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50 Hz AIM Manual - Franklin Electric

1. START CAP 275468115 189 227 MFD START CAPACITOR 220V 275468115 189 227 MFD Bik 220V RED RUN CAP RUN CAP 155327101 155327109 o 30 MFD 45 MFD 370V 370V YEL 5 BEA ORG Lat 2H RED BLK LIGHTNING ARRESTOR IF USED Bag GROUND L1 L2 YELBLKREI LEAD 4 LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER 5 x Bk AND OTHER CONTROL a m GROUND START LEAD MAIN OVERLOAD OVERLOAD 275406102 275411102 MOTOR 5 HP 282 353 9010 H Maintenance Electronic Products Pumptec Pumptec is a load sensing device that monitors the load on submersible pump motors If the load drops below a preset level for a minimum of 4 seconds the Pumptec will shut off the motor The Pumptec is designed for use on Franklin Electric 2 and 3 wire motors 1 3 to 1 1 2 HP 220V The Pumptec is not designed for jet pumps A Is the voltage more than 9096 of nameplate rating Pumptec trips in about 4 sec B Are the pump and motor correctly matched with some water delivery C Is the Pumptec wired correctly Check the wiring diagram and pay special attention to the positioning of the power lead A The pump may be airlocked If there is a check valve on top of the pump put another section of pipe between the pump and the check valve Pumptec trips in about 4 sec B The pump may be out of wat
2. 5 Installation All Motors Use of Check Valves 5 Submersible Motors 29 Well Diameters Casing Top Feeding Screens 6 3 Tightening Lead Connector Jam Nut 30 Water Temperature Flow 6 Pump to Motor Coupling 30 Flow Inducer 6 Shaft Height and Free End Play 30 Head Loss Past Motor pp 7 Submersible Leads and 30 Hot Water Applications 7 8 Da Splicing Submersible 31 Drawdown 9 Heat Shrink Solicin 31 Grounding Control Boxes and Panels 9 Pe USC Uu UE Grounding Surge Arrestors pp 9 Control Box and Panel Environment 9 Maintenance All Motors System Troubleshooting 32 33 Application Single Phase Motors Preliminary 10515 2 34 Insulation Resistance pp 35 3 Wire Control Boxes pa Mu LE LE 10 Resistance of Drop 35 2 Wire Motor Solid State Controls 10 Cable Sele
3. Hew 40 100A 68 136 92 3 69A 48 97A 69 132A 90A 173A 118A 236A 159A 2 44 32A 64A 44 84A 60A 112A 76 152A 104A 76A 111A 76 145A 104A 194A 132A 2634 180A EHE 66A 46A 77A 58A 109A 75A 1534 105A 195A 134A 114A 80A 133 91A 188A 130A 265 181A 337A 232A Based on 30 C maximum ambient with cable length of 100 feet or less Continued on next page 26 Inline Booster Pump Systems continued 17 Open Atmosphere Booster Pump Systems When an open booster is placed in a lake tank etc that is open to atmospheric pressure the water level must provide sufficient head pressure to allow the pump to operate above its NPSHR requirement at all times and all seasons Adequate inlet pressure must be provided prior to booster start up Four Continuous Monitoring System Requirements for Sealed Booster Systems 1 Water Temperature Feed water on each booster must be continuously monitored and not allowed to exceed the motor nameplate maximum ambient temperature at any time IF THE INLET TEMPERATURE EXCEEDS THE MOTOR NAMEPLATE MAXIMUM AMBIENT TEMPERATURE THE SYSTEM MUST SHUTDOWN IMMEDIATELY TO PREVENT PERMANENT MOTOR DAMAGE If feed water temperatures are expected to be above the allowable temperature the motor must be derated See Franklin s AIM Manual Hot Water Applications section for derating guidelines
4. Yes Yes No Set At No Set At Sec Model Volt Hz Volt Hz Magnetic Starter Contactor Mfr Model Size Overload Mfr Ambient Compensated Yes No Overload Class 10 Rated Yes Htr No Circuit Protection Fuse Breaker Mfr If Adjustable Overload Set At Size Type Lightning Surge Arrestor Mfr Model Controls Are Grounded to with No Wire Inlet Feed Water Temp Control Required Mfr Model Set At DC Delay Inlet Pressure Control Required Ea Mtr Mfr Model Set PSIDelay Sec Outlet Flow Control Required Ea Mtr Mfr Model Set GPM Delay Outlet Pressure Control Required Ea Mtr Mfr Model Set PSIDelay Inlet Flow Control Optional If Yes Mfr Model Set GPM Delay Flushing Is there a flushing cycle Yes No If Yes Flushing Occurs Pre Operation Yes IfYes Duration in Min GPM or PSI Post Operation Yes If Yes Duration in Min GPM or PSI Chemicals DYes If Yes list Motor Duty Cycle Starts Per 24hrs Time Between Shutdown amp Start up Insulation Check Initial Megs Motor amp Motor Lead Only T1 T2 T3 Installed Megs Motor Motor Lead amp Cable T1 T2 T3 Motor Phase to Phase Resistance T1 T2 T1 T3 T2 T3 Voltage To Motor Non Operating T1 T2 T1 T2 T2 T3 Operating At Rated Flow GPM
