Troubleshooting your Control Panel

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Troubleshooting - Here are some troubleshooting suggestions .

Description of Operation:

Simplex Control Panels are designed to operate in a three float system as standard. When all floats are in the OPEN or OFF position, the panel is inactive. As the liquid level changes and closes the stop float, the panel remains inactive until the start float also closes. At this point the pump will start, providing the HOA switch is in the AUTOMATIC mode and the power is on. The pump will remain ON until both the stop and start floats open return to the OFF position, if applicable and liquid level travels beyond both the stop and start floats and reaches the alarm float, the alarm will be activated. The alarm horn can silenced by moving the test/normal/silence switch to the silence position.  Duplex panels will have four(4) floats with two (2) pumps to operate in lieu of one(1).

 

Operating Pumps:

  • Make sure that all wires are inside the control box and not in a position to be pinched or shorted when the door is closed.
  • Turn on power to the control box
  • Turn Hand-Off-Auto switches to the HAND position. The pumps should start and the pump run lights should come on. ( On Duplex panels, this should be done for both pumps)
  • The alarm light should activate when the alarm test switch is used.
  • To put into service, put the hand-off-auto switch in the AUTO position.(On Duplex panels, this should be done for both pumps.) See basin instructions.
  • If unit does not operate as described, see troubleshooting chart.

Note: Addition of electrical components and circuitry to this unit is expressly forbidden unless written factory authorization is obtained. Failure to do so will result in warranty cancellation.

 

Rotation of Three Phase Pumps

  • IMPORTANT: Rotation  of three phase pumps must be established by one of the two methods described below.
  • CAUTION: Keep hands and feet clear of impeller when checking rotation.  Be sure to disconnect power to the control box while handling  pumps.  Make sure pump is wired and readied for rotation test before the control box is energized.
  • Before positioning pump in basin, run wires to control box. Lay the pump unit on its side and secure so that the starting torque of the motor will not cause the pump to roll. Energize the pump by turning the circuit breaker on and the hand -off-auto to HAND. The rotation should be counterclockwise as observed facing the bottom of the pump.  If you do not get the proper rotation, disconnect the power to the control box and change the position of any two of the black motor leads in the terminal blocks.
  • Install the pump in the basin and run in some water so the pump can operate.  Energize the pump by turning the circuit breaker on and the hand-off-auto switch to HAND. Let the pump pull the water down in the basin, and when the water reaches the bottom of the pump the rotation of the water can be observed. The water should rotated in a clockwise direction if  the pump rotation is correct.  If you do not get the proper rotation, disconnect the power to the control box change the position of any two of the black motor leads in the terminal blocks.

Checking Pump Current Draw:

  • Use an amprobe to check the amperage of the pump.
  • Turn the hand-off-auto switch to the HAND position and compare the amperage reading to the values shown on the chart.
  • If you get a reading of 0, make sure there is voltage to the motor leads. Push the overload reset button on the overload relay in the control panel. If you still do not get a reading, either the motor has failed or there might be a wiring problem between the control panel and pump( improper connection in the junction box).

 

Cord MeasuredItem MeasuredCorrect ReadingOhmmeterIf you get any other reading check for the following
Power CordMotor Winding (Any Leg)(See Chart)R x 1Damaged winding or cord

Power Cord

Ground to Motor Windings

(Green to Red, Black or White)

Infinity to 200R x 100kDamaged winding or cord moisture in motor
Control Cord

Overload contacts

(Black to White)

0 R x 1Overload tripped, failed, or damaged
Control Cord

Ground to Seal Probe

(Green to Red or Orange)

 Infinity to 200R x100KWater in seal chamber or damaged cord
Control Cord

Ground to Overload Contacts

(Green to Black or White)

Infinity to 200R x 100KOverload has failed or is wet
Float Cord

Ground to Float Contacts

(Green to Black or White)

 Infinity to 200 R x 100KWater in float or damaged cord

Float Cord

Float Contacts

(Black to White)

0-Float On

Infinity-Float Off

R x 1Switch has failed or damaged cord
     

 

NOTE: Reading may vary slightly depending on length of wire running to the motor and the accuracy of the measuring instrument.

