A.O. Smith Voltex Hybrid Electric PHPT-80, homeappliance

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I n s t a l l a t i o n — Maintenance — S e rv i c e — Tro u b l e s h o o t i n g CENTURY® POOL & SPA MOTOR MANUAL INTRODUCTION Welcome to A.O. Smith's line of Century® Motors. This pocket manual is designed for one purpose — to make it simple for you to install, maintain and troubleshoot Century pool and spa motors. Contrary to what you may be thinking just n o w, your last name doesn't have to be Edison in order to p roperly service the motors shown in the following pages. All you need are a few basic tools and some helpful hints; the kind that appear throughout this booklet. We've included all the information we think you'll need to repair the most common pump motor pro b l e m s e n c o u n t e red out in the field. This easy to read manual con tains great illustrations and diagrams for quick re f e rence. Assisting your customers is your job. Helping you do that with minimum delay is our job; that's why we've pre p a red this informative manual. 1 Replacements for every brand. Every now and then you probably come across a motor that's beyond re p a i r. When you do, remember that A.O. Smith manufacture s replacement pool and spa motors for practically every brand you'll ever encounter in the field. So save yourself some time and eff o rt and just ask for Century first — at any A.O. Smith distributor or dealer. Century motors are as rugged as any you'll find, but keep in mind that all motors need service and maintenance at one time or another. Safety first. Remember, before you begin to work on any electrical appliance be sure to TURN OFF THE POWER. The only time you'll need the power on is when you check motor voltage and amperage. If you over look this important guideline, someday you could unex pectedly get a real charge out of your work! Always play it safe — double-check to be certain that the power is off b e f o re you start to work on a pool or spa motor. If you have any suggestions or would like more i n f o rmation about a particular subject, please write or call: A.O. Smith 531 North Fourth Stre e t Tipp City, OH 45371 8 0 0 - 5 4 3 - 9 4 5 0 2 TABLE OF CONTENTS C e n t u ry Pump Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Design Feature s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Nameplate Inform a t i o n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 I n s t a l l a t i o n H e a t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3 M o i s t u re. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 4 Power Sourc e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 4 A l t i t u d e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 4 M o u n t i n g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 4 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 5 G ro u n d i n g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 5 Wi re Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 5 Wi re Selection Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 6 To o l s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 7 M a i n t e n a n c e M o i s t u re. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 7 C o o l i n g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 8 S e a s o n a l. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 8 C l e a n i n g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 8 L u b r i c a t i o n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 8 3 Motor Troubleshooting Motor Fails To Start (makes no sound). . . . . . . . . . . . . . . . . .1 9 Motor Fails To Start (hums, tries to start, blows fuse or trips bre a k e r ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 0 Motor Starts But Shuts Down (overload pro b l e m ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1 Noisy Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1 Motor Hot, Smoking Or Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 2 I n f o rmation Needed For Motor Replacement. . . . . . . . . . . . . .2 3 Troubleshooting A Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 3 Best Way To Use A Vo l t - A m m e t e r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 4 How To Replace Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 4 S e rv i c e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 7 Wiring Diagrams' Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 8 Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 