User Manual for CSI Controls models including: 1105505 3 Wire WellZone Pressure Controller, 1105505, 3 Wire WellZone Pressure Controller, WellZone Pressure Controller, Pressure Controller, Controller
WellZone 3-Wire Pressure Controller - CSI Controls
WellZoneTM Pressure Controller Single Phase 3-Wire Well Pump Control Panel Installation and Operation Manual Parts Included Specifications Input Voltage: 230 VAC, 60Hz Operating Temperature: 14°to 122° (-10° to 50°) Pump Ratings: Single phase, 3-wire (4~17FLA) Enclosure: 10 x 8 x 4 inch (25.4 x 20.3 x 10.2 cm) NEMA 4X thermoplastic Includes liquid tight cable strain relief fittings: · 1 x 1/2" + 1 x 3/4" UF cable · 1 x 1/2" round cable Pressure Transducer: 0-150 PSI (included) 1/4" NPT Male, NSF 61 rated, 4-20mA, with 16.4 ft (5m) cable Auxiliary Alarm Contacts: N.O. 1 amp, 120 VAC Max Part # Description 1105505 1105506 1105507 1105508 1105509 1105510 WELLZONE 3W-050 WELLZONE 3W-075 WELLZONE 3W-100 WELLZONE 3W-150 WELLZONE 3W-200 WELLZONE 3W-300 3-WIRE MOTOR RUN CAP START CAP CB HP Volts SFA Mfd Mfd 1/2 230 4.3 15 43-53 15A 3/4 230 5.7 23 59-71 20A 1 230 7.1 23 86-103 20A 1 1/2 230 11.5 15 105-126 20A 2 230 13.2 20 105-126 25A 3 230 17.0 45 208-250 30A This digital controller does not provide Variable Speed Pump Control or constant pressure operation. This control panel must be installed and serviced by a licensed electrician in accordance with the National Electric Code NFPA-70, state and local electrical codes. UL Type 4X enclosures are for indoor or outdoor use. Warranty void if panel is modified. ? For information regarding operation, available options, or servicing questions, please call CSI Controls Technical Support. CSI Controls offers a five-year limited warranty. For complete terms and conditions, please visit www.sjerhombus.com. Products returned must be cleaned, sanitized, or decontaminated as necessary prior to shipment to ensure that employees will not be exposed to health hazards in handling said material. All applicable laws and regulations shall apply. Manufactured by: CSI Controls Technical Support: +1-800-746-6287 techsupport@sjeinc.com www.csicontrols.com Technical Support Hours: Monday-Friday, 7:00 AM to 6:00 PM Central Time PN 1106426A 03/2024 ©2024 SJE, Inc. All Rights Reserved. CSI Controls is a trademark of SJE, Inc 1 Features The WellZoneTM 3W digital controller provides pressure control for single phase 3-wire submersible well pump applications. It uses a 0-150 PSI pressure transducer to monitor the discharge pressure and turns the pump ON and OFF according to adjustable Start and Stop setpoints. The LCD display allows for quick view of the system pressure, run status, hours run and pump cycles. The rotary button provides the user with a simple navigation method through the menu and program settings. It features built in pump protection including rapid cycling and dry run. It is preprogrammed to run the pump as the pressure drops below 40 PSI and stop as the pressure rises above 60 PSI. High & Low pressure settings are available with an auxiliary alarm relay. Start Relay: Circuit Breaker: The pump circuit has a thermal-magnetic circuit breaker that provides pump disconnect and branch circuit protection. LCD Display: LCD display shows pressure reading, pump amp reading, pump on indicator. 75 L1 L2 50 RUN T TEST 25 PUMP T1 T2 ESC 0 +12V AI C DI AUX Pump Run Light Pump Test Switch: Run pump manually. Rotary Encoder Push Button: Rotate to scroll menu settings. Press to select the desired setting. ESC Button: Exit without saving or jump to previous display. Start Capacitor (Varies with model) Run Capacitor (Varies with model) Pump Connection 230V, 1-phase, 3 wire 3/4" UF strain relief Incoming Power 230V, 1-phase 1/2" UF strain relief Pressure transducer 0-150 PSI / 4-20mA 1/2" round strain relief 2 L1 L2 GND INFEED POWER 230 VAC 1 PHASE, 60 HZ CB108 L1 L2 PUMP CIRCUIT BREAKER WELLZONE CONTROLLER ORA 1 2 5 BLK YEL RED START RUN COMMON RED BLK 240VAC MOT 1 PHASE, 3 WIRE YEL BRN BLU +- AN118 CSI P/N 1105505 1105506 1105507 1105508 WELLZONE PANELS DESCRIPTION WELLZONE 3W-050 (230V,1/2 HP,4.0 SFA) START CAPACITOR RUN CAPACITOR 43-56 MFD/250V 15 MFD/370V WELLZONE 3W-075 (230V,3/4 HP,5.2 SFA) WELLZONE 3W-0100 (230V,1.0 HP,6.2 SFA) 59-71 MFD/250V 25 MFD/370V 88-108 MFD/250V 25 MFD/370V WELLZONE 3W-150 (230V,1.5 HP,11.2 SFA) 108-130 MFD/250V 15 MFD/370V CIRCUIT BREAKER 15 AMP 20 AMP 20 AMP 20 AMP 3 L1 L2 GND INFEED POWER 230 VAC 1 PHASE, 60 HZ CB108 L1 L2 PUMP CIRCUIT BREAKER WELLZONE CONTROLLER ORA 1 2 1 5 3 BLK YEL RED START RUN COMMON RED BLK 240VAC PUMP 1 PHASE, 3 WIRE YEL BRN BLU +- AN118 CSI P/N 1105509 1105510 WELLZONE PANELS WITH KLIXON START OVERLOAD DESCRIPTION START CAPACITOR RUN CAPACITOR WELLZONE 3W-200 (230V,2 HP,11.9 SFA) 108-130 MFD/250V 20 MFD/370V WELLZONE 3W-300 (230V,3 HP,14.3 SFA) 216-259 MFD/250V 45 MFD/370V CIRCUIT BREAKER 25 AMP 30 AMP 4 Mounting the Control Panel 1 Drill and fasten top of the enclosure using appropriate anchor. 