Troubleshooting Guide
Contents
1. OFF F DISCONNECT SWITCH 60A prise PUMP Timer TI T2 T3 Pump Motor Lights 120V 2000 watts 230V 7 1 Amps Aqua Control Inc Service Manual Chapter 8 19 20 CHECKING 1 POLE GFCI INPUT VOLTAGE Input voltage is measured between the top input and Neutral Motor Control Box For use only with same rating Franklin motor HP Control Box Prefix Motor Prefix 1 2824085 214508 Lightning Gnd Y B Gnd N H 1 3 EE O O O Torque ON 18 Ib in DISCONNECT SWITCH 60A Time set knob OFF PUMP Timer O Pump Motor 230V 7 1 Amps Lights 120V 2000 watts Aqua Control Inc Service Manual Chapter 8 CHECKING 1 GFCI OUTPUT VOLTAGE Output voltage is measured between the bottom output terminal and Neutral Motor Control Box For use only with same rating Franklin motor O O HP Control Box Prefix Motor Pre2. DOES MULTIMETER Aqua Control Inc TROUBLESHOOTING YES TEST CAPACITANCE SET OHMMETER TO HIGHEST SETTING TEST CAPACITANCE GOOD READING NO REPLACE CAPACITOR Aqua Control Inc Service Manual Chapter 8 NOU Con tre D WATER FEATURES pov a WATER FEATURES ISOLATE 1 PHASE Aqua Control Inc TROUBLESHOOTING INVESTIGATE LEAKTO GROUND YES NO 1 PHASE pov Contry M WATER FEATURES Aqua Control Inc Service Manual Chapter 8 ISOLATE 3 PHASE o pov Con Rel WATER FEATURES Aqua Control Inc TROUBLESHOOTING The use of a megger is strongly recommended The use of a multimeter will not detect most leaks to ground NO ISOLATE LEAK TO GROUND AFTER PANEL YES USE MEGGER POWER OFF NO RECONNECT CABLE ANOTHER CONNECTION POINT YES DISCONNECT PUMP CABLE AT NEXT CONNECTION POINT POWER ON YES NO PROBLEM BETWEEN LAST POINT AND THIS POINT REPLACE COMPONENT POWER OFF 3 POINT YES CONNECTION POINT DISCONNECT PUMP CABLE AT NEXT MEGG CABLE TOWARD MOTOR YES Y LEAK TO
3. gt WATER FEATURES pov WATER FEATURES Aqua Control Inc INSOLATE 3 PHASE LEAKTO GROUND IN PANEL POWER OFF PANEL CHECK FOR LOOSE WIRES CHECK FOR GROUND NEUTRAL TRACE WIRES TO LAST COMPONENT BEFORE GFCI DISCONNECT OUTPUT WIRES FROM COMPONENT POWER ON PANEL GFCI TRIP YES TROUBLESHOOTING YES REPLACE GFCI Aqua Control Inc Service Manual Chapter 8 POWER OFF PANEL pov WATER FEATURES RECONNECT WIRES TO OUTPUT OF COMPONENT DISCONNECT OUTPUT WIRES FROM NEXT COMPONENT POWER ON PANEL V YES REPLACE COMPONENT NO CHECKING NEUTRAL TO GROUND VOLTAGE Neutral to ground voltage must be very close to 0 Motor Control Box For use only with same rating Franklin motor O HP Control Box Prefix Motor Prefix 1 2824085 214508 cH test test 20A Torque 18 Ib in gm aei O FF O DIS LEO PUMP Timer Gnd Y B Gnd N Pump Motor Lights 120V 2000 watts 230V 7 1 Amps
4. Aqua Control Inc Service Manual Chapter 8 CHECKING SOURCE Source voltage for 1 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 For use only with same rating Franklin motor HP Control Box Prefix Motor Prefix 1 2824085 214508 PUMP Timer Pump Motor Lights 120V 2000 watts 230V 7 1 Amps 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 OKO For use only with same rating Franklin motor HP Control Box Prefix Motor Prefix 1 2824085 214508 Lightning Afrestor towards center ight Contactor PUMP Timer Pump Mot
5. 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 Aqua Control Inc Service Manual Chapter 8 tro WATER FEATURES 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 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 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 INVESTIGATE CAPACITOR VISUALLY INSPECT CAPACITOR V REMOVE ALL WIRES FROM ONE SET OF CONTACTS