5. 1 Motor Inspection C A Verify that the model hp or kW voltage phase and hertz on the motor nameplate match the installation requirements C B Check that the motor lead assembly is not damaged C Measure insulation resistance using 500 or 1000 volt megohmmeter from each lead wire to the motor frame Resistance should be at least 200 megohms without drop cable C D Keep a record of motor model number hp or kW voltage and serial number S N S N is stamped in shell above the nameplate A typical example S N 07A18 01 0123 2 Pump Inspection A Check that the pump rating matches the motor B Check for pump damage and verify that the pump shaft turns freely 3 Pump Motor Assembly C A If not yet assembled check that pump and motor mounting faces are free from dirt debris and uneven paint thickness B Pumps motors over 5 hp should be assembled the vertical position to prevent stress on pump brackets and shafts Assemble the pump and motor together so their mounting faces are in contact and then tighten assembly bolts or nuts evenly to manufacturer specifications L C If accessible check that the pump shaft turns freely C D Assemble the pump lead guard over the motor leads Do not cut or pinch lead wires during assembly or installation 4 Power Supply and Controls Verify that the power supply voltage Hertz capacity match motor requirem
6. A Pressure switch Low water level in well Leak in system Worn pump Loose coupling or broken motor shaft Pump screen blocked Check valve stuck closed Control box malfunction H Maintenance All Motors Check switch for welded contacts Check switch adjustments Pump may exceed well capacity Shut off pump wait for well to recover Check static and drawdown level from well head Check system for leaks Symptoms of worn pump are similar to those of drop pipe leak or low water level in well Reduce pressure switch setting if pump shuts off worn parts may be the fault Check for loose coupling or damaged shaft Check for clogged intake screen Check operation of check valve See pages 36 37 for single phase Motor Runs But Overload Protector Trips C D E Incorrect voltage Overheated protectors Defective control box Defective motor or cable Worn pump or motor Using voltmeter check the line terminals Voltage must be within x 1096 of rated voltage Direct sunlight or other heat source can raise control box temperature causing protectors to trip The box must not be hot to touch For detailed procedures see pages 36 37 For detailed procedures see pages 34 36 Check running current see pages 13 amp 16 18 33 Clean contacts replace switch or adjust setting Throttle pump output or reset pump to lower level Do not lower if
7. SUBMERSIBLE MOTORS APPLICATION INSTALLATION MAINTENANCE Commitment Quality Franklin Electric is committed to provide customers with defect free products through our program of continuous improvement Quality shall in every case take precedence over quantity Franklin Electric www franklin electric com H Submersible Motors Application Installation Maintenance Manual The submersible motor is a reliable efficient and trouble All considerations of application installation and free means of powering a pump Its needs for a long maintenance of submersible motors relate to these four operational life are simple They are areas This manual will acquaint you with these needs 1 A suitable operating environment and assist you if service or maintenance is required 2 An adequate supply of electricity 3 An adequate flow of cooling water over the motor 4 appropriate pump load Application All Motors Submersible Booster Installation Record No 3655 Three Phase Motor Lead Identification 23 ieri sp 3 Reduced Voltage Starters 24 Frequency of Starts 3 2 Inline Booster Pump Systems 24 27 Mounting Position pp 3 Variable S do 28 Transformer 4 Effects of 4 Engine Driven