2 Drill and fasten bottom of the enclosure using appropriate anchors. 5 Wiring the Control Panel CAUTION! Disconnect all power to the control panel before wiring. Ensure that the incoming supply power voltage is the same as the rating of the pump motor being installed. Ensure that the rated Amps of the motor does not exceed the rating of the control panel. Ensure the HP rating and Capacitor values of the control panel are correct for the pump used. 1 Connect the following wires to the proper terminal positions: · Incoming power to the circuit breaker · Motor/Pump power to Motor · Pressure transducer See wiring label on inside the control panel for details. 2 Verify correct operation of control panel after the installation is complete. 3 Maximum motor cable lengths. Vac 230V Motor HP 1/2HP 3/4HP 1.0HP 1.5HP 2.0HP 3.0HP Amps2 4.3 5.7 7.10 11.5 13.2 17 14 AWG 400 300 250 175 150 120 Feet - Motor Cable (75C)1 12 AWG 650 450 400 300 250 200 10 AWG 1000 750 60 450 400 300 1 Cable length is measured from the motor to the main panelboard (Service Entrance) 75C Insulation - AWG Copper Wire only. Do not use aluminum conductors. Use with 2-wire motor only with internal thermal protection. 2 Typical S.F.A. (Service Factor Amps). Check motor nameplate for actual data. 6 8 AWG 1600 1200 1000 750 600 450 Operation Guide - PRESSURE CONTROL Enter Enter 75 50 25 0 Rotate 75 50 25 0 Rotate 75 50 25 0 Main screen Pump runtimes and cycles Filter remaining life 75 50 25 Esc 0 Rotate Start pressure Enter pump start pressure setting Enter Esc 75 50 25 0 Save and return to main screen Enter SEE PARAMETER TABLE BELOW FOR COMPLETE LIST Rotate 75 50 Esc 25 Fault History 75 Select to view last 10 faults 50 Enter Esc 25 Enter 0 0 FLT1 ... Rotate FLT8 75 50 25 0 Notes : A. If there is no operation for 20 sec, the display will return to the main screen. B. The service function is used for alerting the user when it is time to change a filter or to serivce the equipment after the accumulated run time is reached. The icon will flash on main screen when the timer is done (Filter at 0%). Push and hold ESC button 4 seconds to reset the filter or service time. 7 Pressure transducer = 0-150 psi Digital input = Floor sensor (stop pump) or low level float (stop pump) PARAMETER Description Default Range Min Range Max Unit Function START Start Pressure 40.0 STOP HIGH LOW Stop Pressure High Pressure Low Pressure 60.0 70.0 20.0 LOW TMR Low Pressure Timer 30 OVERLOAD SS..FF..AL SAeStteintgting 12.0 DRY RUN Dry Run Amps 0.0 DRY TMR Dry Run Timer 30 RECHARGE Recharge Timer 20 STRT/MIN Starts Per Minute 2 MAX RUN Max Run Time per cycle 0 NO AMPS No Amps detect ON FILTER Filter Life Timer OFF The pump will RUN when the pressure drops below the 1.0 140.0 PSI "START" pressure value and continue to RUN until the pressure rises above the "STOP" value. Set START<STOP. The "STOP" value should be at least 10 PSI over the "START" value. The pump will RUN when the pressure drop below the "START" 10.0 150.0 PSI pressure value and continue to RUN until the pressure rises above the "STOP" value. 