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Aqua Control, Inc. TROUBLESHOOTING UNIT NOT RUNNING YES OUTPUT VOLTS = SOURCE VOLTS INVESTIGATE AMPS NO 1 NO INPUT VOLTS = SOURCE VOLTS CORRECT INPUT VOLTAGE YES NO TIMER SET CORRECTLY? YES SET TIMER NO DID ANYTHING TRIP? OVERLOAD 3 INVESTIGATE GFCI’S 2 INVESTIGATE HIGH AMPS Aqua Control, Inc. Service Manual Chapter 8 1 Aqua Control, Inc. TROUBLESHOOTING INVESTIGATE AMPS 0 AMPS 1 HIGH AMPS OUTPUT AMPS LOW AMPS DISCONNECT PUMP CABLE GOOD LINE-TO-LINE INVESTIGATE LOW AMPS INVESTIGATE HIGH AMPS 4 3 SHORT / OPEN YES ISOLATE / REPLACE FAULTY CABLE 5 2-WIRE MOTOR YES OVERLOAD IN MOTOR TRIPPED 2 Aqua Control, Inc. Service Manual Chapter 8 Aqua Control, Inc. TROUBLESHOOTING INVESTIGATE LOW AMPS 4 INVESTIGATE AMPS 3 NO YES 1-PHASE? EXCESSIVE LINE LOSS? YES INVESTIGATE MOTOR CONTROL BOX 6 1-PHASE? YES ADD BOOST TRANSFORMER NO 6 AERATOR? INCREASE CABLE GAUGE INVESTIGATE MOTOR CONTROL BOX YES CHECK FOR BLOCKED OUTLET CHECK FOR BLOCKED INLET CHECK FOR LOOSE IMPELLER CHECK FOR LOOSE PROPELLER CHECK FOR BROKEN MSE CHECK FOR BROKEN MSE AERATOR? CHECK FOR BLOCKED INLET CHECK FOR BLOCKED OUTLET CHECK FOR LOCKED ROTOR OR BEARINGS High amps, (locked rotor amps) are only needed for very short periods of time, usually 1 second or less. Many multimeters will not register the high amps. Aqua Control, Inc. Service Manual Chapter 8 3 Aqua Control, Inc. TROUBLESHOOTING INVESTIGATE MOTOR CONTROL BOX 6 RED AMPS HP LOW HIGH 1 1.3 43 2 2.6 51 3 6.0 84 5 10.8 121 INVESTIGATE OVERLOADS 9 CHECK RED AMPS Franklin motor control boxes have a complete set of tests included on the inside of the motor control box. High amps, (locked rotor amps) are only needed for very short periods of time, usually 1 second or less. Many multimeters will not register the high amps. YES HIGH, THEN LOW? YES GOOD HIGH, THEN STAYS HIGH? 7 YES INVESTIGATE RELAY COIL HIGH, THEN 0? LOW, THEN LOW? 8 4 INVESTIGATE RELAY CONTACTS INVESTIGATE RELAY CONTACTS 8 INVESTIGATE START CAPACITOR 10 Aqua Control, Inc. Service Manual Chapter 8 INVESTIGATE RUN CAPACITOR 6 Aqua Control, Inc. TROUBLESHOOTING INVESTIGATE GFCI 2 NO TRIP WITHIN A FEW MINUTES? POWER OFF PANEL POWER OFF PANEL CHECK LOOSE WIRES CHECK LOOSE WIRES CHECK NEUTRAL TO GROUND VOLTAGE CHECK NEUTRAL TO GROUND VOLTAGE CHECK EACH HOT TO NEUTRAL CHECK EACH HOT TO NEUTRAL REMOVE PUMP CABLE REMOVE PUMP CABLE POWER ON PANEL MEGG CABLE NO NO LESS THAN 20 M OHMS? GFCI TRIPPED? YES YES POWER OFF PANEL ISOLATE LEAK TO GROUND AFTER PANEL POWER OFF PANEL 13 MEGG CABLE TO VERIFY LEAK TO GROUND 11 12 ISOLATE LEAK TO GROUND IN PANEL ISOLATE LEAK TO GROUND AFTER PANEL INVESTIGATE NUISANCE TRIPPING 12 Aqua Control, Inc. Service Manual Chapter 8 5 Aqua Control, Inc. TROUBLESHOOTING INSOLATE / REPLACE FAULTY CABLE 5 The next component may delineated by a splice, a connector or a junction box. It may be a length of cable, the motor lead or motor. LOCATE NEXT COMPONENT ANOTHER COMPONENT? NO YES GOOD LINE-TO-LINE? YES REPLACE LAST COMPONENT 6 Aqua Control, Inc. Service Manual Chapter 8 Aqua Control, Inc. TROUBLESHOOTING INVESTIGATE RELAY COIL The resistance between the Red wire, terminal #2 and the Yellow connection, terminal #5 on the relay. Reading should be between 4,500 Ohms and 7,500 Ohms. 7 INVESTIGATE CONTACTS REMOVE YELLOW WIRE FROM