Aqua Control SELECT Series 2 User manual

PRE-ASSEMBLY
1. Check the packing list that came with the shipment. Make certain all the boxes have been received. Each label will have a box number
and total for the shipment (1 of 5, 2 of 5). The packing list has the total number of boxes noted at the bottom.
2. Check the pond depth. Is the pond deep enough for the unit being installed?
3. Verify the incoming voltage where it will be connected to the control panel. Does the measured voltage match the rated
motor voltage requirements? Note the HP, voltage and phase on the packing list.
4. Is there a VFD operating from the same power supply or in the vicinity that might interfere with the GFCI?
TABLE OF CONTENTS
SAFETY INFORMATION
WARNING
This product is not intended for use by young children or infirm persons unless they have been adequately supervised by a responsible person
to ensure that they can operate the product safely.
Young children should be supervised to ensure that they do not play with the product.
Your Aqua Control, Inc. products are made entirely of corrosion resistant materials including stainless steel, aluminum alloy, bronze and
engineered plastics. They will provide safe, long and satisfactory service if properly installed, operated and maintained.
1. Follow all applicable local and state electrical codes.
2. Protect exposed or vulnerable wiring with tubing or conduit.
3. Do not operate the unit when it is obvious the flow rate is reduced.
4. Do not work on the unit when it is turned on or operating.
5. Follow all normal safety precautions when working in and around the water.
6. Prevent tension on the electrical wires.
7. Do not carry or pull the unit by the lights or by the cable. Use the finger pockets on the float.
8. Never try to dislodge debris from the impeller or propeller while the motor is connected to the power supply.
10. Any time high voltage electricity is used underwater, a potential safety hazard exists. Aqua Control builds and provides
UL listed control panels that are standard equipped with a Class A Ground Fault Circuit Interrupter (GFCI) for both motors and
lights. Class A GFCI’s are designed to provide protection against electrocution for people. They have a nominal trip level of 5 ma
Maintenance
Prior to installing, verify the correct product has been ordered and received. Aqua Control, Inc. will not accept any returns for refund or exchange
factory or contact the factory for instructions as to how to obtain packaging for safe return of product.
of product or components that have been installed in the water or modified in any way. Keep original packaging for returns to the
PAGE PAGE PAGE
9. Always verify the control panel and all electrical equipment are grounded properly.
and are designed to shut the circuit off in 25 milli seconds. Such a system will shut off a current resulting from shorts or
dangerous leakage, whether from the motor, electrical cables or controls, befor a hazardous current can develop.
Lights 6
Light Cable & T-Connectors 7
Connector Identifications 8
Horizontal 3 Anchoring 11
Safety 1
Cable Troubleshooting
60 Hz. SELECT SERIES 2 DISPLAY AERATOR INSTRUCTION MANUAL
Aqua Control Water Features
Copyright 2014. All Rights Reserved. Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual 1
Nozzles Flotation 12
Nozzle Types 4-5
Installation / Launching
Assembly Control Panel & Start Up 9
Vertical & Torrent 2 Mooring 10
General 15
Cable 16
Motor Control Box 17-18
Overload 19
Freezing Weather Removal 13
Winter Sinking 14

SELECT SERIES 2
VERTICAL DISPLAY AERATOR & TORRENT ASSEMBLY
1. Remove the unit and hardware package from its box.
2. Inspect the motor lead and connector for any shipping
damage.
3. Remove the (3) three bolts with the cap nuts and lock
washers from the bottom holes in the head.
4. Remove the head from the upper tube.
5. Slide the float over the upper tube, flat side of float
toward the lower pump, lining up the key way in the
center of the float with the key on the upper tube.
6. Open the hardware package and remove the (2) two
large eye bolts. The eye bolts need the hex nut screwed
all the way on with the lock washer next and the flat
washer last.
7. Attach the two eye bolts to the underside of the float.
8. Slide the head over the upper tube, lining up the holes.
Replacethe hardware with the head of the bolt on the
inside of the upper tube and the lock washer and cap
nut on the outside of the head.
9. If this is a saltwater unit, all of the threaded inserts
in the float are plugged by the factory during assembly
except under the eye bolts. If the unit has lights, remove
the rubber washer and then attach the brackets (pg 6),
replacing the rubber washer between the bracket and
the float. Plug any remaining inserts with the weight
pins or the 1/2" screws, lock washers, flat washers and
rubber washers. The rubber washer always goes
between the insert and the hardware.
10. Attach the tip rope between the larger hole on the suction
screen and one of the eye bolts attached to the bottom of
the float.
11. The float has 12 finger pockets molded into the underside
for lifting and carrying the assembled unit.
12. See the nozzle and light set instructions for attaching these
to the unit.
2
Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual

