ISM-DRD Grade 3 Dry Run Detector ISM-DRD

ISM-DRD Grade 3
Dry Run Detector ISM-DRD 
This unit is designed specifically to detect dry running of any type of pumping system of 30 Kwatt or
greater. System management has entered a new era! No other product offers system management,
protection and data collection all in one. It’s easy to install with no nonsense wiring. A simple calibration
procedure is all that is required. Your system is managed, your equipment protected, should you need it in
future, you have a great trouble shooting tool in place.
Your ISM-DRD  uses a state of the art microprocessor, programmed with the latest software, designed
using the vast field knowledge and experience that has been built up over many years of successful
participation in the related field.
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Easy to install!
Simple calibration procedure!
Minimized nuisance tripping!
Maximum operating range!
Auto diagnostics!
Peace of mind!
ISM-DRD  manages your pumping system by:
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Avoiding nuisance tripping
Making maximum use of your water reservoir
Allowing the widest possible voltage fluctuation
Anticipating transient overload conditions
Using a simple dry-run management program
Limiting the destructive effects of over currents and
Reducing rapid cycling automatically when required
ISM-DRD  protects pumping system by:
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Monitoring supply voltage
Monitoring current
Monitoring shaft load
Eliminating rapid cycling which can cause motor overheating
Detecting excessive continuous over currents
Detecting dry running
Logging data during operation for fast and versatile technical support
Detecting bad connections
Allowing for voltage and current stabilization during start-up
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With over 15000 units sold in Southern Africa, our engineers have learnt how best to protect your motor.
All this knowledge has been built into the ISM-DRD . Rest assured that all the necessary parameters
are being monitored to protect your motor effectively. ISM-DRD  does not rely only on current ,
voltage or power. We have found that a complex combination of these parameters is required to ensure
efficient protection with out causing nuisance tripping. If it becomes necessary to do fault finding
ISM-DRD  makes it very easy. If it becomes necessary to do fault finding ISM-DRD  makes it
very easy. Either use the coloured Led’s on the front panel by interpreting the combination of the lit Led’s,
or upload the data using our data reader, and displaying the events on a computer screen. Our qualified staff
can offer assistance in interpreting the results. Our web site offers examples of typical installations.
ISM-DRD  Grade 3 Technical specifications (Dry run detection)
Model Number
Voltage Nominal
Voltage Running mode
Voltage Starting
ISM-DRD Grade 3
120V, 230V, 400V, 525V AC 50/60 Hz
-20% +15%
-15% +20%
Voltage response time
Voltage trip recovery time
10 seconds
5 minutes
Operating Temperature
Maximum Current
-5° to 60°C
Direct 5 amps – other currents with C.T.
Relative humidity
Relay contact
Maximum 75% at 40 degrees Celsius
16 Amps resistive
4 secs for 50% and over
20 secs for 10% and over
15 secs for 15% and over
10 secs for 33% and over
4 secs for 50% and over
Overload response on start up
Overload response on run
Overload recovery time
Under Load Control
Reset on Dry-Run
Rapid Cycle protection
Reset On Overload
Switch Control
15 minutes
App. 75% of nominal shaft power OR 75% of
calibrated current
Runtime is automatically matched to water
available for pumping. Time range 15-240 minutes
Maximum of 1starts in a 2 minute run – 5 minute
delay before a new rapid cycle period
Auto Reset after 1st two overloads with 15 min
delay, then reset by power-up with 90 second
delay
Isolator: Used for applying power to the control
box only – not recommended for repeated On/Off
switching activity.
On/Off, Pressure,
Float or other type of switch: Intermittent starting
and stopping of the pump/motor unit
WARNING!
To To avoid possible fatal shock, disconnect power at main power
distribution board before installing, wiring or servicing your
ISM-DRD

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For Wiring Diagram see attached appendix
We recommend that coloured wire be used in accordance with the three phase colour scheme for ease of
fault finding.
A successful installation will depend on you paying attention to minor detail at this
time.
Warning!
Installation and maintenance work should only be carried out by
technically qualified personnel. Serious or fatal injury could result from
tampering by unqualified personnel.
Installation in an existing control board.
These instructions take the assumption that the control signal to switch the present motor control is from
one of the phases.
1.
2.
3.
4.
5.
6.
7.
8.