9 - 5 4 Date of Manufacture Ta b l e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 5 4 CENTURY® CENTURION & C e n t u r i o n®, C-flange Switchless "1081" Motor • Standard Eff i c i e n c y • E-Plus, High Eff i c i e n c y • 1⁄2 – 5 Hp • No Switch, No Govern o r • Single phase or three phase • Suitable for operation at 50 Hz, 1.0 service factor • Aluminum or cast iron NEMA "C" mounting brackets • True NEMA 56-frame • Keyed or threaded shaft • UL standard "1081" appro v a b l e • Full-rated and Up-rated • 50° C Ambient • Available as a Century two-speed motor C e n t u r i o n® SE, C-flange Switchless "1081" Motor • 1⁄2 – 5 Hp • Standard Eff i c i e n c y • Single phase • Aluminum NEMA "C" mounting brackets • 50° C Ambient • True NEMA 56-frame • Keyed or threaded shaft • UL Standard "1081" appro v a b l e • Full-rated and Up-rated • 303 stainless steel shaft 5 E-PLUS® MOTORS C e n t u r i o n®, Square Flange Switchless "1081" Motor • Standard Eff i c i e n c y • E-Plus, High Eff i c i e n c y • 1⁄2 – 5 Hp • No Switch, No Govern o r • 303 stainless steel t h readed shaft • Suitable for operation at 50 Hz, 1.0 service factor • Single or three phase • True NEMA 56-frame • UL standard "1081" appro v a b l e • Full-rated and Up-rated • 50° C Ambient • Available as a C e n t u ry two-speed motor N e p t u n e®, C & Square Flange • Standard Eff i c i e n c y • High Eff i c i e n c y • 1⁄2 – 3 Hp • Advanced Switch Te c h n o l o g y • 48 frame shell diameter • 303 stainless steel threaded shaft • UL standard "1081" appro v a b l e • Full-rated and Up-rated • 50° C Ambient 6 FLEX-48™ POOL AND SPA MOTORS Flex-48™ Single-Speed Motors, Thru-Bolt Mount Suitable for jetted tubs and above-ground pools and spas. • 1⁄2- 3 Hp • 56-frame conversion base • 3-1⁄2" shaft height • 3⁄8" threaded shaft • Auto-reset overload p ro t e c t i o n • 1.0 service factor Flex-48™ Two-Speed Low Amp Start & Run Motors For Spas and above-ground pools, thru-bolt mount. • 3⁄4- 3 Hp • 56-frame conversion base • 3-1⁄2" shaft height • 3⁄8" threaded shaft • Auto-reset overload p ro t e c t i o n • 1.0 service factor CENTURION® DESIGN FEATURES Ce n t u ry pool and spa pump motors are tailored for demanding pool loads and environments. Check these outstanding feature s : 1 . Full-rated 56-Frame diameter gives greater thermal c a p a c i t y, better durability with industrial quality constru c t i o n . 7 CENTURION® DESIGN FEATURES 2 . All Threaded shafts are 303 stainless steel for superior c o rrosion resistance. Keyed shaft of carbon steel is iron phosphate treated to prevent rust. Stainless steel shafts p rovided on cast iron C-flange, keyed shaft pro d u c t . 3 . Double-sealed high thrust bearings protect against dirt and m o i s t u re. Factory lubricated, never need re g re a s i n g . 4. Special aluminum alloy brackets or cast iron NEMA "C" brackets resist corrosion from pool chemicals. 5 . Drive-end bearing locked to limit shaft endplay. 6 . Continuous rated run capacitor provides high running e fficiency and better starting perf o rmance in low voltage s i t u a t i o n s . 7 . Easy connect terminal board is designed with screw post line terminals. All you need is a screwdriver for fast and easy installation wiring. 8 . M o i s t u re resistant, Class B insulated windings for extra p rotection against moisture, high ambient temperatures, salt spray, chemicals, diatomaceous earth, sand, dirt, insects, etc. 9 . Motors designed to meet UL Standard #1081, protects i n t e rnal components from rain, dirt and chemicals. 1 0 . Class B automatic reset overload protector suitable for high ambient temperatures. Prevents nuisance tripping in hot are a s . 8 NAMEPLATE INFORMATION When you need information about the motor y o u ' re servicing, you'll always be able to find it printed on the motor nameplate. On A.O. Smith motors the nameplate is usually found on the side of the m o t o r, below the capacitor. Shown below is a sample pool motor identification nameplate. As you read the nameplate, refer to the guide so that you understand the meaning of each item that the manufacturer p rovides about its motor. Remember also that your dealer or distributor can give you valuable inform a t i o n that can help you to make the correct selection of a replacement motor. 9 1 .C AT NO (Catalog Number): This number indicates that the motor is a stock rating, readily available f rom standard inventory as a replacement pool m o t o r. 2 .PA RT: This identifies the motor's specific design by part number. 