Become a TFP Supporter Pool Math Forum Rules Pool School
Results 1 to 14 of 14

Thread: Help wiring relay for SWG control

  1. Back To Top    #1

    Join Date
    Aug 2013
    Location
    Florida
    Posts
    13

    Help wiring relay for SWG control

    So I finally got my salt cell installed and decided to go with a current sensing relay to drive the power to it since I just put in a VS pump as well. Here is the relay that I purchased:

    Macromatic CAH05A1BC 0.5-5A, 240V, 0.5-50 Sec, Current Sensing Relay


    I'm hoping that someone can help me to sort out how to wire this correctly. Here's what I've done so far...

    I ran the three wires running to the pump (240 - hot, hot & ground) through the loop at the top of the relay.
    I attached the two hot lines (again 240 hot, and hot) from the electrical panel that would run to the SWG to the #1 and #2 pins on the relay.
    I ran wires from the SWG back into the panel that houses the relay, but I did not connect them yet.

    I turned on the pump and the breaker that feeds into the relay. I tested pins 3, 4, and 5 with the relay in both "fault" and non fault mode (this particular relay has a switch to go back and forth between over and under current) and I'm not getting 120 on any of them under either scenario (fault or not). I am getting 120 on both of the "hot" wires that are plugged into pins 1 & 2 though.

    I assumed that the relay would transfer power from pins 1 & 2 to either 3, 4 or 5 when the relay was in one mode or the other, but that doesn't seem to be the case. I'm only getting between .5 and 1.5v on those three pins. Clearly I'm missing something here. Are there any electricians in the house that can edumicate me on what I'm screwing up here?

    (I think I've attached the manual for the relay here too, but I'm not sure if that worked.)

    Thanks in advance!
    Attached Files Attached Files
    In ground plaster pool - ~20k gallons | Hayward Regenex 700 DE Bump Filter | Hayward Max-Flo VS pump | Hayward AquaRite Pro 40K Salt Cell (w/ S&D)

  2. Back To Top    #2
    Mod Squad Jimrahbe's Avatar
    Join Date
    Jul 2014
    Location
    Bedford, TX
    Posts
    9,868

    Re: Help wiring relay for SWG control

    BC,

    Well, I don't read the schematic the same way you do...

    It appears to me that the 240 volts applied to pins 1 and 2 does nothing but power the unit, and is not connected in any way to pins 3, 4 or 5.

    Pin 3 is the common input pin to the relay and when the relay is not energized, pin 3 will be connected to pin 5.. When the relay is energized pin 3 is connected to pin 4.

    To use this unit your SWCG should be powered by 120 VAC. This 120 VAC should be connected to pin 3. You could use the relay to interrupt just one leg of 220 volts, but that is never a good idea.

    I would also only run one of the hot wires going to the pump through the core, and let the other wires bypass the core.

    You may have to wrap the one hot lead going through the core in and out of the core several time to get enough sensitivity for it to work.

    Keep in mind that is my reading of the instructions.. I have never seen this particular unit.

    Thanks,

    Jim R.
    Finished in 2015 - 17K Gal, IG, 20' x 25' Almost Rectangular Pool, Pebble finish, three rockport water falls. Pentair Equipment: EasyTouch 4, IC40 SWG, 3 HP VS Pump, CCP520 Cartridge Filter.
    TF100 with SpeedStir and SampleSizer, ColorQ Pro 7, Dolphin Premier Robot Cleaner, added Screen Logic 2, added small 3 person Caldera Spa.

  3. Back To Top    #3

    Join Date
    Aug 2013
    Location
    Florida
    Posts
    13

    Re: Help wiring relay for SWG control

    Well, bollocks....that makes sense with the 5 pins.

    Ok, so this relay isn't going to work with a 2 pole power supply. Has anyone used one that will work for a 240v supply to the SWG? Does the SWG not use enough power to worry about keeping on 240 vs knocking it down to 120?

    Thank you for explaining that, Jim.
    In ground plaster pool - ~20k gallons | Hayward Regenex 700 DE Bump Filter | Hayward Max-Flo VS pump | Hayward AquaRite Pro 40K Salt Cell (w/ S&D)

  4. Back To Top    #4
    Mod Squad Jimrahbe's Avatar
    Join Date
    Jul 2014
    Location
    Bedford, TX
    Posts
    9,868

    Re: Help wiring relay for SWG control

    BC,

    I'm not up on your particular SWCG, but most them can be powered by 120 or 220 by changing jumpers or input wires inside the control unit. Should be in the manual for the SWCG.