Head Plastic
snap-in-cap
SuctionScreen
End Plate
RubberGrommet
Motor Lead
Assembly
CompositeSuction
Screen
Float
HorizontalDischarge
Assembly
Lower PumpAssembly
SELECT SERIES 2
HORIZONTAL DISPLAY AERATOR ASSEMBLY
Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual
Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual
3
determine the nozzle type, see page 4.
To attach the nozzle, see page 5 for the nozzle instructions.
If the unit has lights, see page 6 for the light set instructions.
The float has 12 finger pockets molded into the underside of lifting and carrying the assembled unit.
All horizontal units are shipped assembled therefore, NO assembly is required.
To

DISPLAY AERATOR NOZZLES NOZZLE TYPE
Lily Type 2
Pentalator Type 1
Quad Type 1
Scepter Type 1
Spider & Arch Type 1
Super Lily Type 2
Vertical Tornado Type 1
Winter Scepter Type 1
Weeping Willow Type 1
Triple Tier Type 2
Trillium Type 1
Torrent Type 1
NOZZLES
Cluster Arch Type 1
Crown Gusher Type 2
Daffodil Type 2
Delmar Type 1
Double Arch Type 1
Horizontal Tornado Type 2
Select Series 2 aerator nozzles are not interchangeable with any other aerator or fountain.
Find the nozzle that is being attached to this unit in the table below. This table will tell you which of the two nozzle types a nozzle falls under to
locate the correct instructions. The flow straightener has beenreplaced by the outlet fairing in the Select Series 2.
Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual
4

NOZZLES
1. Remove the screws with lock washers from the spray cone; and the hex-head bolts, lock
washers, and flat washers from the discharge head spoke.
2. Remove the hardware in the center row of holes in the head using a 5/16” wrench on the cap
nut. This hardware will not be reused.
3. Open the packet of petroleum jelly and apply it generously to the o-ring on the flange of the
nozzle.
4. Holding the nozzle by the tip of the threaded rod, line up the threaded holes of the discharge
head spoke with the center row of holes in the head. Slide the discharge head spoke inside
the head and attach with the hex head bolts, lock washers, and flat washers removed in step
#1.
5. Slide the flange of the spray cone into the head, lining up the holes.
6. Re-attach the screws with lock washers removed in step #1.
7. The nozzle has been pre-set at the factory.
NOZZLE TYPE 2 – SPRAY CONE WITH DISCHARGE HEAD SPOKE
NOZZLE TYPE 1 – MULTIPLE NOZZLE CASTING/SPRAY CONE
1. Remove the screws with lock washers from the threaded holes in the nozzle.
2. Open the packet of petroleum jelly and apply it generously to the O-ring on the flange of the
nozzle.
3. Slide the flange of the nozzle into the head, lining up the holes.
4. Re-attach the hardware removed in step #1.
NOZZLE
HEAD
LILY PLATE
SPRAY CONE
DISCHARGE
HEAD SPOKE
HEAD
Remove and dispose (step 2)
Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual 5
Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual

