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APPLICATIONA . O . S m i thM o t o rM a s t e ryU n i v e r s i t y

INCLUDES:

SWIMMING POOLS

SPA & JETTED TUB

MAINTENANCE

INSTALLATION

REPAIR

TROUBLESHOOTING

OTHER MODULES INCLUDE:

HEATING, VENTILATION, AIR CONDITIONING &

REFRIGERATION MOTORS

GENERAL PURPOSE MOTORS

SPECIAL PURPOSE MOTORS

PUMPMOTORS

A.O. SMITHA.O. SMITHA.O. SMITHA.O. SMITHA.O. SMITH

Contents

© 2006 A.O. Smith Corporation

The information contained in this booklet is general in nature and is drawn from sources believed tobe reliable. It is intended for general information purposes only. The descriptions in this bookletmay not apply to a particular motor or a particular application. No warranties are intended to becreated by this information.

NOTICE:

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Motor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Nameplate Information . . . . . . . . . . . . . . . . . . . . . . . . . .4Cross Referencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . .11eMod® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20eMod® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29Electrical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Component Checks . . . . . . . . . . . . . . . . . . . . . . . . . . .33eMod® Technical Support . . . . . . . . . . . . . . . . . . . . . . .37

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . .48Start Switch Installation

and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

IntroductionWelcome to A.O. Smith’s line of Swimming Pool

and Spa Pump motors. This manual is designed forone purpose – to make it simple for you to install,maintain, troubleshoot and service A.O. Smith pooland spa motors. All you need are a few basic toolsand some helpful hints - the kind that appearthroughout this booklet.

We’ve included all the information we think youwill need to solve the most common pump motorproblems encountered out in the field. This easy toread manual contains great illustrations and dia-grams for quick reference. Mastering the conceptsin this manual will allow you to add the kind ofvalue to your service that your customers will rec-ognize and appreciate.

WARNING! This is not a guide for the do-it-yourselfer. These tips and suggestions are offeredfor persons with the proper qualifications and nec-essary test equipment.

Replacements for every application. Every nowand then you probably come across a motor that’sbeyond repair. When you do, remember that A.O.Smith manufactures replacement pool and spamotors for practically every application you’ll everencounter in the field. So save yourself some timeand effort and just ask for A.O. Smith or A.O. SmithCentury ® motors first – at any A.O. Smith distribu-tor or dealer. A.O. Smith motors are as rugged asyou will find, but keep in mind that all motors needservice or maintenance at one time or another.

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I n s t a l l a t i o nThis section is divided into five parts. The first is

Motor Types followed by Nameplate Information.The third is Cro s s - re f e rencing followed byInstallation Guidelines. The last is eMod® I n s t a l l a t i o n .It is designed to help you select the correct motor foran application and install it pro p e r l y.

There are five distinct electrical designs that arecommonly found on swim pool and spa pumps.

1. Split Phase. This type of single-phase motor isused extensively in spa and jetted tubs andabove ground pool applications. Some are usedon pumps on the lower end of the in groundpool market. This design has a start windingand a start switch, but no capacitors.

2. Capacitor Start. This is a very common single-phase motor found on in ground pool pumpapplications. The starting torque is higher (150-175% of full load) and starting currentlower than the split phase equivalent. The operation is similar to a split phase in that thereis a start switch to take the start winding andcapacitor out of the circuit once the motorreaches 2/3 to 3/4 of full speed.

3. Permanent Split Capacitor. This design doesnot have a start switch and is often referred toas a “switchless” motor. It uses a run capacitorthat remains in the circuit at all times. The PSCdesign has significantly less starting torquethan the capacitor start design.

Motor Types

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4. Capacitor Start/Capacitor Run. This design isused to increase efficiency in run mode. Bothstart and run capacitors are used. In run mode,PSC and Cap. Start/Cap. Run motors are thesame.

5. Three phase (Polyphase). This is the simplest,most efficient design. Its use is limited to commercial and industrial applications becausethree phase power is not available in residentialareas.

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When you need information about the motor you are replacing, you’ll always be able to find itprinted on the motor nameplate. On A.O. Smithmotors the nameplate is usually found on the sideof the motor. Shown below are sample pool motornameplates. As you read the nameplate, refer to theguide so that you can understand the meaning ofeach item that the manufacturer provides about its motor. Remember also that your dealer or distributor can help you choose the correct replacement motor.

NameplateInformation

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AMB: The maximum ambient (surrounding)temperature in which a motor is designed to operate.It is shown in degrees Celsius rather than Fahrenheit.

Amps: Amps is the electrical current flowing throughthe conductors at rated load, rated voltage and ratedfrequency. Pool motors have service factor amps onthe nameplate. This is amps at horsepower times service factor load and is the maximum acceptablecurrent the motor should use.

Catalog Number: (“CAT”). This number indicatesthat the motor is a stock rating, readily available fromstandard inventory as a replacement motor.

Code: This is the NEMA code letter that specifieslocked rotor kVA per HP (volts multiplied by lockedrotor amps, divided by 1000 times rated HP). It isused to determine the correct size breaker needed inthe electric box.

ENCL (Enclosure): Enclosure refers to the openingsor lack of openings in the shell and end frames.Motors are either open or enclosed. There aredifferent categories within each. Pool motors areusually open “dripproof”.

FR (Frame): The Frame identifies the mounting and shaft configuration. It does not indicate the diameter of the shell.

Centurion and Centurion SE motors have a 6 1/2”diameter shell. Flex 48 and A.O. Smith two compart-ment motors have a 5 5/8” diameter shell. Eitherdiameter can be 56C or 56J. That is because the shaftconfiguration and mounting holes are the same onboth shell diameters. Square Flange motors, usuallysignified as 56Y or 48Y, mount the same regardless of the shell diameter. Square Flange motors are notrecognized by NEMA, National ElectricalManufacturer’s Association, so there are

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no consistent frame size designations for them.However, Square Flange is an industry standard and allswim pool Square Flange motors mount the same. Note:A water systems manufacturer uses a square flangemotor with a special shaft. Water system motors shouldnever be used on swim pool applications.

HP (Horsepower): Conventional unit of measurementfor power (One horsepower equals 746 watts output).

HZ: (Hertz): Measurement of frequency, equaling cyclesper second of alternating current. The United States has60 hertz current.

Insul Class (Insulation Class): This is the temperaturerating of insulation used in the construction of themotor. Most pool and spa motors use class “B” or class“F” insulation.

Part or Mod Number: This identifies the motor’s specific design by part number. All motors have a model number. Only catalog motors have a catalog number.

PH (Phase): Denotes whether the motor operates on single-phase AC current or three phase AC current.

Rotation (Rot): Rotation is the direction the shaft turns.Almost all swim pool pump motors turn counterclock-wise when looking at the motor from the end where thepump is located. This can be referred to as CCWPE.

RPM (Revolutions per minute): RPM is how manytimes the shaft makes one complete revolution in oneminute at rated horsepower, voltage and frequency.

Serial: The serial code indicates the plant of manufacture and the date of manufacture. Each manu-facturer is different. A.O. Smith has an explanation of thedate code inside the front cover of the motor catalogs.

Impeller Rotation

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SF (Service Factor): Service factor is a multiplierthat when multiplied by the horsepower of themotor indicates the total permissible horsepowerloading that may be carried when the motor isoperating at rated voltage and frequency.

TIP: The most important thing to remember whenreplacing a motor is that the replacement motor’shorsepower times its service factor must be equal toor greater than the original motor’s horsepowertimes it’s service factor.

Time: Time indicates the duty cycle of the motor.Pool and spa motors are rated for continuous duty.

Type: This is a code for the electrical design of themotor. For example, A. O. Smith uses “CX” to iden-tify its PSC switchless design. Other codes are “CS”for capacitor start; “SP” for split phase and “UAK”for capacitor start/capacitor run. Be sure to checkwith your dealer or distributor, because each manufacturer’s type codes are different.

Volts: Voltage is the required electrical potentialapplied to the motor. It is the force that moves thecurrent in an electrical conductor. Single phase Pooland Spa motors will be 115, 230 or dual voltage,115/230 volt. Dual voltage motors are usually connected for 230 volt at the factory because if 115volts are applied incorrectly in the field the motorwill just hum or run slowly, get hot and trip on theoverload. This does not harm the motor. If themotor was connected for 115 volt at the factory and230 volts were mistakenly applied the motor willburn out immediately.

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Motors are designed to run at plus or minus 10% ofthe nameplated voltage. A motor nameplated 230volts will run from 207 to 253 volts. However, at207 volts the motor amps will be slightly higherand the Rpm’s will be slightly lower.

