Total Control PCTC16F16S User manual

115 / 230 VAC DUAL VOLTAGE UNIT
INSTALLER - PLEASE LEAVE THIS MANUAL WITH THE UNIT OR GIVE TO END USER.
RESIDENTIAL PUMP CONTROLLER - MOD. PCTC16F16S
READ THESE INSTRUCTIONS CAREFULLY BEFORE INSTALLATION
- Provides for an adjustable downstream pressure. - Dual voltage 115 / 230 VAC.
- Avoids pressure and flow fluctuations. - All inoxidable components.
- Eliminates pump pressure switch. - Assists in absorbing water hammer.
- Built-in pressure and flow switch. - Can be used with or without pressure tank.
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FEATURES & BENEFITS
OWNER’S MANUAL
TOTAL CONTROL can be installed on surface and submersible pumps for residential, domestic irrigation
and booster systems.
File No: E191502 Mod. CP
™

TABLE OF CONTENTS
Page
Precautions and warnings…..…………………………………………………………………….. 2
Technical specifications……………………………………………………………………………. 3
Operation……..……………………………………………………………………………………... 3
Troubleshooting…………………………………………………………………………….………. 3
Maintenance and spare parts……………………………………………………………….…….. 3
Hydraulic connection to the system……………………………………………………….……... 4
Conduit connections………………………………………………………………………….……. 4
Typical TOTAL CONTROL installation on surface and submersible pumps.…………….…. 5
TOTAL CONTROL installation guidelines and warnings.…………………………………..... 6
When to use pressure tank………………………………….………………………………..…… 6
Calibration.…………………………………………………………………………………….…….. 7
Pressure loss………………………………………………………………………………………... 7
Pressure adjusting procedure.…………………………………………………………………….. 8
Electrical connections………………………………………………………………………..…….. 9
Installation wiring diagram - 115 VAC 2-wire pumps up to 16 FLA...…………………..…….. 9
Installation wiring diagram - 230 VAC 2-wire pumps up to 20 FLA……………………….…. 10
Installation wiring diagram - 230 VAC 3-wire pumps up to 20 FLA……………………..…....10
When to use contactors…………………………………………………………………….…….. 11
Installation wiring diagram - 115 VAC 2-wire pumps exceeding 16 FLA…………….……… 11
Installation wiring diagram - 230 VAC 2-wire pumps exceeding 20 FLA………………....… 11
Installation wiring diagram - 208 VAC or 230 VAC three phase 3-wire pumps………….…. 12
Installation wiring diagram - 460 VAC…..………………………………………………..…….. 12
Installation wiring diagram - 230 VAC 3-wire pumps exceeding 20 FLA………………....… 13
Overall dimensions……………………………………………………...………………………... 13
Electronic box replacement…………………………………………………………………….… 14
- 1 -

PLEASE READ BEFORE PROCEEDING WITH INSTALLATION
FAILURE TO READ AND CONSIDER SAFETY INSTRUCTIONS IN THIS MANUAL OR ON
TOTAL CONTROL PRES MAY RESULT IN PERSONAL INJURY OR SERIOUS DAMAGE
TO PIPING OR FIXTURES !
Hazardous pressure.
Under certain conditions, submersible pumps can develop extremely high pressure. Install a
pressure reducing valve to limit pressure to safe levels for application. Be sure well is
equipped with a pressure relief valve.
Do not allow pump, TOTAL CONTROL, piping, or any other system component containing water to
freeze. Freezing may damage system, leading to injury or flooding. Allowing TOTAL CONTROL or
system components to freeze will void warranty.
Hazardous voltage.
Can shock, burn or cause death.
Install ground and wire TOTAL CONTROL according to local code and National Electrical Code
requirements.
Depressurize the system and disconnect power supply before installing or servicing
TOTAL CONTROL.
Make sure line voltage and frequency of power supply match motor nameplate voltage and
frequency and TOTAL CONTROL voltage and frequency.
Install TOTAL CONTROL according to all plumbing, pump and well code requirements.
Pipe joint compound can cause cracking in plastic. Use only Teflon tape when sealing joints in plastic pipe or
connecting pipe to thermoplastic pumps and TOTAL CONTROL.
For threaded conduit opening - To be used with UL Listed or Recognized, liquid-tight non-metallic (plastic)
conduit fittings.
The manufacturer is not responsible or liable for damage due to improper
installation or use
.
This is the safety alert. When you see this symbol in this manual, look for one of the following
signal words and be alert to the potential for personal injury.
Warns about hazards that will cause serious personal injury, death or major property
damaged if ignored.
Warns about hazards that can cause serious personal injury, death or major property
damaged if ignored.
- 2 -