U-BRACKET
FLOAT
LIGHT
HEX NUTS HEX BOLTS
HEX BOLTS
ANGLED FLOAT
BRACKETS
U-BRACKET
FLOAT
LIGHT
FLAT BRACKET
ANGLED FLOAT
BRACKETS
FLAT
BRACKET
6Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual
HEX BOLTS HEX NUTS
LIGHT SET ASSEMBLY
SELECT SERIES 2 FRESHWATER & SALTWATER
SELECT SERIES 2FRESHWATER
SELECT SERIES 2 SALTWATER
6. Using (2) two hex head bolts, (2) lock washers
and (2) hex nuts, attach the light bracket(s)
to the flat float bracket(s). The slots in
the light U-bracket need to be pointed up
towards the top of the unit. The light
U-bracket is shown attached at the
optimum height if the unit is floating
at the recommended depth. (See flotation
on page 12 for adding weights.) If the unit
is floating higher and is not going to be
weighted down, then the light bracket
will need to be attached lower. The
lights must be 2" below the surface of
the water when the unit is running.
4. Attach a flat float bracket to each set of
angled brackets using a hex head bolt,
lock washer and hex nut at each angled
bracket.
5. Take the light canisters with light brackets
attached out of the box. Stretch out the
light leads to make sure they are not tangled.
1. Open the light set box and remove the plastic
bagcontaining brackets and hardware. The
packagecontains (1) one straight float
bracket, (2) two angled float brackets, (6)
hex head bolts, (6) lock washers and (4) four
hex nuts for each light set.
2. Attach (1) one of the angled float brackets to
the top of the float at any one of the
threaded inserts. Place a lock washer on a
hex bolt and put the bolt through the
middle hole or the hole furthest from the
angle on the bracket. Thread the hex bolt
into the insertand tighten. Repeat this step
for each light in the set, placing the brackets
symmetrically around the float.
7. For saltwater units, all of the threaded
inserts in the floats are plugged by the
factory during assembly except under the
eye bolts. Remove the rubber washer and
attach the bracket by replacing the rubber
washer between the bracket and thefloat.
Plug any remaining inserts with the weight
pins or the 1/2" screws, lock washers,flat
washer and rubber washers. The rubber
washer always goes between the insert and
the hardware.
3. Attach the remaining angled float brackets
to the bottom of the float directly below
the brackets attached in step 2, using the
same hardware as in step 2. Usethesame
hole in step 3.
8. The unit is ready to be floated after
the cable connection(s) have been
made.
HEX BOLTS

FROM CONTROL PANEL
LIGHT SET CONNECTOR
T-CONNECTOR
LIGHTS
LIGHT SET
CONNECTOR
LIGHT SET CONNECTOR
LIGHT CABLE ASSEMBLY
3-WIRE LIGHT CABLE (one light set)
LIGHT CABLE CONNECTOR
T-CONNECTOR LIGHT CABLE (two light sets)
LIGHT CABLE CONNECTORLIGHT CABLE CONNECTOR
Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual
7
Join and hand tighten connectors.
Join connectors and hand tighten.
The T-Connector Light cable has two 3-wire connectors connected to one 4-wire cable. One of the two connectors is marked with
red tape. Theone without tape gets its power from the black wire in the 4-wire cable. The two connectors share the ground and
neutral line.

Blue connector caps are used to protect the connectors during handling and to keep them dry if submerged
while unconnected to mating connectors.
CONNECTOR CAPS
WIRE IDENTIFICATION
2 Wire with Ground 2 Wire with Ground 3 Wire with Ground 3 Wire with Ground
Neutral
Hot
Ground
Ground
Neutral
Hot
Red
Yellow
Ground
Black
Ground
Black
Red
Yellow
CONNECTOR IDENTIFICATION
FROM CONTROL PANEL
MOTOR LEAD CONNECTOR
FROM CONTROL PANEL
MOTOR LEAD CONNECTOR
WARNING: Do not use grease on connectors. No tools are required for tightening.
FROM CONTROL PANEL
FROM LIGHTS
4-WIRE PUMP CABLE3-WIRE PUMP CABLE
LIGHT CABLE
CONNECTORS
CONNECTOR CAPS
Motor Lead Connector Pump Cable Connector Motor Lead Connector Pump Cable Connector
& Light Set Connector & Light Cable Connector
8Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual

Aqua Control Inc. (ACI) is certified to manufacture UL Listed Industrial Control Panels (UL 508A), and all control panels are UL listed except 460V panels
or panels built with prior agreement for certain special configurations. Certain special configurations, the 1hp-115V, all 460V and all 575V control panels
LOCATION OF CONTROL PANELS
Control panels should always be installed in a manner that minimizes heat inside the panel since the panels generate some heat and they contain heat
sensitive components (motor overloads). Sunlight is the most significant source of heat, so the control panels should be installed out of direct sun as much
as possible. The door of the control panel, particularly, should not face south or west unless it is protected from sunlight.
START UP
changed. The correct voltage and amperage ratings are on the schematic and on the door label of the control panel.
CONTROL PANELS
INSTALLATION
cannot be UL Listed because of the National Electric Code and UL requirements.
At installation and initial start up, it is recommended to record the actual voltage under load (while the unit is running) and the running amperage of the
unit. This can be kept inside the control panel for future reference. This allows for easy determination if something at site or with the installation has
PRE-START UP
Verify voltage at the rotary disconnect prior to start up. Each outer leg should be 120 volts to Neutral unless you have 460/480 volt 3-phase power.
(If an ACI control panel was ordered with your unit, the control panel instruction manual may be found inside the control panel enclosure.)
If you have power with a hot leg e.g., 230 volt 3-phase power, that wire should be connected to the center lug of the rotary disconnect.
9
Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual
Any Aqua Control, Inc. aerator can be operated continuously or intermittently as desired except during freezing weather. If a less than normal flow
is observed, it is imperative that the cause be promptly investigated and corrected. Failure to do so can cause cavitation resulting in pump and
motor damage and will void the warranty. Reduced flow will usually be due to a blockage and must be resolved.