3 .FR (Frame): The frame identifies the mounting and shaft configuration. It doesn't indicate the diameter of the shell. A.O. Smith's line of Centurion and Centurion SE motors have a "56 frame" shell and are 6.5 inches in diameter. Neptune and Flex-48 products are designed in a 48 frame shell and are 5.6 inches in diameter. Common terms you'll see on the nameplate are "56J," "56C" and "56Y." The 56J is always a C-flange, threaded-shaft motor; the 56C is always a C-flange, keyed-shaft motor. M o t o r-frame mountings with the "Y" identification 1 0 NAMEPLATE INFORMATION identify motors not specified by NEMA mounting and shaft standards. 4 .T Y P E : The electrical design of the motor is shown by its type. A.O. Smith uses "CX" to identify its switchless design. Other codes include "CS" for c a p a c i t o r- s t a rt, "S P" for split-phase and "CP" for capacitor start / capacitor run. Be sure to check with the dealer or distributor, because motor type codes may vary among manufacture r s . 5 .HP (Horsepower): Conventional unit of measure - ment for power. One horsepower equals 746 watts. 6 .RPM (Revolutions Per Minute): RPM states the rotational speed of the shaft at rated load. 7 .HZ (Hertz): M e a s u rement of fre q u e n c y, equaling cycles per second of alternating curre n t . 8 .PH (Phase): Denotes a single- or three-phase m o t o r. 9 .SF (Service Factor): S e rvice factor is the measure of the re s e rve margin built into a motor. Motors rated over 1.0 SF allow the motor to operate at a higher margin than designated by the horsepower rating. Maximum horsepower capability equals horsepower multiplied by the SF. (continuous operation). 1 0 .V O LT S : Voltage is the re q u i red electrical potential applied to the motor, the force that produces current in an electrical conductor. 1 1 .A M P S : Electrical current flowing through the conductors. On pool motors, the amperage is maximum or service factor amps that result at 1 1 maximum horsepower (Hp x SF). 1 2 .T I M E : Time indicates the duty cycle of the motor. Pool and spa motors are generally rated for continuous duty. 1 3 .AMB (Ambient Te m p e r a t u re ) : The maximum ambient (surrounding) temperature in which the motor is designed to operate. This temperature is shown in Celsius rather than Fahre n h e i t . 1 4 .INSUL CLASS (Insulation Classification): The temperature rating of insulation used in the c o n s t ruction of the motor. Most pool and spa motors use a Class "B" insulation. 1 5 .ENCL (Enclosure ) : Common enclosures used include DP (dripproof) and TEFC (totally enclosed fan cooled). Most pool and spa motors feature a d r i p p roof design, with "1081" features. 1 6 .CODE: The NEMA code letter specifies locked rotor kVA per Hp (volts multiplied by locked rotor amps, divided by 1000 times rated HP). 1 7 .S E R I A L : The serial indicates the date of m a n u f a c t u re, which often appears as year/month combinations. Serial code information for each pool and spa motor can be found in guides and bulletins provided by the manufacturer (See p.55). 1 8 .V O LTAGE DIAGRAM: This diagram provides i n f o rmation on the correct electrical connections to ensure proper operation of the motor. 1 9 .WA R N I N G : The warning at the bottom of the label re-emphasizes that voltage can be hazardous. Always TURN THE POWER OFF before working on a pool or spa motor. 1 2 INSTALLATION H E AT The number one enemy of a motor is heat. Overheating always re s u l t s whenever there is a lack of clean, continually-circ u l a t i n g air for a motor. Heat can damage a motor's windings, insulation, bearing lubricant and run capacitor. In short , heat can quickly decrease the service life of a motor. R e m e m b e r, proper ventilation is always a crucial consid eration when installing a motor. If at all possible, install a motor in a location that is f ree of dirt, dust or airborne debris, such as leaves. Indoors is best, but not in areas with high humidity, such as a laundry room or shower area. If the motor is installed outdoors, try to choose a shady spot that's pro tected from leaves and grass clippings. If you cover the motor to protect it from possible debris or water, be s u re to leave enough space between the cover and the motor for adequate ventilation. A.O. Smith single phase pool and spa motors f e a t u re a thermal overload protector that will shut down the motor if it overheats. As the windings begin to cool down, the overload protector will automatically re - s t a rt the motor. Blocked ventilation or an overload condition can cause the motor to shutdown on a repeated basis. If a problem cannot be located or if tripping continues after a noted problem is corrected, contact the original equipment contractor for a recommendation on matching motor horsepower to the pump. T I P : In situations where the ambient temperature is exceptionally hot, utilizing an E-Plus (High Efficiency) motor in place of a standard efficient motor can p revent the overload protector from nuisance tripping. 