.
•This Extended Warranty covers only SubDrive 75, SubDrive 150 and MonoDrive controllers.
01000
Cut or fold here
City
City
( )
( )
A
E
C
D
F
H
I
B
E. Sensor Adjustment Tool
F. Sensor Cable
G. Installation Manual
H. Installation Guide
I. Warranty Card
G

6
How It Works
The Franklin Electric SubDrive300 is designed to be part of a system that
consists of only four components:
A. Standard Pump and Franklin Electric Motor.
B. SubDrive Controller.
C. Small Pressure Tank (for tank size, see Table 3).
D. Franklin Electric Pressure Sensor (provided).
E. Franklin Electric Pressure Shut-Off Sensor (provided).
Pressure
Sensor
Leads
Pressure
Shut-o
Sensor
Leads
Power Supply
From Circuit Breaker
PUMP
MOTOR
DE
B
C
Pressure
Relief Valve
Constant Pressure
The Franklin Electric SubDrive300 provides consistent pressure regulation
using advanced electronics to drive a standard motor and pump according
to the pressure demands indicated by a highly accurate, heavy-duty,
long-life pressure sensor. By adjusting the motor/pump speed, the
SubDrive300 can deliver constant pressure dependably, even as water
demand changes. For example, a small demand on the system, such as
a bathroom faucet, results in the motor/pump running at a relatively low
speed. As greater demands are placed on the system, such as opening
additional faucets or using appliances, the speed increases accordingly to
maintain the desired system pressure.

7
Motor Soft Start
Normally, when there is a demand for water, the SubDrive300 will
be operating to accurately maintain system pressure. Whenever the
SubDrive300 detects that water is being used, the controller always “ramps
up” the motor speed while gradually increasing voltage, resulting in a cooler
motor and lower start-up current compared to conventional water systems.
In those cases where the demand for water is small, the system may cycle
on and off at low speed. Due to the controller’s soft-start feature and
sensor’s robust design, this will not harm the motor or the pressure sensor.
System Diagnostics
In addition to regulating pump pressure and accurately controlling motor
operation, the SubDrive300 continuously monitors system performance and
can detect a variety of abnormal conditions. In many cases, the controller
will compensate as needed to maintain continuous system operation. But
if there is high risk of equipment damage, the controller will protect the
system and display the fault condition. If possible, the controller will try to
restart itself when the fault condition subsides.
Unique Features
SubDrive controllers provide the ultimate in system performance, utilizing
Franklin Electric’s three-phase motor series for maximum starting torque,
high efficiency and smooth operation. SubDrives convert residential single-
phase 60Hz power into the variable-frequency three-phase needed by the
motor. In addition, SubDrives can spin a smaller pump slightly faster to
boost output to roughly double its 60Hz horsepower rating. This allows use
of smaller pumps for less system cost. If a smaller pump of the desired flow
rating is not available, the controller can be configured to use larger pumps
up to the horsepower rating of the motor.

8
Pump Sizing
The SubDrive300 is configured at the factory for use with 3 Hp pumps that
are mounted to 5 Hp Franklin Electric three-phase motors. In general, the
SubDrive300 will enhance the performance of a 3 Hp pump to a similar
or better performance than a conventional 5 Hp pump of the same
flowrating (pump series).
To select the proper 3 Hp
pump, first choose a 5 Hp
curve that meets the
application’s head and flow
requirements. Use the 3 Hp
pump in the same pump
series (flow rating). The
SubDrive300 will adjust the
speed of this pump to
produce the performance
of the 5 Hp curve. An
example of this is
illustrated in the graph at right.
Drive Configuration
The SubDrive300 can also be set up to run a 5 Hp pump if desired, but the
larger pump will still produce to the 5 Hp curve and may only be operated
with a 5 Hp motor. To operate a different pump size, a DIP switch must be
positioned to select the correct pump rating. Otherwise, the SubDrive300
may trigger erroneous faults.
To configure the SubDrive300
for a 5 Hp pump, locate the DIP
switch marked “SW1” at the
lower right corner of the main
circuit board. Use a small
screwdriver (provided)
to change the DIP switch
setting according to the chart
as shown.
▲ WARNING
!
Serious or fatal electrical shock may result from contact with internal
electrical components. DO NOT, under any circumstances, attempt
to modify DIP switch settings until power has been removed and 5
minutes have passed for internal voltages to discharge!
700
600
500
400
300
200
100
51530456075
Flow GPM
Typical SubDrive300 Performance
)Q(1.XJUI4VC%SJWF
$POWFOUJPOBM)Q(1.1VNQ
$POWFOUJPOBM)Q(1.1VNQ
SW1
O
N
Configuration Switch
1 Pump Size
OFF 3.0 Hp
ON 5.0 Hp
Total Head (ft)