INSTALLATION
1. Tie the mooring line to the eyebolts on the float.
2. Pull the unit past its final location by a distance at least equal to the depth of the pond at the desired final location.
3. Bring the unit back to the final position. There should be enough slack on the electric cord to allow it to hang straight down without tension on
the unit causing it to tilt the spray pattern.
4. Hold the position of the unit in the water by tying the mooring liness to the mooring stakes on shore.
5. Motor torque causes the unit to try to rotate. Upon startup, watch to make sure the unit cannot rotate more than 1/3 of a turn. If it is allowed to
rotate, the electric cord can pull around the unit very tightly and cause damage.
6. Never allow long lengths of rope to float near the intake of the unit where it can be pulled in and entangled in the propeller or impeller.
MOORING - FLOATING UNITS
MOORING EYE
BOTTOM OF POND
MOORING EYE
FINAL LOCATION OF UNIT
FLOAT EYEBOLT
Aqua Control, Inc. 60 Hz. Select Series 2Instruction Manual
10
SELECT SERIES 2 LAUNCHING

1. Tie the anchoring rope to the eyebolts on the float. Use a rope at least three times the depth and be sure it has no slack.
2. Pull the unit past its final location by a distance at least equal to the depth of the pond at the desired final location.
3. Bring the unit back to the final position. There should be enough slack on the electric cord to allow it to hang straight down without tension on
the unit causing it to tilt the spray pattern.
5. Anchors should be set out at a MAXIMUM of 45 degrees to the surface of the water. It is preferred to have the anchor line as parallel to the surface
as possible. They should be on opposite sides of the float. To ensure the unit remains very close to certain position, a third (or fourth) anchor line
can be used.
6. Be sure that the electrical cord has slack, hangs straight down from the unit and is not tangled with the anchor lines.
7. The anchor lines must be kept tight enough to prevent the unit from rotating due to motor torque. If the water level changes or the anchor lines
otherwise become slack, the unit will rotate and twist the electrical cord causing cord damage.
ANCHORING - FLOATING UNITS
INSTALLATION
BOTTOM OF POND
ANCHOR ANCHOR
FINAL LOCATION OF UNIT
FLOAT EYEBOLT
SELECT SERIES 2 LAUNCHING
Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual
11
4. Tie anchors to the anchor lines. Use multiple anchors if the bottom is smooth or slippery. Heavy or multiple concrete blocks are suitable for
soft bottoms where they will sink into the mud, but they are inadequate on hard, smooth, slippery or sloping bottoms.

FLOTATION
Diagram 1 below shows the optimum floating depth for an Aqua Control Unit. The shaded area of the diagram shows the least amount of float and
nozzle possible. The chart shows the amount of weight that needs to be added to sink the unit to the optimum depth. This is an optional step. The unit
will operate just the same without adding any weights, but more of the float will be showing. The only time weight has to be added is to sink the unit far
enough for the lights to be 2” underwater while operating. Remember that the unit must be running to decide how much weight has to be added. If you
add weights to float at the optimum depth while the unit is off, the thrust of the nozzle could sink the unit.
After turning the unit on, estimate the floating depth from diagram 1 below. Look on the chart to determine the amount of weight that needs to be added.
The chart also gives recommended combinations of weights to accomplish the desired weight.
Attach the weights to the top of the float using the hardware provided in the float hardware package. There are (6) six 2 ¼” long bolts with a 1” diameter
flat washer and a hex nut on each bolt. Slide the flat washer up to the head of the bolt and put the threaded end of the bolt through the center of the weight.
Thread the bolt into any open insert on the top side of the float. The 1” diameter flat washer keeps the weight from sliding off the bolt. The weights must
be distributed evenly around the float to keep it floating level.
DEPTH
WHEN
RUNNING
TOTAL
WEIGHT
REQUIRED
NUMBER OF WEIGHTS
DIAGRAM 1 DIAGRAM 2
WEIGHT PIN
(BARBELL)
WEIGHT
TOP OF FLOAT
2 in.
1.85 in.
2 in.
1 in.
DEPTH 1
DEPTH 2
DEPTH 3
DEPTH 4
DEPTH 5
1/2 in.
SELECT SERIES 2
12Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual
FLOAT VS. WEIGHT
2 3 4 6
DEPTH 1 15 lbs. - 5 - -
DEPTH 2 20 lbs. 10 - 5 -
DEPTH 3 30 lbs. - 10 2x10 + 2x5 5
DEPTH 4 40 lbs. - - 10 -
DEPTH 5 55 lbs. - - - 4x10 + 2x7.5