6. ES REPLACE LAST Aqua Control Inc Service Manual Chapter 8 pov Con tro gt WATER FEATURES The resistance between the Red wire terminal 42 and the Yellow con nection terminal 5 on the relay Reading should be between 4 500 Ohms and 7 500 Ohms Aqua Control Inc TROUBLESHOOTING INVESTIGATE RELAY COIL REMOVE YELLOW WIRE FROM TERMINAL 5 OF RELAY SET OHMMETER TO READ TO 20 000 OHMS REPLACE RELAY INVESTIGATE CONTACTS REMOVE ORANGE WIRE FROM TERMINAL 1 OF RELAY SET OHMMETER TO LOWEST SETTING REPLACE RELAY Aqua Control Inc Service Manual Chapter 8 pov Con tro WATER FEATURES Read resistance between the Orange wire ter minal 21 and the Red connection terminal 2 Reading should be very close to 0 Ohms papa Cong Aqua Control Inc TROUBLESHOOTING a WATER FEATURES INVESTIGATE OVERLOAD SET OHMMETER TO LOWEST SETTING oy WATER FEATURES OPEN LINE GOOD READING NO REPLACE BOTH OVERLOADS RESET OVERLOAD 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
7. GROUND pov Con tro WATER FEATURES NO NO lt BETWEEN THIS POINT LEAK TO GROUND AND LAST POINT REPLACE COMPONENT Aqua Control Inc Service Manual Chapter 8 Conroy Aqua Control Inc sepa Contro TROUBLESHOOTING WATER FEATURES WATER FEATURES INVESTIGATE NUISANCE TRIPPING NO YES NO 200 OF CABLE YES DECREASE CABLE POWER LENGTH 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 Aqua Control Inc Service Manual Chapter 8 pov Contry lt gt WATER FEATURES Aqua Control Inc TROUBLESHOOTING ISOLATE 1 PHASE LEAK TO GROUND IN PANEL POWER OFF PANEL CHECK FOR LOOSE WIRES V CHECK FOR GOOD NEUTRAL V DISCONNECT OUTPUT WIRES FROM GFCI V POWER ON PANEL V YES POWER OFF PANEL REATTACH WIRES TO BOTTOM OF GFCI RECONNECT WIRES TO OUTPUT OF COMPONENT NO TRACE OUTPUT WIRES TO NEXT COMPONENT DISCONNECT OUT PUT WIRES FROM COMPONENT POWER ON PANEL Aqua Control Inc Service Manual Chapter 8 YES REPLACE GFCI REPLACE COMPONENT papa Contry
8. P Control Box Prefix Motor Prefix Torque ON 1 2824085 214508 18 Ib in OFF DISCONNECT SWITCH 60A EJ SJ PUMP Timer Gnd Y Gnd N H D Pump Motor Lights 120V 2000 watts 230V 7 1 Amps Aqua Control Inc Service Manual Chapter 8
9. PS YES ADD BOOST TRANSFORMER INCREASE CABLE GAUGE NO 1 PHASE INVESTIGATE MOTOR CONTROL BOX AERATOR V CHECK FOR CHECK FOR BLOCKED INLET BLOCKED OUTLET CHECK FOR LOCKED ROTOR OR BEARINGS amps locked rotor 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 Cong Aqua Control Inc saga Contro TROUBLESHOOTING WATER FEATURES WATER FEATURES INVESTIGATE MOTOR CONTROL BOX RED AMPS HE HIGH INVESTIGATE 1 1 3 43 OVERLOADS 2 2 6 51 3 6 0 84 5 10 8 121 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 YES for very short periods of time usually 1 second or gt less Many multimeters will not register the high LOW amps YES HIGH THEN GOOD STAYS HIGH INVESTIGATE YES RELAY COIL HIGH THEN 0 V INVESTIGATE RUN CAPACITOR INVESTIGATE RELAY CONTACTS INVESTIGATE RELAY CONTACTS INVESTIGATE START CAPACITOR Aqua Control Inc Service Manual Chapter 8 p
10. fix Torque ON 1 2824085 214508 ON 18 Ib in DISCONNECT SWITCH 60A PUMP GFI C LIGHT GFI CB OFF 20A OFF towards center for ON cyclg PUMP Timer Gnd R Y B Gnd N H Pump Motor 230V 7 1 Amps Lights 120V 2000 watts Aqua Control Inc Service Manual Chapter 8 CHECKING 2 POLE GFCI INPUT VOLTAGE Input voltage is measured between the top two input terminals and should be source voltage For use only with same rating Franklin motor O O HP Control Box Prefix Motor Prefix 1 2824085 214508 Torque 18 DISCONNECT SWITCH 60A ON OD EE PUMP Timer Pump Motor 230V 7 1 Amps Lights 120V 2000 watts 22 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 For use only wit
11. h same rating Franklin motor OG O O HP Control Box Prefix Motor Prefix Torque ION 1 2824085 214508 18 Ib in DISCONNECT SWITCH 60A towards center EE for ON cyclg Elo PUMP Timer B Gnd N Pump Motor 230V 7 1 Amps 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 For use only with same rating Franklin motor HP Control Box Prefix Motor Prefix 1 2824085 214508 Motor Control Box Torque 18 Ib in OFF DISCONNECT SWITCH 60A Gnd R Y B Gnd N H towards center PUMP Timer Pump Motor 230V 7 1 Amps Lights 120V 2000 watts 24 Aqua Control Inc Service Manual Chapter 8 CHECKING LIGHT CONTACTOR OUTPUT VOLTAGE Output voltage is measured between each output terminal and Neutral L1 L3 T For use only with same rating Frank