TURN OFF AC POWER AT THE SOURCE (DB BOARD)
Find a suitable location for the ISM-DRD , close to the main contactor, for convenient wiring.
Connect the ISM-DRD  incoming supply (L1, L2, L3) to the supply side of the contactor, ISMDRD  to always have power. Observe the sequence from the supply to the ISM-DRD 
terminals “L1, L2, L3”.
Connect the C.T. to L3 line either on the incoming or load side of the contactor. Observe the label on
the C.T. if supplied with ISM-DRD . In the case that you are using your own C.T., ensure that the
P1 side of the C.T. faces the load side. This is important, as the ISM-DRD  uses the phase angle
during monitoring, and if incorrectly wired will cause nuisance trips.
Connect the S1, S2 of the C.T. to the respective terminals on the ISM-DRD .
Trace the control line going to the main contactor, and if at all possible change the source supply to
“L2”,(Using “L2” as the source for control, will ensure optimum protection for possible phase failure
on “L2”). Disconnect the control line going to the main contactor auxiliary coil, and take this wire to
the ISM-DRD  “A1” terminal.
Place a wire from the ISM-DRD  “A2” terminal to the open contactor auxiliary coil disconnected
in step 6.
Your ISM-DRD  is ready for final calibration.
Warning!
The Current transformer S1 and S2 terminals are at line potential. Please
ensure that these terminals are insulated to prevent accidental shock!
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Installation in a new control box, using a 400V coil contactor.
1.
2.
3.
4.
5.
6.
7.
8.
9.
TURN OFF AC POWER AT THE SOURCE (DB BOARD)
Find a suitable location for the ISM-DRD , close to the main contactor, for convenient wiring.
Connect the ISM-DRD  incoming supply (L1, L2, L3) to the supply side of the contactor, ISMDRD  to always have power. Observe the sequence from the supply to the ISM-DRD 
terminals “L1, L2, L3”.
Connect the C.T. to L3 line either on the incoming or load side of the contactor. Observe the label on
the C.T. if supplied with ISM-DRD . In the case that you are using your own C.T., ensure that the
P1 side of the C.T. faces the load side. This is important, as the ISM-DRD  uses the phase angle
during monitoring, and if incorrectly wired will cause nuisance trips.
Connect the S1, S2 of the C.T. to the respective terminals on the ISM-DRD .
Connect a wire from “L2” to your control line, (On/Off switch, float switch, pressure switch, timer
switch, etc). Using “L2” as the source for control, will ensure optimum protection for possible phase
failure on “L2”. Connect the return line from the control device to the ISM-DRD  “A1” terminal.
Connect a wire from the ISM-DRD  to the “A1” terminal of the contactor coil.
Place a wire from the ISM-DRD  “A2” terminal to the “A2” terminal of the contactor coil.
Connect your motor wires to the load side of the contactor.
Your ISM-DRD  is ready for final calibration.
Warning!
The Current transformer S1 and S2 terminals are at line potential. Please
ensure that these terminals are insulated to prevent accidental shock!
Installation in a new control box, using a 230V coil contactor.
1.
2.
3.
TURN OFF AC POWER AT THE SOURCE (DB BOARD)
Find a suitable location for the ISM-DRD , close to the main contactor, for convenient wiring.
Connect the ISM-DRD  incoming supply (L1, L2, L3) to the supply side of the contactor, ISMDRD  to always have power. Observe the sequence from the supply to the ISM-DRD 
terminals “L1, L2, L3”.
4. Connect the C.T. to L3 line either on the incoming or load side of the contactor. Observe the label on
the C.T. if supplied with ISM-DRD . In the case that you are using your own C.T., ensure that the
P1 side of the C.T. faces the load side. This is important, as the ISM-DRD  uses the phase angle
during monitoring, and if incorrectly wired will cause nuisance trips.
5. Connect the S1, S2 of the C.T. to the respective terminals on the ISM-DRD .
6. Connect a wire from “L2” to your control line, (On/Off switch, float switch, pressure switch, timer
switch, etc). Using “L2” as the source for control, will ensure optimum protection for possible phase
failure on “L2”. Connect the return line from the control device to the ISM-DRD  “A1” terminal.
7. Connect a wire from the “Neutral” bar to the “A1” terminal of the contactor coil.
8. Place a wire from the ISM-DRD  “A2” terminal to the “A2” terminal of the contactor coil.
9. Connect your motor wires to the load side of the contactor.
10. Your ISM-DRD  is ready for final calibration.
Warning!