FREEZING WEATHER REMOVAL
If the surface of the pond does not normally freeze solid then continued winter operation of either aerators or fountains is seldom a problem.
1. During a cold snap, it may be necessary to shut the unit off to prevent ice accumulation on the float, which could cause the unit to tip. If the unit
tips and has lights, some of the lights could come out of the water, possibly allowing them to break or leak from overheating. It might also allow
the gasket to freeze and water could leak into the fixture.
2. To be certain that operation with a nozzle does not create a large mound of ice which could cause the aerator to roll over and result in motor or
light damage, simply remove the nozzle and let the water gush out to provide circulation of the warmer deep water up to the surface.
3. Do not remove the head or the unit will slip through the float and sink to the bottom.
WINTER OPERATION
SAFETY ADVISORY! If winter activities occur on the lake, operation of a unit during the winter will compromise the thickness and stability of the ice
that develops around the perimeter of the open water and could create a safety hazard for anyone on the ice.
MARGINALLY FREEZING WEATHER
MAINTENANCE
The Aqua Control products do not require yearly maintenance of the motors or pumps. The motors should never be opened for maintenance and doing
so will void the factory warranty.
LIGHT LENS CLEANING: The light lenses should be cleaned frequently to prevent algae and dirt buildup on them. Buildup dims the amount of light
that comes through the lenses and can cause them to overheat as well. If rock guards are used on the lights, the lights should be monitored more
frequently for algae buildup.
GENERAL
1. Disconnect the motor from the cable or cut the cable at the splice.
5. Protect the cable connector in the water by using the winter cap that came with the unit.
2. Store in a heated area that will not freeze.
3. Store with the shaft end of the motor inclined up. If a vertical unit is resting on the float and on the bottom of the lower tube, the angle will be
satisfactory. Do not rest the unit on the lights or light brackets.
Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual 13
SUCTION SCREEN CLEANING: Routine cleaning of the suction screen is required to assure adequate water flow past the motor to cool it during
operation. If the screen becomes fouled with debris the motor can overheat and the spray pattern can be diminished. The mooring and anchoring
installation instructions suggest a trip rope for the vertical units so the suction screen can be lifted to the surface of the water for cleaning. The suction
screens on the horizontal units are close to the water’s surface to make them easy to reach. A stiff bristled household cleaning brush can be used to
remove any debris.
4. The underwater cable should not be left on the ground since it could easily by damaged when brittle from cold weather. Re-immerse the
cable so it below the ice and away from shore traffic.
WARRANTY DISCLAIMER: Many variables must be considered before deciding to operate a Select Series 2Vertical Aerator or Titan Fountain (never
a Select Series 2Fountain or Horizontal Aerator) during the winter. These variables include but are not limited to the depth of the lake, overall size of
the lake, climate variation, predictability of cold, and loss of power in winter conditions. Aqua Control does not warrant any damage incurred
during winter operation, even if the following guidelines are followed.