TECHNICAL SPECIFICATIONS
- Single phase power-supply voltage 115 / 230 VAC
- Voltage variation tolerance +/- 10 %
- Frequency 50 / 60 Hz
- Full load amp rating 115 VAC 16 FLA
- Full load amp rating 230 VAC 20 FLA
- Max working pressure 174 psi
- Pressure adjusting rangem in 45 psi
max 95 psi
- Max working temperature 149 ˚F (65˚C)
- Inlet / Outlet connections 1 ¼”MPT
- Threaded gauge connection ¼” FPT
- Threaded conduit connections ½”FPT
- Electronic box enclosure 12 NEMA
• Displays when power is connected to TOTAL CONTROL unit.
• In the event of a temporary power outage, TOTAL CONTROL resets automatically when
power is restored.
•
Displays when pump is running.
• Displays when there is a problem with the system.
•
Press and hold to reset for 3-5 seconds ( with a tap opened ). Green “Power on” light and
yellow “Pump on” should display. This indicates system is operating properly.
• If red “Failure” light comes back on, refer to Troubleshooting Guide.
OPERATION
TROUBLESHOOTING
MAINTENANCE AND SPARE PARTS
- 3 -
Operating faults Main causes
Pump does not start Check wiring connections.
Check suction pipe, see page 6.
Pump turns on and off (short-cycles) Leakage lower than minimum flow.
Pump does not stop Leakage above minimum flow.
No water flow Suction problems.
Power on
Pump on
Failure
Restart
( green )
( yellow )
( red )
( red )
In the case of a fault in the electronic box, this can be replaced without removing the device as it is inter-
changeable and supplied on request.
Further malfunctioning can be avoided by checking the features of the device, pump and system with the
warnings indicated in the installation guidelines.

HYDRAULIC CONNECTION TO THE SYSTEM
CONDUIT CONNECTIONS
Line voltage and pump wires to the TOTAL CONTROL should be supplied through “liquid-
tight” nonmetallic conduit fittings rated “NEMA 12” or “UL type 12” to achieve NEMA Type
12 enclosure rating.
Failure to install unit without use of liquid tight conduit voids warranty!
- 4 -
Do not over thighten water connections, especially when installing with metal
couplings. Damage to TOTAL CONTROL may result.
Prepare all threads with Teflon tape only.
OK NO
Do not install any tee or tap between pump and TOTAL CONTROL unit.
Always install TOTAL CONTROL with flow arrows in
the vertical position.
Electronic box must be level.
Open the electronic box cover by removing
the six screws from the cover.

SUBMERSIBLE PUMP
- 5 -
TYPICAL TOTAL CONTROL INSTALLATION ON SURFACE AND SUBMERSIBLE PUMPS
If pressure exceeds 174 psi, install a pressure reducing valve.
SURFACE PUMP
TOTAL CONTROL can be installed on surface and submersible pumps for residential, domestic irrigation and booster systems.