9
Underload Sensitivity for
Shallow Wells
The SubDrive300 controller is configured at the factory to ensure detection
of Underload faults in a wide variety of pumping applications. In rare cases
(as with certain pumps in shallow wells) this trip level may result in nuisance
faults. If the pump is installed in a shallow well, activate the controller and
observe system behavior. Once the controller begins to regulate pressure,
check operation at several flow rates to make sure the default sensitivity
does not induce nuisance Underload trips.
If it becomes necessary to desensitize the Underload trip level, remove
power and allow the controller to discharge. Once the internal voltages have
dissipated, locate the DIP switch marked “SW1” at the lower right corner
of the main circuit board. Use a small screwdriver (provided) to change
Position 3 to the “ON” position to select the lower Underload sensitivity as
shown in the chart below.
▲ WARNING
!
Serious or fatal electrical shock may result from contact with internal
electrical components. DO NOT, under any circumstances, attempt
to modify DIP switch settings until power has been removed and 5
minutes have passed for internal voltages to discharge!
POS Underload Sensitivity
3 OFF Normal (default)
ON Low (shallow wells)
SW1
O
N
Configuration Switch

10
▲ WARNING
!
Serious or fatal electrical shock may result from failure
to connect the ground terminal to the motor, SubDrive
controller, metal plumbing, or other metal near the motor
or cable, using wire no smaller than motor cable wires. To
minimize risk of electrical shock, disconnect power before
working on or around the SubDrive300 system.
CAPACITORS INSIDE THE SUBDRIVE300 CONTROL-
LER CAN STILL HOLD LETHAL VOLTAGE EVEN AFTER
POWER HAS BEEN DISCONNECTED.
ALLOW 5 MINUTES FOR DANGEROUS INTERNAL
VOLTAGE TO DISCHARGE BEFORE REMOVING
SUBDRIVE300 COVER.
Do not use motor in swimming areas.
Before Getting Started
▲ ATTENTION
!
This equipment should be installed by technically qualified
personnel. Failure to install it in compliance with national
and local electrical codes and within Franklin Electric
recommendations may result in electrical shock or fire
hazard, unsatisfactory performance, or equipment failure.
Installation information is available through pump
manufacturers and distributors, or directly from Franklin
Electric at our toll-free number 1-800-348-2420.
▲ CAUTION
!
Use SubDrive300 only with Franklin Electric 4-inch
submersible motors as specified in this manual (see Table
1). Use of this unit with any other Franklin Electric motor or
with motors from other manufacturers may result in dam-
age to both motor and electronics.

11
Controller Location Selection
The SubDrive controller is intended for operation in ambient temperatures
up to 125°F (51°C) at 230 VAC input. The following recommendations will
help in selection of the proper location of the SubDrive unit:
1. A tank tee is recommended for mounting the tank, pressure sensor,
pressure gauge, and pressure relief valve at one junction. If a tank
tee is not used, the pressure sensor should be located within 6 feet
(1.8 meters) of the pressure tank to minimize pressure fluctuations.
There should be no elbows between the tank and pressure sensor.
2. The unit should be mounted on a sturdy supporting structure such as a
wall or supporting post. Please take into account the weight of the unit,
which weighs approximately 34 pounds (15.5 kg).
3. The electronics inside the SubDrive are air-cooled. As a result, there
should be at least 6 inches of clearance above and below the unit to
allow room for air flow.
* NOTE: there should be no elbows between the tank and pressure sensor.
▲ CAUTION
!
There should be at least 6 inches of clearance above and below the
unit to allow room for air flow.
Pressure
Sensor
Pressure
Relief Valve
Pressure
Tank
6"
min.
6"
min.
Clearance
For
Air Flow
6 Feet or Less
(Pressure Tank to PressureSensor)*
Pressure
Shut-off
Sensor
PUMP
MOTOR

12
4. For indoor or outdoor installations.
5. The SubDrive300 should only be mounted with the wiring end
oriented downward. The controller should not be placed in direct
sunlight or other locations subject to direct rain or snow.
6. The mounting location should have access to 230 VAC electrical
supply and to the submersible motor wiring. To avoid possible
interference with other appliances, please refer to the enclosed
Installation Guide and observe all precautions regarding power
cable routing.
7. To assure maximum weather protection, the unit must be mounted
vertically with the cover properly aligned and secured with all eight
lid screws.
Wiring
To Motor
Power Supply
From Circuit Breaker
Wiring
To Motor
Pressure Sensor
Wiring
Power Supply
From Circuit Breaker
Pressure Sensor
Wiring
CORRECT INCORRECT