10.0 150.0 PSI High Pressure alarm. The pump will stop if the pressure rises above this value Low Pressure alarm. If the pressure drop below this value, the 0.0 150.0 PSI "LOW TMR" timer will start. The pump will stop when the timer is done and a "LOW PRESS" alarm will be displayed. Low pressure timer. This delay timer needs to be long enough 0 3599s(59m:59s) second to allow the pump to pressurize the system on start up. It can be used to detect a broken discharge pipe or signi cant leak. Value is in Seconds (s). Set to the motor Service Factor Amps (SFA) value as listed on the motor nameplate. The pump will stop if it is pulling excessive 4.0 17.0 Amps amps and the "OVERLOAD" alarm will be displayed. The controller will reset the fault automatically after a cooling period. The controller will reset this fault 4 times automatically before requiring a manual reset. Pump DRY RUN protection. Set this value lower than the normal pump operating amps. 30% lower than the motor 0.0 17.0 Amps Service Factor Amps is common. Adjust up or down as this function is tested. Example: Motor SFA = 10.0A. Set the Dry Run Amps = 7.0A. Set to "0.0" to disable this function (Default) Time delay before stopping the pump on "DRY RUN" as the 0 3599s(59m:59s) Seconds amps are lower than the "DRY RUN" Amps value. Timer value is in seconds (s). Automatic reset timer after a "DRY RUN" trip, allowing for 0 3599m(59h:59m) Minutes enough time for the well to recharge. Timer value is in minutes (m). Set to "0" to disable. Rapid cycle protection. Enter the maximum allowable pump 1 10 Cycles starts per minute. If the number of starts is exceed, the display will show "RPD CYCL" and a manual reset is required for the pump to start again. Set the maximum cycle time. The pump will stop and the a 0 3599m(59h:59m) Minutes "MAX RUN" alarm will be displayed if the cycle time is greater than this value. Set to "0" to disable (default) The No amps detection function informs the user of thermal ON ON, OFF NA switch trip internal to the motor. Allow the motor to cool and it will start again automatically. This detection function is disabled when set to "OFF". Set the estimated pump run time between lter replacements. 0 9999 hours The time is set in hours (h) and corresponds to pump running hours. A ashing wrench will appear on the screen when this timer is done. This function is disabled by default. CAUTION: The DY RUN protection is disabled by default. It must be set according to your pump HP and normal running Amps during start up. 8 ALARM Fault Pump LOW PRES LOW PRESSURE ALARM STOP HIGH PRES HIGH PRESSURE ALARM STOP DRY RUN PUMP RUNNING DRY STOP Auxilary CLOSED CLOSED Auto/Manual Reset Auto reset when PSI is back to normal Auto reset when PSI is back to normal Description LOW PRESSURE ALARM Pressure below the Low Pressure set point for longer than the Low Pressure Timer. HIGH PRESSURE ALARM Pressure greater than the High Pressure set point. Action Check for leaks, broken pipes. Check the pump and motor. Check pump, piping and pressure tank. CLOSED PUMP DRY RUN ALARM Pump DRY RUN protection. Set this Manual reset or by recharge if disabled reset not value lower than the normal pump operating amps. 30% lower than the motor Service Factor Amps is common. Example: Motor SFA = 10.0A. Set the Dry Run Amps = 7.0A. Set to If the pump is tripping on DRY RUN but there is water in the well, decrease this setting. If the pump is NOT tripping on DRY RUN, then increase this value. "0.0" to disable this function (Default). RAPID CYCLE PUMP RAPID CYCLING STOP CLOSED Manual reset Check the pressure tank for damage or incorrect pre-charge RAPID CYCLING ALARM pressure. These commonly result This is the maximum allowable pump in the pump rapid cycling. Correct starts per minute. If the number of or replace pressure tank. cycles per minute is exceeded, the Increase the number starts per pump will not start and the RDP CYCL minute for systems with small alarm will be displayed. pressure tanks. Contact the pump/motor manufacturer for the max allowable starts/minutes. MAX RUN MAXIMUM RUN TIME STOP NO AMPS NO AMPS DETECTED NONE OVERLOAD MOTOR OVERLOAD STOP WATER SW WATER SWITCH ACTIVE STOP XDR OPEN TRANSDUCER OPEN STOP CLOSED CLOSED CLOSED CLOSED CLOSED Manual reset Auto reset Check for pipe leaks or faucet MAXIMIM RUN TIME ALARM left open. Increase time if Maximum runtime allowed in one cycle. necessary NO AMPS DETECTED No amps are detected which implies If it is a motor thermal trip, then that the thermal switch internal to the allow the motor to cool and it will motor has tripped or that the pump is start again automatically. not connected. Investigate the cause of the When the "NO AMPS" function is motor internal trip. If the motor is enabled, it will ignore the Low not connected, check the motor Pressure and Dry Run conditions and wiring. The NO AMPS function maintained the RUN command to the can be disabled when set to pump unitl the motor has cooled