1 3 M O I S T U R E C e n t u ry and Neptune motors have superior resistance to moisture, but you should avoid placing the motor where it can be splashed. Avoid installing the motor in low spots where it could collect water and be flooded. In fact, it's probably a good idea to elevate the motor at least two inches off the gro u n d . P OW E R S O U R C E B e f o re you turn the motor on, check to see that the line voltage, phase and fre q u e n c y match the specifications shown on the motor name plate. Current capacity must be adequate enough to maintain rated voltage at the motor terminals under all conditions. If it's too high, contact the local utility. If it's too low check for overloaded circuits, loose connections or wire of the wrong gauge (see wire selection guide). A LT I T U D E G e n e r a l l y, motors will run hotter with increasing altitudes. For installations more than 3,300 feet above sea level, it's advisable to use a motor with the next l a rger horsepower rating than the one recommended for that application at sea level or use a A.O. Smith E-Plus (High Efficiency) motor of the same rating when available. M O U N T I N G Fastening the pump and motor assembly securely to a foundation or base will prevent vibration, loosening, and future misalignment. Make sure that the motor and pump assembly rotate freely before starting the motor. 1 4 E L E C T R I C A L C O N N E C T I O N S The task of wiring your motor is fairly simple. The wiring diagrams shown on the following pages are color- c o d e d for easy reading. The appropriate part number is listed in each illustration, just in case you need to order the complete wiring diagram or connection label sticker for your motor. Make sure the connections are tight to prevent failure or overheating. If you do find loose connections, check for excessive vibration. G RO U N D I N G Without proper gro u n d i n g of a motor, serious elec tric shock is possible. A grounding conductor should always be connected under the green grounding scre w, which is located within the terminal compartment of the m o t o r. National and local electrical codes are import a n t , and should be adhered to when working on a motor. W I R E S I Z E I n c o rrect voltage at the motor terminals can cause the motor to overheat. It's a good idea to check the electrical supply wires to confirm that they are suff i c i e n t to handle the motor load. For example, if you're using a 1-1⁄2 Hp motor at 115 volts over a distance of 150 feet, use #8 wire. If the motor can be installed to operate on 230 volts, #12 wire should be sufficient for a 150 foot distance. 1 5 WIRE SELECTION GUIDE THE SIZES SHOWN IN THE FOLLOWING WIRE SELECTION C H A RTS ARE RECOMMENDATIONS ONLY. ALWAYS FOLLOW LOCAL AND NATIONAL ELECTRIC CODES. 115V Power Line Maximum Distance from Fuse Box to Motor Motor Hp 5 0 ' 1 0 0 ' 1 5 0 ' 2 0 0 ' 1⁄3 1 4 1 4 1 2 1 2 1⁄2 1 4 1 2 1 0 1 0 3⁄4 1 2 1 2 1 0 8 1 1 2 1 0 8 8 1 -1⁄2 1 0 1 0 8 6 2 1 0 8 6 6 3 — — — — 230V Power Line Maximum Distance from Fuse Box to Motor Motor Hp 5 0 ' 1 0 0 ' 1 5 0 ' 2 0 0 ' 1⁄3 1 4 1 4 1 4 1 4 1⁄2 1 4 1 4 1 4 1 4 3⁄4 1 4 1 4 1 4 1 4 1 1 4 1 4 1 4 1 2 1 -1⁄2 1 4 1 4 1 2 1 2 2 1 4 1 4 1 2 1 0 3 1 2 1 2 1 0 1 0 Guides for copper conductors only. 1 6 TOOLS With a few simple tools, you'll be ready for just about any kind of basic motor service. To make your job easier when installing or servicing a pool or spa motor, make sure that you have these tools in your toolbox before you begin working... • S t a n d a rd scre w d r i v e r • Wide blade scre w d r i v e r • 1⁄2" open end wre n c h • Rubber mallet • Clamp-on ammeter/voltmeter • A m m e t e r • 5⁄1 6" nut driver • Needle-nose pliers • Tape for marking MAINTENANCE A.O. Smith pool and spa pump motors are built tough, to run day after day without being serv i c e d . When service is necessary, serviceable