Some motors are rated 208-230 volts. These motorswill operate in a range from 208 volts minus 10% to230 volts plus 10% or 187 volts to 253 volts.

TIP: Occasionally 200 or 208 volt motors are used. If a motor that has been designed for 200 volts or208 volts is not readily available you can use a 230 volt motor with the next higher horsepower. For instance, a 1Hp 230 volt motor can replace a 3/4 HP 200 volt motor.

TIP: There are no energy savings when connectingthe motor to 230 volts versus 115 volts or vise versa.The advantage to the higher voltage is you can usesmaller wire to connect the motor to the service andit reduces light flicker or dimming when the motorstarts.

Warning Labels: Make sure you read and under-stand all the warning information on the motor.Always TURN THE POWER OFF before workingon a pool or spa motor.

Wiring Diagram: On or near the nameplate is aschematic of how to connect the motor to the powersource, change the voltage (if applicable), changethe rotation (if applicable) or connect for differentspeeds (if applicable). When installing a replace-ment motor make sure the motor is connected forthe same voltage as the power source.

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The nameplate of the motor being replaced contains much of the critical information needed toselect a new motor. Some of the nameplate datadetailed in the previous section is repeated below inorder to reemphasize its importance when choosinga replacement motor

Choosing the right replacement motor is easyusing these 5 steps:

1. Know the end frame you need. Is it:

2. Know the total horsepower output.Find the horsepower and service factor on thenameplate of the motor to be replaced. Multiplythe horsepower times (x) the service factor. Theresult is the “total horsepower” of the motor.Do the same for the possible replacementmotors. Select the replacement motor that has atotal horsepower (horsepower times the servicefactor) that is equal to or greater than that ofthe original motor’s total horsepower

3. Is the original motor single or three phase?The original and replacement motors must bethe same unless the power supply is beingchanged.

Thru Bolt5.146 Bolt Circle

Square FlangeC-Face Keyed56C Frame

C-Face Threaded56J Frame

CrossReferencing

Thru Bolt5.812 Bolt Circle

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4. What is the correct voltage?The operating voltage of the replacement motormust be capable of operating on the same volt-age as the original motor.

TIP: If the original motor was dual voltage (115/230volt) and an equivalent dual voltage replacement isnot readily available, a single voltage motor (115volt motor or a 230 volt motor) of the actual voltagebeing used at the installation may be used.

5. What is the motor’s cycle or hertz?As a general rule, 50-cycle motors should not besubstituted for 60-cycle motors and vice versa.

Your distributor or dealer is also a great resourcefor determining what replacement motor you need.In addition motors can be cross-referenced on theA.O. Smith web site www.aosmithmotors.com.

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InstallationGuidelines

When replacing a motor that has failed, if possible,determine the cause of failure. If you know why theoriginal motor failed you may be able to improve theinstallation so the new motor doesn’t fail for the samereason. Be particularly conscious of external condi-tions such as moisture, low voltage or dirt and debristhat could have contributed to the failure. Here aremore things you should consider when installing amotor:

Heat The number one enemy of a motor is heat.Overheating always results whenever there is a lackof clean, continually circulating air through a motor.Heat can damage a motor’s windings, insulation,bearing lubricant and capacitors. In short, heat canquickly decrease the service life of a motor. Rememberthat proper ventilation is always a crucial considera-tion when installing a motor.

If at all possible, install a motor in a location that isfree 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 isinstalled outdoors, try to choose a shady spot that’sprotected from leaves and grass clippings. If youcover the motor to protect it from possible debris orwater, there must be enough room between the coverand the motor to allow for a continual supply of un-recirculated outside air to flow through the motor.

A.O. Smith single-phase pool and spa motors fea-ture a thermal overload protector that will shut downthe motor if it overheats. As the windings begin tocool down, the overload protector will automaticallyre-start the motor. Blocked ventilation or an overloadcondition can cause the motor to shutdown on arepeated basis. The motor is operating as it wasdesigned. It is important to determine what is causingthe motor to overheat and correct the problem.

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TIP: In situations where the ambient temperature is exceptionally hot, utilizing a highefficiency E-Plus or Conservationist motor in placeof a standard efficient motor can prevent the overload protector from nuisance tripping.

Moisture A.O. Smith motors have superior resistance to moisture, but you should avoid placing the motor where it can be splashed. Avoidinstalling the motor in low spots that could flood orunder roof overhangs where gutters could overflowduring heavy rains. Avoid locating the motor in thehighest humidity area. It is best to elevate themotors at least two inches from the ground.

Power source Before you turn the motor on,check to see that the line voltage, phase and frequency match the specifications shown on themotor nameplate. Current capacity must be adequate enough to maintain rated voltage at themotor terminals under all conditions. If it’s toohigh, contact your local utility. If it is too low checkfor overloaded circuits, loose connectors or wire ofthe wrong gauge (see wire selection guide).

Altitude Generally, motors will run hotter withincreasing altitudes. For installations more than3,300 feet above sea level, it’s advisable to use amotor with the next larger horsepower rating thanthe one recommended for that application at sealevel or use an E-Plus or Conservationist (high efficiency) motor of the same rating.

Mounting Fastening the motor to the pump andthe pump and motor assembly securely to a foun-dation or base, will prevent vibration, looseningand future misalignment. Make sure that the motorand pump assemblies rotate freely before startingthe motor.

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Electrical connections Thewiring diagrams shown on themotor make wiring your motoreasy. Make sure the connectionsare tight to prevent failure oroverheating.

Grounding Always make sure the motor is properly grounded before applying power. In addition to the green grounding screw inside themotor, which grounds the motor to the serviceground, every pool and spa motor has a bondinglug. The bonding lug is on the outside of the motorand is used to bond the motor and all other conductive surfaces together to prevent a potentialdifference between the surfaces. Grounding shouldbe done in compliance with all local and nationalelectrical codes.

Wire Size I n c o r rect voltage at the motor terminals can cause the motor to overheat. It’s a goodidea to check the electrical supply wires to confirmthat the wire size is sufficient to carry the re q u i re dvoltage. For example, if you’re using a 1 HP motor at115 volts over a distance of 150 feet use #8 wire. If themotor is being installed to operate on 230 volts, #10

DISTANCE FROM SERVICE ENTRANCE/MAIN PANEL TO MOTOR

50 feet 100 feet 150 feet 200 feet

115V 230V 115V 230V 115V 230V 115V 230V1/3 14 14 12 14 10 12 8 121/2 14 14 10 14 8 12 8 103/4 12 14 10 12 8 12 6 101 12 14 8 12 8 10 6 8

1-1/2 10 14 8 12 6 10 6 82 10 14 8 10 6 10 6 83 12 10 8 8

MotorH.P.**

*Always follow all applicable codes. **Pump Motors with service factors greater than 1, and split phase designs. No more than 15 volts drop at start, in worst case.

Pump Motor Recommended Wire Size

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w i re is sufficient for the 150 feet distance. Larger wiresizes reduce the voltage drop to the motor in both thestart and run modes. A lower voltage drop means themotor will run more efficiently (cooler) and havei n c reased service life.

Pump Seal Always install a new seal whenreassembling a pump or installing a replacementmotor. A leaking pump seal may cause a motor tofail very quickly. To best protect the motor, A.O.Smith recommends the use of a Sintered CarbonGraphite Seal.

It is important that the pump seal be installedcorrectly. The following are installation instructionsprovided courtesy of U. S. Seal Mfg.

1. Disassemble pump cavity to expose defectiveseal. Removal of old seal and assembly of newseal requires careful operations and precau-tions.

Caution: Lapped and polished faces ofnew seal are easily scratched and dam-aged. PROTECT FROM DAMAGE, DIRTand FINGERPRINTS.

2 . C a refully remove old seal head and seat takingc a re not to scratch shaft or seat counterbore .NOTE HOW THE OLD SEAL IS A S S E M B L E D ,TO BE SURE REPLACEMENT SEAL I SI N S TALLED IN IDENTICAL M A N N E R .

3 . Clean shaft and counterbore surfaces using fineemery cloth or equivalent. Remove rust, burrsand wipe clean.

4 . Shaft, seat counterbore and rubber members ofseal head and seat should be lubricated with alubricant compatible with the seal elastomer.Check seals surfaces to be sure they are free ofany dirt, grit or lubricants.

5 . P ress seal seat firmly into counterbore to be sureit is bottomed square. SLIDE SEAL H E A DALONG SHAFT MAKING SURE THAT SPRINGIS CORRECTLY ENGAGED INTO SEAL.

6. Re-assemble pump and remember that troublefree operation of a pump includes a correct sealinstallation.

TIP: If the pump has been run dry longenough for the plastic pump to overheat, consider replacing the pump also.Overheating can cause the pump to warpmaking it impossible for the pump seal toprevent leaking.