TOTAL CONTROL INSTALLATION GUIDELINES AND WARNINGS
PLEASE READ PRECAUTIONS AND WARNINGS ON PAGE 2 BEFORE PROCEEDING WITH INSTALLATION
REMOVE PRESSURE SWITCH FROM PUMP AND WIRE TOTAL CONTROL DIRECTLY TO PUMP.
• TOTAL CONTROL provides for an adjustable downstream pressure between 45 psi to 95 psi. • Install TOTAL CONTROL only in clean water applications. • Always confirm pump and system characteristics before installation, see pages 7, 8. • Confirm electrical characteristics of pump motor before installation, e.g. full load amps and voltage. • Must always be installed in the vertical position, flow arrows up, electronic box level. • Do not install any tap or tee between the pump and the TOTAL CONTROL. • Install a gate valve after the TOTAL CONTROL unit. This allows testing of the pump and TOTAL CONTROL unit for
efficiency and to confirm pump pressure.
WHEN TO USE PRESSURE TANK
- 6 -
A small pressure tank ( 1/2 to 2 gallons ) may be used: 1 - In case of pumps using BIAC switch starting system motors.
It allows bi-metal switch strips to cool in such a way to warrant the regular pump restart. 2 - In case of minimal delivery demands. It allows for reducing the pump start-ups. ( Example: a glass of water, ice-making machine, inverse osmosis systems, or old systems with small losses).

CALIBRATION
- 7 -
TOTAL CONTROL has a built-in pressure reducing valve, allowing for downstream pressure
adjustement according to system requirements.
System pressure can be adjusted between minimum 45 psi and maximum 95 psi.
Open a tap to start up the pump, close the tap and wait for pump to stop, then check the system
pressare on the pressure gauge, normally factory calibrated at 45 psi.
Flow rate gpm 15 18 20 25 30 35
Total control psi loss 4 6 7 10 14 19
PRESSURE LOSS
Max 95 psi
Min 45 psi
Max 174 psi

Open a tap to start up the pump, close it again
and wait for the pump to stop in order to read
the system pressure on the pressure gauge,
which is normally factory-calibrated at 45 psi.
To adjust the pressure open the tap again, turn
the knob in a clockwise direction to increase the
pressure, and in a counterclockwise direction
to reduce it, close the tap and with the pump
stopped read the pressure set on the pressure
gauge.
Repeat this operation until the desired pressure
value is reached
PRESSURE ADJUSTING PROCEDURE
The system pressure (P2) must be approximately 25 psi lower than the pump pressure (P1), and approximate-
ly 15 psi higher than the pressure in the water column feeding the TOTAL CONTROL (P3).
If the pressure of the pump (P1) fails to reach the values indicated in the pressure adjustment table, the pump
will stop working.
In the event of the height of the water column (P3) being higher than the values indicated in the pressure ad-
justment table, the pump will turn on without starting to operate.
To overcome this shortcoming either positions the device higher up in order to recreate the conditions specied
above or set a higher system pressure (P2).
Adjusting example:
P1- Pressure pump (maximum 174 psi)
P2 - System pressure (maximum 95 psi)
P3 - Water column pressure
P4 - Tap pressure
How to deliver a 45 psi pressure to the tap located at a height
of 90 ft:
Pressure requested by the service = 45 psi = P4
Service height 90 ft = 40 psi = P3
The system pressure (P2) must be adjusted to 85 psi, seeing
that P2 = P4 + P3.
The pump pressure (P1) must be a minimum of 110 psi, seeing
that P1 = P2 + 25 psi.

ELECTRICAL CONNECTIONS
INSTALLATION WIRING DIAGRAM - 115VAC 2-WIRE PUMPS UP TO 16 FLA
- 9 -
Electrical connections should made by a qualified professional in compliance with
applicable local codes and National Electric Code.
ALWAYS SHUT OFF POWER FOR INSTALLATION OR SERVICE.
Check voltage of pump and supply to determine pump motor FLA and follow applicable
TOTAL CONTROL wiring diagram. If pump motor FLA exceeds TOTAL CONTROL rating,
use magnetic starter wiring diagram for the applicable voltage ( see pages 12, 13).
Use Copper Conductors only.
Use 140 / 167 ˚F wire.
Use minimum 13 AWG wire.
Device must be properly grounded.
Always remove pressure switch from surface pump and wire TOTAL CONTROL
directly to pump.
OBSERVE WARNINGS AND PRECAUTIONS LISTED AT THE FRONT
OF THIS MANUAL.