parts usu ally can be accessed quite easily. For example, capaci tors are externally mounted, and single-phase motors have screw-type connectors for quick reconnection in the field. M O I S T U R E Water leaks from pump seals or pipe joints should be re p a i red to prevent failure of bearings and insulation. DO NOT splash or spray the motor. Mount the motor away from low spots and damp areas, and take mea s u res to protect it from windblown rain. 1 7 MAINTENANCEC O O L I N G An operating motor is usually too hot to touch by hand. It should be located away from direct sunlight and other heat sources, such as laundry appliances and water heaters. Provide for ample air circulation around the m o t o r. Clean the air inlets as re q u i red, making sure that the POWER IS OFF first. S E A S O N A L Whenever the motor must be shut down for extended periods, be sure all surfaces, vents and interiors are dry to prevent rust. If the motor is kept outdoors, cover it to prevent debris such as blowing leaves, dirt and snow f rom clogging the inlets. DO NOT SEAL THE MOTOR IN PLASTIC OR OTHER AIR-TIGHT WRAPPINGS, because condensation may form on the inside, damaging bearings and insulation. C L E A N I N G In general, the inside of the motor should not need cleaning if proper safeguards are made against contami nation by dirt, lint or sand. If you want to clean the outside, simply use a damp cloth. Don't spray the motor with a water hose. If it's accidentally flooded, have it inspected at a A.O. Smith authorized service center. L U B R I CAT I O N The ball bearings in A.O. Smith motors are double sealed, permanently lubricated. If it appears the bearings have failed, simply replace them. 1 8 MOTOR TROUBLESHOOTING WA R N I N G B e f o re you even touch the m o t o r, MAKE SURE THE POWER IS OFF. Always turn the power off at the electrical service entrance fuse or breaker box, to p revent possible electric shock. To prevent electrical shock when touching the motor, be sure windings and capacitor are securely grounded to the ground term i n a l which should be used in conformity with local codes. D o n 't work on electrical operations if water or moist conditions cannot be avoided. If the motor is not operating pro p e r l y, refer to the following guide. MOTOR FAILS TO STA RT (makes no sound) 1 .Check the obvious first — are the power switch and timer on? 2 .Be sure fuses are of proper size and type, then check for a blown fuse or tripped circuit bre a k e r. 3 .Be sure the motor is connected correctly (as shown on motor nameplate), but first — TURN OFF THE POWER. Check the terminal screw to see if it was tightened onto wire insulation instead of the wire itself. Verify that the ground wire is firmly connected to the green ground scre w. 4 .Check the voltage at terminal board after first TURNING THE POWER BACK ON. Be sure you turn the POWER BACK OFF after completing this step. NOTE: Voltage at motor terminals should be ±10% of voltage on nameplate. If the voltage is high ( m o re than ±10% above nameplate number), consult the local power company. If the voltage is low (±10% below rated voltage), check the size of the power line from fuse box to motor. If the 1 9 voltage is within the proper range, check for continuity through the pro t e c t o r. 5 .Check for overloading from other appliances on the same circuit as the motor. 6 .Inspect the motor windings for continuity. 7 .If voltage is proper at terminals and the motor is cold, remove the motor and take it to a A.O. Smith Authorized Service Center. MOTOR FAILS TO STA RT (hums, tries to start, blows fuse or trips bre a k e r ) 1 .Check the motor connections after TURNING OFF THE POWER. 2 .Check the voltage (see #5 above) as the motor tries to start. If voltage is too low, look for undersized wiring, an overloaded circuit or a burned start w i n d i n g . 3 .If the voltage is proper at terminals and motor is hot, TURN OFF THE POWER and allow the motor to cool to ambient temperature then reapply power. If the motor starts then shuts down, you have an overload. Check the amp draw at the motor t e rminal and compare it to amps shown on the motor nameplate. If the amp draw is greater then the nameplate current, check for impeller rub in the pump or a tight seal. If this fails to correct the p roblem, remove the motor from pump and take to a A.O. Smith Authorized Service Center. 