8. 84 o 84 0 76 0 69 380 231 131000 85 84 81 0 88 0 84 0 77 279 106 380 415 400 224 130000 03 05 86 84 81 0 85 0 81 0 72 415 222 130000 86 84 0 83 0 77 0 68 Performance is typical not guaranteed at specific voltages Locked rotor amps for Wye start 6 lead motors is 3396 of value shown Performance also applies to 6 lead model numbers where not listed Six lead individual phase resistance table X 1 5 Refer to Table 17 for fuse sizing recommendations at equal KW values 18 Locked Rotor Amps 49 9 52 5 54 5 78 6 83 0 86 0 105 110 114 152 160 166 195 205 213 253 266 276 289 304 316 419 441 458 474 499 518 654 692 720 835 884 920 876 927 965 1185 1254 1306 1404 1482 1544 1596 1690 1760 3 Application Three Phase Motors Overload Protection Three Phase Submersible Motors Motor Protection Selection of Thermal Overload Relays Characteristics of submersible motors differ from standard motors and special overload protection is required In order to provide sufficient protection against overload and locked rotor the relay has to be of the following characteristic Conform to European standards e g VDE providing trip time lt 10 sec at 500 IN name plate current based on cold bimetal Protection against single phasing Must trip at 120 IN name plate current Temperature comp
9. ie Gu Ke 2 2kW 230 V Single Phase Motor Irem 12 Circuit Breakers Fuse Amps Std Fuse or Time Delay 3 4 1 2 FL 3 4 1 2 Circuit Breaker Fuse 59 51 73 64 53 Line to Line 1 Resistance Ohms 220 220 39 610 63 77 62 25 0 15 5 244555 230 230 4 1 630 63 77 89 55 47 68 50 26 1 15 5 220 220 6 0 880 3 7 4 6 63 59 52 70 62 53 30 0 20 7 244557 3 4 a 230 230 6 5 920 3 7 4 6 61 56 48 67 59 49 36 6 20 7 5 220 220 7 3 1180 32 39 65162 55 75 66 54 42 0 20 9 244558 IEG 230 230 7 6 1200 3 2 3 9 68 59 52 71 63 52 43 9 20 9 220 220 10 6 1800 2 2 2 7 64 61 56 78 70 58 50 6 30 12 244359 11 2 230 230 10 8 1820 22 2 7 63 60 53 73 65 54 52 9 30 12 5 amp 214555 220 220 42 650 6 4 7 8 19 4 23 7 57 54 46 72 64 58 15 4 15 45 5 c o 214557 220 220 63 940 38 46 14 7 18 0 59 55 47 69 60 50 23 0 15 7 214558 220 220 7 6 1200 32 39 12 8 15 7 62 59 52 73 65 53 29 1 20 9 5 224350 220 220 10 0 1690 24 29 6 4 7 8 67 63 55 79 63 55 40 6 20 12 T 9 ct amp 224351 BH 220 220 12 1 2160 20 25 80 97
10. 1055 26 1 31 9 71 83 9 0 15 234554 220 5 2 1465 4 3 5 2 76 83 24 15 234524 Se 380 3 0 1465 13 2 16 2 76 83 14 15 234355 220 6 9 1970 3 0 3 7 76 84 35 15 234325 380 4 0 1970 76 84 20 15 234356 220 110 4 2930 2 1 2 7 76 86 46 25 380 6 0 2930 76 86 26 234326 400 6 0 2920 6 7 8 2 77 82 27 15 415 6 2 2925 77 77 28 234394 220 12 6 3940 1 5 1 8 76 87 64 35 380 7 3 3940 76 87 36 234395 400 7 3 3910 4 9 6 0 76 84 38 20 415 7 6 3920 76 81 39 234357 220 15 5 4860 1 1 1 4 77 84 80 40 380 9 0 4860 77 84 46 234327 400 9 1 4875 3 6 4 4 77 79 48 25 415 9 5 4910 76 74 49 234396 220 18 0 5275 1 0 1 3 78 86 89 45 380 10 1 5275 78 86 51 5 1 2 234397 400 10 4 5210 3 2 3 9 79 82 53 25 415 10 6 5240 78 79 55 234358 220 22 8 7175 75 92 78 85 120 60 380 13 0 7175 78 85 69 71 2 234328 400 13 1 7155 2 3 2 8 78 80 73 35 415 13 5 7205 78 76 76 380 18 7 9580 78 86 99 234595 1 7 2 1 50 400 18 8 9550 78 81 102 Performance is typical not guaranteed at specified voltages Performance of 1984 and older models not listed is similar but not identical 16 Resistance Ohms 1 i Dual Element Std Fuse or 66 82 2 5 1 2 3 1 8 4 2 5 4 5 12 15 20 10 20 12 30 15 25 Inch Inch itl TABLE 11 Three Phase Motor Spec
11. FIG 14 OHMMETER FIG 15 SETATRX1 34 H Maintenance All Motors Insulation Resistance Readings TABLE 17 Normal Ohm and Megohm Valves Between All Leads and Ground A new motor without drop cable 200 000 000 or more 200 or more A used motor which can be reinstalled in well 10 000 000 or more 10 or more New motor 2 000 000 or more 2 0 or more Motor in good condition 500 000 2 000 000 0 5 2 0 Insulation damage locate and repair Less than 500 000 Less than 5 Insulation resistance varies very little with rating Motors of all HP voltage and phase rating have similar values of insulation resistance Table 33 is based on readings taken with a megohm meter with a 500VDC output Readings may very