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Therma-Kleen Technical Support

Ultra 600E Electrical Connection
Because our THERMA-KLEEN™ Ultra 600E pump motor rotation cannot be determined when connecting to a 3-Phase power source, the customer must use the following procedure for proper power connection and operation.

Warning: Failure to follow these procedures could permanently damage pump and/or motor assembly.

This procedure requires the customer obtain a "Motor Rotation Test Meter" Ideal #61-521 from:

Ideal Industries, Inc.,
Sycamore, IL 60178, USA
800-435-0705
www.testersandmeters.com

This is only an example of a test meter that will work. Their areother meters that will also do the same function.

Tester

  1. Using the 3 Phase tester half of rotation test meter (see above figure), connect the RED - YELLOW - BLUE leads on the meter to the 240VAC 3 Phase power source.
  2. Observe rotation lamps on meter. Is the clock wise rotation lamp (No. 3 on figure) lit?
      If YES, goto step 4. Else, goto step 3.
  3. Switch two of the three test meter lead connections on power source. Then go back to step 2.
  4. Connect RED - WHITE - BLACK leads in the Ultra 600E power cord to the corresponding power source terminals identified by the RED - YELLOW - BLUE leads on the test meter. Match RED to RED, WHITE to YELLOW, BLACK to BLUE.
  5. Connect water source, pressure hose and wand to Ultra 600E and prepare to test for proper operation.
  6. Before activating the unit, turn on the water supply and purge all air from the Ultra 600E by squeezing the wand trigger and waiting for a steady stream of water from the wand tip.
  7. You must be prepared to immediately turn off the Ultra 600E if the pump motor is observed to run opposite the proper rotation. This is determined by sound and absence of high pressure at the wand tip. If a humming sound is heard and no large increase in pressure is observed at the wand tip then immediately turn the unit off. Failure to quickly turn the unit off will result in a burnt out motor.
  8. Test Ultra 600E for proper rotation by switching the unit on momentarily.
  9. Did the unit run properly?
      If YES, goto next step.
      Else, STOP all testing and turn off water and power source. Disconnect cord from power source but note which color on power cord is connected to which terminal on power source.
      Goto Pump Repair Procedure below.
  10. You are here because the unit is now operating properly. If you unit is permanently connected to a power source then you are finished with this procedure. If you are using multiple outlets and moving the unit between them, you must wire all other outlets the same as the working outlet. Using the test meter, verify each outlet is wired the same as the working outlet.
  11. Finished.
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Pump Repair Procedure

If after connecting the Ultra 600E using the above procedure, the pump motor ran in reverse, you must now repair the pump bearing on the motor shaft. The following procedure will step you through this repair. We highly recommend you read and understand this procedure completely before starting the repair. You will need a 1/4" nut driver or socket with ratchet and a 3/16" Allen Wrench.

  • Remove the Ultra 600E side panel by removing the screws using the nut driver or socket with ratchet. The side panel to remove is opposite the side with the input water connection.

  • Pump The pump and motor sits on a pedestal. The pump is attached to the end of the motor and is bright blue in color. Four allen head cap bolts hold the pump to the motor and are gold or silver in color (See photo at left).

    Before removing these bolts, understand that a bearing threaded onto the end of the motor shaft will probably fall out when the pump is removed. The bearing could fall out because when the motor ran in reverse it UN-threaded the bearing from the shaft and jammed it against the pump piston shaft. You might ask, "Why not just reverse the motor direction and let the bearing thread itself back onto the motor shaft on its own?" This will certainly not work as the bearing will cross-thread back onto the shaft out of alignment and not completely seated back onto the motor shaft. This will cause complete pump failure and damage the motor shaft.


    Also, realize the bearing has only one right direction for installation. Be careful not to install the bearing incorrectly which could again damage the pump. The correct way to install the bearing is to identify the side of the bearing with a small gutter in the threaded hole. This side will go toward the motor. After the bearing is installed the end of the motor shaft must be flush with the end of the bearing. If the bearing is sticking out from the motor shaft with threads showing, it is install incorrectly.

    Go ahead now and remove the four pump mounting bolts using the allen wrench.

  • There should be enough slack in hoses etc. to pull the pump away from the motor and thread the bearing back onto the motor shaft. Try to keep all the grease in the bearing area and smear it all over the bearing after you have it reinstalled.
  • Reinstall the pump on the motor and side panel on the Ultra 600E.
  • Before reconnecting the unit to a power source you should have marked which power cord lead on the Ultra 600E was connected to which power source terminal. Reverse any two power cord leads going to the power source. This will reverse the pump motor rotation to the correct direction. Make sure all other power outlets the Ultra 600E will be used with are wired exactly the same as the working outlet.
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