4 .Check the capacitor but first — TURN OFF THE POWER. After removing the capacitor from the m o t o r, discharge it by laying an insulated s c rewdriver across its terminals. Check the 2 0 MOTOR TROUBLESHOOTING capacitor using an ohmmeter (see " Troubleshooting A Capacitor" page 23). 5 .Rotate the motor shaft. If you hear a grinding sound, disassemble the motor and check: the conditions of bearings, a rotor rubbing the stator, c o rrosion, a cracked frame, clogged fan or o b s t ruction(s). Repair or replace any faulty part ( s ) . 6 .If the motor has a switch, disassemble the motor and check the contacts for dirt. Use brown Kraft paper to gently clean. If the motor still doesn't work, replace the switch. 7 .If the switch contacts are open, check the governor for free movement on the shaft. (Incidentally, with a Centurion motor you won't have this problem, because it doesn't have a switch to malfunction.) MOTOR STA RTS BUT SHUTS DOWN (Therm a l Overload Pro t e c t i o n ) 1 .Check the voltage at motor terminal (see #5 under "Motor Fails To Start"). If the voltage is too high, call power company. 2 .Check amperage. If high, find out it the pump impeller was recently replaced (it could be sized i n c o rrectly). Remember, motor Hp x SF = the maximum Hp capability of motor. This number must be equal to or greater than the pump rating. NOISY MOTOR Air noise is normal, but an excessively high sound level or rough operation can mean trouble. If necessary, separate the motor and pump to find out where the fault lies. If it's in the motor, check the following items: 2 1 1 .Mounting, motor coupling and brackets. Tighten loose nuts, bolts or set scre w s . 2 .If a noticeable drag is present, check the bearings and bearing load spring. 3 .Make sure motor fan moves freely and rotor isn't rubbing stator. Look for loose or binding parts inside the motor or pump. 4 .Check for malfunctioning motor start switch and g o v e rn o r. If the problem appears to be with the pump, look for a loose motor coupling, loose or damaged pump impeller, clogged pump filter or strainer, or cavitation (loss of prime or air leaks on the pump's suction side). MOTOR HOT, SMOKING OR CYCLING 1 .Check the motor's ventilation by looking for clogged air vents or openings. Clean out all leaves, d i rt and other pool and spa gunk. 2 .C o m p a re connections and wiring to diagrams. Test the motor voltage to verify that it's within ±10% of nameplate listing. 3 .If the voltage checks out but amps are higher than the maximum on the nameplate, inspect motor and pump for mechanical obstructions, but not before TURNING OFF THE POWER. 4 .E n s u re that the motor's horsepower (Hp), times the s e rvice factor (SF), is equal to or greater than the pump rating (Hp x SF to Pump Rating). A full-load current greater than the nameplate listing can mean excessive pump load. 5 .Look at motor windings for damage or signs of s h o rting. Measure winding re s i s t a n c e . 2 2 MOTOR TROUBLESHOOTING 6 .Check the start switch for broken contact welds or a broken spring. 7 .Check the capacitor with an ohmmeter. A bulged capacitor indicates failure on most motors. But with a Centurion, the only way to verify a failed capacitor is with the ohmmeter. I N F O R M ATION NEEDED FOR MOTOR REPLACEMENT To get the right replacement motor, you'll need impor tant information. Fort u n a t e l y, they all can be found on the motor nameplate. Here 's what you'll need to know: 1 .Mounting configuration - C-Bracket, Square Flange, or Through-bolt Mount (See page 5-7). 2 .H o r s e p o w e r 3 .S e rvice factor 4 .Vo l t a g e 5 .Pump part number, manufacturer brand name TROUBLESHOOTING A CAPA C I T O R To check a capacitor with an ohmmeter, first TURN OFF THE POWER. If possible, remove the capacitor from the motor. Use an insulated screwdriver to discharg e the capacitor by shorting it across its terminals. Then set the ohmmeter to its highest setting and attach the ohmmeter's clips to the capacitor's terminals. Check for the following indications: 1 .Needle drops to zero range and slowly rises — capacitor is probably OK. 2 .Needle drops to zero and stays there — capacitor most likely is short e d . 3 .Needle remains at a high value — capacitor may have an open circ u i t . 2 3 BEST WAY TO USE A VOLT-AMMETER For Voltage Check 1 .Attach leads to the volt-ammeter and select the proper voltage scale. 2 .Test voltage at the motor line terminals and verify that it's within limits while the motor is operating. 