Additional Protection. Do not remove the waterslinger (washer) from the shaft. It helps deflectwater away from the motor bearing.

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Overview

The eMod load sensing electronic module is anaccessory to a pool pump motor. It is permanentlyattached to the motor and is used to protect themotor and pump from damage. eMod is SVRS compliant per ASME A112.19.17-2002 for suction liftapplications.

The load sensing module can turn the pool pumpmotor off if the input power to the motor is too low,indicating either a lack of fluid flow, or a dry run-ning pump. It can also turn the motor off if theinput power gets too high, indicating excessive load

eMod®

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on the pump. The module can also shut the pump motoroff if input current is too high, indicating a locked rotor orblocked pump impeller condition.

eMod Set Up

The eMod module is permanently mounted and wired tothe motor. All necessary electrical connections are madeat the factory.

Basic Operation

While the pool pump is running, the eMod module moni-tors pump motor input power. If the motor input powerdrops 10% below its normal running condition value formore than 1 second, the eMod will fault and the pumpmotor will be turned off. When faulted, the eMod modulewill flash the red LED on the end of the enclosure.

If the motor input power increases more than 12% over itsnormal running condition value for more than 4 seconds,the eMod will fault and the motor will be turned off. Ifeither of the out of normal conditions does not last for therequired amount of time, however, the fault condition willnot be latched, and the motor will continue to run.

Startup Lockout Time

Often times when starting a pool pump, there is air in theplumbing system. If the volume of air is large, it can takea minute or two to fully evacuate the air in the systemand prime the pump. To keep the eMod module fromdetecting a low input power condition (lack of flow) astartup lockout period is employed. When the eMod ispowered up, it will ignore the motor power input for up to 3 minutes before it starts to monitor the motor

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operating conditions. While the eMod module is in thisstartup lockout state, the green LED on the end of theenclosure will flash.

If the pump primes faster than the 3 minute limit, theeMod circuitry will detect this and immediately go intorunning mode. When in run mode, the green LED on theend of the enclosure will be on.

Calibration

Because every pool is hydraulically different, the eModmodule must be individually calibrated to each poolinstallation. The unit will automatically calibrate afterrunning through the 3 minute priming period for the firsttime. When calibrating the unit, it is important to makesure that the pump is fully primed, and that all valvesand filters are in their normal operating conditions. Alsomake sure that there are no leaves or other obstructionson the pool drains. This will result in the pump motorinput power being at its normal operating value.

During the three minute startup lockout time, the greenand red LEDs will flash alternately. The alternate flash-ing LEDs indicates that the eMod unit is in auto-calibratemode. At the end of the three minute priming period,the eMod will automatically calibrate and go into runmode (green LED on).

If for some reason the pump is not yet fully primed, letthe eMod unit fault out. Cycle input power and pressthe Reset button as discussed below.

Note: It is important that the pump be fully primed andrunning at normal conditions when the eMod unit is calibrated.

Note: For two speed motors, the eMod must be calibrat-ed at both operating speeds. It is recommended that theeMod be calibrated at both speeds when the motor is initially installed on the pool, and the motor is still cool.

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Test of Proper Calibration

Upon completing the installation of an eMod equipped motorto the pump and pool plumbing, and after calibration is complete, the manufacturer recommends that the unit be tested for proper function. This can be accomplished byeither blocking the inlet of the drain or closing a main valve.The motor and the pump should shutdown in less than 10seconds of this action. The red LED on the eMod unit shouldalso be flashing. Remove the blockage or return the valve tothe original position and the unit should begin functioningagain in approximately two (2) minutes. It is recommendedthat this test be performed monthly to assure no changeshave occurred in the calibration the pool system.

If the eMod unit does not shutdown the motor and pump inless than 10 seconds, the unit should be Reset. Please refer tothe Reset section of the installation guide. Once the unit isReset, the unit will then calibrate to the new load point oncepower is applied to the unit. The blockage test should berepeated once the unit has completed the calibration and isoperating with a solid green LED illuminated.

Reset

If for some reason it becomes necessary to reset the calibra-tion of the eMod module (change in plumbing or other poolconditions), press the button next to the red LED on the endof the enclosure and hold it down for at least three seconds.Please note that this function is only active during the firstthree minutes of operation after the power is applied. Thiswill erase the calibration memory and the motor will stop.Cycle power to the unit (wait 10 seconds with the power offto allow the internal power supply to reset). The unit willnow go through a new auto-calibration period and thenestablish new values for motor input power and current, aswas discussed in the calibration section above.

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Bypass Mode

It may be necessary to defeat the eMod motor inputpower monitoring functions during unusual operatingconditions in the pool. This might include hand wandvacuuming the pool, back flushing of filters or replace-ment of filters, or clearing a large volume of air fromthe pool plumbing system.

To enter Bypass mode, press and hold the Bypassmode button for at least three seconds. The Bypassmode button is located next to the green LED on theend of the enclosure. The eMod will respond by starting to blink the red LED with the green LED on.Bypass mode will last for 30 minutes, or until theBypass mode button is pushed for at least three sec-onds a second time. If at any time during the cleaningprocess the power is cycled off, the Bypass mode button must be pressed again once the power is cycledback on, otherwise the unit believes that cleaning hasbeen completed and has returned to normal operationmode. If the unit stops during any cleaning activity,cycle the power off, wait 10 seconds, power on, and press the Bypass mode to continue cleaning operations.

Caution: Bypass mode defeats the pump monitoringfunctions of the eMod. While in Bypass mode, there isno protection from a drain blockage suction conditionor dry running pump.

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M a i n t e n a n c eAs with a car or any other mechanical device, period-

ic maintenance is required to keep an A. O. Smith motoroperating properly. While the motor itself does notoften need attention, providing the proper environmen-tal conditions around the motor can be the key to a longservice life. Conditions change. It is important to moni-tor and correct any situation that might cause damageto the motor.

Moisture Water leaks from pump seals or pipe jointsshould be repaired to prevent failure of bearings andinsulation. DO NOT splash or spray the motor. Mountthe motor away from low spots and damp areas, andtake measures to protect it from windblown rain.

Cooling Provide for ample air circulation aroundmotor. If an external motor cover is used, be certain itdoes not trap moisture and has enough space betweenthe motor and the cover to allow fresh air to circulatethrough the motor. Clean the air inlets as required,making sure that the POWER IS OFF first.

TIP: A running motor that is too hot to touch is notnecessarily overloaded. Class B insulated motorshave a maximum operating temperature of 130degrees Centigrade (266 degrees Fahrenheit). If theautomatic protector is not tripping and the actualrunning amps do not exceed the maximum amps onthe nameplate, the motor is not overheating.

Seasonal Whenever the motor must be shut down forextended periods, be sure all surfaces, vents and interi-ors are dry to prevent rust. If the motor is kept out-doors, cover it to prevent debris such as blowing leaves,dirt and snow from clogging the inlets. DO NOT SEALTHE MOTOR IN PLASTIC OR OTHER AIRTIGHTWRAPPINGS because condensation may form on theinside damaging bearings and insulation.

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TIP: When restarting the pump and motor afteran extended down time, make sure the suctionis flooded so the pump seal is wet. Starting themotor with a dry pump seal can damage theseal.

Cleaning In general, the inside of the motorshould not need cleaning if proper safeguards aremade against contamination by dirt, lint or sand. Ifyou want to clean the outside, simply use a dampcloth. Don’t spray the motor with a water hose.Flooding the motor can cause permanent damage.

Lubrication The ball bearings in A.O. Smithmotors are double sealed permanently lubricated. Ifit appears the bearings have failed, simply replacethem.

TIP: Noisy bearings are the first sign of bearingfailure. If the bearings are not replaced promptly,the motor can overheat causing the windings tofail. Bearing noise is often a sign that the pumpseal has been leaking. Always change the pumpseal when you change the bearings.

Chemicals Do not store or use chemicals close tothe motor.

Dirt Avoid sweeping or stirring dust near themotor while it is running.

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Operating Fault

If a fault occurs while the eMod is in the running mode,the motor will be turned off and the red LED will flash.After two minutes, the module will attempt to re-start themotor. After the three minute startup lockout, or if the circuit senses that the pump is primed, the unit will onceagain start monitoring motor input power. If conditions arestill not normal, the unit will fault out again. The eModwill attempt to restart like this four times. After the fourthattempt, the module will go to lockup mode. In lockupmode the red LED will be on. The only way to get out oflockup mode is to cycle power to the motor.