using a lower voltage ohmmeter consult Franklin Electric if readings are in question Resistance of Drop Cable Ohms The values below are for copper conductors If aluminum Winding Resistance Measuring conductor drop cable is used the resistance will be higher To determine the actual resistance of the aluminum drop cable divide the ohm readings from this chart by 0 61 This chart shows total resistance of cable from control to motor and back The winding resistance measured at the motor should fall within the values in tables 7 amp 10 12 When measured through the drop cable the resistance of the drop cable must be subtracted from the ohmmeter readings to get the winding resistance
12. Jam nut tightening torques recommended for field 20 to 27 Nm 15 to 20 ft Ib assembly are shown Rubber compression set within 4 Motors with 2 Screw Clamp Plate the first few hours after assembly may reduce the jam nut torque This is a normal condition which does not 4 0 to 5 1 Nm 35 to 45 in Ib ue dun indicate reduced seal effectiveness Retightening is not 6 Motors required but is permissible and recommended if original 54 to 68 Nm 40 to 50 ft lb torque was questionable 8 Motors with 1 3 16 to 1 5 8 Jam Nut A motor lead assembly should not be reused A new 68 to 81 Nm 50 to 60 ft lb lead assembly should be used whenever one is removed 8 Motors with 4 Screw Clamp Plate from the motor because rubber set and possible Apply increasing torque to the screws equally in a damage from removal may prevent proper resealing of criss cross pattern until 9 0 to 10 2 Nm the old lead 80 to 90 in Ib is reached All motors returned for warranty consideration must have the lead returned with the motor Pump to Motor Coupling Pump to Motor Assemhly Assemble coupling with non toxic FDA approved After assembling the motor to the pump torque waterproof grease such as Mobile FM102 Texaco mounting fasteners to the following CYGNUS2661 or approved equivalent This prevents from entering the spline area and prolongs 4 Pump and Motor 14 Nm 10 Ib ft 6 Pump and Motor 68 Nm 50 Ib ft 8 Pump and Motor 163 Nm 120 Ib ft Shaft
13. Maximum Length in Feet 23 gt oo m RE 33 55 EE gt gt 185 22 55 11 2 33 3 5 EN oo 5 gt gt EE ss NEM Eg 1420 960 750 520 390 260 190 150 130 1580 1210 800 580 470 420 320 230 160 2290 1550 1210 840 640 430 310 3640 2470 1930 1340 1030 680 500 400 1300 2060 950 1510 770 1220 690 1100 520 840 370 600 270 430 0 330 0 260 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 5620 3820 2980 2080 1600 1070 780 630 3210 2350 1910 1710 1310 930 680 520 410 340 8800 5980 4660 3270 2510 1680 1230 1000 9320 7260 5090 3920 2630 1920 1560 5030 3690 3000 2690 2060 1470 1070 820 640 540 7870 5760 4690 4200 3230 2300 1690 1290 1010 860 6 Delta 8090 6620 9650 7230 5580 4410 3730 2760 2200 1840 1580 1190 920 770 670 9280 7600 8310 6430 5080 4290 3170 2530 2120 1820 1370 1050 890 780 600 690 8710 9550 7410 5860 4950 3650 2910 2440 2100 1580 1210 1020 900 790 9810 8380 6630 5590 4120 3290 2750 2380 1790 1360 1160 1020 900 M
14. The high temperature feed water derating is in addition to the exchange to DI water derating if the motor factory fill solution was exchanged to DI water Inlet Pressure The inlet pressure on each booster module must be continuously monitored It must always be positive and higher than the NPSHR Net Positive Suction Head Requirement of the pump A minimum of 20 PSIG 1 38 Bar is required at all times except for 10 seconds or less when the motor is starting and the system is coming up to pressure Even during these 10 seconds the pressure must remain positive and be higher than the NPSHR Net Positive Suction Head Requirement of the pump 27 Application Three Phase Motors PSIG is the actual value displayed on a pressure gauge in the system piping PSIG is the pressure above the atmospheric conditions If at any time these pressure requirements are not being met the motor must be de energized immediately to prevent permanent damage to the motor Once the motor is damaged it is usually not immediately noticeable but progresses and results in a premature motor failure weeks or months after the damage occurred Motors that will be exposed to pressure in excess of 500 psi 34 47 Bar must undergo special high pressure testing Consult factory for details and availability Discharge Flow The flow rate for each pump must not be allowed to drop below the motor minimum cooling flow requirement IF THE MOTOR MINIMUM COOL
