How to Troubleshoot a Pump Comm Surge Board
LESSON SUMMARY: This lesson is designed to assist the user in troubleshooting a Pump Comm Surge Board.
Special Tools Needed: Digital Multimeter, Phillips Screwdriver
⚠ CAUTION: THIS LESSON MAY INCLUDE INSTRUCTIONS TO TEST HAZARDOUS VOLTAGES (120V-240V) THAT CAN CAUSE SERIOUS INJURY OR DEATH. IT IS RECOMMENDED THAT A LICENSED ELECTRICIAN BE CONTRACTED TO PERFORM SUCH TESTS.
🛑 STOP: ALWAYS TURN OFF THE POWER TO THE SATELLITE BEFORE REMOVING ELECTRONIC COMPONENTS.
The Pump Comm Surge Board has dual functionality; it protects both the Pump/Common side of the satellite as well as the Communication side of the satellite. If the Pump Comm Surge Board is damaged, or if it is not functioning properly, there may be a disruption in the functionality of other components throughout the satellite. To determine if a Pump Comm Surge Board is damaged, follow the guided steps below.
Testing the .5 Amp Pump Line Fuse:
*Note: Visually inspecting a fuse is never a trustworthy method to determine the failure or functionality of the fuse.
Power off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.
Start by locating the fuse on the Pump Comm Surge Board associated with the Pump line.
The Pump line is protected by a .5 Amp fuse.
When looking at the Pump Comm Surge Board, the .5 Amp fuse protecting the Pump line is fuse in the furthest position on the right-hand side.
Remove the .5 Amp fuse from its fuse holders on the Pump Comm Surge Board.
Use a digital multimeter on the resistance setting or continuity setting with an audible beep. If using the resistance setting, touch the two multimeter probes together and note the reading on the display; it should be 0 or very close to 0. *Note: Different multimeters will vary slightly.
Proceed to place one probe on each end of the fuse.
If using a digital multimeter on the resistance setting, a working fuse will display a reading close to the reading that was displayed when the two probes were touched together: 0 or very close to 0.
If using a digital multimeter on the continuity setting, a working fuse will create an audible beep.
If the digital multimeter reads Over Limit “OL” on the resistance setting, or no audible beep is heard on the continuity setting, the fuse is damaged and should be replaced.
Replacement .5 Amp fuses can be purchased here.
Testing the 7.5 Amp Common Line Fuse:
*Note: Visually inspecting a fuse is never a trustworthy method to determine the failure or functionality of the fuse.
Power off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.
Start by locating the fuse on the Pump Comm Surge Board associated with the Common line.
The Common line is protected by a 7.5 Amp fuse.
When looking at the Pump Comm Surge Board, the 7.5 Amp fuse protecting the Common line is directly to the left of the .5 Amp fuse protecting the Pump line.
Remove the 7.5 Amp fuse from its fuse holders on the Pump Comm Surge Board.
Use a digital multimeter on the resistance setting or continuity setting with an audible beep. If using the resistance setting, touch the two multimeter probes together and note the reading on the display; it should be 0 or very close to 0. *Note: Different multimeters will vary slightly.
Proceed to place one probe on each end of the fuse.
If using a digital multimeter on the resistance setting, a working fuse will display a reading close to the reading that was displayed when the two probes were touched together: 0 or very close to 0.
If using a digital multimeter on the continuity setting, a working fuse will create an audible beep.
If the digital multimeter reads Over Limit “OL” on the resistance setting, or no audible beep is heard on the continuity setting, the fuse is damaged and should be replaced.
Replacement 7.5 Amp fuses can be purchased here.
Testing the Pump Line:
If a Pump Comm Surge Board is continually blowing either the Pump fuse or the Common fuse, it is possible that the Pump Comm Surge Board or a solenoid in the field are shorted.
A guide to testing solenoids can be found here.
If the solenoids corresponding to the satellite location have been tested and are known to be functioning properly, proceed with testing the Pump Comm Surge Board as follows:
Start by powering off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.
Next, unplug the white 2-position plug containing one orange wire and one blue wire from the Pump Comm Surge Board.
Locate the Pump wire position on the 10-position screw terminal block. The Pump wire is located in the furthest right-hand position on the 10-position screw terminal block and is labeled “PUMP”.
Using a Phillips screwdriver, unscrew and remove the Pump wire from the 10-position screw terminal block located at the base of the Pump Comm Surge Board.
Use a digital multimeter on the resistance setting or continuity setting with an audible beep. If using the resistance setting, touch the two multimeter probes together and note the reading on the display; it should be 0 or very close to 0. *Note: Different multimeters will vary slightly.
Proceed to test the Pump portion of the Pump Comm Surge Board by placing one probe of the multimeter on the far right position on the 10-position screw terminal block labeled “PUMP” and place the other probe of the multimeter on the screw containing the Ground wire.
*Note: The Ground wire is a green and yellow colored wire and the screw containing the Ground wire is located below the Pump Comm Surge Board on the right-hand side.
When using a multimeter on the resistance setting, a shorted Pump Comm Surge Board will cause the multimeter to display a reading close to the reading displayed when touching the two probes together; 0 or very close to 0.
When using a multimeter on the continuity setting, a shorted Pump Comm Surge Board will create an audible beep.
If the digital multimeter reads Over Limit “OL” on the resistance setting, or no audible beep is heard on the continuity setting, the Pump line is functioning properly.
Testing the Common Lines:
If the Pump line of the Pump Comm Surge Board was tested and no short was found, the Common portion of the Pump Comm Surge Board will need to be tested.
Start by powering off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.
Next, locate the Common wire positions on the 10-position screw terminal block.
There are three positions on the 10-position screw terminal block labeled “COMMON”.
