Fully Automatic Water Level Controller & Indicator with Dry Run Protection MODEL NO-IT180WLC

Model No: IT180WLC

Fully Automatic Water Level Controller with Dry Run Protection

1. PRODUCT OVERVIEW

The IT180WLC is a fully automatic water level controller designed to manage water flow between a sump (underground) tank and an overhead storage tank, providing dry run protection, manual override, and LED status indications. It eliminates the need for manual monitoring and prevents pump damage due to dry run conditions or overflow.

2. PACKAGE CONTENTS

    IT180WLC Water Level Controller Unit

    6 × Stainless Steel (SS) Sensors

        3 for Sump Tank

        3 for Overhead Tank

    User Manual with Wiring Diagram

3. SYSTEM COMPONENTS & SENSOR LABELS

Label    Tank      Description
G (Sump Low)    Sump Tank       Low-level sensor – triggers dry run stop
B (Sump High)    Sump Tank     High-level sensor – allows pump operation
R1 (Sump Ref)    Sump Tank     Reference ground for sump
G1 (OHT Low)           Overhead Tank             Low-level sensor – triggers pump start
B1 (OHT High)    Overhead Tank    High-level sensor – triggers pump stop
R1 (OHT Ref)    Overhead Tank    Reference ground for OHT
Motor LED    —    Indicates motor ON/OFF
Auto/Manual    —    Mode selector switch
Start Button    —    Start motor in Manual mode
Stop Button    —    Stop motor in Manual mode



4. WORKING MODES

✅ Automatic Mode (Default)

    Dry Run Protection:

        If sump water falls below G, the motor is stopped to prevent dry running.

        Once water level reaches B, dry run condition clears.

    Pump Control:

        If the overhead tank water falls below G1 and sump water is available (B is active), the pump starts.

        Pump stops when overhead tank reaches full (B1 active).

⚙️ Manual Mode

    Switch to Manual using Auto/Manual toggle.

    Use Start Button to manually turn ON pump.

    Use Stop Button to manually turn OFF pump.

    Dry run protection remains active in Manual mode.

5. LED INDICATIONS

LED    Meaning
G    Sump Low – triggers dry run protection
B    Sump High – sufficient water available
R1 (Sump)    Sump tank reference sensor
G1    Overhead Low – pump should start
B1    Overhead Full – pump should stop
R1 (Overhead)    Overhead tank reference sensor
Motor LED    Glows when pump is ON



6. KEY FEATURES

     Fully Automatic and Manual Control

     Dual Tank Monitoring (Sump + Overhead)

    Dry Run Protection (with Auto Retry Logic)

     Manual Start/Stop Buttons

    Auto Mode for Complete Automation

     Works with Monoblock, Openwell, Submersible pumps (up to 2 HP)

     Real-Time LED Indicators

     Energy and Water Saving Operation

     Supports Easy Installation with Standard SS Sensors

7. TECHNICAL SPECIFICATIONS

Parameter    Value
Input Voltage    220–250V AC (Single Phase)
Frequency    50 Hz
Load Capacity    Up to 2 HP Motor
Relay Rating    15A (Heavy Duty)
Sensor Type    Stainless Steel Rods
Compatibility    MCB starters only (not push-button starters)

8. INSTALLATION GUIDELINES

    Sensor Placement:

        Sump Tank:

            G – Near bottom (Dry run cutoff)

            B – Mid/upper level (Water available)

            R1 (Sump) – Always at bottom (Reference)

        Overhead Tank:

            G1 – Low level (Start motor)

            B1 – High level (Stop motor)

            R1 (Overhead) – Always at bottom (Reference)

    Control Panel Mounting:

        Mount the controller near your motor or switchboard.

        Ensure proper ventilation and avoid water contact.

    Switch and Button:

        Keep Auto/Manual switch and Start/Stop buttons in easy access.

    Wiring Notes:

        Use quality wires for sensor connections (preferably shielded).

        Keep sensor wiring away from high voltage lines to avoid false triggers.

        Follow provided wiring diagram strictly.

9. SAFETY & PRECAUTIONS

    Do NOT bypass the dry run protection to avoid pump damage.

    Ensure correct wiring to avoid electrical hazards.

    Keep sensor cables and power lines separate.

    Test the system thoroughly after installation.

    Only trained technicians should attempt installation or service.

10. TROUBLESHOOTING TIPS

Issue    Possible Cause    Solution
Motor not turning ON    Sump tank has no water (G active)    Wait until sump fills above B
Motor not stopping    Overhead sensor B1 not detecting    Check sensor placement or wiring
False dry run activation    Loose or corroded G sensor    Clean and tighten sensor connections
Manual Mode not working    Faulty button/switch or wiring    Inspect and replace if needed