Wiring a pump

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I have a pump start relay that is wired for 230v going in and coming out.  It is supposed to start a pump that is wired for 120v.  The 240v wire from the start relay runs underground to a junction box. I wired the junction box as I would for 230v, that is, black to one leg and white to the other leg.  It is grounded.  I then put a single  breaker in the box and ran that leg directly to the pump. My thinking was that by doing that I would get 230v into the junction box and 120v out to the pump. Is that right? it doesn't work.  Ideally the pump should stay wired to run on 120v ( In case there was any doubt, I am not an electrician but I do need some help).
Reply:Submersible well pump? I have never heard of one running 120 volts from a 240 volt control box. 3 wire pumps (actually 3 wires and a 4th ground) are all 240 volts in my experience. I *think* 120 volt pumps are all 2 wire and don't need a control box. Someone with more experience will come along I am sure.Miller Multimatic 255
Reply:It's an above ground pump for a sprinkling system. The pump can be wired to run either way. I'm running it 120v because I'm using the remaining power for something else. It worked for several years the way it's wired but the 200 amp main breaker in my house recently failed badly and caused several problems. This is just one of them.Last edited by hvw; 4 Days Ago at 05:10 PM.
Reply:DeletedLast edited by IAMsteelworker; 4 Days Ago at 05:20 PM.
Reply:Can you draw what you have wired and post it.So you have a pump start relay you say is wired for 240 volt. Then you say you put a breaker and wired 120 volt directly to the pump. If breaker is straight to pump and pump is wired with windings in parallel with hot at one end and neutral at the other then it should run. You have a hot and neutral and a meter reading 120 volt on your pump input ? How is the 240 volt pump start relay part of the 120 volt going to the pump ?Last edited by danielplace; 4 Days Ago at 06:46 PM.
Reply:You need to run a separate neutral wire from your load center to the junction box where you're splitting the 240.Using the ground as a neutral is not a good idea.Miller Trailblazer Pro 350DMiller Suitcase MIGMiller Spectrum 2050Miller Syncrowave 250DXLincoln 210MP
Reply:

Originally Posted by scsmith42

You need to run a separate neutral wire from your load center to the junction box where you're splitting the 240.Using the ground as a neutral is not a good idea.
Reply:Pump relay is a bit vague. I'll guess a relay where the magnetic coil is 240 volt, so he needs a 240 volt circuit to energize the coil. I'm not clearNever mind. I'm not clear.An optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.
Reply:A drawing of wiring and pic of relay andwiring would help a lot.Miller a/c-d/c Thunderbolt XLMillermatic 180 Purox O/ASmith Littletorch O/AHobart Champion Elite
Reply:What I have is a pump start relay that runs off 240v power that is connected to the input side of the relay. The output side of the relay goes to a junction box by the pump. The relay is connected to the sprinkler system timer by two 24v wire's which are on the relay. It is connected to the timer by those two 24vires. One is connected to the master valve and the other to the common, both of which are on the timer.  When the timer turns a watering zone on it sends a 24v signal to the pump relay. The relay then energizes and sends 240v to the pump which remains on until the timer stops the signal. Then the relay cuts off the output side and the pump turns off.  But, my pump is wired internally to run off 120v. So, to feed it 120v I installed a junction box and put a single pole breaker on one of the junction box lugs. The pump is connected to that breaker.  The junction box sits next to the pump and would otherwise send 240 volts to the pump. The junction box is connected to a 10/3 wire. Black to one lug, white to the other lug and the ground connected separately to it's own lug. The pump is connected to the breaker by the black wire. And that supplies 120v to the pump. The pump's neutral wire is attached separately from any ground wires.  So what I have is a pump relay that sends 240 volts to a junction box. But I only connected one side of the box to the pump in order to run 120 volts to it. Hope some of this makes sense.
Reply:“…… Pumps neutral is attached separately from any ground wires…..”   Still not completely clear on what you’re doing, but if you’re creating a neutral from “any ground wires” you can be creating a very real potential for electrocution, along with other issues.If you don’t have a neutral in your incoming line to your junction box, you need to wire your pump for 240v.Miller a/c-d/c Thunderbolt XLMillermatic 180 Purox O/ASmith Littletorch O/AHobart Champion Elite
Reply:Or change the circuit going through the relay to 120V. 120V in/120V out.
Reply:

Originally Posted by cwby

Or change the circuit going through the relay to 120V. 120V in/120V out.
Reply:

Originally Posted by hvw

What I have is a pump start relay that runs off 240v power that is connected to the input side of the relay. The output side of the relay goes to a junction box by the pump. The relay is connected to the sprinkler system timer by two 24v wire's which are on the relay. It is connected to the timer by those two 24vires. One is connected to the master valve and the other to the common, both of which are on the timer.  When the timer turns a watering zone on it sends a 24v signal to the pump relay. The relay then energizes and sends 240v to the pump which remains on until the timer stops the signal. Then the relay cuts off the output side and the pump turns off.  But, my pump is wired internally to run off 120v. So, to feed it 120v I installed a junction box and put a single pole breaker on one of the junction box lugs. The pump is connected to that breaker.  The junction box sits next to the pump and would otherwise send 240 volts to the pump. The junction box is connected to a 10/3 wire. Black to one lug, white to the other lug and the ground connected separately to it's own lug. The pump is connected to the breaker by the black wire. And that supplies 120v to the pump. The pump's neutral wire is attached separately from any ground wires.  So what I have is a pump relay that sends 240 volts to a junction box. But I only connected one side of the box to the pump in order to run 120 volts to it. Hope some of this makes sense.
Reply:The relay is just a switch. It is a double pole single throw switch. The coil is 24 volt. The contacts do not know or care what the voltage is on them or it there is one or both sets being used.Why don't you do it properly and come out of breaker and feed one side of relay. Leave that side and go to the pump. Wire your neutral straight through panel to pump.I do not understand all the confusion with a single pole switch. Use side like a single pole switch to your 120 volt hot leg.24 volt to coil. 120 breaker to line side of relay. Pump wire to load side and neutral panel to pump.
Reply:OP posted on another thread.  

Originally Posted by hvw

Thanks to all for the advice and suggestions. I believe I'm either going to wire the pump for 240v or just continue running a 120v leg to the pump. The thing was working for years until we had the electrical storm which burnt up the main breaker. It created all kinds of problems that I'm just now getting resolved. The pump business was just one of them.