Control Panel Troubleshooting Help?

[TheMerkle]

Since the new appliance uses separate 110 and 220 circuits, it needs neutral to return one circuit and ground to return the other. Since they are bonded in the subpanel, the main breaker seems this is a hot to hot short and throws the main breaker.

 

[doug293cz]

Since the new appliance uses separate 110 and 220 circuits, it needs neutral to return one circuit and ground to return the other. Since they are bonded in the subpanel, the main breaker seems this is a hot to hot short and throws the main breaker.

The 240V loads do not have any current flowing thru the neutral wire. The 120V load return current flows thru the neutral (unless you have balanced 120V loads running off of each hot.) None of the load current should flow thru the ground. The ground should only carry current if something is leaking to it, or shorted to it. The problem with connecting the ground and neutral in the sub-panel is that the 120V return current will get split between the ground and neutral connections back to the main panel. This isn't allowed by code, but the more that I think about it, it also shouldn't trip the GFCI in the sub-panel (if the GFCI is wired correctly.)

Do you have a locking (curved slots) or non-locking (straight slots) plug/receptacle combo?

Brew on

 

[doug293cz]

Assuming you have a non-locking plug/receptacle, the voltages at the plug should read as below:

Voltage between ground and neutral should be very close to zero, and voltage from ground to either hot should be 120V (just like for neutral.)

Brew on

 

[lschiavo]

Are you sure of the connections on your relays? You could be connecting L1 to L2 when you turn the key if you have something swapped.

 

[Tartan1]

I was thinking this ^^^^^ earlier when I inquired about a pinout diagram for his contactors/relays. Also if the coil voltage was 240VAC vs 120VAC as the wiring for both are different.

 

[TheMerkle]

I will check the voltages on the receptacle this afternoon.

 

[TheMerkle]

I attached a photo of the relays I've used. Are the relays sensitive to polarity? ...or do they just work like switches and close the circuit?

 

[Tartan1]

Polarity as far as L1 L2 IN and L1 L2 OUT no, however these should be kept consistent as it is easier to do diagnostics when problems arise. The concern would be as @Ischiavo mentions if you have L1 IN and L2 IN (on the OUT pin) on the same side of the contactor/ relay then that is a problem.
One way to check would be remove the L1 L2 terminals OUT (which feed the other 2 contacors /relays) tape them off or otherwise isolate them and only leave what you figure is the IN L1 L2 connected and switch the keyed switch on. This isolates the 240V from the 120V side and leaves you with the 120V circuit as hot and of course the L1 L2 feeding IN to the relay as well as the coil if it is in fact 120VAC.
Also as @doug293cz mentions above if you have a mixup on the 4 wire receptacle you may be thinking you have L1 and L2 but could in fact have a neutral or ground swapped at the receptacle or plug .

 

[TheMerkle]

I had not considered that. For some reason I took one glance at this thing and I was certain I understood the pin out... though now it has just occurred to me that I'm not sure at all...

 

[TheMerkle]

I had not considered that. For some reason I took one glance at this thing and I was certain I understood the pin out... though now it has just occurred to me that I'm not sure at all...

 

[passedpawn]

I had not considered that. For some reason I took one glance at this thing and I was certain I understood the pin out... though now it has just occurred to me that I'm not sure at all...

2 Form A, DPST. Coil is 0/1, first contact pair is 2/4, second contact pair 6/8.

 

[TheMerkle]

Yep, you've nailed it. I've wired the relays incorrectly, and I have no good excuse because I used the exact same relay on the previous appliance and apparently got it right that time. I will fix the wiring, and repair my GFCI then test and update you guys within a few days. Thanks again!

 

[TheMerkle]

So, I rewired the panel using the correct pinout configuration on the relays and I had an electrician review the wiring in my panels and guarantee that the GFCI breaker is operating as intended. Everything fired right up and operated perfectly. Thanks for all of your help!

 

[doug293cz]

Great news! Enjoy your system.

Brew on

 

[Stoney315]

So, I rewired the panel using the correct pinout configuration on the relays and I had an electrician review the wiring in my panels and guarantee that the GFCI breaker is operating as intended. Everything fired right up and operated perfectly. Thanks for all of your help!

Happy brewing...or hoppy brewing what ever you like. Lol