INSTALLATION WIRING DIAGRAM - 230VAC 2-WIRE PUMPS UP TO 20 FLA
INSTALLATION WIRING DIAGRAM - 230VAC 3-WIRE PUMPS UP TO 20 FLA
- 10 -

INSTALLATION WIRING DIAGRAM - 115VAC 2-WIRE PUMPS EXCEEDING 16 FLA
WHEN TO USE CONTACTORS
- 11 -
Use a contactor when:
• On 115V installations pump motor full load amps exceed 16 FLA.
• On 230V installations pump motor full load amps exceed 20 FLA.
•
On all three-phase applications.
Remember, match coil voltage on contactor with TOTAL CONTROL voltage.
Either 115V or 230V coils may be used.
Use of magnetic starter to avoid damage to the device is determined by pump motor.
INSTALLATION WIRING DIAGRAM - 230VAC 2-WIRE PUMPS EXCEEDING 20 FLA

INSTALLATION WIRING DIAGRAM - 208 VAC
OR 230 VAC THREE PHASE - 3-WIRE PUMPS
INSTALLATION WIRING DIAGRAM - 460VAC
For 460Vac motors, use magnetic starter to avoid damage to TOTAL CONTROL.
- 12 -
For 208Vac or 230Vac three- phase motors, use magnetic starter to avoid damage to TOTAL CONTROL.

OVERALL DIMENSIONS
- 13 -
INSTALLATION WIRING DIAGRAM - 230VAC 3-WIRE PUMPS EXCEEDING 20 FLA

Before removing the electronic box ensure that power unit is off and unit is depressurized.
5) Tighten the six screws on the cover of
the electronic box to ensure water tight
s eal.
If cover is not securely fastened,
RESET button will not operate.
WARNING: Do not turn on power until the box cover has been securely fastened.
4) Install the new electronic box and
tighten the three screws.
Do not overthighten or damage to
t hreads may result.
3) Remove the electronic box.
1) Remove the box cover and disconnect
the electrical wires.
1
3
4
5
ELECTRONIC BOX REPLACEMENT
2) Take off the box by removing the three
screws attaching the electronic box to
the unit body.
- 14 -

DOMESTIC PUMP CONTROL
SUBMERSIBLE PUMPS JET PUMPS BOOSTER PUMPS
WARRANTY
THE WARRANTY PERIOD IS ONE YEAR FROM INSTALLATION DATE
WARRANTY AND DISCLAIMER OF WARRANTY
The following warranty for the product is in lieu of all other conditions or warranties, whether express, implied
or statutory, including but not limited to any implied conditions or warranties of merchantability or fitness for a
particular purpose and on any implied conditions or warranty obligation on the part of manufacturer or its
distributors, which are hereby expressly disclaimed. TOTAL CONTROL is warranted to be free of defects
occurring either in hydraulic or electronic parts for a period of one year from the date of installation w hen
installed by a licensed professional in accordance with the product manual and due professional care.
PATENT INFRINGEMENT
Our devices are protected under world-wide patents including the United States Patent Office. Any violation
and or attempt to copy the products in any part or form to the extent such copying or duplication in any part
or form infriges upon the patents will be swiftly and aggressively prosecuted.
U.S. Patent 5,259,733.
™
Rev. CP09 05.09
Locally distributed by:
3000 W 16Th Ave.
Miami, Florida 33012
ph. 001 954 474 9090
fax [phone]
www.pdwatersystems.com
PD WATER SYSTEMS