Trouble Shooting for Zoeller Engineered Products

PUMP SYSTEM TROUBLE SHOOTING
When trouble shooting a pump system, you will find the following information, supplies, and equipment to be helpful in the field.
# 1)	AN ACCURATE PANEL WIRING DIAGRAM
# 2)	A SET OF JUMPER WIRES
# 3)	VOLTAGE , OHM AND AMP METER
# 4)	START-UP REPORT
# 5)	SPARE PANEL CONTROL FUSES
# 6)	EXTRA CAPACITORS/RELAYS FOR SINGLE PHASE SYSTEM
# 7)	MOTOR WINDING RESISTANCE VALUES
# 8)	PUMP PERFORMANCE & ELEC. DATA
# 9)	TROUBLE SHOOTING CHECK LIST
Whenever working around electrical equipment, think safety. The wrong move can have dangerous consequences. Use the panel disconnects to remove system power . Use your voltage meter to verify that the system’s power is deactivated.
Objective...Determine where the problem exists
# 1)	WITH THE PUMPS
# 2)	IN THE PANEL
# 3)	WITH THE FLOAT SWITCHES
The following steps will assist in your efforts to isolate the problem area:
STEP # 1)	Make a visual overview of the system —FAMILIARIZE YOURSELF WITH THE SYSTEM COMPONENTS —VERIFY THE PUMP VOLTAGE TO THE SYSTEM POWER SOURCE —PUMP CAPABILITY VS. SYSTEM CHARACTERISTICS —VERIFY THAT ALL ELECTRICAL CONNECTIONS TO PANEL ARE CORRECT —INSPECT SYSTEM FOR ABUSE OR DAMAGE —INSPECT EVERY INCH OF CORDAGE FOR DAMAGE —REVIEW START-UP REPORT’S INSTALLATION CHECK LIST
STEP # 2)	Check the supply voltage at the panel.
STEP #3)	Check the control voltage (usually 120 volt)
STEP #4)	Check the alarm circuit with test switch, jumper, or float
STEP #5)	Operate each pump by placing selector switch in hand mode —CHECK THE PUMP RUN LIGHT —TAKE AN AMP AND VOLTAGE READING WITH PUMP RUNNING —CHECK FOR PROPER ROTATION (3 PHASE SYSTEM)
STEP #6)	Simulate float switch operation with jumper wires… repeat through numerous lead/lag cycles —TAKE A VOLTAGE READING WITH BOTH PUMPS OPERATING
STEP #7)	Check motor windings...must disconnect from panel —CHECK RESISTANCE THROUGH EACH WINDING —CHECK EACH MOTOR LEAD TO GROUND...THERE SHOULD BE NO CONTINUITY —CHECK INSULATION WITH MEGOHMMETER, SHOULD BE GREATER THAN 10
During the above steps, stop and investigate if you detect a malfunction...if all components operate correctly during the above steps you will want to check out your float switches and all junction box connections (if you are using one).