TERMINAL 5 OF RELAY REMOVE ORANGE WIRE FROM TERMINAL 1 OF RELAY SET OHMMETER TO READ TO 20,000 OHMS SET OHMMETER TO LOWEST SETTING GOOD READING? GOOD READING? NO NO REPLACE RELAY REPLACE RELAY Aqua Control, Inc. Service Manual Chapter 8 8 Read resistance between the Orange wire, terminal #1 and the Red connection, terminal #2. Reading should be very close to 0 Ohms. 7 Aqua Control, Inc. TROUBLESHOOTING INVESTIGATE OVERLOAD 9 SET OHMMETER TO LOWEST SETTING OPEN LINE GOOD READING? NO RESET OVERLOAD REPLACE BOTH OVERLOADS To test an overload, read the resistance between the two soldered connections on the top of the overload. The overload should have a resistance of 0.5 Ohms or less. If the reading indicates open line the overloads must be reset and retested. Other readings indicate that both overloads should be replaced. Resetting an overload may be quite difficult. It may require pressing extremely hard to reset them. The only certain method for determining whether an overload has been reset is to read the resistance between the two soldered connections at the top of the overload. 8 Aqua Control, Inc. Service Manual Chapter 8 Aqua Control, Inc. TROUBLESHOOTING For Franklin motor control boxes, the “start” capacitor is large and black. The “run” capacitor is smaller and silver. ACI motor control boxes will have a single gray “run” capacitor. 2-wire motors have the capacitors in the motor and are not directly testable. INVESTIGATE CAPACITOR 10 Inspect for bulging or leaking. There are two sets of terminals on the bottom of each capacitor. Remove all wires from one of the terminals. Capacitance us usually designed by “Cap” “II”, or ”I(-”. It is measured in microFarads, usually displayed as “uF”. VISUALLY INSPECT CAPACITOR The capacitor’s rating will be designated on the capacitor e.g. 45 uF or 180-225 uF. Readings should start low and climb toward “open line”. The exception to this is the start capacitor of a 5 HP unit. It will only climb to 15,000 Ohms. If the reading starts at “open line” switch probes of your multimeter and retest. REMOVE ALL WIRES FROM ONE SET OF CONTACTS DOES MULTIMETER TEST CAPACITANCE? NO YES TEST CAPACITANCE SET OHMMETER TO HIGHEST SETTING GOOD READING? GOOD READING? NO NO REPLACE CAPACITOR Aqua Control, Inc. Service Manual Chapter 8 9 Aqua Control, Inc. TROUBLESHOOTING INVESTIGATE LEAK TO GROUND YES ISOLATE 1-PHASE 11 NO 1-PHASE 14 10 ISOLATE 3-PHASE 15 Aqua Control, Inc. Service Manual Chapter 8 Aqua Control, Inc. TROUBLESHOOTING The use of a megger is strongly recommended. The use of a multimeter will not detect most leaks to ground. ISOLATE LEAK TO GROUND AFTER PANEL 12 YES USE MEGGER? NO POWER OFF POWER OFF ANOTHER CONNECTION POINT? NO YES RECONNECT CABLE DISCONNECT PUMP CABLE AT NEXT CONNECTION POINT ANOTHER CONNECTION POINT? NO MEGG CABLE TOWARD MOTOR YES DISCONNECT PUMP CABLE AT NEXT CONNECTION POINT YES LEAK TO GROUND? NO POWER ON LEAK TO GROUND BETWEEN THIS POINT AND LAST POINT NO GFCI TRIPS? REPLACE COMPONENT YES PROBLEM BETWEEN LAST POINT AND THIS POINT REPLACE COMPONENT Aqua Control, Inc. Service Manual Chapter 8 11 Aqua Control, Inc. TROUBLESHOOTING INVESTIGATE NUISANCE TRIPPING 13 NO 1-PHASE YES NO 200’ OF CABLE? YES DECREASE CABLE LENGTH POWER FLUCTUATIONS USE EP GFCI THUNDERSTORMS VFD The use of an equipment-protection GFCI will remove the UL certification. Additionally, a leak-to-ground may result in electrocution. 