3 .Voltage should be within ±10% of the design voltage specified on the motor nameplate. For Amperage Check 1 .Remove the leads from the volt-ammeter if attached. Select lowest reading amperage scale a c c o rding to motor nameplate rating. 2 .Clamp instrument around one incoming lead at the motor terminal board . 3 .O b s e rve the amperage as motor runs. With proper voltage, the reading should not exceed the MAXIMUM LOAD or SF amps rating of the motor. HOW TO REPLACE BEARINGS Replacing the bearings in a motor isn't a difficult task, p rovided you follow set pro c e d u res. These instru c t i o n s explain the correct method of motor bearing re m o v a l and replacement. If a bearing is noisy or doesn't ru n s m o o t h l y, it should be replaced. If a bearing has been removed for any reason, it should be replaced with a new one. As a rule, if it's necessary to replace one bearing, replace the other as well. Use only A.O. Smith bearings with the proper part number for the motor that you're working on. A.O. Smith bearings are lubricated and re q u i re no furt h e r attention during their life. Do not substitute or reuse old 2 4 MOTOR TROUBLESHOOTING bearings because this could damage the motor and cause a re t u rn service call. 1.TURN THE POWER OFF 2 .Remove the cover from the motor and disconnect the electrical supply leads from the terminal board. Then remove the electrical cable or conduit from the end frame. 3 .Remove the motor from the pump unit. 4 .Mark the brackets and frame of the motor, to assure corre c t alignment of these parts when reassembling them. 5 .Remove the rotor and shaft from the frame of the m o t o r, following these steps as necessary : a )Take out the thru-bolts that secure the brackets to the frame. b )Remove the bracket opposite the shaft by placing a screwdriver blade in the notches of this bracket and tapping the handle of the s c re w d r i v e r. c )Remove the locking collar screws and washers if their use prevents removal of the rotor assembly f rom the shaft end bracket. d )C a refully pull the shaft/rotor assembly out of the shell or stator toward the shaft extension end. e )Be careful not to lose the washer and bearing load spring that is positioned in the bottom of the bearing bore of the bracket opposite the shaft extension. Be sure to replace this spring during re a s s e m b l y. 2 5 6 .Remove the bearing(s) from the motor shaft, following these steps as necessary : a )Remove shaft collars used to secure bearings. D o n 't reuse a bearing that is removed from the shaft. 7 .Install the new shaft bearing(s). It is important to press only on the bearing inner race. The bearing will be damaged if the outer race surface is pressed. a )Fan end. Place the short end of the shaft on a wood block. Place the bearing (and other parts used) over the long end of the shaft. Tap the bearing into place, using the proper size tube and a mallet. Attach any other parts (as used) to the long shaft end. b )Opposite end. Place the long end of the shaft on the wood block. Place the bearing over the short end of the shaft. Tap the bearing into place, using the proper size tube and a mallet. 8 .Reassemble the motor in reverse of the disassembly pro c e d u re . a )O b s e rve all reassembly pre c a u t i o n s . b )Check wiring diagrams to assure proper wiring if the leads have been removed from the term i n a l s . c )TURN ON THE POWER. Check the motor for p roper electrical and mechanical operation when it has been re i n s t a l l e d . 2 6 SERVICE If your pool or spa motor should need attention while still under warr a n t y, we re q u i re that you have it serviced at a Authorized A.O. Smith Service Center to qualify for warranty coverage. When ordering part s , refer to the part number and serial number on the motor nameplate. For your convenience, a separate Century Stock Pool and Spa Motor Parts List is available. Ask for Bulletin #3996. 2 7 WIRING DIAGRAMS TABLE OF CONTENTS C e n t u r i o n® Switchless (Easy Connect) . . . . . . . . . . . . . . . . . . 29, 30 C e n t u r i o n® Switchless (Mfg. prior 11/91). . . . . . . 31, 32, 45 10 81, Wishbone (Old Style). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33, 34, 35 10 81, Single Arm Switch (Old Style). . . . . . . . . . . . . . . . . . . . . 36, 37 E - P l us®, Switchless (Old Style),230 volt. . . . . . . . . . . . . . . . . . . . . 3 8 2-Speed, Wishbone (Old Style). . . . . . . . . . . . . . . . . . . . . . . 39, 40, 41 M i c ro-Switch (Formerly Gould-Guard ). . . . . . . . . . . . . . . . . . . . . . . . 