15. When a deionized water fill is required the motor must be derated as indicated on the below chart The exchange of the motor fill solution to DI water must be done by an approved Franklin service shop or representative using a vacuum fill system per Franklin s Motor Service Manual instruction The Continued on next page 25 H Application Three Phase Motors motor shell then must be permanently stamped with a D closely behind the serial number The maximum pressure that can be applied to the motor internal components during the removal of the factory fill solution is 7 psi 0 5 bar Derating Factor for Motors That Must Have Their Factory Fill Replaced With Deionized Water 8 Encapsulated Motor 1 8 1 75 17 1 65 2 1 6 155 3 1 5 1 45 5 14 o 135 1 1 00 Service Factor 50Hz a 1 25 1 2 115 11 _ 1 05 1 15 Service Facti 1 40 35 30 25 20 15 10 Feed Water Temperature FIG 11 First Determine maximum feed water temperature that will be experienced in this application If the feed water exceeds the maximum ambient of the motor both the DI water derating and a hot water application derating must be applied Second Determine the pump load multiplier from the appropriate Service Factor curve Typical 1 15 Service Factor is for 60 Hz ratings amp 1 00 Service Factor for 50 Hz ratings Third Multiply the pump
16. hammer and upthrust Any of these can lead to early pump or motor failure NOTE Only positive sealing check valves should be used in submersible installations Although drilling the check valves or using drain back check valves may prevent back spinning they create upthrust and water hammer problems A Backspin With no check valve or a failed check valve the water in the drop pipe and the water in the system can flow down the discharge pipe when the motor stops This can cause the pump to rotate in a reverse direction If the motor is started while it is backspinning an excessive force is placed across the pump motor assembly that can cause impeller damage motor or pump shaft breakage excessive bearing wear etc 3 Application All Motors Upthrust With no check valve a leaking check valve or drilled check valve the unit starts under a zero head condition This causes an uplifting or upthrust on the impeller shaft assembly in the pump This upward movement carries across the pump motor coupling and creates an upthrust condition in the motor Repeated upthrust can cause premature failure of both the pump and the motor Water Hammer If the lowest check valve is more than 9 1 m 30 feet above the standing lowest static water level or a lower check valve leaks and the check valve above holds a vacuum is created in the discharge piping On the next pump start water moving at very high velocity fills the void and st
17. tap should be used Six Lead Motors Wye Delta starters are used with six lead Wye Delta motors All Franklin 6 and 8 three phase motors are available six lead Wye Delta construction Consult the factory for details and availability Part winding starters are not compatible with Franklin Electric submersible motors and should not be used Wye Delta starters of the open transition type which momentarily interrupt power during the starting cycle are not recommended Closed transition starters have no interruption of power during the start cycle and can be used with satisfactory results Reduced voltage starters have adjustable settings for acceleration ramp time typically preset at 30 seconds They must be adjusted so the motor is at full voltage within THREE SECONDS MAXIMUM to prevent excessive radial and thrust bearing wear If Subtrol Plus or SubMonitor is used the acceleration time must be set to TWO SECONDS MAXIMUM due to the 3 second reaction time of the Subtrol Plus or SubMonitor Solid state starters AKA soft starts may not be compatible with Subtrol Plus SubMonitor However in some cases a bypass contactor has been used Consult the factory for details During shutdown Franklin Electric s recommendation is for the power to be removed allowing the pump motor to coast down Stopping the motor by ramping down the voltage is possible but should be limited to three 3 seconds maximum are often experienced in