 

 

Testing Components in Control Box

Warning: To prevent electrical shock, disconnect power entering the control box and turn the circuit breaker in the control box to the OFF position

I. Contactor

  • Physically examine the contactor for badly burnt or sticky contacts. The contactor arm should move in and  out freely.
  • Remove the wires on the coil to the contactor and measure the resistance. Zero the ohmmeter, and on the R x 1 scale you should read approximately 138 ohms (1-3 H.P. pumps), approximately 75 ohms (5-7 1/2 H.P. pumps), approximately 75 ohms (10-15 H.P. pumps-460 VSAC), approximately 23 ohms (10-15 H.P. pumps-208/230 VASC).
  • Often a burnt coil can be spotted by merely looking to see if it is badly discolored or has a dark burnt spot on it.

II. Overload Block

  • Remove the wires from the terminals on the side of the overload block.
  • With an ohmmeter on the R x 1 scale touch the two terminals, you should get a reading of 0. If you do not get  this reading, push the large black reset button on the front of the overload block.

III. Overload Heater

  • Remove the heater from the overload block and examine it for physical damage. A slight discoloration is normal, but if it is melted or warped is should be replaced.

IV. Fuses

  • Pull the fuse out of the fuse block and check for continuity with an ohmmeter.
  • With the ohmmeter on the R x 1 scale, you should get a reading of 0. If you do not , replace it with the same type and rating that is shown on the decal located next to the fuse block.

V. Override Relay (Duplex Panels Only)

  • Physically examine the relay for burnt or stuck contacts and for a burnt or discolored coil.
  • Remove the relay from the socket and with an ohmmeter or R x 1000 scale, you should read approximately 7.68 ohms on pins 13 and 14. Often a burnt coil can be spotted by merely looking to see if it is badly discolored or has a dark burnt spot on it.

VI. Alarm Light

  • The light should activate when the alarm test switch is used, if not replace the light bulb.
  • If light still does not work, replace flasher unit.

VII. Alternator Relay (Duplex Panels Only)

  • When the power is on and the relay is functioning properly, one of the two lights on top of the relay should be on.
  • With circuit breaker turned off, remove relay from socket. With an ohmmeter on the R x 1000 scale, touch the alternator coil terminals. The black lead should be on pin 3, and the red lead should be on pin 5. You should have a reading of  approximately 920-1020 ohms.
  • If alternator shows physical damage or does not test properly, replace it.

VIII. Transformer 208 Volt

  • Remove the wires from the primary side (H3-H4) and also from the secondary side (X2-XF-X1).
  • With an ohmmeter on the R x 1 scale touch terminals H3 and Hr (Primary), you should get a reading of approximately 12-16 ohms for 100 VA and 3.5-6.0 ohms for 200 VA transformers.
  • With an ohmmeter on the R x 1 scale touch terminals X1 and X1 (secondary), you should get a reading  of approximately 2.5-4.0 ohms for  100 VA transformers, .9-1.6 ohms for 150 VA transformers, and less than 1 ohm for 200 VA transformers.
  • With an ohmmeter on the R x 1 touch terminals XF and X1, you should get a reading of 0.  If you do not , replace the fuse.

X. Transformer 460 Volt

  • Remove the wires from the primary side (H1-H4) and also from the secondary side (X2-XF-X1).
  • With an ohmmeter on the R x 1 scale touch terminals H1 and H4 (Primary), you should get a reading of approximately 39-53 ohms for 100 VA transformers, 16-23 ohms for  150 VA transformers, and 14-20 ohms for 200 VA transformers.
  • With an ohmmeter on the R x 1 scale touch terminals XF and X1, you should get a reading of 0. if you do not, replace the fuse.

NOTE: Ohm readings will vary with ambient temperatures.