Faults that the eMod will attempt to recover from are:

• Motor input power too low

• Motor input power too high

• Motor current too high

• Motor temperature too high

• Power line voltage too low

• Circuit power supply fault

• Momentary loss of power

If the motor runs normally for at least nine minutes whenthe eMod returns to run mode, the fault counter will bereset back to zero. This means that it will now require fivenew faults to reach lockup mode again.

eMod®

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Fault Mode

If the eMod faults and goes immediately to a steady redLED condition, this means the fault that was detected wascritical, and the eMod went to lockup mode. The onlyway to get out of lockup mode is to cycle power to themotor.

The faults that are considered critical are:

• Power line voltage too high

• Ambient temperature too low

• Microprocessor fault

• Reset switch is stuck closed

• Bypass mode switch is stuck closed

The eMod performs a self check of its electronic circuitson startup. If upon application of power to the eMod, itimmediately goes to the fault condition, it is likely faultingon a failure of one of these circuits. Allow 15 or 20 min-utes for the circuitry and motor to cool down if excessiverunning temperature is suspected. If the fault will still notclear, the eMod system will need to be replaced.

The self check faults include:

• Circuit power supply fault

• Ambient temperature too low

• Microprocessor fault

• Software fault

• Line voltage sense circuitry not working

• Motor current sense circuitry not working

• Motor control relays stuck

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LED Indicator Map

Green LED Red LED Operating ModeOn Off Run ModeFlashing Off Priming ModeOff Flashing Non-Critical Fault

(circuit will attempt restart)Off On Lockup Mode

(cycle power to attempt restart)Alternate Flashing Alternate Flashing Calibration ModeFlashing Together Flashing Together Reset Mode

(cycle power to restart motor)On Flashing Bypass Mode

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eMod Load Sensing Module Specifications

Input Power

Voltage 102 to 130 vac rms single phase (low voltage connected)195 to 250 vac rms single phase (high voltage connected)

F re q u e n c y 58 to 62 hertz **Power Consumption 5 Watts maximum (eMOD only)Line Loss Ride Thro u g h 20 milliseconds minimum

E n v i r o n m e n t

Operating Te m p e r a t u re Range 14 to 122 °F (-10 to 50°C)Storage Te m p e r a t u re Range -15 to 150 °F (-25 to 65°C) H u m i d i t y 10 to 95% non-condensingA l t i t u d e 5000 feet maximumShock / Vi b r a t i o n 1G maximum (any axis)

E n c l o s u r e

L e n g t h 5.4 inchesWi d t h 3.5 inchesD e p t h 2.6 inchesWe i g h t 1 poundO t h e r drip and splash pro o f

O t h e r

U L / CSA C o m p l i a n c e tested to UL 6 0 7 3 0 - 1 AFCC compliance tested to CISPR11 Class BASME A 112-19.17 – 2002 SVRS Suction Lift Compliant

**Note: 50 Hz operation will result in incorrect timing. The eMod is rated for only 60Hz operation at the present time.

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Tro u b l e s h o o t i n gT h e re is not a single listing of motor trouble shoot-

ing pro c e d u res to be followed in a given ord e r. Thep ro c e d u res will differ depending on the situation.

As with anything dealing with electricity, personalsafety is of prime concern. Before you even touchthe motor, MAKE SURE THE POWER IS OFF.Always turn the power off at the electric servicefuse or breaker box. To prevent electrical shock, usea meter to check for electrical shorts and be sure the motor is securely grounded and bonded in conformity with local codes. Do not work on electrical devices if water or moist conditions arep resent and cannot be avoided.

If the motor is not operating pro p e r l y, refer to thef o l l o w i n g :Motor fails to start (makes no sound)

• Check the obvious first. A re the power switchand timer on?

• Check for blown fuse or circuit bre a k e r. If fusesa re used be sure fuses are the proper size or type.

• WITH THE POWER OFF, check all connectionson the terminal board. Verify they are correct byconsulting the wiring diagram on the motor.Make sure all connections are tight includingthe ground wire.

• Check the voltage at the terminal board afterfirst turning the power back on. Be sure toTURN THE POWER BACK OFF after complet-ing this step. Note: Voltage at motor terminalsshould be + or – 10% of the voltage on thenameplate. If the voltage is high, contact thelocal Power Company. If the voltage is lowcheck the wire size of the power line from theelectric box to the motor.

Checklist

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• Check for overloading from other appliances onthe same circuit as the motor.

• Inspect motor windings for continuity.

• P rotector tripped – wait until the motor coolsdown then restart – check protector for c o n t i n u i t y

Motor starts but shuts down (thermal overloadp r o t e c t i o n )

• Check the voltage at motor terminal. If it is toohigh call the local Power Company.

• Check amperage. If high, find out if the pumpimpeller was recently replaced (it could be sizedi n c o r rectly). Remember, motor horsepowertimes the service factor = total horsepower. To t a lhorsepower must be equal to or greater than theimpeller rating. Check for overloads.

Noisy Motor

• Check motor coupling, brackets and otherattached parts. Tighten loose nuts, bolts or sets c rews.

• Turn shaft. If it is rough or tight, check bearings

• Look for loose or binding parts inside the motoror the pump.

• Pump cavitation

Overheating (smoking or cycling)

• Check the motor’s ventilation by looking forclogged air vents or openings. Clean away alldirt and leaves or other debris from around them o t o r.

• Check internal cooling fan. Is it intact and operating pro p e r l y ?

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• C o m p a re connections to wiring diagram. Make suremotor is connected correctly for applied voltage.

• Low or high voltage. Voltage should be + or – 10% ofnameplated voltage. If it is higher that +10% call thelocal power company. If lower than –10% of thenameplated voltage check wire size from the servicefuse box or circuit bre a k e r. If the voltage is low fro mthe service use a motor one increment higher inhorsepower or an E-plus or Conservationist high eff i-ciency motor of the same horsepower and servicef a c t o r.

T I P: Electric demand on the power companyvaries. If the motor is nuisance tripping because oflow voltage it may only trip during the part of theday when electrical usage is the highest. Do yourvoltage checks at that time of day.

• High ambient temperatures. Pool motors are usuallydesigned to operate in 50 degree C ambients (122d e g rees Fahrenheit). Artificially high ambients canoccur if a motor operates in a confined space and re -c i rculates the same air or circulates air from anothermotor next to it.

• Check amp draw. If the amps are higher than name-plate amps but the voltage is acceptable, WITH THEPOWER OFF, inspect the motor and the pump formechanical obstructions that could cause an over-load.

• Look at motor windings and capacitors for damageor signs of shorting. Check for continuity.

• Application overload. In cases of flooded suction orpositive pre s s u re on the inlet side of the pump, flowmay be increased overloading the pump.

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• Misapplication. Make sure the motor is notundersized. Remember that total horsepower ishorsepower times service factor. The total horsepower must be equal to or greater than the pump/impeller rating.

• Check the motor start switch and governor (ifapplicable) to make sure it is adjusted pro p e r l yand is operational.

This section explains how to use test equipment.

Conventional Multimeter or Ohmmeter

An ohmmeter can be used to measure the resistance of the various motor windings as well as to test the insulation. The ohmmeter will haven u m e rous ranges from R x 1 where the meter re a d sd i rectly in ohms, to a Rx100K where the actualmeter reading must be multiplied by 100,000 for the actual ohm value.

B e f o re using an ohmmeter:

• Make sure the power is off .

• Read the instruction manual for the meter.

• All troubleshooting checks specify the ohmme-ter range to be used. If your meter does nothave the exact range, use the next higher range.

Test Equipment

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Digital Ohmmeter/Multimeter

D i rect reading digital ohmmeters are readily available in the field. To use this type:

• Make sure the power is off .

• Read instruction manual for the meter.

• You do not have to set the ohmmeter to a partic-ular scale as the meter displays the ohm valueup to maximum capability of the meter.

• Install probes and take resistance readings in thenormal manner.

Ammeter and Vo l t m e t e r

Voltmeter Readings:

Install leads in bottom of ammeter. Select thedesired voltage scale. Take readings by touchingone probe to each of the lead line terminals.

Ammeter Readings:

• Arrange leads so the jaws of the ammeter willencircle one lead.

• Set meter on maximum amp scale and encirclejaws around one lead and take reading. It maybe necessary to reset to a lower scale.

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Voltage Check• Make sure power is off.• Determine motor voltage and set meter• Reconnect power• Start the motor

Caution: All wires are live (hot) so use extensive care.

Touch one probe to L1 and the other to L2.Voltage reading to be within 10% of nameplate voltage, i.e. between 207 and 253 volts for a motornameplated 230 volts.

If no voltage is recorded, check fuses, circuitbreakers, timers, wiring, etc. for open connection or broken wires.