18. 1580 o o o 150 200 280 380 1330 0 120 170 240 330 1170 0 0 180 240 880 190 650 550 0 10 1 NE 500 440 6 Lead Wye Delta Motor Rating Metric Cable Size Square Millimeters Copper Wire 70 C Rated Insulation E 1540 1060 750 550 420 Lengths in BOLD meet 330 the IEC ampacity only 280 for individual conductor cable in free air or water not in conduit Ampacities are determined from IEC publication 364 5 523 1983 edition Jacketed cable is based on Table 52 B1 Installation method C using Column C in Table 52 C3 70 Individual Conductor is based on Table 52 B2 Installation method G using Column 6 in Table 52 C10 70 220v 50Hz 30 6 Lead 230 11096 240 119 130 150 200 1 Meter 3 3 feet 380 50Hz 30 6 Lead 400V may use 110 of table 415V may use 119 of table E 15 1851 ES 5 71 EIN 15 EH 22 30 ES ES En 0 0 0 0 0 0 0 0 0 0 14 itl Application Three Phase Motors TABLE 9 Three and Six Wire Cable 50Hz Service Entrance to Motor
19. 2150 2520 4640 a2 50 80 120 200 320 490 670 920 1240 1590 1910 2240 4070 SS 90 150 240 380 520 710 960 1240 1490 1750 3250 E 55 o 110 170 270 370 500 680 870 1050 1230 2230 N OBS o o 40 80 120 190 270 370 500 650 790 930 1740 o o o 90 150 200 280 380 500 610 720 1370 o o 70 110 160 220 300 390 480 570 1090 60 190 260 400 9790 490 820 1300 1950 3200 5020 7620 340 570 910 1360 2240 3520 5350 7280 9890 260 430 700 1040 1720 2700 4120 5630 7690 170 290 460 700 1150 1810 2770 3790 5190 6950 120 210 340 510 840 1330 2030 2770 3790 5070 32 100 170 270 410 680 1080 1650 2260 3090 4140 535 90 150 250 370 610 970 1480 2020 2770 3700 uh e 70 110 190 280 470 740 1140 1560 2140 2870 9700 55 50 80 130 200 330 530 810 1110 1510 2030 6680 e FE 90 140 240 380 590 810 1120 1510 5200 88 70 110 180 290 450 620 860 1160 4110 5 gt gt 0 80 140 230 350 490 680 910 3260 ERES o 120 190 300 410 570 770 2740 9325 o o o o 140 220 310 420 570 1990 o 110 180 240 340 460
20. 62 77 16 21 52 64 34 42 25 32 25 32 o 2 22 27 17 Efficiency 96 Power Factor 96 Application Three Phase Motors Locked Rotor Circuit Breakers Fuse Amps Typical Submersible TABLE 12 Hi Temp 90 C Three Phase Motor Specifications 50 2 2875 RPM 1 0 Service Factor ned Nameplate Rating a EE T to Line 1 Efficiency 90 Power Factor 96 Prefix n Resistance Ohms 380 8 8 5000 74 72 66 88 85 78 276 610 EWAN 380 415 400 8 5 5000 2 79 3 41 75 72 66 86 82 74 415 8 4 5000 75 72 65 84 79 70 380 12 7 7300 75 85 77 276 611 AJ 380 415 400 12 3 7200 166 203 77 75 70 86 81 72 415 12 3 7200 77 75 69 84 77 67 380 24 4 9400 80 78 74 88 84 76 276612 EAM 380 415 400 242 9300 118 144 81 79 74 85 79 69 9 415 24 4 9400 80 77 71 83 76 65 2 380 33 3 13900 80 79 75 85 83 74 276613 380 415 400 33 0 13800 78 96 79 74 82 77 415 333 14000 79 73 79 73 61 380 40 7 18700 79 76 87 82 73 I 276614 Pi 380 415 400 40 5 18700 58 72 79 75 65 A 415 41 4 18700 80 78 74 80 72 eo 380 492 22600 82 82 79 86 80 70 276 615 380 415 400 48 0 22500 41 51 82 78 82 74 62 415
21. 69 67 60 85 77 65 54 3 30 15 5 9 224352 220 220 17 8 3270 11 14 3 7 4 5 68 66 63 85 77 65 87 5 50 25 5 224353 220 220 26 0 5150 79 97 2 4 2 9 73 71 64 93 89 78 118 30 1 Main winding yellow to black Performance is typical not guaranteed at specified Start winding yellow to red voltages and specified capacitor values Performance at voltage ratings not shown is similar except amps vary inversely with voltage 13 H Application Three Phase Motors TABLE 8 Three and Six Wire Cable 50 Hz Service Entrance to Motor Maximum Length in Meters 70 C Metric Cable Size Square Millimeters Copper Wire 70 C Rated Insulation EEE eee eu E 70 95 120 150 185 240 300 510 820 1230 2010 3160 4810 6540 8890 350 550 830 1370 2150 3280 4460 6060 8060 TT 270 430 650 1070 1680 2550 3470 4710 6250 7970 9510 s 8 190 300 450 750 1170 1790 2430 3310 4400 5620 6700 7790 55 140 230 340 570 900 1380 1880 2570 3430 4410 5290 6180 50 90 150 230 380 600 920 1270 1740 2330 3000 3610 4230 7790 2 40 70 110 170 280 440 670 920 1270 1700 2180 2630 3080 5630 S 30 50 90 130 220 360 550 750 1030 1390 1790
