Completely agree, took the call box out and hooked up the pump properly to the timer, works just fine... they did replace the call box, same issue. And like I said this use to work fine, and then one day with no one touching it, it stopped working fine.
I have another possibility. Working for a power company, I am very familiar with load controls (call box). Load controls are normally installed on 240VAC devices (water heater, HVAC condensor units, etc.). For your 240VAC motor, it should not matter if L1 or L2 is removed. It is impossible for power to flow. If L1 is connected and L2 is not, where would the power flow to? This is the principle as to why it is connected the way it is. Your description of the connections sounds correct. For the company I work for, it is unusal for the load control to be used (only at the very worst peak times (ie Summer on 99 deg days)). However, the power company still gives the $8 credit to the customer during the seasonal times of the year for the extra insurance.
It is quite possible for you to bypass the load control without the power company ever finding out......many folks do. It usually happens on 99 deg days when the power company needs the extra power, but people discover that their HVAC unit is off on the hot as hell day and the desire to save $8 goes out the window.
It is possible that your motor or some component thereof (ie cap) is going bad and causing excess heat. There could also be a bad L1/L2 connection causing reduced voltage at the motor terminals that may also cause overheating.
Pool Clown has the right idea by eliminating the suspects one at a time. Eventually, you'll find out that it was Professor Plum in the Library with the candlestick.
Let us know what you find.
Thanks. So whats happening is removing the load control of course fixes it. When its connected and the timer is in the on position it works when the timer switches off, L1 has no power but L2 which is connected to the load control box is still getting power and still flowing to the pump, so its half on. Again this just started happening. I have replaced the timer and had the power company replace the load controller, same issue. The only thing left is the pump.
Does anyone know the inner workings of these pumps? are there any devices in the pump it self that could be causing this?