The Current transformer S1 and S2 terminals are at line potential. Please
ensure that these terminals are insulated to prevent accidental shock!
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External switch – Rapid Cycle Protection.
Your electric motor accumulates a certain amount of heat each time it is switched on. It must run for a
period of time during which it has the opportunity to dissipate the heat.
The ISM-DRD  will do the necessary calculations and management of the switching process. If too
many starting cycles are called for, a 5 minute waiting period will be applied. The water distribution system
must be designed to allow the pump to run for as long as possible before switching off.
When a pressure switch is connected as an external switch, the rapid cycle protection function of the ISMDRD  is activated, Rapid cycling will now be prevented. Try to set your system parameters so that the
motor will run for about 2 minutes before stopping.
Warning!
Motor size will depict the minimum run period for that motor. Ensure that the
pressure system is suited to motor size for optimum rapid cycle protection! The
ISM-DRD  does not know your motor size!
The ISM-DRD  uses a general algorithm for rapid cycling!
Calibration of the ISM-DRD 
Before calibration of the ISM-DRD , ensure that all valves are in an open position. Ensure there are no
blockages in the pipeline. Ensure there is water in the bore hole, well, reservoir.
1.
2.
3.
4.
5.
6.
ENSURE THAT AC POWER IS TURNED OFF AT THE CONTROL BOX ISOLATOR.
Ensure that your wiring is according to the specific wiring diagram
Before connecting the motor, use a 500V insulation tester (megger) to test the insulation resistance of
each motor lead to earth.
Lightly press and hold the water drop on the ISM-DRD  . Switch the mains on.
The ISM-DRD  flashes a Green-Red-Green+Red sequence three times. Release the water drop
after the first sequence has flashed. The motor starts up, if control circuit is on, (400V coil), in the case
of a 230V coil the motor will start even if the control circuit is On or not.
ISM-DRD  now allows you the opportunity to confirm that the amperage drawn is with in the
motor manufacturers specifications and rotation is correct.
IMPORTANT!
Make use of a tong tester (amp meter) and volt meter to confirm that the electrical supply is with in
specifications. Readings outside these specifications must be correct before proceeding.
7.
Once the running readings have been confirmed as acceptable, press and release the water drop. ISMDRD  stops the motor and flashes the Green-Red-Green+Red sequence three times, and adds the
volts and amperage readings to memory.It is for this reason that the amps and volts are measured.
ISM-DRD  takes these readings as being acceptable.
Failure to measure the running amps and volts could lead to motor failure.
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8.
After approximately 5 seconds, ISM-DRD
and Green light glows.
 restarts the motor in normal running mode. The Red
Your ISM-DRD  is now on guard!!
9.
Should you have any problems in setting up your ISM-DRD
further assistance.
 please contact your supplier for
Operation.
Under normal conditions, switching on will result in a click (relay activating), or a clunk (contactor
activating) being heard and water being discharged. No special attention is required under normal running
conditions. The ISM-DRD  acts as a controlling switch that will interrupt power to your motor if all is
not well. The ISM-DRD  checks for voltage variation and continuously measures various parameters
of the motor.
Operation with Mains Switch.
In some cases it may be necessary or desirable to use a Mains Switch, which will interrupt power to the
ISM-DRD  completely. In such a case the ISM-DRD  protects the motor although it cannot store
some of the operating data.
Light indicators.
The ISM-DRD  has two coloured LED’s which indicate the state of the unit.
LED sequence is deciphered under the trouble shooting table.
External LED display.
The ISM-DRD  can extend the LED’s to a control box front panel, eliminating the need to open a
control box to see the LED status on the ISM-DRD . Ask for ISM-DRD  LED extension kit, P/N
151600XXX. This kit will interface to the DB15 header at the top side of the ISM-DRD .
WARNING!
Under no circumstances connect a cable other than from the
ISM-DRD  external LED extension kit to the DB15 header.
THERE ARE DANGEROUSLY HIGH VOLTAGES WHICH ARE
AT LINE POTENTIAL PRESENT ON THIS CONNECTOR
WHICH CAN CAUSE FATAL HARM TO THE USER.
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Trouble Shooting.
