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HeadHunter X-CALIBER XR-124 - User Manual

HeadHunter X-CALIBER XR-124
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Doc No. XG-0042 Rev No. 042808
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Summary

X-Caliber Introduction and Technical Data

Technical Data

Lists operating conditions, pressure, flow rate, temperatures, and electrical data.

Dimensional Drawings

Provides visual diagrams of the pump with key dimensions for installation.

Performance Curves and Product Details

Performance Curves

Illustrates pump flow rate and pressure capabilities across different power settings.

Whats in the Box

Lists all components included with the X-Caliber pump.

Fluid Requirements and Certifications

Details fluid compatibility for XR/XRS models and product certifications.

Mounting the X-Caliber Pump

Mounting Bracket and Orientation

Instructions for using the rotating bracket for vertical or horizontal pump mounting.

Plumbing Installation Guide

Suction and Discharge Piping

Steps for correct suction and discharge connections, including hose, strainer, and leak prevention.

Electrical Requirements and Wiring

Voltage Selection and Wire Sizing

Guidance on selecting 12V or 24VDC operation and determining correct wire gauge.

Initial Start Up and Priming Procedures

Priming the Pump

Step-by-step guide to prime the pump for initial operation, including warnings.

Accumulator Tanks and Water Filters

Recommendations for using accumulator tanks and water filters with the pump.

Control Panel and Power Settings

Control Panel Overview

Explanation of the control panel buttons, LEDs, and their functions.

Introduction to Power Settings

Details the three available power settings (300W, 400W, 500W) and selection factors.

Changing Pump Settings

How to Change Power and Cut-In Settings

Step-by-step instructions for adjusting pump power and cut-in pressure settings.

Pump Operation and Status Indication

Start and Stop Operation

Describes the pump's soft-start and stop behavior based on pressure and flow.

Pressure Boosting Applications

Guidelines for using the pump in pressure boosting scenarios.

Status Indication with LEDs

Interpreting LED signals for cut-in pressure and power settings.

Alarm Conditions and Management

Alarm Conditions and LED Codes

Lists all alarm problems, their LED indications, and alarm codes.

Alarm Acknowledgement and Voltage Alarms

Procedures for clearing alarms and details on under/over voltage alarms.

Specific Alarms, Maintenance, and Winterization

Specific Alarm Types

Explains Over Temperature, Over Current, Over Pressure, and Anti-Flooding alarms.

Maintenance and Winterization

Recommendations for monthly maintenance and seasonal winterization procedures.

Installation Accessories

Lists optional accessories available for purchase.

Troubleshooting and Support

Troubleshooting Guide

A table identifying common problems, their causes, and recommended remedies.

Technical Support and Warranty

Contact information for technical assistance and details of the limited product warranty.

Overview

The X-Caliber is a high-performance water pressure system designed for marine and other 12 or 24VDC applications. It is comprised of a water-cooled motor, integrated flow and pressure control, and a quiet multi-stage self-priming impeller system. The system utilizes advanced technology to provide superior performance while maintaining constant input power. It offers three input power settings and cut-in pressures that can be programmed via the integrated control panel. Power settings and alarm conditions are displayed using four colored LEDs on the control panel. The XR-124 model is specifically designed for freshwater applications, while the XRS-124 model is suitable for both salt and freshwater applications, featuring 316 Stainless Steel wetted components for enhanced corrosion resistance. Both models are approved for drinking water use and are suitable for rainwater applications. The X-Caliber is not intended for pumping fuel or any other flammable fluids.

Function Description:

The X-Caliber operates as a constant pressure water system, automatically adjusting its RPM to maintain a consistent water pressure regardless of demand. It soft-starts when the pressure drops to a pre-set cut-in pressure or when it detects a high flow condition (defined as a drop in pressure of 1.4 psi/sec or 0.1 bar/sec). The pump soft-stops when it reaches its maximum pressure. The system includes built-in self-protecting features that indicate various alarm conditions via LED configurations.

Important Technical Specifications:

  • Maximum Pressure: 67 psi (4.5 bar)
  • Maximum System Pressure: 110 psi (7.5 bar)
  • Maximum Inlet Pressure: 36 psi (2.5 Bar)
  • Maximum Flow Rate: 10 GPM (38 LPM)
  • Maximum Suction Lift: 26 ft (8m)
  • Minimum Ambient Temperature: 32°F (0°C)
  • Maximum Ambient Temperature: 120°F (48°C)
  • Maximum Fluid Temperature: 95°F (35°C)
  • Inlet and Discharge Fitting: 3/4" inch female NPT (3/4" Gas male adapter included)
  • Sound Pressure Level: <70 dB(A)
  • Dry Weight: 14 lbs (6.3 kg)
  • Enclosure: IP55
  • Insulation Class: B
  • Supply Cables: Tinned Stranded Copper-Type BC #10 AWG (6 ISOmm²)
  • Power Settings (12VDC / 24VDC):
    • Low-300W: 25 Amps (12VDC), 12.5 Amps (24VDC)
    • Medium-400W: 34 Amps (12VDC), 17 Amps (24VDC)
    • High-500W: 42 Amps (12VDC), 21 Amps (24VDC)