4 2 Switchless (Formerly Gould-Guard ). . . . . . . . . . . . . . . . . . . . . . 43, 44 C e n t u r i o n® Solid State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46, 47 E - P l us® Switchless (Mfg. prior 11/91) . . . . . . . . . . . . . . . . . . . 48, 49 L a s ar®48 Frame (Two Speed). . . . . . . . . . . . . . . . . . . . . . . . . 50, 51, 52 Flex 48 (Single Speed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53, 54 N e p t u n e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 58 2 8 CENTURION®/SE/II For motors manufactured in/after Nov., 1991 (Serial #BJ11) Dual Vo l t a g e Type CX-1⁄2to 11⁄2 H p 230/115 Vo l t S w i t c h l e s s 2 9 CENTURION®/SE/II For motors manufactured in/after Nov., 1991 (Serial #BJ11) Single Vo l t a g e Type CX-11⁄2- 5 H p 230 Vo l t S w i t c h l e s s 3 0 CENTURION® For motors manufactured prior to Nov. 1991. (Serial #BJ11) Dual Vo l t a g e 115/230 Vo l t Type CX–1⁄2to 11⁄2 H p Switchless 3 1 CENTURION® For motors manufactured prior to Nov. 1991. (Serial #BJ11) Single Vo l t a g e 230 Vo l t Type CX–2, 3 & 4 Hp Switchless 3 2 1081 115/230 Vo l t Type CS–1⁄2to 11⁄2 H p Wishbone (Old Style) 3 3 1081 115/230 Vo l t Type CP–2 Hp Wishbone (Old Style) 3 4 1081 230 Vo l t Type CP–3 Hp Wishbone (Old Style) 3 5 1081 115/230 Vo l t Type CS–1⁄2to 11⁄2 H p Single Arm Switch (Old Style) 3 6 1081 115/230 Vo l t Type CP–2 Hp Single Arm Switch (Old Style) 3 7 E-PLUS® 230 Vo l t Type CX–2 and 3 Hp Switchless (Old Style) 3 8 2-SPEED 115 Vo l t Type CSM–1⁄2to 3⁄4 H p Wishbone (Old Style) 3 9 2-SPEED 230 Vo l t Type CSM–1 and 11⁄2 H p Wishbone (Old Style) 4 0 2-SPEED 230 Vo l t Type CPM–2 Hp Wishbone (Old Style) 4 1 MICRO-SWITCH MOTOR ( F o rmerly identified as G o u l d - G u a rd ) 115/230 Vo l t Type CS–1⁄2to 1 Hp (Old Style) 4 2 SWITCHLESS MOTOR( F o rmerly identified as Type CX–11⁄2 H P G o u l d - G u a rd ) 230 Vo l t Switchless (Old Style) 4 3 SWITCHLESS MOTOR( F o rmerly identified as Type CX–2 and 3 HP G o u l d - G u a rd ) 230 Vo l t Switchless (Old Style) 4 4 CENTURION® Two-Speed Single Vo l t a g e 115 Vo l t Type CXPM–1⁄2/.06 to 3⁄4/.10 Hp Solid-State Switch 4 6 CENTURION® Two-Speed Single Vo l t a g e 230 Vo l t Type CXPM–1/.12 to 2/.25 Hp Solid-State Switch 4 7 E-PLUS® SWITCHLESS Dual Vo l t a g e 115/230 Vo l t Type CX–3⁄4to 11⁄2 H p Switchless 4 8 E-PLUS® SWITCHLESS Single Vo l t a g e 230 Vo l t Type CX–2 and 3 Hp Switchless 4 9 FLEX 48® FRAME Two Speed Single Vo l t a g e 115 Vo l t 5 0 Type SPM–3⁄4 /.10 HP FLEX 48® FRAME Two-Speed Single Vo l t a g e 115 or 230 Vo l t 5 1 Type CXSM 11⁄2/.18 HP Type CXSM 2.0/.25 HP t h rough 4.5/.50 Spl HP FLEX 48® FRAME Two-Speed Single Vo l t a g e 115 or 230 Vo l t Type CSM 1.0/.12 Hp 115 Vo l t Type CSM 1.0/.16 Hp 115 Vo l t Type CSM 1.5/.18 Hp 230 Vo l t Type CSM 2.0/.25 Hp 230 Vo l t 5 2 FLEX 48® Single Vo l t a g e 115 Vo l t 5 3 Type SP–1⁄2to 11⁄2 H p FLEX 48® Dual Vo l t a g e 230/115 Vo l t 5 4 Type CS–11⁄2to 4 Spl Hp HOW TO IDENTIFY THE DATE OF MANUFACTURE For Century Pool, Spa or Jetted Tub Motors To identify the month and year your Century pool, spa or jetted tub motor was manufactured you need to know the serial code. The serial code on the nameplate is made up of thre e p a rts: serial letter (year), serial number (month), and manufacturing sequence number. Example: SERIAL BH 1 1 - 1 6 Serial Letter Serial Number Mfg. Sequence This motor was manufactured in November 1990. Serial Letter Designation S e r i a l S e r i a l S e r i a l L e t t e r Ye a r L e t t e r Ye a r L e t t e r Ye a r K 1 9 7 0 W 1 9 7 9 B F 1 9 8 8 L 1 9 7 1 X 1 9 8 0 B G 1 9 8 9 M 1 9 7 2 Y 1 9 8 1 B H 1 9 9 0 N 1 9 7 3 Z 1 9 8 2 B J 1 9 9 1 P 1 9 7 4 B A 1 9 8 3 B K 1 9 9 2 R 1 9 7 5 B B 1 9 8 4 B L 1 9 9 3 S 1 9 7 6 B C 1 9 8 5 B M 1 9 9 4 T 1 9 7 7 B D 1 9 8 6 B N 1 9 9 5 U 1 9 7 8 B E 1 9 8 7 B P 1 9 9 6 Serial No. Designation S e r i a l S e r i a l L e t t e r Ye a r L e t t e r Ye a r 1 J A N 7 J U LY 2 F E B 8 A U G 3 M A R 9 S E P T 4 A P R 1 0 O C T 5 M AY 1 1 N O V 6 J U N E 1 2 D E C 5 5 N E P T U N E® 2 Compartment Motors Single Vo l t a g e 230 Vo l t Type CP 11⁄2 2&3 Hp 5 6 N E P T U N E® 2 Compartment Motors Dual Voltage Type CP 230/115 Volt 1⁄2-11⁄2 Hp 5 7 N E P T U N E® 2 Compartment Motors Dual Vo l t a g e Type CS 230/115 Vo l t 1⁄3- 11⁄2 H p 5 8 A.O. Smith 531 North Fourth Stre e t Tipp City, OH 45371 9 3 7 - 6 6 7 - 6 8 0 0 Fax (937) 667-5873 1 Bulletin 2944 ©A . O . Smith 2000 Litho in USA #2944 11/00