down "OFF". and restarts automatically. Class10 overload protection, calculated based on the motor S.F.A. load. Auto reset / Manual The overload will automatically reset Check the pump for clogging or reset after a cooling period. It must be locked rotor condition. manually reset after four consecutive times trips. Auto reset Digital input from the optional oor sensor or oat switch. If the input of water sensor is ON for more than 5 sec, shut down the pump and display "WATER SW". This alarm will auto reset when the switch opens. Check the water sensor or oat switch. Correct the cause of water leakage or water supply prior to resetting the fault. Auto reset PRESSURE TRANSDUCER OPEN CONNECTION Active when the 4-20mA signal input value is < 3.0mA Check the transducer cable connection to the pressure sensor. Make sure it is connected properly and hand tightened. Check the transducer cable for damage. Replace cable if damaged. Check the transducer cable connections to the controller. Make sure there is a good connection. XDR SHORT TRANSDUCER SHORT RECHARGE WELL IS RECHARGING CHNG FILTER CHANGE FILTER STOP STOP NONE CLOSED Auto reset PRESSURE TRANSDUCER SHORT CIRCUIT Active when the 4-20mA signal input value is > 21mA Same as above. In addition, check the pressure transducer. Remove it and inspect for damage. Replace if is it damaged. CLOSED Hold ESC for 4 sec if WELL IS RECHARGING - PLEASE Wait for the recharge timer to you want to cancel STAND BY complete. the timer and re-start This is the waiting time after the pump Increase or decrease this timer the pump as tripped on "Dry Run" fault, before value as needed to match the immediately performing an automatic reset. recovery time of your well. NONE Hold ESC for 4 sec to reset the lter capacity to 100% CHNG FILTER & Wrench Icon is displayed for 2 second every 7 seconds when the pump has run for the time listed in the users lter setting. Replace or clean the lter regularly to keep the pumping system running at optimal e iciency. 9 Start Circuitry Overload Protector (For 2HP & 3HP only) There is an additional overload (OL) protection device on 2HP and 3HP control panels. This OL device is for the protection of the START Circuitry and is located below the terminal blocks. Press the red button to reset. Q: What are symptoms when the start overload is tripped? A: There is a short in the start circuitry or a locked rotor situation. The pump will not start when this overload protector has tripped. Press the red button to reset. The digital display may also display "OVERLOAD" and must be reset (Press ESC button for 4 sec). Q: How to check the circuit with a multimeter? A: If the pump does not start after a reset. To verify that OL has reset, measure the resistance (ohm) from T1 and the black wires in the cap kit. It should measure continuity (<10 ohms). Check the start relay and capacitors as well. Q: How to reset? A: To reset, wait at least 10 minutes after the trip to allow for the unit to cool down and press the red button. Q: What do you do if the start overload keeps tripping? A: Check the capacitors and start relay. Check the motor if locked. Check ambient temperature in the control panel. The overload module will trip sooner if hot. Protect the control panel from direct sunlight. 10 REPLACEMENT PART NUMBERS Part# 1105505 1105506 1105507 WellZone 3W-050 WellZone 3W-075 WellZone 3W-100 HP 1/2 3/4 1 1105508 1105509 1105510 WellZone 3W- WellZone 3W- WellZone 150 200 3W-300 1 1/2 2 3 SFA 4.3 5.7 7.1 11.5 13.2 17.0 Volts 230 230 230 230 230 230 RUN CAP 15mF 23mF 23mF 15mF 20mF 45mF Part# 1036323 1004023 1004023 1036323 1003706 1003829 12210 Mars 370V 12215 370V 12215 370V 12210 370V 12214 370V 12223 370V START CAP 43-56mF 59-71mF 88-108mF 108-130mF 108-130mF 216-59mF Part# 1098476 1098478 6001275 1027120 1027120 1002979 Volt 250 250 250 250 250 250 Mars 11942 11943 11945 11946 11946 11952 Start Relay HLR38002AL3D HLR3800- HR3800- 2AL3D 2AL3D HR3800-2AL3D HR38002AL3D HR38002AL3D Part# 1098479 Start OL Par# CB 15A 1098479 1098479 20A 20A 1098479 1098479 1098479 GA3VPA7421 GA3VRA0021 1104244 1104245 20A 25A 30A NOTES: _______________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________ ? Technical support, service questions: +1-800-746-6287 techsupport@sjeinc.com Monday - Friday 7:00 AM to 6:00 PM Central Time 12GPL Ghostscript 9.55.0