If voltage is outside the acceptable limits, checkfor adequate wire size. Look for loose terminals and connections or pitted contacts. Check pumpdisconnect switch.

Check voltage at service entrance. If not withinplus or minus 10% contact power company.

ElectricalChecks

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Amperage Check

• Make sure power is off.

• Set ammeter scale based on Max. Load amps.

• Position one line lead (L1 or L2) so that the jawsof ammeter can encircle one power lead. (It willusually be necessary to install a test loop tohave room for the meter jaws.)

• Make sure switch and governor are free ofobstructions (if applicable).

• Reconnect power

• Start the motor

Caution: All wires are live (hot) so use extensive care.

• Take a reading. The value should not exceedmaximum load amps (service factor amps) onthe motor nameplate.

Excessive amps means an overloaded conditionor incorrect voltage applied. Problem could also bea short in the motor.

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Perform the following checks to confirm that eachcomponent is functioning properly.

Ground Check

• Turn the power off.

• Set ohmmeter to R x 1K.

• Attach one probe to ground screw on the endframe and touch the other probe to all terminalson the terminal board, switch, capacitor and protector. A reading of less than 10K could indi-cate a ground. New motors typically read overone megohm. Old motors with dust, dirt andmoisture could show resistance to ground below10K and still run satisfactorily. A cleaning may bein order. Readings may vary from day to daydepending on humidity levels. Approximately25K at 115 volts will trip the ground fault device.Keep in mind the ground fault device is seeingthe total leakage of all loads on the circuit. GFI’snormally trip on readings from 4 to 6 milliamps.

• If grounded, check all external leads for cuts,breaks, frayed wires, etc. Replace damaged leadsand recheck for grounds and proper lead rout-ings, Make sure replaced leads are not pinchedbetween canopy or cover and end frame. Ifground is in the stator, the motor must bereplaced.

Start Switch Check (if applicable)

• Visual Checks

1. Make sure power is off.

2. Remove Canopy

• Discharge capacitor by touching the two terminals simultaneously with the blade of aninsulated handle screwdriver.

ComponentChecks

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• Make sure there are no obstructions preventing theproper operation of the rotating governor. Checkwiring and make sure none of the leads are in the areaof the governor where they can be cut or interfere withthe governor. Check governor for proper operationand make sure flipper moves freely.

• Check switch contacts for severely burned or pittedcontacts, sticking etc. Some blackening or pitting is normal after the motor has been used. Replace switch if there is any doubt. DO NOT try to repair the switch by bending the contact blades.

• The switch contacts in motors are plated and shouldnever be sanded which would remove the plating andcause early failure. They may be cleaned by wiping thecontacts with a piece of cardboard or paper bag.

• Attach one lead to each terminal of the switch.Ohmmeter reading should be 0. With one lead on eachterminal, flip governor weight to the run position.Reading should be infinity.

• Reconnect power

• Start the motor. Visually check the action of the switchand governor. Switch contacts must be closed whenmotor is at rest and should open when the motor reaches about 2/3 of full load speed.

TIP: Replace the capacitor and switch at the sametime. A defective switch usually stresses the startcapacitor.

Winding Continuity

For typical two compartment, single phase, dual voltageonly, capacitor start, single speed motor, connected for 230volts. Set meter to R x 1.

(For single voltage motors, check between L1 and L2.)

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Disconnect one of the red leads to the switch. Discharge capacitor byshorting across the terminals with the blade of an insulated handledscrewdriver. Take the following ohm readings.

Resistance between L2 and A must be the same as resistance betweenA and Yellow.

Yellow to Red (winding side of switch) must be same as L2 to sameRed terminal.

L2 & A A & YELLOW

L2 TO REDYELLOW TO RED

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Protector (Thermal Overload) Check

• Set ohmmeter to R x 1.

• Resistance between terminals:

1 & 2 should be approximately 0 (Disc.)

2 & 3 should be approximately 0 (Heater)

• Replace if either value exceeds 1 ohm.

TIP: Motor cycling on overload indicates someother problem not just a defective overload.

Capacitor Check (Start or Run)

• Set ohmmeter at Rx 1K.

• Slip a heavy piece of paper between points onthe switch.

• Discharge capacitor by touching the two terminals simultaneously with the blade of aninsulated handle screwdriver

• Attach one probe to each terminal. Ohmmeterneedle should move rapidly to right then slow-ly drift to the left. (Low ohm reading to highohm reading.)

• If digital meter is used, readings should startlow and rapidly increase to maximum value.

• Replace capacitor if bad.

TIP: The replacement capacitor must be thesame MFD as the original. However, if thesame voltage rating is not available it isacceptable to use the next higher voltage.Example; if a 370 volt unit is not available, use the next rating, 440 volt.

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eMod Technical Support Questions and Answers

S y m p t o m :My eMod equipped motor nuisance trips

(and has never run correctly).

Possible Pro b l e m :The motor is configured for the wrong input power line voltage.

S o l u t i o n :Verify what the line voltage to the pool pump motor is with an AC voltage meter. Ifthe line voltage is in the range of 110 and 120 volts, the motor should be configure dfor low voltage. If the line voltage is in the range of 208 to 240 volts, it should be c o n f i g u red for high voltage. Change the motor configuration with the voltage selectorswitch, or by moving wires on the motor terminal board as necessary.

Possible Pro b l e m :The motor rotor or pump impeller is jammed.

S o l u t i o n :Remove power from the motor, and then remove the rear cover from the motor. Ve r i f ythat the motor shaft turns freely by inserting a screwdriver into the slot on the end ofthe shaft, or by gently turning on the governor switch assembly with your hand. If themotor shaft does not turn fre e l y, it will be necessary to separate the pump and themotor so that it can be determined which of the two is binding. If the motor is bind-ing, it will need to be returned. If the pump is binding, verify that the pump partsw e re assembled corre c t l y, and that all parts are in good condition.

Possible Pro b l e m :Power line wiring is insufficient for the motor load.

S o l u t i o n :M e a s u re the voltage on the motor terminal board with an AC voltage meter whenpower is applied and the motor is making the humming sound. If the voltage sagsbelow 85 volts for 115 volt systems, or below 190 volts for 240 volt systems, there istoo much resistance in the wiring to the motor to start re l i a b l y. A s t ronger electricalsupply to the pump motor will need to be pro v i d e d .

Possible Pro b l e m :The eMod equipped motor is calibrated to the wrong motor load point.

S o l u t i o n :Follow the instructions in the Un-Calibrate section of this manual.

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A.O.Smith

S y m p t o m :When I plug the hose to my suction cleaner in, the eMod equipped

motor faults out.

Possible Pro b l e m :Air in the cleaner hose is being drawn into the pump. This causes the pump to temporarily lose prime. The eMod detects this and shuts the pump off .

S o l u t i o n :Use the water flow from the return line to the pool to chase the air out of the suctioncleaner hose before plugging it in. This will keep the pump from losing prime whenyou plug the hose in.

Allow the eMod to go through its reset period of two minutes. It will then restart thepump and try for three minutes to re-establish pump prime. This is usually enoughtime to clear the air out of the lines and return to normal operating conditions.

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S y m p t o m :My eMod equipped motor used to run fine, but now seems to fault a lot.

Possible Pro b l e m :Skimmer basket, strainer basket, or main drain in pool is plugged with debris.

S o l u t i o n :Verify that the baskets and drains are clear and clean if necessary.

Possible Pro b l e m :Filter needs to be cleaned.

S o l u t i o n :Check the pre s s u re gauge on the filter. If the pre s s u re has gone up more than 5 PSIf rom where it was when the filter was clean, the water flow through the system maybe reduced enough to cause the eMod to fault. Clean the filter if necessary. If the filteris a sand type filter, back-flush if necessary.

Possible Pro b l e m :Not enough water in pool to cover the skimmer.

S o l u t i o n :Pump is drawing air into the system because the skimmer is not covered in water. Theair causes the pump to partially lose prime and this causes the eMod to fault out. A d dwater to the pool if necessary.

Possible Pro b l e m :Diverter valve(s) that choose return lines from pool to pump are in wrong position.

S o l u t i o n :Check to verify that diverter valve(s) are in the position that they were when theeMod was first installed and calibrated. Return valve(s) to the original position if n e c e s s a r y. If it is desired to operate the pool with a new valve position as the “new”normal position, please recalibrate the eMod. Instructions on how to do this are located in the Un-Calibrate section of this manual.

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S y m p t o m :My two speed pump runs OK on high speed, but faults on low speed after

running several hours.

