Pentair Pool Products STA-RITE IntelliPro 4x160 User manual

IntelliPro™
4x160 and 4x100
Four Speed Variable
Centrifugal Pump with Integral Trap
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS

© 2006 Pentair Water Pool and Spa, Inc. All rights reserved
This document is subject to change without notice
1620 Hawkins Ave., Sanford, NC 27330 • [phone]
10951 West Los Angeles Ave., Moorpark, CA 93021 • [phone]
Sta-Rite, IntelliTouch, EasyTouch, IntelliPro and the Pentair Water Pool and Spa logo are trademarks of Pentair
Water Pool and Spa, Inc. Other trademarks and trade names may be used in this document to refer to either the
entities claiming the marks and names or their products. Pentair Water Pool and Spa, Inc. disclaims proprietary
interest in marks and names of others.
P/N 357291 Rev A - 10/18/06
Technical Support
Sanford, North Carolina (8 A.M. to 5 P.M.)
Phone: [phone]
Moorpark, California (8 A.M. to 5 P.M.)
Phone: [phone]
Fax: [phone]
Web sites: visit www.pentairpool.com and staritepool.com

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IntelliPro Installation and User’s Guide
Contents
Important Safety Precautions .............................................................................. iii
Section 1: Overview .............................................................................................. 1
IntelliPro Variable Speed Pump ............................................................................... 1
IntelliPro models ...................................................................................................... 1
External Control....................................................................................................... 1
Features .................................................................................................................. 2
IntelliPro Motor Assembly........................................................................................ 2
Drive assembly and electronics enclosure ................................................. 2
Motor fan cover ........................................................................................... 2
Motor assembly ........................................................................................... 2
Operator Control Panel ................................................................................ 2
Communication Port for communication to IntelliTouch,
or IntelliComm via the two-wire RS-485 cable......................................................... 2
IntelliPro Drive Assembly and Control Panel ........................................................... 3
IntelliPro Motor Features ......................................................................................... 3
IntelliPro Operator Control Panel ............................................................................. 4
Controls and LEDs ...................................................................................... 4
Section 2: Installation ........................................................................................... 5
Before installation .................................................................................................... 5
Teflon Taping Instructions ............................................................................ 5
Piping ........................................................................................................... 6
Fittings ......................................................................................................... 6
Wiring the IntelliPro .................................................................................................. 7
External Control with IntelliComm Communication Center ...................................... 8
Connecting IntelliPro 4 to an EasyTouch System ................................................... 9
Connecting IntelliPro 4 to an IntelliTouch System .................................................... 12
Section 3: Operation ............................................................................................. 15
Setting the pump preset speed ................................................................................ 15
Adjusting the pump speed ........................................................................... 16
Starting the pump ........................................................................................ 16
Stopping the pump ....................................................................................... 16
Setting the pump communication address .............................................................. 16
Resetting the pump to factory defaults .................................................................... 17
Priming the pump for the first time or after service .................................................. 18
Priming the Pump ........................................................................................ 19
Storage/Winterizing: ................................................................................................ 20
Draining Pump ......................................................................................................... 20
Startup For Winterized Equipment........................................................................... 21
Pump Service .......................................................................................................... 21

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IntelliPro Installation and User’s Guide
Section 4: User Maintenance ................................................................................ 23
Pump Strainer Basket ............................................................................................. 23
Pump Strainer Basket Service ................................................................................ 23
Motor Service .......................................................................................................... 24
Winterizing ................................................................................................... 25
Priming the pump after service ................................................................................ 25
Pump Disassembly ................................................................................................. 27
Section 5: Removal and Replacement ................................................................. 27
Drive Assembly Removal and Installation ............................................................... 27
Pump Disassembly/Removing Old Seal ................................................................. 29
Pump Reassembly/Installing New Seal .................................................................. 30
Illustrated Parts List ................................................................................................. 31
IntelliPro Flow and Power vs Flow Pump Curve ..................................................... 32
IntelliPro Electrical Specifications ........................................................................... 32
IntelliPro Pump Dimensions .................................................................................... 32
Section 6: Troubleshooting .................................................................................. 33
Warning and Alarm conditions ................................................................................. 33
Alarm and warning LED sequence .......................................................................... 33
General IntelliPro Troubleshooting Problems ........................................................... 34
Contents (Continued)

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IntelliPro Installation and User’s Guide
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 [phone] 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, Hot Tubs and Catch Basins. If suction outlets
are not used, additional entrapment avoidance measures as described in the CPSC
Guidelines or ANSI/IAF-7 should be employed.
The covers used on suction outlets should be approved and listed as conforming to the
currently published edition of ANSI/ASME A112.19.8 Standard covering Suction Fittings
for Use in Swimming Pools, Wading Pools, Spas and Hot Tubs. These covers should 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 ENTANGLEMENT WHICH 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
serviceman in accordance with the National Electrical Code and all applicable local codes
and ordinances. Improper installation will create an electrical hazard which could result in
death or serious injury to pool users, installers, or others due to electrical shock, and may
also cause damage to property.
Always disconnect power to the pool pump at the circuit breaker before servicing the
pump. Failure to do so could result in death or serious injury to serviceman, pool users
or others due to electric shock.
IMPORTANT SAFETY PRECAUTIONS

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IntelliPro Installation and User’s Guide
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 (No. 6 AWG in Canada) 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 — IntelliPro 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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IntelliPro Installation and User’s Guide
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.
IMPORTANT SAFETY PRECAUTIONS (continued)
General Warnings
• Never open the inside of 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 IntelliPro 4 pump is not submersible
• The IntelliPro 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 IntelliPro 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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IntelliPro Installation and User’s Guide
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IntelliPro Installation and User’s Guide
Section 1
Overview
IntelliPro Variable Speed Pump
The IntelliPro variable speed pump is well suited for all of your pool, spa, cleaner, waterfall and other water
application. Using the control panel, IntelliPro can use one of the four selectable preset speeds or the pump
speed can be adjusted to run at a specific speed. The IntelliPro pump out performs all conventional pumps
in its class. Advanced energy conservation features ensure that your filtration system is operating at peak
efficiency.
IntelliPro models
There are two IntelliPro models which operate identically with the exception of the maximum flow rate:
• IntelliPro 160 operates at a maximum system flow of 160 gallons per minute (GPM)
• IntelliPro 100 operates at a maximum system flow of 100 gallons per minute (GPM)
The IntelliPro 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 IntelliPro pump control panel alarm LED
warns the user against under and over voltage, high temperature, over current and freeze protection.
External Control
The IntelliPro can communicate with an IntelliTouch system or IntelliComm via a two-wire RS-485
communication cable for remote speed control.
IntelliPro variable speed pump

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IntelliPro Installation and User’s Guide
Features
• Adjusts to various pool sizes
• Prevents thermal overload
• Detects and prevents damage from under and over voltage conditions
• Protects against freezing
• Communicates with the Pentair IntelliTouch system via a two-wire cable 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
IntelliPro Motor Assembly
The IntelliPro 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.
Drive assembly and
electronics enclosure
Motor fan cover
Communication Port for
communication to IntelliTouch,
or IntelliComm via the two-wire
RS-485 cable
Motor assembly
Operator Control Panel