    The SWCG will function the same with whatever power you choice..

    Thanks,

    Jim R.
    Finished in 2015 - 17K Gal, IG, 20' x 25' Almost Rectangular Pool, Pebble finish, three rockport water falls. Pentair Equipment: EasyTouch 4, IC40 SWG, 3 HP VS Pump, CCP520 Cartridge Filter.
    TF100 with SpeedStir and SampleSizer, ColorQ Pro 7, Dolphin Premier Robot Cleaner, added Screen Logic 2, added small 3 person Caldera Spa.

  5. Back To Top    #5
    JoeGolan's Avatar
    Join Date
    Nov 2016
    Location
    Palm Coast, FL
    Posts
    200

    Re: Help wiring relay for SWG control

    You could also just add a double pole 2nd relay
    120 Volt coil to be powered off your 1st relay's contacts
    240V interrupted by the contacts
    I'm a black and white type of guy ... the only gray in my life is the hair on my head
    750 gal fiberglass built in spa with Hayward equipment. Pump is SP3010X15AZ Control is Aqua Plus with a T-cell-3 SWG and a H400FD Heater, Hayward C12002 cartridge filter filter

  6. Back To Top    #6
    Mod Squad Jimrahbe's Avatar
    Join Date
    Jul 2014
    Location
    Bedford, TX
    Posts
    9,868

    Re: Help wiring relay for SWG control

    Quote Originally Posted by JoeGolan View Post
    You could also just add a double pole 2nd relay
    120 Volt coil to be powered off your 1st relay's contacts
    240V interrupted by the contacts
    Joe,

    Good idea... I'd want to make sure the current sensing portion of the unit worked first. I admit I have not searched a lot for this info, but so far I have yet to see someone report that it has actually worked for them.

    Thanks,

    Jim R.
    Finished in 2015 - 17K Gal, IG, 20' x 25' Almost Rectangular Pool, Pebble finish, three rockport water falls. Pentair Equipment: EasyTouch 4, IC40 SWG, 3 HP VS Pump, CCP520 Cartridge Filter.
    TF100 with SpeedStir and SampleSizer, ColorQ Pro 7, Dolphin Premier Robot Cleaner, added Screen Logic 2, added small 3 person Caldera Spa.

  7. Back To Top    #7

    Join Date
    Aug 2013
    Location
    Florida
    Posts
    13

    Re: Help wiring relay for SWG control

    Quote Originally Posted by JoeGolan View Post
    You could also just add a double pole 2nd relay
    120 Volt coil to be powered off your 1st relay's contacts
    240V interrupted by the contacts
    Thanks, Joe - I like this idea. I have this one on order to go this route:

    SCHNEIDER ELECTRIC 120VAC, 6-Pin Bottom Flange, Din Rail Enclosed Power Relay92S7A22D-120A - Grainger

    Thanks for the help, guys...I'll advise when the final product is up and working.
    In ground plaster pool - ~20k gallons | Hayward Regenex 700 DE Bump Filter | Hayward Max-Flo VS pump | Hayward AquaRite Pro 40K Salt Cell (w/ S&D)

  8. Back To Top    #8

    Join Date
    Aug 2013
    Location
    Florida
    Posts
    13

    Re: Help wiring relay for SWG control

    FWIW - the current sensor does actually work. I rewired a few things to get 120 to the SWCG today. It's all working as planned. The current sensor has a dial to adjust the fault point, so I can actually adjust it to trip above/below a certain percentage of run speed on the VS pump. I did have to separate the three wires and just run one of the hot lines through the sensor, but I didn't end up having to loop any additional passes to get it to work as desired.

    It may be a while before I get back to rewire everything to 240 with the additional relay (since it "ain't broke" at the moment), but I'll update when I do.

    Thanks again for the help.
    In ground plaster pool - ~20k gallons | Hayward Regenex 700 DE Bump Filter | Hayward Max-Flo VS pump | Hayward AquaRite Pro 40K Salt Cell (w/ S&D)

  9. Back To Top    #9
    Mod Squad Jimrahbe's Avatar
    Join Date
    Jul 2014
    Location
    Bedford, TX
    Posts
    9,868

    Re: Help wiring relay for SWG control

    BC,

    With your permission I would like to condense this thread into a new one showing what you did. I'll give you credit, I just want to be able to provide a link to a working unit.