Possible Pro b l e m :Leak in plumbing system causes pump to lose prime. In high speed mode the pumpmoves enough water to absorb the air being leaked into the system. In low speedmode, however, the water flow is reduced to the point where the air bubbles accumulate in the strainer basket. Eventually the air bubble becomes large enoughthat the pump loses prime.

S o l u t i o n :Check to see that the strainer basket cover is tight, and the gasket is in good condition.Check the diverter valve(s) to make sure that it is in good condition and that the sealsin it are in good condition. Check any unions in the piping system for proper fit upand that the O-ring seal is in good condition.

S y m p t o m :The eMod runs for less than one second when power is applied and then quits.

Possible Pro b l e m :Failed relay on the eMod board. Each time the motor is powered up, the electro n i c schecks the motor control relays to verify that they are working pro p e r l y. If one of therelays is stuck shut, the motor will run for 1/2 to 1 second before the eMod electro n i c srealizes that something is wrong and turns the motor off .

S o l u t i o n :The eMod equipped motor will need to be re p l a c e d .

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S y m p t o m :My eMod equipped motor nuisance trips (and has never run correctly).

Possible Pro b l e m :The eMod mis-calibrated when system was first set up.

S o l u t i o n :Sometimes the pump has a hard time clearing all the air from the pool return lines inthe three minute window allowed by the eMod to do this. If this seems to be the case,follow the instructions in the Un-Calibrate section of this manual.

Possible Pro b l e m :Air leak in the pool plumbing system.

S o l u t i o n :Check the water flow in the strainer basket of the pool pump. If there is a heavy flowof air bubbles in the water, or if the strainer basket never fills with water, there may bean air leak in the suction side plumbing to the pump. Check to see that the strainerbasket cover is tight, and that the gasket is in good condition. Check the divertervalve(s) to make sure that it is in good condition and that the seals in it are in goodcondition. Check any unions in the piping system for proper fit up and that the O-ringseal is in good condition. Check for cracked pipes.

Possible Pro b l e m :Pump/motor is too large for pool plumbing system.

S o l u t i o n :Check the water flow in the strainer basket of the pool pump for a heavy flow of airbubbles in the water. How does the pump sound? If it is making lots of noise, similarto the sound of a car tire on a gravel road, the pump is cavitating. There are both signsthat the pump is trying to move more water than the pool plumbing is capable ofdelivering. Common causes of plumbing flow restrictions are long runs of small diameter pipe, too many elbows or valves, or the pump being located too high abovethe water level of the pool. If a change to the plumbing cannot be made to rectify thelimit to water flow, the best solution would be to try a smaller pump/motor c o m b i n a t i o n .

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S y m p t o m :My eMod equipped motor nuisance trips (and has never run correctly).

Possible Pro b l e m :Suction release valve of SVRS not adjusted corre c t l y.

S o l u t i o n :If a mechanical type suction release valve is located upstream of the pump, it may bebleeding air into the system. Adjust the release setting on the valve to keep a tighterseal during normal running conditions. NOTE: If any adjustment is made to the SVRS device protecting a pool, its pro p e roperation should be verified before allowing swimmers back in the pool. See the o p e r a t o r’s manual for the SVRS device in question for the proper pro c e d u re on howto do this.

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S y m p t o m :When I apply power to my pump motor, the eMod immediately displays a solid

red light. The motor doesn’t even attempt to start.

Possible Pro b l e m :Voltage applied to the motor is out of the allowable operation range.

S o l u t i o n :M e a s u re the voltage on the motor terminal board with an AC voltage meter whenpower is applied. If the voltage is not between 102 and 130 volts for 115 volt systems,or between 195 and 250 volts for 240 volt systems, the supply voltage is outside theallowable range for the motor. Check the voltage at other locations in the house to seeif they are within normal limits. If other circuits are OK, inspect the wiring of the poolpump branch circuit. If all the house voltages are out of limits, contact the local poweru t i l i t y.

Possible Pro b l e m :Te m p e r a t u re of the eMod electronics is too high or too low. The rated temperature ofoperation for the eMod and pump motor is from 14˚F (-10˚C) to 122˚F (50˚C).

S o l u t i o n :If the temperature is around 14˚F (-10˚C), the pump may be in danger of freezing up.If the pool water is heated and just the pump motor is cold, a method of keeping theeMod and motor at a more moderate temperature will need to be pro v i d e d .

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S y m p t o m :When I apply power to my pump motor, the eMod immediately displays a solid

red light. The motor doesn’t even attempt to start.

Possible Pro b l e m :Te m p e r a t u re of the eMod electronics is too high or too low. The rated temperature ofoperation for the eMod and pump motor is from 14˚F (-10˚C) to 122˚F (50˚C).

S o l u t i o n :If the temperature is around 120˚F (50˚C), wait until a cooler part of the day to see ifthe motor will now run again. If temperatures this hot are seen re g u l a r l y, pro v i d i n gshade from the sun for the eMod and pump motor will give more reliable service.Also check to see that the cooling holes around the bottom of the motor are free ofo b s t ructions and debris.

Possible Pro b l e m :Internal fault in the electro n i c s .

S o l u t i o n :If voltage temperature issues can be discarded, it is likely an internal fault in the eMode l e c t ronics that is causing the problem. The motor will need to be re p l a c e d .

S y m p t o m :When the power is applied to my eMod equipped motor, it runs for about 30

seconds and then stops. A solid red light is displayed.

Possible Pro b l e m :The un-calibrate button or clean mode button is stuck.

S o l u t i o n :With the power to the motor off, try pushing the un-calibrate button and the cleanmode button several times. Also wiggle the rubber actuator back and forth in thehousing a little as occasionally the button gets hung up in the housing. Re-applypower to the motor to see if this clears the problem. If not, the motor will need to bere p l a c e d .

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A. O. Smith pool and spa motors are builttough, to run day after day without being ser-viced. When service is necessary serviceable partscan be accessed quite easily. Whether it is theA.O. Smith two compartment design with mostserviceable parts in the “control room” under therear canopy or the Century Centurion with externally mounted capacitor and“switchless” design, installing new parts is easy and quick.

All of the motors covered by this manual are similar in design and construc-tion but may vary in type of protector, type of flange or electrical type. Whendisassembling, make sure you note the exact location of all components so theycan be reassembled properly. This is especially true of the bearing assemblywhere the number of small parts (rings, washers, etc.) could easily be assembledincorrectly.

Make sure you note the position of all the lead wires on the terminal boardand where they are routed.

Motor Assembly

CENTURION56 FRAME SQUARE FLANGE

POOL & SPA ASSEMBLY

S e r v i c e

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CENTURYFLEX-48

POOL & SPA ASSEMBLY

TWO COMPARTMENT56J FRAME

POOL & SPA ASSEMBLY

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When ordering parts refer to the catalog numberor model number and serial number on the motornameplate.

All A.O.Smith motors have some method of locking the shaft so the impeller can be removed.Do not stick a screwdriver into the vent holes toprevent the cooling fan from turning to lock up the shaft. Some fans are plastic and will break.

Two compartment designs have a flat on theshaft under the governor assembly. It can beaccessed by carefully sliding a 7/16” open-endwrench under the protector at 12 O’clock until itdrops over the flats on the shaft.

Older Century Centurion models have flats onthe rear end of the shaft. Access to the flatted portion of the shaft is achieved by removing asmall metal cover on the rear end frame with ascrewdriver.

Current Century Centurion models have aplastic cover that can be removed by turning it 1/4 turn counterclockwise with a 15/16” wrenchand pulling out. The end of the flatted shaftextends out from the rear of the motor. The shaftcan be locked using a 1/2” wrench .

Century Flex 48 motors have a screwdriver slot or a hex hole (that requires a 5/16” hex socket wrench) on the end of the shaft.

ImpellerRemoval

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BearingReplacement

Replacing a bearing in a motor is not a diffi-cult task, provided you follow these set proce-dures. If a bearing is noisy or doesn’t runsmoothly, it should be replaced. If a bearing isremoved for any reason, it should be replacedwith a new one. If it’s necessary to replace onebearing, replace the other as well to preventreturn service calls and pump down time.

Use only A.O. Smith bearings obtained fromA.O. Smith and ordered by the proper A.O. Smith part number. Bearings obtained from A.O. Smith are built with balls having a specificfit, checked for sound level and filled with high-grade grease for the temperature and serviceconditions. A.O. Smith bearings are lubricatedand require no further attention during their life.Do not substitute. Do not reuse old bearingspulled from shafts because this could damagethe motor and cause a return service call.

After the power has been shut off and themotor disassembled from the pump follow thesesteps:

Note: Disassemble the pump in accordance with the pump manufacturer’srecommendations.

1. Mark the end frames and shell of the motorwith two pieces of tape or a marker so themotor can be reassembled in the original configuration.

