Overload - Aqua Control COMBO Series Instruction Manual

1. Check motor amps
a. Determine "true" amp (yellow) requirement of motor. This is listed on the schematic as "Pump Motor amps," on a decal on the panel
door as "Motor FLA" and in the ACI brochures.
b. Power on control panel.
c. Check all output leads to motor for proper amps.
d. If amps are good, go to "Nuisance Tripping."
e. If amps are high, continue.
HP
3
5
2. Check line-to-line resistance. Verify the power is off before testing.
a. Power off control panel.
b. Remove the pump cord connections from the terminal blocks at the bottom of control panel.
c. Set the ohmmeter to lowest resistance range.
i. Check each pair of pump cord wires, excluding Ground. Readings should be 2 – 20 ohms.
1. Single Phase 3-wire: Black-Yellow < Red-Yellow < Black-Red.
2. Single Phase 2-wire: T1-T2.
3. Three Phase: T1-T2, T1-T3, T2-T3; all readings should be identical.
ii. Readings of zero indicate a "Short"; readings greater than 20 ohms indicate an "Open" or partially broken line. Either of
these readings indicate a problem.
d. If line-to-line readings indicated a problem, it is necessary to isolate the problem.
i. Any connection points, e.g. junction boxes, splices, connectors etc., provide a potential problem area.
Additionally, animal bites, cuts or scrapes could create a problem.
ii. Perform step# 2c at each connection point from the end of the cord at the control panel to the motor lead, until a good
reading is found. The problem will be in the previous connection tested. If the final test is at the motor lead, the
problem is with either the motor or the motor lead.
e. If line-to-line readings are good, continue.
3. Investigate Mechanical Problems
a. 70% of overload problems are mechanical e.g. worn or bad bearings, locked rotors, bent motor shafts, or broken shrouds. An
improperly pitched prop, missing shims or nozzle problems may cause overloads to trip.
b. When thrust bearings are worn, the motor shaft may be pulled 1/8" or more. When radial bearings are worn, the motor shaft
may be moved side to side slightly.
4. Nuisance Tripping
a. Nuisance tripping can be caused by temporary voltage irregularities e.g. brownouts, spikes.
b. Excessive heat, above 122ºF may cause overload tripping. A control panel in direct sunlight will heat up and temporarily de grade
thermal overloads protection. One possible solution is to remove the cover of the motor control box.
Another solution is to cover the control panel with an awning or face the panel North or West.
GENERAL TROUBLESHOOTING
60Hz MOTOR CONTROL BOX (MCB) continued
OVERLOAD TROUBLESHOOTING
1-PHASE
VOLTS AMPS
230 17
230 27.5
Aqua Control, Inc. 60Hz / 50Hz Combo Series Instruction Manual
3-PHASE
HP VOLTS
3 208
3 230
3 460
5 208
5 230
5 460
AMPS
12.5
12.2
6.5
20.5
19.8
19.8
17