13
Circuit Breaker and Wire Sizing
The minimum circuit breaker size and maximum allowable wire lengths for
connection of motor to the SubDrive300 are given in the following table:
A 10-foot section of cable is provided with the SubDrive300 to connect
the pressure sensors.
NOTE:
• Maximum allowable wire lengths are measured between the
controller and motor.
• Aluminum wires should not be used with the SubDrive300.
• Wire sizing between the service entrance and the controller must
be sufficient to provide the required maximum input amps to the
controller while conforming to local standards and codes.
• SubDrive300 minimum breaker amps may be lower than AIM
Manual specifications for the motors listed due to the soft-starting
characteristic of the SubDrive300 controller.
Controller
Model
Franklin Electric
Motor Model HP
Breaker
Amps
AWG Copper Wire Size
14 12 10 8 6 4
SubDrive300 234 317 xxxx 5 40 140 230 370 590 920 1430
Table 2: Minimum Breaker Size and Maximum Cable Length (in Feet)

14
Power Supply
From Circuit Breaker*
Quick Reference Guid
e
P/N 587 020 6300
P
u
Fr
a
El
e
M
o
PRESSURE
SENSOR SHUT-OFF
INT
FAN
INV
FAN
PFC
FAN
NO NO
COM
RELAY
SW2 SW1
O
N
Congur
a
1
OFF
ON
Outp
u
From Power Source
L1 L2
(Input)
*Note: To avoid possible interference with other appliances,
please refer to the enclosed installation guide and observe all
precautions regarding power cable routing
NOTICE
The Safety earth ground connections
are marked at their terminals using
the “ ” symbol
BlkRed GrnWh
Sensor Connection
PRESSURE
SENSOR
PRESSURE
SHUT-OFF

15
e
SubDrive300 (not to scale)
Tank Precharge
Ination Valve
Pressure Gauge
Pressure
Sensor
To Residence
Pressure Switch
Set Point (PSI)
25
30
35
40
45
55
60
65
70
75
80
Pressure Tank
Pre-Charge (PSI)
18
21
25
28
32
35
39
42
46
49
53
56
Pressure Setting Guide
50 (Factory set)
Pressure
Relief Valve
Discharge into
drain rated for
max pump output
at relief pressure
Drain Valve
Sensor Cable
Supplied
u
mp
a
nklin
e
ctric
o
tor
Submersible pumps can
develop very high pressure in
some situations. Always
install a pressure relief valve
able to pass full pump ow at
100 PSI. Install the pressure
relief valve between the
pump and pressure tank.
WARNING
a
tion Switch
Pump Size
3.0 Hp
5.0 Hp
u
t to Motor
Red Yel Blk
(Brn) (Blue) (Blk)
(Output)
Pressure Tank
See Table 3
(page 16) for
recommened
minimum tank size
Pressure
Shut-o
Sensor

16
Pressure Tank
The SubDrive needs only a small pressure tank to maintain constant
pressure (see table below for recommended tank size). For pumps rated 12
gpm or more, a slightly larger tank is recommended for optimum pressure
regulation. The SubDrive can also use an existing tank with a much larger
capacity
.
Table 3: Minimum Pressure Tank Size (Total Capacity)
Pump Flow Rating Controller Model Minimum Tank Size
Less than 12 gpm SubDrive300 8 gallon
12 gpm and higher SubDrive300 20 gallon
NOTE: Check tank precharge regularly to maintain optimum
pressure regulation.
The pressure tank pre-charge setting should be 70% of the system pressure
sensor setting as indicated in the following table.
System Pressure
(at Pressure Sensor)
Pressure Tank
Setting (±2 psi)
25 18
30 21
35 25
40 28
45 32
50 35 Factory Setting
55 39
60 42
65 46
70 49
75 53
80 56
Table 4: Pressure Tank Precharge (PSI)

17
Installation Procedure
1. Disconnect electrical power at the main breaker.
2. Drain the system (if applicable).
3. Install the pressure sensor and pressure shut-off sensor at the
pressure tank tee downstream of the pressure tank (the pressure
tank should be between the pressure sensor and the pump). The
sensors have a ¼-18 National Pipe Thread (NPT) connection.
The pressure sensors should not be installed in an inverted
orientation (up-side down). Make sure the pressure sensor and tank
are not located more than 3 feet off the main piping.
4. Install the unit to the wall using four mounting screws (not included) as
shown in Figure 1 below. Remove the SubDrive lid by removing the eight
lid screws.
Figure 1: Mounting Screws
Mounting Screw Locations
(User Supplied Quantity 4)
Lid Screws (Included Quantity 8)