The three Common positions on the 10-position screw terminal block are located directly to the left of the Pump position on the 10-position screw terminal block.
Using a Phillips screwdriver, unscrew and remove the Common wires from the 10-position screw terminal block located at the base of the Pump Comm Surge Board.
Using a digital multimeter on the resistance setting or continuity setting with an audible beep, place one probe of the multimeter on one of the screws on the 10-position screw terminal block labeled “COMMON” and place the other probe of the multimeter on the screw containing the Ground wire.
*Note: The Ground wire is a green and yellow colored wire and the screw containing the Ground wire is located below the Pump Comm Surge Board on the right-hand side.
When using a multimeter on the resistance setting, a shorted Pump Comm Surge Board will cause the multimeter to display a reading close to the reading displayed when touching the two probes together; 0 or very close to 0.
When using a multimeter on the continuity setting, a shorted Pump Comm Surge Board will create an audible beep.
If the digital multimeter reads Over Limit “OL” on the resistance setting, or no audible beep is heard on the continuity setting, the Common position being tested is functioning properly.
Proceed to test the remaining two Common positions on the 10-position screw terminal block.
If during the course of testing the Common positions the multimeter displays a reading of 0 or very close to 0 on the resistance setting or if an audible beep is heard when using the continuity setting, the Common position being measured is shorted and the Pump Comm Surge Board should be replaced.
Replacement Pump Comm Surge Boards can be purchased here.
Testing the .5 Amp Communication Line Fuses:
If the Pump and Common lines and their corresponding fuses have been tested and are functioning properly, the Communication lines and their corresponding fuses will need to be tested.
*Note: Visually inspecting a fuse is never a trustworthy method to determine the failure or functionality of the fuse.
Power off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.
Start by locating the fuses on the Pump Comm Surge Board associated with the Communication lines.
The Communication lines are protected by two .5 Amp fuses.
When looking at the Pump Comm Surge Board, the .5 Amp fuses protecting the Communication lines are directly to the left of the 7.5 Amp fuse protecting the Common line.
Remove the .5 Amp fuses from their fuse holders on the Pump Comm Surge Board.
Use a digital multimeter on the resistance setting or continuity setting with an audible beep. If using the resistance setting, touch the two multimeter probes together and note the reading on the display; it should be 0 or very close to 0. *Note: Different multimeters will vary slightly.
Proceed to place one probe on each end of the fuse.
If using a digital multimeter on the resistance setting, a working fuse will display a reading close to the reading that was displayed when the two probes were touched together: 0 or very close to 0.
If using a digital multimeter on the continuity setting, a working fuse will create an audible beep.
If the digital multimeter reads Over Limit “OL” on the resistance setting, or no audible beep is heard on the continuity setting, the fuse is damaged and should be replaced.
Replacement .5 Amp fuses can be purchased here.
Testing the Communication Lines:
If a Pump Comm Surge Board is continually blowing one or more of the Communication line fuses, it is possible that the Pump Comm Surge Board is shorted.
To test the Communication lines, proceed with the follow steps:
Start by powering off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.
Next, unplug the green 3-position plug on the left-hand side of the Pump Comm Surge Board.
Proceed to locate the Communication wire positions on the 10-position screw terminal block.
The Communication wire positions on the 10-position screw terminal block are labeled “COM A” and “COM B”.
Using a Phillips screwdriver, unscrew and remove the Communication wires from the 10-position screw terminal block located at the base of the Pump Comm Surge Board.
Using a digital multimeter on the resistance setting or continuity setting with an audible beep, place one probe of the multimeter on the screw on the 10-position screw terminal block labeled “COM A” and place the other probe of the multimeter on the screw containing the Ground wire.
*Note: The Ground wire is a green and yellow colored wire and the screw containing the Ground wire is located below the Pump Comm Surge Board on the right-hand side.
When using a multimeter on the resistance setting, a shorted Pump Comm Surge Board will cause the multimeter to display a low reading; 0 or very close to 0.
When using a multimeter on the continuity setting, a shorted Pump Comm Surge Board will create an audible beep.
If the digital multimeter reads Over Limit “OL” on the resistance setting, or no audible beep is heard on the continuity setting, the COM A position being tested is functioning properly.
Proceed to test the “COM B” position on the 10-position screw terminal block.
Place one probe of the multimeter on the screw on the 10-position screw terminal block labeled “COM B” and place the other probe of the multimeter on the screw containing the Ground wire.
When using a multimeter on the resistance setting, a shorted Pump Comm Surge Board will display a low reading; 0 or very close to 0.
When using a multimeter on the continuity setting, a shorted Pump Comm Surge Board will create an audible beep.
If the digital multimeter reads Over Limit “OL” on the resistance setting, or no audible beep is heard on the continuity setting, the COM B position being tested is functioning properly.
Replacement Pump Comm Surge Boards can be purchased here.
Testing the Communication Lines – Part 2:
The final step to testing the Pump Comm Surge Board is checking if COM A and COM B are shorted together.
Using a digital multimeter on the resistance setting or continuity setting with an audible beep, place one probe of the multimeter on the screw on the 10-position screw terminal block labeled “COM A” and place the other probe of the multimeter on the screw on the 10-position terminal block labeled “COM B”.
When using a multimeter on the resistance setting, a shorted Pump Comm Surge Board will display a low reading; 0 or very close to 0.
When using a multimeter on the continuity setting, a shorted Pump Comm Surge Board will create an audible beep.
Replacement Pump Comm Surge Boards can be purchased here.
Lesson Tags: pump comm surge board, toro, troubleshooting, comm surge, shorted, board exchange, replacement parts, shorted solenoid, pcsb, toro pcsb, network vp, network ltc