SymCom PumpSaver Plus 234-P User manual

INSTALLATION Revision B1
INSTRUCTIONS
Rapid City, SD, USA, 08/2009
MODEL 234-P
II_234-P_B1
2880 North Plaza Drive, Rapid City, South Dakota 57702
[phone] ·[phone] ·fax [phone]

BE SURE POWER IS DISCONNECTED PRIOR TO INSTALLATION!
FOLLOW NATIONAL, STATE AND LOCAL CODES.
READ THESE INSTRUCTIONS ENTIRELY BEFORE INSTALLATION.
SymCom PumpSaver®Model 234-P protects single-phase pumps from dry-well, dead-head,
rapid-cycle, jammed-impeller, and over/undervoltage conditions. Typical applications include
residential waterwells, commercial waterwells, irrigation wells, and golf course and other sprinkler
systems.
The PumpSaver®Model 234-P is designed to be mounted inside a Grundfos®control box to
protect 1/3–3hp, 2- or 3-wire, 230V pumps.
CONNECTIONS
NOTE: This product is for installation in a Grundfos®control box only.
1. Remove the top plastic cover from inside the control box.
2. Remove the knock-out from the plastic cover.
3. Mount the PumpSaver®to the plastic cover using the four screws provided.
4. Remove the yellow jumper wire between L2 and YEL. See Figure 1.
5. Insert the three wires under the screw terminals in the control box as shown in Fig. 2.
6. Replace the plastic cover in the control box.
*** WARNING ***
PROPER OPERATION REQUIRES FIELD CALIBRATION
© 2009 SymCom, Inc. All Rights Reserved 2

CAPACITOR
START
RUN
CAPACITOR
RELAY
REMOVE YELLOW
JUMPER
YELLOW
BLUE RED
ORANGE
BLACK
BLACK
L1SW L2 YEL RED BLK
Figure 1: Grundfos Control Box without PumpSaver
®
Plus Installed
© 2009 SymCom, Inc. All Rights Reserved 3

START
CAPACITOR
RUN
CAPACITOR
RELAY
YELLOW RED
ORANGE
BLACK
BLACK
YEL
BLK
BLU
SW L1 L2 YEL RED BLK
RESTART DELAY/
1.5 to 3hp at 230VAC
_+
IR
LINK
Fi
g
ure 2: Grundfos Control Box with Pum
p
Save
r
®
Plus Connections
© 2009 SymCom, Inc. All Rights Reserved 4

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. (Note: the
calibration is stored in permanent memory — the PumpSaver®Plus does not need to be
recalibrated if power is lost.)
CALIBRATION
NOTE: The PumpSaver®Plus should be calibrated during normal pumping conditions.
_+
IR
LINK
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.
CALIBRATING WHILE PUMPING
The PumpSaver®Plus can also be calibrated while the pump is already 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
ell is very low relative to the pump’s capabilities.w
WARNING: Decreasing the SENSITIVITY may compromise the PumpSaver®Plus’ ability to
detect dry-run and/or dead-head conditions.
MANUAL RESET MODE / RESTART DELAY
Any restart delay can be by-passed by rotating the RESTART DELAY/ CALIBRATION knob to
he RESET position and back to the desired restart delay setting.t
NOTE: The restart delay setting can be changed at any time. The current and subsequent
rips will follow the new restart delay setting.t
The RESTART DELAY/ CALIBRATION knob can be placed in the RESET 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.
© 2009 SymCom, Inc. All Rights Reserved 5