12 Aqua Control, Inc. Service Manual Chapter 8 Aqua Control, Inc. TROUBLESHOOTING ISOLATE 1-PHASE LEAK TO GROUND IN PANEL 14 POWER OFF PANEL CHECK FOR LOOSE WIRES CHECK FOR GOOD NEUTRAL DISCONNECT OUTPUT WIRES FROM GFCI POWER ON PANEL YES GFCI TRIP? POWER OFF PANEL REPLACE GFCI REATTACH WIRES TO BOTTOM OF GFCI TRACE OUTPUT WIRES TO NEXT COMPONENT DISCONNECT OUTPUT WIRES FROM COMPONENT POWER ON PANEL RECONNECT WIRES TO OUTPUT OF COMPONENT NO YES GFCI TRIP? Aqua Control, Inc. Service Manual Chapter 8 REPLACE COMPONENT 13 Aqua Control, Inc. TROUBLESHOOTING INSOLATE 3-PHASE LEAK TO GROUND IN PANEL 15 POWER OFF PANEL CHECK FOR LOOSE WIRES POWER OFF PANEL CHECK FOR GROUND NEUTRAL RECONNECT WIRES TO OUTPUT OF COMPONENT TRACE WIRES TO LAST COMPONENT BEFORE GFCI DISCONNECT OUTPUT WIRES FROM NEXT COMPONENT DISCONNECT OUTPUT WIRES FROM COMPONENT POWER ON PANEL POWER ON PANEL GFCI TRIP? YES GFCI TRIP? YES REPLACE COMPONENT YES REPLACE GFCI 14 Aqua Control, Inc. Service Manual Chapter 8 NO CHECKING NEUTRAL TO GROUND VOLTAGE Neutral to ground voltage must be very close to 0. Motor Control Box L1 L2 L3 G For use only with same rating Franklin motor Motor Prefix # 214508 HP Control Box Prefix # 2824085 1 ON ON PUMP GFI CB LIGHT GFI CB OFF 20A OFF test test 20A N L1 L2 N Torque: ON N 18 lb-in OFF DISCONNECT SWITCH 60A T1 T2 T3 R Y B Time set knob Lightning Arrestor ON A1 OFF A2 G 13 motor switch Timer 440 Volt Push pins towards center for "ON" cycle Light Contactor 14 G R Gnd R Y B G Y B Y B Pump Motor 230V, 7.1 Amps Gnd N LIGHTS PUMP Timer A2 H Lights - 120V, 2000 watts Aqua Control, Inc. Service Manual Chapter 8 15 CHECKING SOURCE VOLTAGE Source voltage for 1-phase panels is measured between terminals L1 and L3 of the rotary disconnect switch. Source voltage for 3-phase panels is measured between each pair of terminals (L1 - L2, L1- L3, L2 - L3). The readings should be the source voltage. Motor Control Box L1 L2 L3 G For use only with same rating Franklin motor Motor Prefix # 214508 HP Control Box Prefix # 2824085 1 ON ON PUMP GFI CB LIGHT GFI CB OFF 20A OFF test test 20A N L1 L2 N N Torque: ON 18 lb-in OFF DISCONNECT SWITCH 60A T1 T2 T3 R Y B Time set knob Lightning Arrestor ON A1 A2 G 13 motor switch Timer 440 Volt Push pins towards center for "ON" cycle Light Contactor 14 G R Gnd R Y B G Y B Y B Pump Motor 230V, 7.1 Amps 16 OFF Gnd N LIGHTS PUMP Timer A2 H Lights - 120V, 2000 watts Aqua Control, Inc. Service Manual Chapter 8 CHECKING INDIVIDUAL SOURCE VOLTAGES Individual source voltage is measured between each input terminal with a wire and Neutral. The readings at L1 and L3 MUST be 1/2 source voltage. Motor Control Box L1 L2 L3 G For use only with same rating Franklin motor Motor Prefix # 214508 HP Control Box Prefix # 2824085 1 ON ON PUMP GFI CB LIGHT GFI CB OFF 20A OFF test test 20A N L1 L2 N N Torque: ON 18 lb-in OFF DISCONNECT SWITCH 60A T1 T2 T3 R Y B Time set knob Lightning Arrestor ON A1 OFF A2 G 13 motor switch Timer 440 Volt Push pins towards center for "ON" cycle Light Contactor 14 G R Y B G Y B Gnd R Y B Pump Motor 230V, 7.1 Amps Gnd N LIGHTS PUMP Timer A2 H Lights - 120V, 2000 watts Aqua Control, Inc. Service Manual Chapter 8 17 CHECKING PANEL VOLTAGE Panel voltage for 1-phase