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2. Remove the rotor and shaft from the shell by:

(Century designs skip to 3.) For TwoCompartment design, remove the canopy.Remove the switch to get access to the governoron the end of the shaft. Remove governorsprings. Remove governor weight by spreadingthe bracket with a screwdriver. Take out screwon the end of the shaft and remove governorbracket. (See section on “Switch Adjustment”for instructions on how to set the switch whenthe motor is reassembled.)

3. Remove the four thru-bolts.

4. Remove the end frame opposite the shaft byputting a screwdriver in the notch and tappingthe handle of the screwdriver.

5. Remove the shaft end frame, using the samemethod. Carefully pull the rotor and shaftassembly out of the shell from shaft extensionend. Be careful not to lose the washer and bear-ing load spring that is positioned in the bearingbore in the end frame opposite the shaft exten-sion. Be sure to replace the washer and springduring re-assembly.

6. Remove the bearing locking screws from theshaft end frame.

NOTE: New motors do not have a lock plate.They have a lock clip that is attached to the endframe with a single screw. The screw is locatedin one of the two holes that used to be used forthe lock plate screw. Turn the screw 1/2 turn torelease the bearing from the end frame.

Lock clip

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7. Remove the shaft collars or snaprings used to secure the bearings.(You will need a pair of external ringpliers).

8. Use a bearing puller. (See“Recommended Tools”) to removedefective bearing(s).

9. Install new bearing using a tube thatpresses only on the inner race of thebearing. (See “Bearing InformationTable” for size of tube that isrequired.) Do not put pressure on theouter race of the bearing. The bearingwill be damaged.

Re-assemble in the reverse order of thedisassembly instructions. If the motor isa Two Compartment design make sureyou adjust the start switch correctly. (Seepages 35-36). Make sure there are noleads in the area of the rotating governor.When the canopy is installed make sureno leads are pinched between the canopyand end bracket.

Warning: Pinched wires or wires thatcome into contact with the rotatinggovernor could cause a ground faultthat is very dangerous should powerbe applied without the motor beingproperly grounded.

For all designs, recheck wiring. Checkrotor and shaft to make sure it turnsfreely by hand. Check motor for groundsbefore applying power.

Pump Motors 51

A.O.Smith

Bearing Installation Tube Dimensions(In Inches)Bearing Dimensions

A.O. SmithBearingPart No. Outer

Diameterof Tube

WallThickness

MinimumLength

BearingSize Width

(Inches)

Diameter (Inches)

Inside Outside

203

204

304

205

.6693

.7874

.7874

.9843

1.5750

1.8504

2.0472

2.0472

.470

.5512

.5906

.5906

604005-001

100025-002

603628-001

603628-003

7/8

1

1-1/4

.095

.095

.125

3

3

3

BEARING INFORMATION TABLE

RECOMMENDED TOOLS

Single Speed

• In November 2001, A.O. Smith began pro d u c i n gmotors with a no-adjust switch. It is a one-piecedesign eliminating the need for the “U” bracket.The new switch needs no adjustment. Justassemble to the end frame. Make sure the plasticbutton is riding on the governor projection.

• Older models use only one screw to secure andadjust the switch. Very old models have twoscrews. One to hold the switch in place andone for adjustment.

• Fasten switch snugly to end frame, through “U”bracket with screw provided.

EXTERNAL RING PLIER SNAP-ON TOOLSMODEL NO. PRS 22 OR EQUAL

TRU-ARC PLIERS

BEARING INSTALLATION TOOLS

BEARING PULLER SNAP-ONTOOLSMODEL NO. CG-250 OR EQUAL

Start SwitchInstallation andAdjustment

52 Pump Motors

A.O.Smith

• A slight amount of switch movement is possible before the screw (s) aretightened. Check to see that the switch button is centered over the governorprojection.

• Reach in and move the governor weight (overcoming the spring tension)until it touches the stops on the governor. The clearance between the projection on the governor weight and the white button on the switchshould be .010” to .040” (.040 is about the thickness of paper clip wire).

• When installing a new or used switch, the “U” bracket should be openedslightly to insure sufficient tension against the screw. Tighten only whenadjusting. If the screw is loosened, it should be removed and the “U” bracket should again be opened slightly.

• Under no circumstances should switch contact blades be bent or deformedin an attempt to obtain proper contact clearance.

2 Speed

Proper starting switch adjustment on two-speed motors is essential for satisfactory operation and contact life. • Disconnect all power to the motor before attempting any repair. Repair

work should only be performed by a qualified electric motor technician.• Fasten switch snugly to end bell, through “U” bracket with switch

mounting screw provided.• A slight amount of switch movement is possible before the screw(s) are

tightened. Check to see that the switch button is centered over the governor projection.

PLASTIC BUTTON

GOVERNOR PROJECTION

MOTOR SHAFT

START SWITCH

"U" BRACKET

SWITCH ADJUSTING SCREW—TIGHTEN ONLY—

GOVERNOR WEIGHT

REMOVE AND OPEN "U" BRACKET SLIGHTLY TO INSURESUFFICIENT SCREW TENSION WHEN INSTALLING NEWSWITCH OR AFTER SCREW HAS BEEN LOOSENED.

.010”

.040”

Pump Motors 53

• Lift governor weight (overcoming spring tension) until it touches the stopson the governor. Clearance between the governor projection and the switchbutton should be .010” to .040 “.

• Most newer models use only one screw to secure and adjust the switch.When a new switch is installed, or an existing switch is being reinstalled,the “U” bracket should be opened slightly to insure sufficient tensionagainst the screw. Tighten only when adjusting. If the screw is loosened, itshould be removed and the “U” bracket should again be opened slightly.

• Under no circumstances should switch contact blades be bent or deformedin an attempt to obtain proper contact clearance.

• Once the governor weight is released and the governor projection pushes onthe switch button, contact “Z” should move away from the motor byapproximately .030”. This movement assures that the points will have suffi-cient contact, no matter what position the rotor/shaft and governor projec-tion are in at rest.

• In run position contacts “X” and “Y” must be open and contact “Z” closed.At rest contacts “X” and ‘Y” must be closed and contact “Z” open.

Other information valuable in servicing an Electric Motor can be found in theTrouble Shooting section.

SWITCH ADJUSTING SCREW—TIGHTEN ONLY TO OBTAIN PROPER CLEARANCE—

SWITCH BUTTON

X

Z

Y

SWITCH ASSEMBLY

SWITCH MOUNTING “U” BRACKET GOVERNOR ASSEMBLY SHOWNIN OPEN POSITION

CLEARANCE WHENACTUATOR IS INRUN POSITION ASSHOWN

.010

.040

START CONTACTS

REMOVE AND OPEN "U" BRACKET SLIGHTLY TO INSURESUFFICIENT SCREW TENSION WHEN INSTALLING NEWSWITCH OR AFTER SCREW HAS BEEN LOOSENED.

2 SPEED SWITCH ADJUSTMENT

531 NORTH FOURTH STREETTIPP CITY, OH 45371

937) 667-2431FAX: (937) 667-5873

www.aosmithmotors.com

© 2006 A.O. Smith Corporation Bulletin #3400 11/06

For motors manufactured in/after Nov., 1991 (Serial #BJ11)Dual Vo l t a g e Type CX-1⁄2 to 11⁄2 H p230/115 Vo l t S w i t c h l e s s

HIGH VOLTAGE LOW VOLTAGE

Centurion®/SE/II

38 Pump Motors

For motors manufactured in/after Nov., 1991 (Serial #BJ11)Single Vo l t a g e Type CX-11⁄2- 5 H p230 Vo l t S w i t c h l e s s

EXTERNAL CONNECTIONS

A.O.Smith

A.O.Smith


Wiring Diagram #166359. Connection Label #166362.

Dual Vo l t a g e115/230 Vo l t

Type CX–1⁄2 to 11⁄2 H pSwitchless

For motors manufactured prior to Nov. 1991. (Serial #BJ11)

Pump Motors 39

Centurion®

Single Vo l t a g e230 Vo l t

Type CX–2, 3 & 4 HpSwitchless


Wiring Diagram #166360. , 166361 Connection Label #166363.

For motors manufactured prior to Nov. 1991. (Serial #BJ11)

1081

40 Pump Motors

A.O.Smith


INTERNAL WIRING EXTERNAL CONNECTIONS

115/230 Vo l t Type CS–1⁄2 to 11⁄2 H pWishbone (Old Style)



115/230 Vo l t Type CP–2 HpWishbone (Old Style)

A.O.Smith

Pump Motors 41

1081



LOW VOLTAGE HIGH VOLTAGE


115/230 Vo l t Type CS–1⁄2 to 11⁄2 H pSingle Arm Switch (Old Style)

230 Vo l t Type CP–3 HpWishbone (Old Style)

1081

E-Plus®

42 Pump Motors

A.O.Smith

115/230 Vo l t Type CP–2 HpSingle Arm Switch (Old Style)




Wiring Diagram #156228.

