IntelliFlo has lost it's connection

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Palazzo’D

Member
May 19, 2021
9
Fresno, CA
Hi folks,

I am trying to troubleshoot my filter pump that previously worked fine for many years. The pump no longer runs upon command from the controller.

The pump is an IntelliFlo 4 160.

The controller is an IntelliTouch i9+3.

The pump runs fine in manual mode, confirming power is at the motor.

The controller RS485 comms (and cable) work, confirmed by moving comm cable to a different pump.

There is evidence the pump is receiving some communication via RS485 because the manual start works only if the comms cable is disconnected OR the IntelliTouch is in the “service” mode.

I conclude that the Variable Speed Drive on the motor/pump has gone bad and should be replaced but my reason for the post to ask if there is disagreement or any additional trouble shooting suggestions to further confirm (or disprove_ my conclusion.

Thanks to all.

Tom
 
Tom,

If the VS drive was bad the pump would not run when in the Service mode..

Does your IntelliFlo have a display?? If so, with the system in AUTO, the display should show.. "Display not Active" Obviously, with the cable attached.

Has anyone made any recent programming changes to your system?? Did anyone swap the cables before this problem showed up?

I ask, because if anyone changes the "pump type" it will wipe out all your speeds..

You check by going to Menu, Setting, IntelliFlo (may or may not show Pump 1 or 2) .

You should see the pump type = VS

Below that you will see "Speeds" and you should be able to scroll through the speeds for each circuit.

Thanks,

Jim R.
 
Hi Jim, thanks for the reply.

I do not have a display. My controller looks similar to this image below.

I do have a pool service but they would not be making any changes like the examples you gave.

So can I check the configuration some way without a display?

Where does the RS485 get processed, if not on that main circuit board on top of the VS ? Keyboard circuit board?

I noticed today that the keyboard membrane has some breaks, so likely the circuit board has had some moisture exposure.

Again many thanks for your help, Tom
 
Tom,

You have to have something to control your automation.. :scratch:

You should either have Pentair remotes, that have a little display, or you have ScreenLogic, and can control things using your phone..

If you look at the panel above, on the top left side it says "System Control".. See which of the 3 lights are on..

Then just to the right are 4 lights.. Tell me which of those lights are on.

Thanks,

Jim R.
 
Tom,

If you look at the pic of your main panel you will see that you are in Auto and that the Filter/Pump relay is closed, because both have red lights..

But... you are not in the Pool mode or Spa mode.. I suspect that is why your pump is not running.

It appears that your remote has Pool on, but it is not on in the IntelliTouch. Go out and push the V button and see if you can get the Pool light to come on.

Let me know..

Let's see if we can get some help from @ogdento....

Jim R.
 
Jim,

The V button does not bring up the "pool" indicator light.
When the "pool" button on the remote is pressed I can hear a relay activate.
Also note the picture of the remote in set-up mode which indicates "no communication" with Pump #1 (pool filter). To reiterate, I have moved the comms cable to one of the other pumps to verify both the IntelliFlo comms circuitry and the cable itself are working.
 
Hey Tom,
Just as a quick test... from the main menu of your remote, press the "Heat" button (the label is on the bottom row of the display)... that will initiate a request from the remote to the outdoor board, and the outdoor should respond and you should see the heat screen. If that works then your comms are good at your indoor and outdoor panel (as you've assumed).

For the intelliflo vfd, there is an 8-pin comm chip inside the keypad board, to the right of the 9-pin connector. I've taken apart an intelliflo 4160 keypad here:

Pentair EasyTouch - Control Panel & Remote Won't Run Pool

The black booster pump should be wired across one of the ET's relays. Perhaps you accidentally wired it to the Line side of the relay instead of the Load side? And is your pump truly an Intelliflo? Your signature says "Main pump : 4 x 160 pentair var speed", and I don't know what that means.
www.troublefreepool.com www.troublefreepool.com

I think there is another inside the drive unit itself though... I've never actually used a multimeter to trace where the external comm jack terminates inside the drive (i.e. does it go straight to the keypad), but you could do that if you have a meter handy.
 

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hey @Jimrahbe, not sure... I saw that the "pool" led is lit on the indoor panel when the "Filter" button outside is lit, but yeah - I'll have to check what happens on the indoor when I press the "Valve" button on the outdoor.
 
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well that's embarrassing... I forgot that before you can press the "V" button, you have to put the Intellitouch into service mode - at which point the indoor panel switches to an entirely un-helpful screen saying only that "the system is in service mode".

So, you don't actually see any change on the indoor panel... but at the outdoor panel you will see the LEDs cycle through pool/spa/fill/drain as you continue to press "V"
 
@ogdento

Really, are you sure?? :scratch:

When you push the "V" button on the EasyTouch it will move the valves and the system between the Pool mode and the Spa when in AUTO.. When in the Service mode it will scroll through all 4 options... Pool, Spa, Fill, and Drain.

Thanks,

Jim R.
 
@ogdento

"Just as a quick test... from the main menu of your remote, press the "Heat" button (the label is on the bottom row of the display)... that will initiate a request from the remote to the outdoor board, and the outdoor should respond and you should see the heat screen. If that works then your comms are good at your indoor and outdoor panel (as you've assumed)."

Yes it works. All of the remote functions work, including the Spa, Spa heater, etc. There are 4 IntelliFlo pumps in this system. The other 3 all respond to the remote or the controller (in service mode).

One comment on the pool LED indicator on the outdoor panel: I have a second pump (no filter) on the pool for the floor cleaner. It is working fine, (as stated all other pumps respond) however the "pool" LED does not illuminate for this pump either. I think it used to, but honestly don't remember for sure.

Thanks for the info on the keypad. I will take a look.
 
@Palazzo’D oops, i forgot you had two pumps!

@Jimrahbe when in "Auto", none of the buttons on an Intellitouch outdoor panel do anything... except for the button that switches between modes of course. Seems like in some ways the Easytouch is better than the Intellitouch ;)
 
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@ogdento

OK, after reading the thread you linked to, I feel I need to replace the whole variable drive unit since that main board is not reparable. Attached is the ID tag from my current unit. Must I use the 350521 as the only replacement or will other (possibly newer) versions work?

IMG_2320.JPEG
 
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