22. Capacitor Run Control Deionized Rise Time of the Voltage Efficiency Degree Fahrenheit Food amp Drug Administration Full Load Foot Foot Pound Feet per Second Ground Fault Circuit Interrupter Gallon per Minute High Efficiency Reverse Osmosis Horsepower Hertz Inside Diameter Insulated Gate Bipolar Transistor Inch Kilovolt Amp Kilovolt Amp Rating Kilowatt 1000 watts Line One Line Two Line Three Pound Feet Liter per Minute Milliamp Maximum Abbreviations MCM MOV NEC NEMA NPSH OD OL PF psi PWM QD RMA RMS rpm SF SFhp S N TDH UNF VAC VDC VFD XFMR Y D 48 Thousand Circular Mils Millimeter Metal Oxide Varister National Electrical Code National Electrical Manufacturer Association Newton Meter Net Positive Suction Head Outside Diameter Overload Power Factor Pounds per Square Inch Pulse Width Modulation Quick Disconnect Resistance Return Material Authorization Root Mean Squared Revolutions per Minute Service Factor Service Factor Horsepower Serial Number Total Dynamic Head Fine Thread Voltage Voltage Alternating Current Voltage Direct Current Variable Frequency Drive Watts Transformer Wye Delta ohms TOLL FREE HELP FROM A FRIEND 800 348 2420 260 827 5102 fax Phone Franklin s toll free SERVICE HOTLINE for answers to your pump motor installation questions When you call a Franklin expert will offer assistance in troubleshootin
23. T1 T2 T1 T2 T2 T3 Operating At Open Flow GPM T1 T2 T1 T2 T2 T3 Amps To Motor Operating At Rated Flow GPM T1 T2 T3 Operating At Open Flow GPM T1 T2 T3 Current System Reading Inlet Pressure PSI Outlet Pressure PSI Water Temperature O C Warranty on three phase motors is void unless Subtrol or proper quick trip ambient compensated protection is used or all three 3 motor lines If you have any questions or problems call the Franklin Electric Toll Free Hot Line 1 800 348 2420 Comments Please attach a sketch of the system Form No 3655 10 03 H Application Three Phase Motors Three Phase Motor Lead Identification 90 Lead Spacing T5 V2 YELLOW CHECK VALVE OR PIPE PLUG ON RIGHT SIDE FACING MOTOR WARNING When installing 6 lead motors extra care must be T3 W1 BLACK used to ensure lead identification RED at the surface Leads must be marked and connected per diagram Motor leads are not FOR 3 LEAD DOL MOTORS connected red to red yellow to yellow etc FIG 10 LEADS LOCATED HERE ONLY Line Connections Six Lead Motors Connections for across the line starting WYE DELTA starters connect the motor as running and any reduced voltage starting shown below during starting then change to except WYE DELTA type starters the running connection shown at the left L1 L2 L3 L1 L2 L3 T1 T6 T2 T4 T3 T5 T1 T2 T3 T4 T5 T6 U1 W2 V1 U2 w1 V2 U1 V1 wi
24. The time for the protector to reset is longer than the reset of the starting switch Therefore the start switch will have closed and the motor will operate A waterlogged tank will cause fast cycling When a waterlogged condition does occur the user will be alerted to the problem during the off time overload reset time since the pressure will drop drastically When the waterlogged tank condition is detected the condition should be corrected to prevent nuisance tripping of the overload protector Bound Pump Sandlocked When the motor is not free to turn as with a sandlocked pump the BIAC switch creates a reverse impact torque in the motor in either direction When the sand is dislodged the motor will start and operate in the correct direction CAUTION Restarting the motor within 5 seconds after power is removed may cause the motor overload to trip Application Single Phase Motors 2 or 3 Wire Cable 50 Hz Service Entrance to Motor Maximum Length In Meters amp Feet Cable for submersible motors must be suitable for Minimum AWG Cable sizes are based on the National submerged operation and adequate in size to operate Electrical Code in Table 430 150 for 75 Cable In within rated temperature and maintain adequate 30 C Maximum Ambient Use Larger Cable if Local voltage at the motor Cable may be twisted conductors Codes Or Higher Temperatures Require It Lengths in with or without jacket or flat