panels is measured between terminals T1 and T3 of the rotary disconnect switch. Panel voltage for 3-phase panels is measured between each pair of terminals at the bottom of the rotary disconnnect switch (T1 - T2, T1 - T3, T2 - T3) . Motor Control Box L1 L2 L3 For use only with same rating Franklin motor HP Control Box Prefix # Motor Prefix # 214508 2824085 1 ON ON PUMP GFI CB LIGHT GFI CB OFF 20A OFF test test 20A N L1 L2 N N Torque: ON 18 lb-in OFF DISCONNECT SWITCH 60A T1 T2 T3 R Y B Time set knob Lightning Arrestor ON A1 13 motor switch Timer 440 Volt Push pins towards center for "ON" cycle Light Contactor 14 G R Y B G Y B Gnd R Y Pump Motor 230V, 7.1 Amps 18 OFF A2 G B Gnd N G LIGHTS PUMP Timer A2 H Lights - 120V, 2000 watts Aqua Control, Inc. Service Manual Chapter 8 CHECKING PANEL OUTPUT VOLTAGE 1-Phase output voltage is measured between Yellow and Black pump cable terminals. 3-Phase output voltage is measured between each pair of pump cable terminals (T1 - T2, T1 - T3, T2 - T3). Motor Control Box L3 L1 For use only with same rating Franklin motor HP Control Box Prefix # Motor Prefix # 214508 2824085 1 ON ON PUMP GFI CB LIGHT GFI CB OFF 20A OFF test test 20A N L1 L2 G Torque: ON N 18 lb-in OFF DISCONNECT SWITCH 60A N R Y B Time set knob Lightning Arrestor ON A1 OFF A2 G 13 motor switch Timer 440 Volt Push pins towards center for "ON" cycle Light Contactor 14 G R Y B G Y B Gnd R Y T1 B Gnd N LIGHTS A2 PUMP Timer H T2 T3 Pump Motor 230V, 7.1 Amps Lights - 120V, 2000 watts Aqua Control, Inc. Service Manual Chapter 8 19 CHECKING 1-POLE GFCI INPUT VOLTAGE Input voltage is measured between the top input and Neutral. Motor Control Box L3 L1 For use only with same rating Franklin motor Motor Prefix # 214508 HP Control Box Prefix # 2824085 1 ON ON PUMP GFI CB LIGHT GFI CB OFF 20A OFF test test 20A N L1 L2 Torque: ON N 18 lb-in OFF DISCONNECT SWITCH 60A N R Y B Time set knob Lightning Arrestor ON A1 13 motor switch Timer 440 Volt Push pins towards center for "ON" cycle Light Contactor 14 G R Y B G Y B Gnd R Y Pump Motor 230V, 7.1 Amps 20 OFF A2 G B Gnd N G LIGHTS PUMP Timer A2 H Lights - 120V, 2000 watts Aqua Control, Inc. Service Manual Chapter 8 CHECKING 1-POLE GFCI OUTPUT VOLTAGE Output voltage is measured between the bottom output terminal and Neutral. Motor Control Box L3 L1 For use only with same rating Franklin motor Motor Prefix # 214508 HP Control Box Prefix # 2824085 1 ON ON PUMP GFI CB LIGHT GFI CB OFF 20A OFF test test 20A N L1 L2 G Torque: ON N 18 lb-in OFF DISCONNECT SWITCH 60A N R Y B Time set knob Lightning Arrestor ON A1 OFF A2 G 13 motor switch Timer 440 Volt Push pins towards center for "ON" cycle Light Contactor 14 G R Y B G Y B Gnd R Y B Pump Motor 230V, 7.1 Amps Gnd N LIGHTS A2 PUMP Timer H Lights - 120V, 2000 watts Aqua Control, Inc. Service Manual Chapter 8 21 CHECKING 2-POLE GFCI INPUT VOLTAGE Input voltage is measured between the top two input terminals and should be source voltage. Motor Control Box L3 L1 For use only with same rating Franklin motor Motor Prefix # 214508 HP Control Box Prefix # 2824085 1 ON ON PUMP GFI CB LIGHT GFI CB OFF 20A OFF test test 20A N L1 L2 N Torque: ON 18 lb-in OFF DISCONNECT SWITCH 60A N R Y B Time set knob Lightning Arrestor ON A1 13 motor switch Timer 440 Volt Push pins towards center for "ON" cycle Light Contactor 