18
Wiring Connections
1. Verify that the power has been shut off at the main breaker.
2. Verify that the dedicated branch circuit for the SubDrive300 is
equipped with a properly-sized circuit breaker. Refer to Table 2
(Page 13) for minimum breaker size.
3. Use the appropriate strain relief or conduit connectors. Type B liquid
tight fittings are recommended for maximum weather protection.
4. Remove the SubDrive300 lid.
5. Feed the motor leads through the opening on the bottom right side
of the unit and connect them to the terminal block positions marked
GND (Green ground wire), Red, Yellow and Black (Figure 2).
Figure 2: Motor Lead Connections
▲ WARNING
!
Serious or fatal electrical shock may result from failure to connect
the motor, the SubDrive300, metal plumbing and all other metal near
the motor, or cable to the power supply ground terminal, using wire
no smaller than motor cable wires. To reduce risk of electrical shock,
disconnect power before working on or around the water system.
Do not use motor in swimming areas.
PRESSURE
SENSOR SHUT-OFF
INT
FAN
INV
FAN
PFC
FAN
NO NO
COM
RELAY
SW2 SW1
O
N
Output to Motor
Red Yel Blk
(Brn) (Blue) (Blk)
(Output)

19
6. Feed the 230 VAC power leads through the bottom left side of the
SubDrive300 controller and connect them to the terminals marked
L1, L2, and GND (Figure 3).
A 10-foot section of pressure sensor cable is provided with the
controller, but it is possible to use similar 22 AWG wire for distances
up to 100 feet from the pressure sensor. A 100-foot section of
pressure sensor cable is available as an accessory.
7. Feedthepressuresensor leadsthroughthe smalleropeninglocatedinthe
bottom middle of the SubDrive300 unit and press on the quick
connect terminals.
8. Verify that the SubDrive300 unit is properly configured for the
horsepower rating of the motor and pump being used. Please refer to
the section on Pump Sizing for information on drive configuration.
9. Replace the lid. Do not over-tighten the screws.
Figure 3: Power and Pressure
Sensor Connections
PRESSURE
SENSOR SHUT-OFF
INT
FAN
INV
FAN
PFC
FAN
NO NO
COM
RELAY
SW2 SW1
O
N
From Power Source
L2L1
(Input) BlkRed GrnWh
Sensor Connection
PRESSURE
SENSOR
PRESSURE
SHUT-OFF

20
10A. Connect the other end of the pressure sensor cable with the two
spade terminals to the pressure sensor. The connections are
interchangeable (Figure 4A).
10B. Connect the other end of the pressure sensor cable with the two
¼" quick connect terminals to the pressure shut-off sensor. The
connections are interchangeable (Figure 4B).
11. Set the pressure tank pre-charge at 70% of the desired water
pressure setting. To check the tank’s pre-charge, de-pressurize
the water system by opening a tap. Measure the tank pre-charge
with a pressure gauge at its inflation valve and make the necessary
adjustments.
12. The pressure sensor communicates the system pressure to the
SubDrive300 controller. The sensor is preset at the factory to 50 psi,
but can be adjusted by the installer using the following procedure:
a. Remove the rubber end-cap (Figure 4A).
b. Using a 7/32” Allen wrench (provided), turn the adjusting screw
clockwise to increase pressure and counter-clockwise to
decrease pressure. The adjustment range is between 25 and 80
psi (¼ turn = approximately 3 psi).
c. Replace the rubber end cap.
d. Reset the pressure tank pre-charge to the appropriate pressure.
e. Cover the pressure sensor terminals with the rubber boot
provided (Figure 4A).
NOTE: Ensure that the system is properly grounded all the way to the service
entrance panel. Improper grounding may result in the loss of voltage surge
protection and interference filtering.
▲ CAUTION
!
When increasing the pressure, do not exceed the mechanical stop on
the pressure sensor or 80 psi. The pressure sensor may be damaged.
Figure 4A:
Pressure Sensor
Figure 4B:
Pressure Shut-off Sensor
Non-Adjustable
Set at 100PSI
Quick Connect
lead connect
Pressure
Sensor
Boot
Remove Rubber End Cap To Adjust Pressure
With 7/32" Allen Wrench