TROUBLESHOOTING PROBLEMS WITH A SD 75, 100, 150 OR 300
CONSTANT PRESSURE PUMP CONTROLLER
CP Pump Controllers are SD Controllers
DIAGNOSTICS FOR FAULT CODES

FLASHERS
Error Code
FAULT POSSIBLE CAUSE CORRECTIVE ACTION
1 MOTOR
UNDERLOAD
Overpumped well
Broken Shaft or Coupling
Blocked Screen, Worn Pump
Air/Gas Locked Pump
SubDrive not set properly for pump end.
Frequency near maximum with less than 65%
     of expected load, 42% if DIP #3 is on.

System is drawing down to pump inlet
     Out of Water
High Static. light loading pump - reset DIP #3
     to "on" for less sensitivity if not out of water.
Check pump rotation (SubDrive only) reconnect
     if necessary for proper rotation.
Air / Gas locked pump - if possible, set deeper
     in the well to reduce.
Verify DIP switches are set properly.
2 UNDERVOLTAGE Low Line Voltage
Misconnected input leads
Line voltage low, less than approximately 150 VAC
     (normal operating range is 190 - 260 VAC)

Check incoming power connections and correct
     or tighten if necessary
Correct incoming voltage - check circuit breaker
     or fuses, contact power company
3 LOCKED PUMP Motor and/or pump misallignment
Dragging motor and/or pump
Abrasives in pump
Amperage above SFL at 10 Hz
Remove and repair or replace as required
4 INCORRECTLY
WIRED
MonoDrive only
Wrong resistance values on main and start
Wrong resistance on DC test at start
Check wiring, check motor size and DIP switch
     setting, adjust or repair as needed
5 OPEN CIRCUIT Loose connection
Defective motor or drop cable
Wrong motor
Open reading on DC test at start
Check drop cable and motor resistance, tighten
     output connections, repair or replace as
     necessary, use "dry" motor to check drive
     functions, if drive will not run and exhibits
     underload fault replace drive
6 SHORT CIRCUIT Shorted motor
Damaged cable
Damaged pump or motor
Amperage exceeded 50 amps on DC teat at start
     or SF amps during running

Incorrect output wiring, phase to phase short,
     phase to ground short in wiring or motor
If fault is present after resetting and removing
     motor leads, replace drive
7 OVERHEATED
DRIVE
High ambient temperature
Direct sunlight
Obstruction of airflow
Drive heat sink has exceeded max rated
     temperature, needs to drop below 85 degrees C
     to restart

Fan blocked or inoperable, ambient above 125
     degrees F, direct sunlight, air flow blocked
Repair, relocate as necessary, NEMA 1 or 3R
     fan failure - replace drive

Power down, disconnect leads to the motor and power up the SubDrive.
     If the SubDrive does not give an "open phase" fault (5 flashes every 2 seconds), then there is a problem with the SubDrive.
     Connect the SubDrive to a dry motor. If the motor goes through DC test and gives "underload" fault (1 flash every 2 seconds), the
     SubDrive is working properly.

 

SUBDRIVE TROUBLESHOOTING
CONDITION INDICATOR
LIGHTS
POSSIBLE CAUSE

CORRECTIVE ACTION

NO WATER NONE No supply voltage present If correct voltage is present, replace drive
SOLID GREEN Pressure sensor circuit Verify water pressure is below system set point.
Jumper wires together at pressure sensor, if
     pump starts, replace sensor.
If pump doesn't start, check sensor connection
     at PCB, if loose, repair.
If pump doesn't start, jumper sensor connection
     at PCB, if pump starts, replace wire.
If pump doesn't start with sensor PCB connection
     jumped, replace drive.
SOLID RED OR
SOLID RED AND GREEN
Power Surge, bad component Power system down to clear fault, verify voltage,
     if repetitive, replace drive.
FLASHING RED Fault detected Proceed to fault code description and remedy.
FLASHING GREEN Drive and motor are operating





Loose switch or cable connection
Gulping water at pump inlet.
Frequency max, amps low, check for closed valve
 or stuck check valve.
Frequency max, amps high, check for hole in pipe.
Frequency max, amps erratic, check pump
     operation, dragging impellers.
This is not a drive problem.
Check all connections.
Disconnect power and allow well to recover for
     a short time, then retry.
PRESSURE
FLUCTUATIONS
(POOR REGULATION)
FLASHING GREEN Pressure sensor replacement and setting
Pressure gauge replacement
Pressure tank size and precharge
Leak in system
Air entrainment into pump intake
(lack of submergence)
Correct pressure and placement as necessary.
Tank may be too small for system flow.
This is not a drive problem.
Disconnect power and check pressure gauge for
     pressure drop.
Set deeper in the well or tank; install a flow sleeve
     with airtight seal around drop pipe and cable.
If fluctuation is only on branches before sensor,
     flip DIP switch #4 to "on" (07C and newer).
RUN ON
WON'T SHUT OFF
FLASHING GREEN Pressure sensor placement and setting
Tank precharge pressure
Impeller damage
Leaky system
Sized improperly (pump can't build enough head)
Check frequency at low flows, pressure setting
     may be to close to pump max head.
Verify precharge at 70% if tank size is larger
     than minimum, increase precharge (up to 85%).
Verify that the system will build and hold pressure.
RUNS BUT TRIPS FLASHING RED Check fault code and see corrective action Proceed to fault code description and remedy.
LOW PRESSURE FLASHING GREEN Pressure sensor setting, pump rotation,
pump sizing
Adjust pressure sensor, check pump rotation.
Check frequency at max flow, check maximum pressure.
HIGH PRESSURE FLASHING GREEN Pressure sensor setting
Shorted sensor wire
Adjust pressure sensor.
Remove sensor wire at PCB, if drive continues
     to run, replace drive.
Verify condition of sensor wire and repair or
     replace if necessary.
AUDIBLE NOISE FLASHING GREEN Fan, hydraulic, plumbing For excessive fan noise, drive must be replaces on
     NEMA 1 and 3R, fan is replaceable on NEMA 4.
If fan noise is normal, drive will need to be relocated
     to a more remote area.
If hydraulic, try raising or lowering depth of pump.
Pressure tank location should be at entrance
     of water line into house.
NO LIGHTS NONE Ribbon cable detached from LED printed
Circuit board
Reattach cable - if cable is attached, replace drive.
RFI-EMI
INTERFERENCE
FLASHING GREEN See interference troubleshooting procedure.  

 

Constant Pressure Pump Systems