12. lin motor HP Control Box Prefix Motor Prefix Torque 1 2824085 214508 N 48 Ib in OFF DISCONNECT SWITCH 60A PUMP Timer Gnd R Y B Gnd N H Pump Motor 230V 7 1 Amps Lights 120V 2000 watts Aqua Control Inc Service Manual Chapter 8 CHECKING MCB INPUT VOLTAGE Input voltage is measured between terminals L1 and L2 Motor Control Box For use only with same rating Franklin motor O O HP Control Box Prefix Motor Prefix Torque ION 1 2824085 214508 18 Ib in ED DISCONNECT SWITCH 60A Time knob PUMP Timer Gnd R Y B Gnd N H Pump Motor 230V 7 1 Amps Lights 120V 2000 watts 26 Aqua Control Inc Service Manual Chapter 8 CHECKING MCB OUTPUT VOLTAGE Output voltage for MCB is measured between Y and B Motor Control Box For use only with same rating Franklin motor O H
13. or 230V 7 1 Amps Lights 120V 2000 watts Aqua Control Inc Service Manual Chapter 8 CHECKING PANEL VOLTAGE Panel voltage for 1 panels is measured between terminals 1 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 TI T2 TI T3 T2 T3 Motor Control Box For use only with same rating Franklin motor HP Control Box Prefix Motor Prefix 1 2824085 214508 Lightning rrestor Q VIO Emo Gnd R Y B Gnd N D Pump Motor Lights 120V 2000 watts 230V 7 1 Amps Aqua Control Inc Service Manual Chapter 8 QO O O Torque ON 18 OFF DISCONNECT SWITCH 60A PUMP Timer CHECKING PANEL OUTPUT 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 T2 TI T3 T2 T3 Motor Control Box For use only with same rating Franklin motor HP Control Box Prefix Motor Prefix 1 2824085 214508 Torque 18 Ib in
14. ov Con tro gt WATER FEATURES Aqua Control Inc TROUBLESHOOTING INVESTIGATE GFCI TRIP WITHIN A FEW MINUTES POWER OFF PANEL CHECK LOOSE WIRES CHECK NEUTRAL TO GROUND VOLTAGE CHECK EACH HOT TO NEUTRAL REMOVE PUMP CABLE POWER ON PANEL GFCI TRIPPED YES POWER OFF PANEL NO POWER OFF PANEL CHECK LOOSE WIRES CHECK NEUTRAL TO GROUND VOLTAGE CHECK EACH HOT TO NEUTRAL REMOVE PUMP CABLE MEGG CABLE POWER OFF PANEL LESS THAN 20 M OHMS YES NO pov Con tro WATER FEATURES ISOLATE LEAKTO GROUND IN PANEL MEGG CABLETO VERIFY LEAKTO GROUND ISOLATE LEAKTO GROUND AFTER PANEL ISOLATE LEAKTO GROUND AFTER PANEL Aqua Control Inc Service Manual Chapter 8 INVESTIGATE NUISANCE TRIPPING pov A 2 WATER FEATURES Aqua Control Inc sepa Contry TROUBLESHOOTING INSOLATE REPLACE FAULTY CABLE LOCATE NEXT COMPONENT NO ANOTHER COMPONENT GOOD LINE TO LINE WATER FEATURES 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 Y
15. pov Con tre gt WATER FEATURES Aqua Control Inc TROUBLESHOOTING UNIT NOT RUNNING YES OUTPUTVOLTS SOURCE VOLTS NO INVESTIGATE AMPS NO INPUT VOLTS SOURCE VOLTS YES CORRECT INPUT VOLTAGE NO TIMER SET CORRECTLY ves SET TIMER NO DID ANYTHING TRIP OVERLOAD INVESTIGATE GFCI S INVESTIGATE HIGH AMPS Aqua Control Inc Service Manual Chapter 8 pov Con tro lt gt WATER FEATURES popa Aqua Control Inc TROUBLESHOOTING Re WATER FEATURES INVESTIGATE AMPS 0 AMPS INVESTIGATE HIGH FAULTY CABLE 2 WIRE MOTOR YES OVERLOAD IN MOTOR TRIPPED Aqua Control Inc Service Manual Chapter 8 HIGH AMPS OUTPUT AMPS LOW AMPS V DISCONNECT PUMP INVESTIGATE LOW CABLE AMPS AMPS GOOD SHORT OPEN LINE TO LIN ISOLATE REPLACE povi Con tro D WATER FEATURES YES INVESTIGATE MOTOR CONTROL BOX Aqua Control Inc INVESTIGATE LOW AMPS 1 PHASE V YES AERATOR CHECK FOR BLOCKED OUTLET CHECK FOR BLOCKED INLET CHECK FOR LOOSE IMPELLER CHECK FOR LOOSE PROPELLER CHECK FOR BROKEN MSE CHECK FOR BROKEN MSE TROUBLESHOOTING INVESTIGATE AM
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