SymCom PumpSaver Plus 235P User manual

2880 North Plaza Drive, Rapid City, South Dakota 57702
[phone] ·[phone] ·fax [phone]
INSTALLATION
INSTRUCTIONS
MODEL 235P
Revision A1
Rapid City, SD, USA, 02/2009
II_235P_A1

© 2009 SymCom, Inc. All Rights Reserved 2
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

© 2009 SymCom, Inc. All Rights Reserved 3
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

© 2009 SymCom, Inc. All Rights Reserved 4

© 2009 SymCom, Inc. All Rights Reserved 5
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
IR
LINK
L1 CT1 CT2
PILOT DUTY
RATING 480VA
@240VAC

© 2009 SymCom, Inc. All Rights Reserved 6
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.

© 2009 SymCom, Inc. All Rights Reserved 7
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.

© 2009 SymCom, Inc. All Rights Reserved 8
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.

© 2009 SymCom, Inc. All Rights Reserved 9
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

© 2009 SymCom, Inc. All Rights Reserved 10
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

© 2009 SymCom, Inc. All Rights Reserved 11
NOTES
For warranty information, please see Terms and Conditions at
www.symcom.com

© 2009 SymCom, Inc. All Rights Reserved 12
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