Usage Features:

  • Voltage Recognition: The X-Caliber automatically recognizes and adjusts for 12VDC or 24VDC operation upon initial power-up.
  • Programmable Power Settings: Users can select one of three power settings (300W, 400W, 500W) to optimize performance based on system requirements and available wire size.
  • Adjustable Cut-in Pressure: The pump allows for programming of different cut-in pressure settings (low, medium, high) to suit specific application needs. The default cut-in pressure is 29 psi (2 bar).
  • Control Panel: An integrated control panel with four colored LEDs (Blue, Red, Yellow, Green/Red) provides visual feedback on power settings, alarm conditions, and operational status.
  • Hidden Mode Switch: A hidden switch on the control panel allows access to programming routines for power settings and cut-in pressures.
  • On/Off Switch: Used to toggle between "active" and "standby" modes, exit selection menus during programming, and reset the pump after an alarm.
  • Priming Mode: The pump features an automatic priming mode with a series of trial runs and pauses to ensure proper priming. If not primed after five trials, it enters an alarm state.
  • Pressure Boosting Applications: Can be used to boost pressure in systems with pressurized inlet water, provided the total pressure does not exceed the system's rated pressure.
  • Status Indication: Momentarily pressing the hidden mode switch displays the currently programmed settings via LED flashes.
  • Anti-Flooding Protection: An optional feature that detects prolonged pump operation at constant RPM, input power, and pressure, then turns off the pump and triggers an alarm. This feature can be enabled or disabled via the on/off switch.
  • Innovative Rotating Mounting Bracket: Allows for versatile installation in various configurations (horizontal, vertical, or angled planes). The bracket can be rotated by loosening four mounting screws, rotating the pump body, and then re-securing the bracket. For vertical installations, the inlet must face down.

Maintenance Features:

  • Maintenance-Free Design: The X-Caliber is designed to be a low-maintenance water pressure pump.
  • Inlet Strainer Check: It is recommended to check the inlet strainer monthly for any accumulation of debris to ensure optimal performance. Headhunter-approved strainers (IS-750, IS-1000S, IS-1000L) are recommended.
  • Winterization Procedure: To prevent freezing damage, users should open a faucet, allow the pump to run and empty the freshwater tank, then remove the drain plug to completely drain water from the pump body. Automotive antifreeze should not be used for potable water systems.

Alarms and Troubleshooting:

The X-Caliber incorporates several self-protection features that trigger alarms indicated by specific LED patterns:

  • Dry Run Alarm: Continuous Red LED. Caused by an empty water tank or suction piping leak.
  • Under Voltage Alarm: Continuous Red LED with one Blue status LED blink. Occurs when voltage falls below nominal range, triggering a 300W emergency mode (continuous Blue LED) before shutting off.
  • Over Voltage Alarm: Continuous Red LED with two Blue status LED blinks. Occurs when voltage exceeds maximum rated input voltage.
  • Over Current Alarm: One Red LED blink. Caused by debris stuck in the pump.
  • Electronic High Temperature Alarm: Four Red LED blinks. Caused by high ambient temperature.
  • Over Pressure Alarm: Five Red LED blinks. Occurs if the pump exceeds its maximum operating pressure (110 psi / 7.5 Bar).
  • Anti-Flooding Alarm: Six Red LED blinks. Triggered if the optional anti-flooding routine is enabled and detects prolonged constant operation.

Alarm Acknowledgement:

After an alarm condition, the pump will not automatically restart. To restore normal operation, the alarm condition must be rectified, the pump primed, and then the on/off switch pressed twice. Alternatively, power can be cycled off and on. If the alarm persists, only pressing the on/off switch will acknowledge it once the condition is resolved.

Installation Guidelines:

  • Locate the pump close to the water supply to minimize suction piping length.
  • Use 3/4" or 1" I.D. non-collapsible suction piping, ensuring no leaks or restrictive fittings.
  • Install a Headhunter-approved strainer on the suction side; do not install charcoal or sediment water filters on the suction piping.
  • For long suction runs, a spring check valve or foot valve near the tank is recommended to maintain prime.
  • Suction piping should have a gradual uphill or horizontal run to the pump inlet to prevent air pocket formation.
  • Ensure inlet and discharge piping is well supported to prevent stress on fittings.
  • A check valve is built into the inlet fitting and should not be removed.
  • Do not install a check valve on the discharge of the pump, as this may affect pressure monitoring.
  • Installation of a Headhunter PGV-100 or PGH-100 pressure gauge on the discharge piping is recommended for monitoring system pressure.
  • For European pipe connections, 3/4" male Gas x 3/4" male NPT adapters are available from Headhunter.
  • Headhunter recommends sizing supply cables for the maximum power setting (500W) for future upgrade flexibility.
  • Protect the circuit with an appropriately sized breaker or fuse.

HeadHunter X-CALIBER XR-124 Specifications

General IconGeneral
BrandHeadHunter
ModelX-CALIBER XR-124
CategoryWater System
LanguageEnglish

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