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USER MANUAL
Fully Automatic Three-Phase Water Level Controller with Dry Run Protection
The IT192WLC is a fully automatic water level controller for three-phase motors using a DOL starter. It controls the water pump based on water levels in the sump and overhead tanks, with inbuilt dry run protection. The controller supports both automatic and manual modes and is designed for industrial and residential use with 3-phase 440V supply (R & Y phases for operation).
- IT192WLC Water Level Controller Unit - 6 × Stainless Steel (SS) Sensors - 3 for Sump Tank - 3 for Overhead Tank - User Manual with Wiring Diagram
Label
Tank
Description
G (Sump Low)
Sump Tank
Low-level sensor – triggers dry run stop
B (Sump High)
High-level sensor – allows pump operation
R1 (Sump Ref)
Reference ground for sump
G1 (OHT Low)
Overhead Tank
Low-level sensor – triggers pump start
B1 (OHT High)
High-level sensor – triggers pump stop
R1 (OHT Ref)
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
- 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).
- 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.
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
Glows when pump is ON
- Fully Automatic and Manual Control - Dual Tank Monitoring (Sump + Overhead) - Dry Run Protection (with Auto Retry Logic) - Manual Start/Stop Buttons - Compatible with 3-Phase DOL Starters - Works with Monoblock, Openwell, Submersible pumps (up to 5 HP) - Real-Time LED Indicators - Rugged Design for Industrial Use
Parameter
Value
Input Voltage
440V AC Two Phase (R & Y)
Frequency
50 Hz
Load Capacity
Up to 5 HP Motor via DOL Starter
Relay Rating
25A (Heavy Duty)
Sensor Type
Stainless Steel Rods
Starter Compatibility
DOL Starter Only
- 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 inside the starter panel. - Ensure protection against water, dust, and heat. - Wiring Notes: - Use proper gauge wires and terminal connections. - Keep sensor wires away from high voltage lines. - Follow wiring diagram provided in the manual.
- Ensure proper phase connection (R & Y input only). - Do NOT bypass dry run protection. - Always use with DOL starter, not direct connection. - Use qualified electrician for installation. - Test system after installation before regular use.
Issue
Possible Cause
Solution
Motor not starting
No water in sump or dry run active
Check sump water level and sensor wiring
Motor does not stop
Overhead tank sensor B1 not working
Check sensor placement and wiring
Dry run triggers early
Loose or faulty G sensor
Tighten or replace G sensor
Manual mode not working
Button or switch wiring fault
Inspect manual switch and button circuit