    Let me know,

    Thanks,

    Jim R.
    Finished in 2015 - 17K Gal, IG, 20' x 25' Almost Rectangular Pool, Pebble finish, three rockport water falls. Pentair Equipment: EasyTouch 4, IC40 SWG, 3 HP VS Pump, CCP520 Cartridge Filter.
    TF100 with SpeedStir and SampleSizer, ColorQ Pro 7, Dolphin Premier Robot Cleaner, added Screen Logic 2, added small 3 person Caldera Spa.

  10. Back To Top    #10

    Join Date
    Aug 2013
    Location
    Florida
    Posts
    13

    Re: Help wiring relay for SWG control

    Hi Jim,

    Yes, of course - feel free to reformat anything however you think the information will be most useful. I'm just happy I actually got it working as planned!
    In ground plaster pool - ~20k gallons | Hayward Regenex 700 DE Bump Filter | Hayward Max-Flo VS pump | Hayward AquaRite Pro 40K Salt Cell (w/ S&D)

  11. Back To Top    #11
    JoeGolan's Avatar
    Join Date
    Nov 2016
    Location
    Palm Coast, FL
    Posts
    200

    Re: Help wiring relay for SWG control

    Quote Originally Posted by BC in the Bay View Post
    Thanks, Joe - I like this idea. I have this one on order to go this route:

    SCHNEIDER ELECTRIC 120VAC, 6-Pin Bottom Flange, Din Rail Enclosed Power Relay92S7A22D-120A - Grainger

    Thanks for the help, guys...I'll advise when the final product is up and working.
    Looks like a good choice for the relay, contact rating well exceeds your intended load so it should last a good while.

    To make the connection to the relay terminals use a "Sta-con" type INSULATED SLIP-ON CONNECTORS such as seen here

    PVC TERMINALS FULLY INSULATED SLIP-ON CONNECTORS - PVC Terminals - Wire Terminals

    choose the proper color of connectors to match the wire size of the connecting wires, the chart I pointed out gives you the specs.

    You can purchase these at Home Depot or the like..... maybe also an automotive part store will have them too.
    I'm a black and white type of guy ... the only gray in my life is the hair on my head
    750 gal fiberglass built in spa with Hayward equipment. Pump is SP3010X15AZ Control is Aqua Plus with a T-cell-3 SWG and a H400FD Heater, Hayward C12002 cartridge filter filter

  12. Back To Top    #12

    Join Date
    Feb 2018
    Location
    Ashburn, Virginia
    Posts
    1

    Re: Help wiring relay for SWG control

    Hi...If you're connecting the limit switches to the DIO ports or the limit switch terminals on a motor controller, then yes, it's signal level wiring. The signal wire is not "constant polarity", but the ground line are. Even though the color code isn't mandatory for signal level, it makes things much easier to identify and understand. We usually use PWM wires in appropriate colors for our limit switches.

    pcb assembly

  13. Back To Top    #13
    hopkiba's Avatar
    Join Date
    Apr 2011
    Location
    Cleveland, TN
    Posts
    19

    Re: Help wiring relay for SWG control

    I have been struggling with how to hook up a planned SWCG to my system that has a VS pump with no external timer. The time solution does not seem fail safe since if the pump were to fault, the SWCG would still run. Your solution seems to be the best. Can you provide pictures of your final set-up? Thanks!
    18x36 Vinyl Rectangular Pool. 20,000 gallons. Pentair Superflo VS pump. Hayward Sand Filter. Circupool Si 40 SWG. Southeastern Tennessee

  14. Back To Top    #14

    Join Date
    Oct 2017
    Location
    Lutz/fl
    Posts
    10

    Re: Help wiring relay for SWG control

    Quote Originally Posted by Jimrahbe View Post
    BC,

    Well, I don't read the schematic the same way you do...

    It appears to me that the 240 volts applied to pins 1 and 2 does nothing but power the unit, and is not connected in any way to pins 3, 4 or 5.

    Pin 3 is the common input pin to the relay and when the relay is not energized, pin 3 will be connected to pin 5.. When the relay is energized pin 3 is connected to pin 4.

    To use this unit your SWCG should be powered by 120 VAC. This 120 VAC should be connected to pin 3. You could use the relay to interrupt just one leg of 220 volts, but that is never a good idea.

    I would also only run one of the hot wires going to the pump through the core, and let the other wires bypass the core.

    You may have to wrap the one hot lead going through the core in and out of the core several time to get enough sensitivity for it to work.

    Keep in mind that is my reading of the instructions.. I have never seen this particular unit.

    Thanks,

    Jim R.

    How are you to power the relay with a double pole 240v when there's only a single + and - input? Are you allowed to tie the 2 poles together at the +?

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •