Troubleshooting Guide: Borehole Pump Not Switching On? – Critical Causes & Expert Fixes

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Troubleshooting Guide Borehole Pump Not Switching On? Causes, Fixes & Troubleshooting Guide

Overview

Troubleshooting guide: A borehole pump not switching on is one of the most common problems faced by homeowners, farmers, installers, as well as maintenance teams. In most cases, the cause is linked to an electrical fault, control equipment issue, or motor-related problem. However, replacing parts too quickly can often lead to unnecessary costs.

Fortunately, many faults can be identified through a structured troubleshooting process before major repairs become necessary.

This guide also explains:

  • Reasons for a borehole pump that is not switching on
  • Common electrical and mechanical faults
  • Step-by-step troubleshooting procedures
  • Practical repair solutions
  • When professional assistance may be required

Borehole Pump Products

Solar Drives for Borehole Pumps

Common Symptoms of a Borehole Pump Not Switching On

Several warning signs can indicate that a fault exists within the pumping system.

Your system may also:

  • Produce no sound or vibration
  • Deliver no water flow
  • Show no lights on the control box
  • Trip the circuit breaker repeatedly
  • Start and then immediately stop
  • Hum without starting properly

Additionally, some pumps may appear completely dead even though power is available at the installation. Different faults can produce similar symptoms; it is therefore important to work through each troubleshooting step systematically.

 

Step-by-Step Borehole Pump Troubleshooting Guide

Step 1: Go check the Power Supply

Why This Matters

Cases of a borehole pump not switching on are caused by simple power supply problems rather than pump failure; therefore, the power supply should be checked first.

Before investigating the pump itself, confirm that power is reaching the system correctly.

What to Check

  • See whether Eskom or municipal power is available
  • Does the DB board breaker trip when switched on?
  • Does the socket or isolator have power?
  • Are plug connections secure and undamaged?

Possible Quick Fixes

  • Reset any tripped breakers
  • Tighten loose electrical connections
  • Identify Damaged Plugs or Sockets and Replace Them
  • Avoid extension leads that may cause voltage drop

Even a minor power supply issue can also prevent the pump from starting normally.

Step 2: Inspect the Pump Control Box

Reason Why It Matters

For single-phase borehole pumps, the control box plays a critical role in starting and also protecting the motor.

As a result, a fault inside the control box can stop the pump from switching on altogether.

Look for the Following

  • Burnt smell
  • Swollen or bulging capacitor
  • Loose terminals
  • Water ingress
  • Tripped thermal overload

Here are some Quick Fixes

  • Reset the thermal overload
  • Tighten loose terminals
  • Remove and Replace the Capacitor if It Is Damaged
  • Replace the control box if severe damage is present

A faulty capacitor is one of the most common causes of a borehole pump not switching on in single-phase installations.

Step 3: Test the Pressure Switch or Float Switch

The pump cannot start if power is not being sent through the switching system. Pressure switches, as well as float switches often act as safety controls. As a result, they can prevent the pump from operating under certain conditions.

Look for the Following

  • Make sure and go check if the pressure switch stuck in the OFF position?
  • Are the contacts burnt or damaged?
  • Is the float switch stuck?
  • Has the control box been wired correctly?

Some Quick Fixes

  • Manually operate the pressure switch
  • Renew damaged switches
  • Free any stuck float mechanisms
  • Correct wiring faults according to the pump diagram

Switch failures can often imitate more serious pump problems; however, the motor itself may still be in good condition.

 

Step 4: Check for Low Voltage or Voltage Drop

Signs of Voltage Problems

Voltage issues commonly occur because of:

  • Undersized cable
  • Long cable runs
  • Poor power supply quality
  • Loose electrical connections

Consequently, the motor may not receive enough voltage to start correctly.

Quick Fixes

  • Measure voltage under load
  • Upgrade cable sizing where necessary
  • Repair damaged joints
  • Install voltage protection equipment

If a pump hums without starting, first check for voltage problems, as they are often the cause

Step 5: Inspect Motor Protection Devices

Lots of installations include additional protection equipment designed to prevent motor damage.

These may also include:

  • DOL starters
  • Overload relays
  • Motor protection breakers
  • Variable speed drives (VSDs)

Inspect the Following

  • Has the overload tripped?
  • Are protection settings too sensitive?
  • Has the VSD entered fault mode?

Fixes

  • Reset overload protection
  • Verify motor protection settings
  • Clear VSD faults and restart the system

Protection devices are designed to stop damage from occurring. Therefore, repeated trips should always be investigated rather than bypassed.

Step 6: Check for Water Level Problems

Many modern borehole systems include dry-run protection. Water levels may fall below safe operating limits. As a result, the system may intentionally prevent the pump from starting.

Common Causes

  • Water level has dropped in borehole
  • Float switch activation
  • Level sensor shutdown
  • Dry-run controller intervention

Quick Fixes

  • Allow the borehole time to recover
  • Inspect float movement
  • Test level sensors
  • Temporarily bypass dry-run protection for testing purposes only

Low water levels can also be mistaken for electrical faults; however, the protection system may actually be operating correctly.

 

Step 7: Inspect Wiring and Connections

Electrical connections naturally deteriorate over time, especially in outdoor environments, and as a result, loose or corroded connections can prevent a borehole pump from switching on.

Inspect

  • Junction boxes
  • Borehole cable joints
  • Control box wiring
  • Earth leakage protection
  • Cable runs

Quick Fixes

  • Renew damaged connectors
  • Re-do cable joins using approved kits
  • Remove corrosion
  • Improve waterproof sealing

Connection problems can be difficult to identify; after all, faults are often hidden inside cable joints or enclosures.

Step 8: Investigate Possible Motor Failure

If all electrical checks have been completed successfully, attention should shift to the motor itself.

Symptoms

How to Confirm

Recommended Fix

  • Rewind the motor if practical
  • Replace the motor if damage is severe

In many situations, motor replacement can also be more economical than extensive repairs.

When to Contact a Technician

Professional assistance is also recommended if:

  • Breaker trips repeatedly
  • A burning smell is present
  • Cable damage is suspected
  • Insulation tests fail
  • The control box shows signs of damage
  • The pump still will not start after troubleshooting

Some faults can be difficult to identify through visual inspection alone. As a result, professional testing equipment can help locate the problem more accurately.

 

Borehole Pump Troubleshooting and Repairs in South Africa

We also assist customers across South Africa with:

  • Electrical faults in Borehole pump
  • Pump control box failures
  • Motor testing and diagnostics
  • Cable repairs on Borehole 
  • Pressure system troubleshooting
  • Irrigation pump support
  • Electrical control panel faults

We also supply:

  • Borehole pumps
  • Borehole motors
  • Pump controllers
  • Pressure systems
  • Borehole cables
  • Solar pumping equipment

Troubleshooting guide: Related Borehole Pump Problems

You may also find these troubleshooting guides useful:

Need Help with a Borehole Pump Not Switching On?

Troubleshooting guide – If your borehole pump is not switching on and you are unsure of the cause; Pumps Africa and Tools can help identify the fault, as well as recommend the most effective solution.

Our technical team can also assist with:

  • Electrical fault diagnosis
  • Control box troubleshooting
  • Capacitor failures
  • Cable faults
  • Motor winding problems
  • Pump performance issues

Contact Pumps Africa and Tools for professional borehole pump troubleshooting, as well as repair assistance anywhere in South Africa.

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