Light indication
or Symptom
(See Fig. 2)
Unit appears dead
Flashing RED-GREEN
RED and GREEN light
on while pump is
running
RED light on and
GREEN light flashing
while pump is running
GREEN light on and
RED light flashing while
pump is running
Lights flashing
RED-RED-GREEN and
pump not running
Lights flashing
GREEN-GREEN-RED
and pump not running
RED light on constantly
Red light flashing
GREEN light on
constantly
GREEN light flashing
Possible Cause
No power to the unit
ISM-DRD  needs to be
calibrated
All OK
Solution
Check wiring. AC power should be applied to
L1 and L2. In some cases the pressure switch
or other control device may be wired to the
power input.
Check that the control switch is wired
according to the instructions. See Figure 2.
Follow the calibration procedure
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Supply voltage is less than
90% nominal
Supply voltage is more than
110% of nominal
Supply voltage exceeded
115% of nominal
Supply voltage below 80%
of nominal.
If condition occurs intermittently installation
will work satisfactorily. If condition remains,
contact electrician to investigate supply.
If condition occurs intermittently installation
will work satisfactorily. If condition remains,
contact electrician to investigate supply.
Wait 3 minutes for retry. If condition prevails,
contact electrician to attend to AC supply.
Wait 3 minutes for retry. If condition prevails,
contact electrician to attend to AC supply.
Remove power from the ISM-DRD  for
at least 5 seconds. Pump will restart with in 90
seconds of re-applying power. If fault persists,
call an electrician to check the motor
The motor will auto restart within 15 minutes.
Overload condition has been To reset manually, switch external switch off
detected and external switch and on again. Do not do this more than twice.
in on position
Correct the fault before attempting any further
starts
A dry run has been detected Switch on and resume pumping. A float
and the On/Off switch or
switch or other external control switch may
external control switch has
have opened. Check for external switches or
opened
control devices
The motor will restart automatically with in
15-240 minutes. Flash rate is proportional to
A dry run or under load has
the amount of time left. Slow indicates up to 4
been detected
hours waiting time. A fast flash rate indicates
a few minutes
3 overloads in a row caused
a lock-out condition
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Calibration Mode Trouble shooting
Light indication
or Symptom (See
Fig. 2)
RED-GREENRED/GREEN sequence
flash
GREEN flashing
RED flashing
Possible Cause
Start or end of calibration
procedure
The ISM-DRD  has
not detected any current
flowing in S1 and S2
The ISM-DRD  has
detected that the current
flowing in S1 and S2 is
greater than 5 amps
Solution
Switch On external switch. Contactor not
pulled in OR C.T. to large for motor size, get
smaller ratio C.T. (NOTE! Secondary ratio
must always be 5 amps) OR motor not
connected OR wiring incorrect – check wiring
according to Figure 1
Use a larger ratio C.T.
NOTE! C.T. secondary ratio must always be 5
amps
Data Reader Option
While the ISM-DRD  is on guard, it records various pump parameters. Switching events are also
recorded. Fault diagnosis has never been easier!. It is now possible to get to the root of an installation
problem before serious damage occurs. The data can also be emailed anywhere in the country or the world.
This means that the best possible technical backup is as far as your telephone.
Contact your supplier for more information on the ISM
 Data Reader 381000500 and how to use it.
Figure 3: ISM © Data Reader
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Figure 4: Sample data extracted from a ISM-DRD
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Limited Warranty
The manufacturer of ISM-DRD  warrants to the original equipment manufacturers and authorized ISM-DRD 
dealers and service centers that each ISM-DRD  unit sold will be free from defects in workmanship and materials
and will perform consistent with samples previously supplied and will conform to specifications published or mutually
established for a period of one year from date of installation but not more than two years from date of manufacture in
water pumping applications.
Any ISM-DRD  unit which fails to conform to the sales contract, including the above warrant, will be replaced at
the option of the ISM-DRD  manufacturer. The remedy of repair or replacement is the sole and exclusive remedy
afforded for breach of the above warranty. Warranty on the repaired or replaced equipment will be for the time
remaining under the terms of the original warranty.
Under no circumstances shall the ISM-DRD  manufacturer be liable for any special, incidental or consequential
economic or other damages resulting from the failure of the ISM-DRD  manufacturer to comply with the contract
of sale or breach of the above warranty, negligence or otherwise.
This warranty is applicable only for water well installations.
The ISM-DRD  and specifications are subject to change without notice
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ISM-DRD 
Notes.
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