OPERATION IN FREEZING WEATHER
SINKING
1. Attach poly rope for retrieval. Use a rope that floats for finding and retrieving the unit. Attach a small marker float to the rope end if desired.
3. Weight lifting weights are a convenient and economical source of such weight. Do not use concrete blocks as weights. They are bulky and weigh
only about ½ their normal weight when in water.
4. Secure a 25 lb. weight to each eyebolt on the float. Tie a rope thru the hole of one weight. Tie the other end of the rope to a float eyebolt or
tie it to a snap hook and snap the hook over the eyebolt (the snap must fit over the 3/8” diameter eye of the eyebolt). Repeat for the other float
eyebolt. The ropes must be long enough so that these weights hang down below the bottom of the unit. Attach a poly rope for retrieval. Use a
rope that floats for finding and retrieving the unit. Attach a small marker float to the rope end if desired or if a non-floating rope is used.
6. Repeat until all the weights have been added. When the last weights are added the assembly should gently sink until deepest weights rest on the
bottom. The unit will then float upright in this position until pulled back up in the spring.
7. Spring retrieval will require very little effort since just enough weight has been added to sink the unit.
8. When properly submerged, the top of the unit should be at least 2’ to 3’ below the surface of the water so that it is out of the ice layer.
9. Be sure to follow the instructions so that the unit is not driven into the mud.
This procedure is the best and simplest method of winter storage, if a boat is available. By sinking the unit, the motor has no possibility of losing some
of its internal motor fluid, it cannot freeze, the unit is not damaged by handling, seals do not dry out and it saves the work of removing and re-installing
the unit. To sink a unit for winter storage, the pond depth must be 4 to 6 feet plus the height of the unit itself. Get the minimum water depth from the
Aqua Control brochure, add 4 to 6 feet plus the normal depth of ice on the pond. If the pond does not have sufficient depth, then sinking is not an
option for winter storage. Any Aqua Control unit can be stored by sinking with enough depth in the pond.
SMALL MARKER FLOAT
UNIT
ANCHOR ANCHOR
WEIGHTS
14Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual
2. Determine how many inches of float are above the water when the unit is off. Use the information under flotation, page 12, to determine the
amount of weight it will take to sink the unit.
5. Using another rope 6’ to 8’ long, secure additional weights to the unit as needed. Keep the weights clear of lights or cord. These weights do not
need to hang down past the lower tube.

1. Set Up the Multimeter
a. Ohms
i. Know the range of Ohms available for your multimeter and whether your meter is auto-ranging.
ii. Set the multimeter to the lowest Ohm (resistance) setting. Resistance is designated by Ohms.
iii. Determine how your multimeter designates open line. Observe the reading when both probes are held in the air, not
touching.
iv. Determine how your multimeter designates continuity. This is done by touching the two probes. This should be
either zero or very close to zero. If not zero, this may be resistance internal to the meter and should be subtracted from all
subsequent readings. If your meter has an “auto-zero” feature, use it to zero the meter.
b. Volts
i. Set the multimeter to the highest setting
ii. Select AC volts. This is usually designated by VAC.
c. Amps - Use only a clamp ammeter e.g. Amprobe.
2. Check Neutral to Ground Voltage
a. Set multimeter to AC voltage, highest rating.
b. Check the voltage between Neutral and Ground.
c. The voltage should be zero.
d. If the voltage is other than zero, the neutral line may be bad.
e. A bad neutral may lead to faulty GFCI tripping.
3. Check Input Voltages - readings should be within 10% of nominal voltage.
a. Single Phase
i. Each line to Neutral should be approximately ½ of the input voltage.
ii. Each line to one another should be the source voltage.
b. Three Phase
i. 208 volt, Y
1. Each line to Neutral should be 120 volts.
2. Each line to one another should be source voltage.
ii. volt, Delta
1. L1 and L3 to Neutral should be half source voltage.
2. L2 to Neutral should be substantially higher. This must be the wild leg connection.
iii. volt / 480 volt grounded.
1. Each line to Neutral should be approximately 277 volts.
2. Each line to one another should be source voltage.
iv. 480 volt Delta
1. Each line to one another should be source voltage.
c. Analysis
i. If lines read good to Neutral but zero to one another, the same leg is used for both lines. Correct this at the source.
ii. If the lines read bad to one another or bad to Neutral, the power source or power cable must be corrected
iii. A three-phase 240 volt delta power source must have the wild leg connected to L2, the center input of the disconnect
switch.
4. Check Output Voltages
a. 2-Wire: T1 - T2
b. 1-Phase: Black - Yellow
c. 3-Phase: T1 – T2, T1 – T3, T2 – T3
d. Analysis
i. Each reading should give source voltage.
ii. If good, problem is not in control panel although overloads or GFCIs may be too sensitive and cause premature tripping.
iv. If low voltage: very unlikely, control panel wired incorrectly.
5. Check Amps – readings should be within 10% of nominal voltage.
a. Single phase – check yellow wire.
b. Three phase – check each hot wire; readings should be within 5% of one another.
6. If GFCI tripped, perform “GFCI Troubleshooting Procedures”
7. If overload tripped, perform “Overload Troubleshooting Procedures”
TROUBLESHOOTING
GENERAL TROUBLESHOOTING
iii. If zero voltage: backtrack through components, checking input vs. output voltages, to determine which one is tripped
or faulty.
Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual 15