230 Vo l tType CX–2 and 3 Hp

Switchless (Old Style)

A.O.Smith

Pump Motors 43

2 Speed



115 Vo l t Type CSM–1⁄2 to 3⁄4 H pWishbone (Old Style)



230 Vo l t Type CSM–1 and 11⁄2 H pWishbone (Old Style)

2 Speed

Micro-Switch Motor

44 Pump Motors

A.O.Smith



230 Vo l t Type CPM–2 HpWishbone (Old Style)



( F o rmerly identified asG o u l d - G u a rd )115/230 Vo l t

Type CS–1⁄2 to 1 Hp(Old Style)

A.O.Smith

Pump Motors 45

Switchless Motor

HIGH VOLTAGE


( F o rmerly identified as G o u l d - G u a rd )230 Vo l t

Type CX–11⁄2 H PSwitchless (Old Style)

HIGH VOLTAGE


( F o rmerly identified as G o u l d - G u a rd )230 Vo l t

Type CX–2 and 3 HPSwitchless (Old Style)

Centurion®

46 Pump Motors

A.O.Smith



Two-Speed Single Vo l t a g e115 Vo l t

Type CXPM–1⁄2 /.06 to 3⁄4 /.10 HpSolid-State Switch



Two-Speed Single Vo l t a g e230 Vo l t

Type CXPM–1/.12 to 2/.25 HpSolid-State Switch

A.O.Smith

Pump Motors 47

E-Plus® Switchless



Dual Vo l t a g e115/230 Vo l t

Type CX–3⁄4 to 11⁄2 H pSwitchless



Single Vo l t a g e230 Vo l t

Type CX–2 and 3 HpSwitchless

Flex 48® Frame48 Pump Motors

A.O.Smith



Two Speed Single Vo l t a g e115 Vo l t

Type SPM–3⁄4 /.10 HP



Two-Speed Single Vo l t a g e115 or 230 Vo l t

Type CXSM 11⁄2 /.18 HP Type CXSM 2.0/.25 HP t h rough 4.5/.50 Spl HP

A.O.Smith

Pump Motors 49

Flex 48® Frame

Flex 48®



Two-Speed Single Vo l t a g e115 or 230 Vo l t

Type CSM 1.0/.12 Hp 115 Vo l tType CSM 1.0/.16 Hp 115 Vo l tType CSM 1.5/.18 Hp 230 Vo l tType CSM 2.0/.25 Hp 230 Vo l t

WITHOUT AIR SWITCH WITH AIR SWITCH


Single Vo l t a g e115 Vo l t Type SP–1⁄2 to 11⁄2 H p

SINGLE SPEED MOTOR — TYPICAL SCHEMATIC DIAGRAMSCapacitor Start

Induction Run — Single Speed

EXT. & WIRE ROUTINGDual Voltage — Single Speed — Capacitor Start

With Voltage Change Plug

NOTE: When the voltagechange plug is in the 115 voltposition, the black lead is onthe "L2" terminal and theblack/white tracer is on the

"A" terminal. Whenthe voltage changeplug is in the 230volt position, theblack lead is in the

"A" terminal and theblack/white tracer is isolated.

50 Pump Motors

A.O.Smith

A.O.Smith

Pump Motors 51

Capacitor StartCapacitor Run — Single Speed

SWITCH

RUN. CAP.

SINGLE SPEED MOTOR — TYPICAL SCHEMATIC DIAGRAMSCapacitor Start* or Split Phase

Single Voltage on Winding Protector

*Capacitor not shown in schematic.

SWITCH

52 Pump Motors

A.O.Smith

SWITCH CONNECTIONS — HIGH SPEED START

WHITE

(COMMON)

(FROM START WINDING)RED TRACER

BLACK TO #3

YELLOW TO #1

(4 POLE MAIN)

(2 POLE MAIN)

STARTCAPACITOR

LOW

HI

YELLOW TO #5

YELLOW TO #1 TO #5

TERMINAL #1

TERMINAL #5

TERMINAL #4

TERMINAL #3

TERMINAL #2

BLACK TO #4

RED TO #2

END VIEW

TOP VIEW

SWITCH CONNECTIONS — LOW SPEED STARTLow speed start — this design motor always starts on the low speed

(4-pole) windings. When the control calls for high speed run, the start switchautomatically switches the motor to high.

WHITE

(COMMON)

LOW

HI

YELLOW TO #4BLACK TO #5

BLACK #1 TO #5

TERMINAL #1

TERMINAL #5

TERMINAL #2

BLACK TO #1(2 POLE MAIN)

(4 POLE MAIN)

RED TRACER(FROM START WINDING)

YELLOW TO #3

RED TO#2

YELLOW TO #4

TERMINAL #3

TERMINAL #4

TOP VIEW

END VIEW

▼

▼

A.O.Smith

Pump Motors 53

54 Pump Motors

A.O.Smith

2-SPEED MOTORS — HIGH SPEED STARTSCHEMATIC DIAGRAM

2-Speed for Remote Switch Operation

LINE VOLTS(HIGH SPEED)

LINE VOLTS(LOW SPEED)

BLACK

YELLOW

START - X & Y CLOSED ZOPENRUN - X & Y OPEN Z CLOSED

BLACK

REDCAPACITOR

START

HI

YX

WHITE

Z

Pump Motors 55

A.O.Smith

2-SPEED MOTORS — HIGH SPEED START SCHEMATICDIAGRAMS AND RECONNECTION INSTRUCTIONS FOR

REMOTE OPERATION2-Speed with Hi - Low Switch

Mounted on Motor Canopy

RECONNECTION FOR REMOTE SWITCH OPERATION

BLACK

BLACK

PURPLE

CANOPY SWITCH

LINE VOLTS

YELLOW MUST BE CONNECTEDTO BOTTOM TERMINAL WITHSWITCH IN POSITION SHOWN

START - X & Y CLOSED Z OPENRUN - X & Y OPEN Z CLOSED

RED

RED

HI

WHITE

CAPACITOR

START

YELLOW

LOW

YELLOW

HI-LOW SWITCH

PURPLE

REMOVE BOTH YELLOW LEADSFROM ‘A’ TERMINAL AND CONNECTTO TERMINAL L1.

REMOVE BLACK LEAD FROM HI-LOWSWITCH AND CONNECT IT TOTERMINAL A.

LEAVE SWITCH IN CANOPY ANDLEAVE PURPLE LEAD CONNECTEDTO SWITCH.

CONNECT POWER SUPPLY LINES TOTERMINAL BOARD

L2-L1 HIGH SPEEDL2-A LOW SPEED

BEFORE REPLACING MOTORCANOPY, BE SURE ALL LEADS AREPROPERLY PLACED TO PREVENTDAMAGE FROM GOVERNOR AND/ORCANOPY.

NOTE: Several different connections have been used in production. If the wiring on the motoryou are reconnecting does not match these diagrams contact A.O. Smith and we willFAX or mail a connection for that model.

56 Pump Motors

A.O.Smith

PURPLE

SWITCH BOX

BLACK TRACER

YELLOW

COMMON

DISCONNECT PURPLE AND YELLOWLEADS FROM HI-LOW SWITCH ANDCONNECT TOGETHER.

DISCONNECT BLACK TRACER LEADFROM HI-LOW SWITCH PERMANENT-LY. TAPE UP EXPOSED END.

CONNECT POWER SUPPLY LINES TOTERMINAL BOARD

L2-L1 HIGH SPEEDL2-A LOW SPEED

2-SPEED MOTORS — HIGH SPEED START SCHEMATICDIAGRAMS AND RECONNECTION INSTRUCTIONS FOR

REMOTE OPERATION2-Speed with Hi - Low Switch

Mounted in External Box

START

BLACK

CAPACITOR

YELLOW

RECONNECTION FOR REMOTE SWITCH OPERATION

L2

L1

B

A

NOTE: Several different connections have been used in production. If the wiring on the motoryou are reconnecting does not match these diagrams contact A.O. Smith and we willFAX or mail a connection for that model.

531 NORTH FOURTH STREETTIPP CITY, OH 45371

937) 667-2431FAX: (937) 667-5873

www.aosmithmotors.com

© 2006 A.O. Smith Corporation Bulletin #3400 12/06

pump motors - pool1.com or swimming pool … · 2 pump motors a.o.smith i n s t a l l a t i o n...

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