Hayward VSP “DC VOLTAGE TOO HIGH”

[JamesR]

Ugh, my second post of the day. Not a good day for me.
First day with the new Hayward SP2603VSP setup.
It was running fine for about an hour. Then I heard it shut off. Display said DC VOLTAGE TOO HIGH. It reset itself, went into an auto prime, got the same error. It repeated this about 4 times in a row and now is running again.
My voltage at the pump is 249 VAC.
Pump spec says +/- 10% of rated motor voltage. Motor plate says 240/230.
At 240 that’s a range of 216-264 Vac
At 230 that’s a range of 207-253 Vac.
Either way, I’m in range.
Thoughts?

 

[ajw22]

Document it in pics and make a warranty claim.

DC Voltage comes from the Drive to the motor. The error indicates a problem with the drive electronics.

 

[ajw22]

https://www.bing.com/ck/a?!&&p=11d0a201efede4e5JmltdHM9MTY4ODYwMTYwMCZpZ3VpZD0xMDkzMmNiMi03MjhkLTY2YWUtMTUyOS0zZGU5NzM1OTY3M2ImaW5zaWQ9NTQ0OA&ptn=3&hsh=3&fclid=10932cb2-728d-66ae-1529-3de97359673b&u=a1aHR0cHM6Ly93d3cudG90YWxseWhheXdhcmQuY29tL3RlY2hzZXJ2aWNlcy9hdHRhY2htZW50cy9UZWNobmljYWwlMjBTZXJ2aWNlJTIwQnVsbGV0aW4lMjBQRkMlMjBIaSUyMGVycm9yJTIwY29kZS5wZGYjOn46dGV4dD1XaGVuJTIweW91JTIwZW5jb3VudGVyJTIwYSUyMCVFMiU4MCU5OERDJTIwdm9sdGFnZSUyMEhpZ2glMkZMb3clRTIlODAlOTklMjBlcnJvcixvbi4lMjBUaGUlMjBwdW1wJTIwc2hvdWxkJTIwbm93JTIwcmVzdW1lJTIwbm9ybWFsJTIwb3BlcmF0aW9uLg&ntb=1

 

[ajw22]

My voltage at the pump is 249 VAC.
Pump spec says +/- 10% of rated motor voltage. Motor plate says 240/230.
At 240 that’s a range of 216-264 Vac
At 230 that’s a range of 207-253 Vac.
Either way, I’m in range.
Thoughts?

You don't know if voltage was in range when the pump glitched.

We discussed in your other thread that you have sketchy electrical wiring. I don't know how far it extends into your house electrical systems.

The VS pump is more sensitive to voltage drops then your old SS pump. Your house may be having voltage dips that did not effect any equipment until now.

If this continues you may need to put a voltage recorder on your house lines to see what is going on.

 

[ajw22]

Whole House Voltage Monitor for Trouble Shooting?

I mostly work residential in a gentrifying city -meaning lots of old panels & meters, loose bugs, crappy grounding. I get a lot of situations where 1 leg of the service entrance isn't working/intermittent arcing. I'm looking for recommendations to get a *voltage logger* to see if problems are...

www.electriciantalk.com

 

[JamesR]

True, I do not know what the voltage was at that instant. Could have been a utility surge???
I put a meter on it and will monitor.
Right now, running, it measuring 243 VAC.
max and min is being recorded.
It’s pretty steady at the moment, but it’s only been recording for about 7 minutes. I’ll leave it on there all day.

 

[ajw22]

Nice meter to have.

You have to catch a pump glitch and correlate it to what your meter recorded.

 

[JamesW]

Can you check the pump's error log and post the results?

 

[JamesR]

I kicked on the house AC, the meter showed a quick 7 volt drop to 237 VAC. When the AC turned off, not much drama there. It came up to 241 VAC and is staying there.
For the event log,
It had 4 of these. All within a minute or two of each other.

 

[JamesW]

Keep tracking the voltage and note the voltage at the time of an error.

It seems to be known error.

https://www.hayward-pool.ca/assets/documents/pools/pdf/manuals/2014-TriStar-VS-TSG.pdf

https://www.totallyhayward.com/techservices/attachments/Technical%20Service%20Bulletin%20PFC%20Hi%20error%20code.pdf

 

[JamesW]

If you can verify that the voltage is good during an error event, maybe file a warranty claim with Hayward.

 

[JamesR]

Yes, I’ll keep monitoring 24/7. My user manual troubleshooting section is similar to what Allen posted. Ie; check that the line voltage is within 10% of pump rated voltage. They list 240/230 on the pump motor plate. I wish I knew which one they were basing that range on.
Guess I have to call Hayward tech.

 

[JamesR]

No further issues, it ran all night long with nothing in the event log.
My scope also shows no voltage issue either.
So, I’m still trying to figure out the actual spec for incoming line voltage.
Since the motor plate says 240/230 I not sure if the acceptable range is 216-264 vac or 207-253 vac.
I called Hayward tech support and she said “we cannot give out that sort of information because we don’t want to be incorrect and misinform the caller”. Huh??? It’s a spec. It should be listed somewhere. The controller is obviously programmed to monitor that voltage and shut down at some predetermined value.

 

[ajw22]

No further issues, it ran all night long with nothing in the event log.
My scope also shows no voltage issue either.
So, I’m still trying to figure out the actual spec for incoming line voltage.
Since the motor plate says 240/230 I not sure if the acceptable range is 216-264 vac or 207-253 vac.
I called Hayward tech support and she said “we cannot give out that sort of information because we don’t want to be incorrect and misinform the caller”. Huh??? It’s a spec. It should be listed somewhere. The controller is obviously programmed to monitor that voltage and shut down at some predetermined value.

Translation - We do not know. We are just techs and the answer is not in our script. The drive firmware was done by some contractor in China who is no longer on our payroll. The days of going next door and talking to the engineer who designed the pump are gone.

 

[JamesR]

That’s pretty much what my thought was.

 

[JamesW]

 

[JamesR]

Ooohhhh 207-253. I may have gone over that 253. Today it has not faulted, but the meter says it hit 249.

 

[JamesW]

The drive converts the AC voltage to DC and then it generates a “Digital” AC waveform by turning switches on and off quickly to simulate a 3 phase AC voltage with the correct frequency to make the rotor turn at the correct RPM.

The “DC Voltage High” indicates that the DC bus voltage has risen above 400 VDC and the pump stops.

I think that the DC voltage is based on the peak AC voltage, which is V_RMS X √2.

So, 400/√2 = 282.8 volts to trip the “DC Voltage High” error.

 

[JamesR]

That’s pretty high. I cannot Imagine it went that high 4 times in 2 minutes. Hmmmmm
So far still good though. Running continuously

 

[JamesW]

You can get transient spikes at certain times that can be pretty high.