TROUBLESHOOTING
1. Set up the multimeter
a. Set the multimeter to the lowest Ohm (resistance) setting. Resistance is designated by Ohms.
b. Determine how your multimeter designates open line. This is done by observing the reading when both probes are held in the
air, not touching.
c. Determine how your multimeter designates continuity. This is done by touching the two probes. This should be either zero or
very close to zero. If not zero, this may be resistance internal to the meter and should be subtracted from all subsequent readings.
3. Check for shorted lines. A short is an unintentional electrical path and can be caused by faulty insulation.
a. Set the multimeter to the highest Ohm (resistance) setting.
b. Take readings by touching the probes to each pair of wires; e.g. red-black, red-yellow, black-yellow, etc.
c. Analyze the readings.
i. The readings should be the same as the open line readings you observed in step 1b.
ii. If the readings designate continuity by giving a zero reading or any reading less than open line, a short exists.
iii. If any of the readings with green (ground) indicate continuity, a leak to ground exists.
d. Determine the action to take
ii. Any manual connection sites are candidates for inspection, e.g. junction boxes, splices.
4. Check for open lines. An open line is a break in a wire.
a. Set the multimeter to the lowest Ohm (resistance) setting.
ends together. If you have four wires, you may wish to connect the other two together. Note which wires are connected.
or socket of the connector.
d. Analyze the readings.
i. The readings should indicate continuity, (either zero or close to zero). The readings should not exceed a few
Ohms.
ii. If the readings indicate either open line or a very high number, a break or partial break exists.
iii. If a break exists, one or both of the wires tested may be involved.
iv. Determine the action to take.
2. Any manual connection sites are candidates for inspection, e.g. junction boxes, splices.
e. Perform these steps for each combination of wire pairs.
CABLE TROUBLESHOOTING
Two problems affect cable integrity, shorted lines and broken or open lines. the following porcedures will determine cable integrity, The cable should
2. Disconnect the cable from the control panel and the load (pump or lights). Both ends must be dry. Verify the power is off before removing the
cable.
be disconnected from both the motor and the control panel. Verify the power is off before removing the cable.
i. Visually inspect the cable.
iii. It may be impossible to determine the location of the short and a new cable may be the best solution.
b. At the control panel, with the cable disconnected from the control panel, join two wires, e.g. red and yellow, by wrapping the
c. From the other end of the cable select one of the pairs of joined wires and take reading by touching the probes to each wire
1. Visually inspect teh cable.
3. It may be impossible to determine the location of the open line and a new cable may be the best solution.
16 Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual

HP YELLOW AMPS BLACK AMPS RED AMPS
1 10 10 0
2 13 12 3
3 17 13 6
5 28 19 11
HP # RUN CAPS RUN µF # START CAPS START µF
2 1 20 1 105-126
3 1 45 1 208-250
5 2 20/40 1 270-324
TROUBLESHOOTING
1. Test Overloads – perform test for each overload. Verify the power is off before testing.
a. Overload identification
i. Left overload is “Run” or “Main.”
ii. Right overload is “Start.”
b. Push red reset button to verify closure. It may be necessary to press these buttons very hard to reset.
c. Set ohmmeter to lowest range.
d. Test resistance between the two soldered connections on the top of the overload.
e. If the resistance is less than 0.5 ohms, the overload is good.
f. If the resistance is greater than 0.5 ohms, replace both overloads.
2. Check the amps on the red wire from MCB.
a. This test requires careful attention. The amp readings may change within seconds.
b. Power off the control panel.
c. Attach the ammeter to the wire connected to the “RED” terminal of the MCB.
d. Power on the control panel.
e. If amps do not jump, go to “Test Capacitor” and check “Start” capacitors.
f. If amps jump and stay high, go to “Test Relay.”
g. If amps jump and return to zero, go to “Test Capacitor” and check “Run” capacitors.
h. If amps jump and return to normal “Red” amps (see table below) the MCB is functioning correctly.
i. Normal Amp Readings
MOTOR CONTROL BOX (MCB)
3. Test Capacitor. Verify the power is off before testing.
a. Capacitor Identification – usually “Start” capacitors are large and black and “Run” capacitors are small and silver.
b. Set ohmmeter to 20,000 ohms.
c. Remove all wires from one terminal of the capacitor.
d. Test resistance between the two terminals.
i. Resistance should climb towards infinity (open line). If testing the 5HP Start Capacitor, the resistance should climb to
15,000 ohms.
ii. If resistance does not climb, switch meter leads.
iii. If the resistance still does not climb, replace capacitor.
e. If the meter has capacitance checking capability, check the capacitance. See table below.
f. Reconnect the leads to the capacitor.
Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual 17