14 Gnd R Y B G Y B Y B Pump Motor 230V, 7.1 Amps 22 OFF A2 G G R Gnd N G LIGHTS PUMP Timer A2 H Lights - 120V, 2000 watts Aqua Control, Inc. Service Manual Chapter 8 CHECKING 2-POLE GFCI OUTPUT VOLTAGE Output voltage is measured between the bottom two output terminals. Motor Control Box L3 L1 For use only with same rating Franklin motor Motor Prefix # 214508 HP Control Box Prefix # 2824085 1 ON ON PUMP GFI CB LIGHT GFI CB OFF 20A OFF test test 20A N L1 L2 G Torque: ON N 18 lb-in OFF DISCONNECT SWITCH 60A N R Y B Time set knob Lightning Arrestor ON A1 OFF A2 G 13 motor switch Timer 440 Volt Push pins towards center for "ON" cycle Light Contactor 14 G R Y B G Y B Gnd R Y B Pump Motor 230V, 7.1 Amps Gnd N LIGHTS A2 PUMP Timer H Lights - 120V, 2000 watts Aqua Control, Inc. Service Manual Chapter 8 23 CHECKING LIGHT CONTACTOR COIL VOLTAGE Coil voltage is measured between terminals A1 and A2. Motor Control Box L3 L1 For use only with same rating Franklin motor HP Control Box Prefix # Motor Prefix # 214508 2824085 1 ON ON PUMP GFI CB LIGHT GFI CB OFF 20A OFF test test 20A N L1 L2 N Torque: ON 18 lb-in OFF DISCONNECT SWITCH 60A N R Y B Time set knob Lightning Arrestor ON A1 13 motor switch Timer 440 Volt Push pins towards center for "ON" cycle Light Contactor 14 G R Y B G Y B Gnd R Y Pump Motor 230V, 7.1 Amps 24 OFF A2 G B Gnd N G LIGHTS PUMP Timer A2 H Lights - 120V, 2000 watts Aqua Control, Inc. Service Manual Chapter 8 CHECKING LIGHT CONTACTOR OUTPUT VOLTAGE Output voltage is measured between each output terminal and Neutral. Motor Control Box L3 L1 For use only with same rating Franklin motor Motor Prefix # 214508 HP Control Box Prefix # 2824085 1 ON ON PUMP GFI CB LIGHT GFI CB OFF 20A OFF test test 20A N L1 L2 N G Torque: ON 18 lb-in OFF DISCONNECT SWITCH 60A N R Y B Time set knob Lightning Arrestor ON A1 OFF A2 G 13 motor switch Timer 440 Volt Push pins towards center for "ON" cycle Light Contactor 14 G R Gnd R Y B G Y B Y B Pump Motor 230V, 7.1 Amps Gnd N LIGHTS PUMP Timer A2 H Lights - 120V, 2000 watts Aqua Control, Inc. Service Manual Chapter 8 25 CHECKING MCB INPUT VOLTAGE Input voltage is measured between terminals L1 and L2 Motor Control Box L3 L1 For use only with same rating Franklin motor Motor Prefix # 214508 HP Control Box Prefix # 2824085 1 ON ON PUMP GFI CB LIGHT GFI CB OFF 20A OFF test test 20A N L1 L2 Torque: ON N 18 lb-in OFF DISCONNECT SWITCH 60A N R Y B Time set knob Lightning Arrestor ON A1 13 motor switch Timer 440 Volt Push pins towards center for "ON" cycle Light Contactor 14 G R Y B G Y B Y B Pump Motor 230V, 7.1 Amps 26 OFF A2 G Gnd R Gnd N G LIGHTS PUMP Timer A2 H Lights - 120V, 2000 watts Aqua Control, Inc. Service Manual Chapter 8 CHECKING MCB OUTPUT VOLTAGE Output voltage for MCB is measured between Y and B Motor Control Box L3 L1 For use only with same rating Franklin motor Motor Prefix # 214508 HP Control Box Prefix # 2824085 1 ON ON PUMP GFI CB LIGHT GFI CB OFF 20A OFF test test 20A N L1 L2 G Torque: ON N 18 lb-in OFF DISCONNECT SWITCH 60A N R Y B Time set knob Lightning Arrestor ON A1 OFF A2 G 13 motor switch Timer 440 Volt Push pins towards center for "ON" cycle Light Contactor 14 G R Y B G Y B Gnd R Y B Pump Motor 230V, 7.1 Amps Gnd N LIGHTS A2 PUMP Timer H Lights - 120V, 2000 watts Aqua Control, Inc. Service Manual Chapter 8 27