Scenarios of Problems Found in Field

I. Power to the Panel-Pump Will Not Run

  • Heat sensor not wired up (If pump does not have a heat sensor-jump out heat sensor)
  • H.O.A. switch not in hand or auto position
  • Control fuse-blown or broken
  • No neutral wire run to panel or not wired into panel
  • Double check to verify correct voltage
  • Phase/voltage monitor not adjusted/set properly
  • Relays not making connection inside socket

II. Pump Will Run in Hand, But Not in Auto

  • Float is bad-check continuity of each float. (Disconnect from terminals inside control panel before testing.)
  • Floats not wired in properly (i.e. out of sequence)
  • If a junction box is used, insure wires are properly marked and carried thru to control panel
  • While floats are disconnected-jump out each float, in proper sequence, to insure control panel is working properly.
  • If jumping the wires does not get the motor running-consult factory.

III.Single Phase Pump Problem

  • Check voltage (208 or 230volt?)
  • Pump motor is not wired correctly to control panel (check junction box connections)
  • Correct wiring-wrong pump
  • Correct pump- wrong start components
  • Pump jammed (locked rotor)
  • Are overloads set properly
  • Check junction box wiring

Troubleshooting Chart (Duplex Panels)

Problem

Position of Hand-Auto Switch

Run LightCheck

Pump 1 And 2 Will Not Run

   Hand   ON   G-A-L-K
Pump 1 And 2 Will Not Run   Hand   Off   C-E-B-G
Pump 1 And 2 Will Not Run   Auto   On   A-G-L-K
Pump 1 And 2 Will Not Run   Auto   Off   F-I-C-B-E-G
Pump 1 And 2 Will Not Run   Hand   On   A-G-K
Pump 1 And 2 Will Not Run   Hand   Off   C-G-L
Pump 1 And 2 Will Not Run   Auto   On   A-G-K-L
Pump 1 And 2 Will Not Run   Auto   Off   M-F-G
Alarm Activities   Auto   Both Lights On   H-I-J
Alarm Activities   Auto   Only One Light On   G-D
Alarm Activities   Auto   No Run Light On   E-L
Circuit Breaker Tripped   Auto-Off-Hand   Off   G-N
Fuse in Control Circuit Blown   Auto-Off-Hand   Off   H-I-J-K
Control Box Buzzes   Auto-Off-Hand   On or Off   L

 

 Below is the Chart to refer to Troubleshooting it correlates  with the above letters in the Check column.

CAUSEREMEDY
A-Motor overload tripped

Reset by pushing overload reset button. If overload does not trip again problem may be fixed.If overload trips again, check power supply voltage. Check motor winding resistance, make sure pump shaft is not locked.

B-Tripped Circuit breaker or fuse at power supply panel-wrong supply voltageReset breakers or replace fuses. If they continue to blow, check amp capacity of wire and breakers. Make sure it is wired properly and that you have the correct power supply system. (See instruction "Power Supply")
C-Tripped circuit breaker in control panelReset by pushing handle down to OFF position and resetting to ON position. Make sure that wires are not shorted and that the box is wired properly.
D-Override rely not working properlyTry operating both pumps in HAND position. If the run lights come on and pumps operate properly. Replace override relay.
E-Control circuit fuse blown.Check fuses per instructions. Replace fuse with same type and rating.
F-Level in basin may not be high enough to turn switch on.Check basin. Run pump manually to see if pump operates properly.
G- May not be wired properlyCheck wiring per wiring diagram. make sure pump is connected to terminal block properly.
H- Too much water coming into basinReduce water flow. Pump may need servicing.
I -Float switch may have failedOperate manually to see if basin pumps down and alarm goes off. Repair float if necessary.
J- Pump or discharge line may be pluggedPull pump and check discharge line and pump Inlet. (CAUTION: Never put hands on grinder impeller unless power is turned off).
K- May be failed component operating coilCheck components per instructions.
L- Wrong operating voltage or wrong voltage components.Check voltage and make sure relays and contactors are of the proper voltage.  
M-May not be lead pump in alternating phase-alternator may not be working properly.Let float switches cycle basin to see if alternator is alternating pumps. If not, check alternator relay per instructions.
 N- May be short circuit in wiring or pump power supply-Short in motor.Check wiring. (Short will not be located in control circuit unless control circuit fuse is blown). Check motor. (See chart for checking pump cable).

 


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