1. Check motor amps
a. Determine “true” amp (yellow) requirement of motor. This is listed on the schematic as “Pump Motor amps,” on a decal on the
panel door as “Motor FLA” and in the ACI brochures.
b. Power on control panel.
c. Check all output leads to motor for proper amps.
d. If amps are good, go to “Nuisance Tripping.”
e. If amps are high, continue.
TROUBLESHOOTING
OVERLOAD TROUBLESHOOTING
4. Test Relay. Verify the power is off before testing.
a. Test Coil
i. Disconnect all wires from terminal 5 (upper right terminal); yellow wire and possibly red if panel has light circuit(s).
ii. Set ohmmeter to 10,000 ohms.
iii. Check resistance between terminals 2 (center terminal, red) and 5 (where the yellow wire was connected).
iv. Readings between 4,500 ohms and 7,000 ohms are good.
v. If resistances are out of that range, replace relay.
vi. Reconnect the all wires removed from terminal 5 in step i.
b. Test Contact
i. Disconnect the orange lead from terminal 1.
ii. Set ohmmeter to lowest range.
iii. Check resistance between terminals 2 (red) and 5 (where the orange wire was connected).
iv. If resistance is greater than 1 ohm, replace relay.
1-PHASE 3-PHASE
HP VOLTS AMPS HP VOLTS AMPS
1/2 115 12 1 208 6
1/2 230 6 1 230 5
1 115 16 1 460 3
1 208 11 2 208 9
1 230 10 2 230 8
2 208 14 2 460 4
2 230 13 3 200 12.5
3 208 20 3 230 10.9
3 230 18 3 460 5.5
5 208 30 5 200 20.5
5 230 28 5 230 17.8
7.5 230 15 5 460 8.9
MOTOR CONTROL BOX (MCB) continued
18 Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual

2. Check line-to-line resistance. Verify the power is off before testing.
a. Power off control panel.
b. Remove the pump cable connections from the terminal blocks at the bottom of control panel.
c. Set the ohmmeter to lowest resistance range.
i. Check each pair of pump cable wires, excluding Ground. Readings should be 2 – 20 ohms.
1. Single Phase 3-wire: Black-Yellow < Red-Yellow < Black-Red.
2. Single Phase 2-wire: T1-T2.
3. Three Phase: T1-T2, T1-T3, T2-T3; all readings should be identical.
ii. Readings of zero indicate a “Short”; readings greater than 20 ohms indicate an “Open” or partially broken line. Either
e. If line-to-line readings are good, continue.
3. Investigate Mechanical Problems
a. 70% of overload problems are mechanical e.g. worn or bad bearings, locked rotors, bent motor shafts, or broken shrouds.
TROUBLESHOOTING
OVERLOAD TROUBLESHOOTING
An improperly pitched prop, missing shims or nozzle problems may cause overloads to trip.
b. When thrust bearings are worn, the motor shaft may be pulled 1/8” or more. When radial bearings are worn, the motor shaft
may be moved side to side slightly.
4. Nuisance Tripping
a. Nuisance tripping can be caused by temporary voltage irregularities e.g. brownouts, spikes.
b. Excessive heat, above 122ºF may cause overload tripping. A control panel in direct sunlight will heat up and temporarily
degrade thermal overloads protection. One possible solution is to remove the cover of the motor control box.
Another solution is to cover the control panel with an awning or face the panel North or West.
of these readings indicate a problem.
d. If line-to-line readings indicated a problem, it is necessary to isolate the problem.
i. Any connection points, e.g. junction boxes, splices, connectors etc., provide a potential problem area.
Additionally, animal bites, cuts or scrapes could create a problem.
ii. Perform step# 2c at each connection point from the end of the cable at the control panel to the motor lead, until a good
reading is found. The problem will be in the previous connection tested. If the final test is at the motor lead, the problem
is with either the motor or the motor lead.
Aqua Control, Inc. 60 Hz. Select Series 2 Instruction Manual 19