© 2009 SymCom, Inc. All Rights Reserved 6
RUN HOURS / FAULT HISTORY
The PumpSaver®Plus records pump run hours and fault history. This data can be displayed by a
PumpSaver®Plus Informer (see USING AN INFORMER). Run hours and fault history can be
cleared on the PumpSaver®Plus. Read the following instructions fully before performing the
rocedure.p
NOTE: Turn the SENSITIVITY knob completely to the left (counter-clockwise) or completely
o the right (clockwise) when directed. The knob must be turned in quick succession.t
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, preventing damage to the pump. To reset the PumpSaver®Plus, remove and re-apply
power.
R
APID CYCLING (Line Side / Upstream)
Rapid cycling of the line side of the PumpSaver®Plus may be caused by several naturally
occurring conditions which are indistinguishable from true rapid cycling. For this reason, once
tripped, the PumpSaver®Plus will wait 30 minutes and restart. If the restart is successful (the
pump runs for more than one minute), the rapid cycle counter will reset to zero. If the
PumpSaver®Plus encounters rapid cycle 4 times without a successful restart, it will lock-out and
equire a manual reset. To reset the PumpSaver®Plus, remove and re-apply power.r
*Protection against rapid cycling of a control device installed before the PumpSaver®Plus is
disabled by default. Read the following instructions fully before performing the procedure to
nable his feature.e
NOTE: Turn the SENSITIVITY knob completely to the left (counter-clockwise) or completely
to the right (clockwise) when directed. The knob must be turned in quick succession.
To Enable Line Side / Upstream Rapid-Cycle Protection: (to disable, follow the same
rocedure)p
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.

© 2009 SymCom, Inc. All Rights Reserved 7
7. After 2 seconds, the CAL. and RUN LIGHTS will blink once indicating line-side rapid-cycle
protection has been enabled.
RAPID CYCLING (Load Side / Downstream)
Load-side rapid cycling of the pump will immediately result in a manual lock-out. The pump will
ot restart automatically. To reset the PumpSaver®Plus, remove and re-apply power.n
Note: Protection against rapid cycling of a control device installed after the PumpSaver®Plus is
always enabled. Disabling line-side detection will not disable load-side detection.
USING AN INFORMER
The PumpSaver®Plus is equipped with an infrared LED that will communicate to a SymCom
PumpSaver®Plus 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® equipped with an infrared
LED transmitter. Contact SymCom for more information at 800-843-8848 or visit our website:
www.symcom.com.

© 2009 SymCom, Inc. All Rights Reserved 8
TROUBLESHOOTING
RUN
LIGHT CAL LIGHT PROBLEM or FUNCTION CORRECTIVE ACTION
On Steady Off RUN:
Pump is running—or ready to
run—no problems in operation
If pump is not running, check for
loose wiring and ensure proper
function of pressure or float
switches.
On Steady On Steady CAL: The PumpSaver®Plus is in
the calibration process. None
Off On Steady
CAL COMPLETE:
The PumpSaver®Plus has
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.

SPECIFICATIONS
Functional Characteristics
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 a 60-
second period (rapid-cycling) 4
Trip Delay Times
Overcurrent 5 seconds
Dry well 4 seconds
Reset DelayTime
Over/undervoltage 2 seconds
All Other Faults Manual, 2-225 minutes
Input Characterisitcs
Supply Voltage 230VAC
Load Range 1/3 – 3hp
Frequency 501/60Hz
Output Characteristics
Output Contact Rating—SPST 3hp, 240VAC (17 amps max.)
General Characteristics
Maximum Input Power 5 W
Weight 14 oz.
Standards Passed
Electrostatic Discharge (ESD) IEC 61000-4-2, Level 2, 4kV contact, 6kV air
Ambient Operating Temperature -40° to 70°C (-40° to 158°F)
1NOTE: 50Hz will increase all delay timers by 20%
© 2009 SymCom, Inc. All Rights Reserved 9

© 2009 SymCom, Inc. All Rights Reserved 10
NOTES

© 2009 SymCom, Inc. All Rights Reserved 11
NOTES

For warranty information, please see Terms and Conditions at
www.symcom.com
Visit us at www.s
y
mcom.com to see
our complete product listing!
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for your custom solution!
800-843-8848
© 2009 SymCom, Inc. All Rights Reserved 12