25. U2 V2 W2 Each motor lead is numbered with two markers one near each end To reverse rotation interchange any two line connections 23 Reduced Voltage Starters All Franklin three phase submersible motors are suitable for full voltage starting Under this condition the motor speed goes from zero to full speed within a half second or less The motor current goes from zero to locked rotor amps then drops to running amps at full speed This may dim lights cause momentary voltage dips to other electrical equipment and shock power distribution transformers In some cases the power companies may require reduced voltage starters to limit this voltage dip There are also times when reduced voltage starters may be desirable to reduce motor starting torque thus reducing the stress on shafts couplings and discharge piping Reduced voltage starters also slow the rapid acceleration of the water on start up to help control upthrust and water hammer Reduced voltage starters may not be required if the maximum recommended cable length is used With maximum recommended cable length there is a 5 voltage drop in the cable at running amps resulting in about 20 reduction in starting current and about 36 reduction in starting torque compared to having rated voltage at the motor This may be enough reduction in starting current so that reduced voltage starters are not required Three Lead Motors Autotransformer or solid state reduced vol
26. conduit also increases Check Valves Spring loaded check valves must be used on start up to minimize motor upthrusting water hammer or in multiple booster parallel applications to prevent reverse flow Pressure Relief Valves A pressure relief valve is required and must be selected to ensure that as the pump approaches shut off it never reaches the point that the motor will not have adequate cooling flow past it System Purge Can Flooding An air bleeder valve must be installed on the booster sleeve so that flooding may be accomplished prior to booster start up Once flooding is complete the booster should be started and brought up to operating pressure as quickly as possible to minimize the duration of an upthrust condition At no time should air be allowed to gather in the booster sleeve because this will prevent proper cooling of the motor and permanently damage it System Flush Must Not Spin Pump Applications may utilize a low flow flushing operation Flow through the booster sleeve must not spin the pump impellers and the motor shaft If spinning takes place the bearing system will be permanently damaged and the motor life shortened Consult the booster pump manufacturer for maximum flow rate through the pump when the motor is not energized 8 AWG In Conduit In Air In Conduit In Conduit In Conduit inair inconduit 28A 56A 40A 76A 52A
27. for safety purposes so that the water column itself does not become the conductive path to ground When an installation has abnormally corrosive water AND the drop pipe or casing is plastic Franklin Electric recommends the use of a GFCI with a 10 mA set point In this case the motor ground wire should be routed through the current sensing device along with the motor power leads Wired this way the GFCI will trip only when a ground fault has occurred AND the motor ground wire is no longer functional 3 Wire Control Boxes Single phase three wire submersible motors require the use of control boxes Operation of motors without control boxes or with incorrect boxes can result in motor failure and voids warranty Control boxes contain starting capacitors a starting relay overload protectors and in some sizes running capacitors Potential Voltage Relays Potential relays have normally closed contacts When power is applied both start and main motor windings are energized and the motor starts At this instant the voltage across the start winding is relatively low and not enough to open the contacts of the relay 2 Wire Motor Solid State Controls BIAC Switch Operation When power is applied the bi metal switch contacts are closed so the triac is conducting and energizes the start winding As RPM increases the voltage in the sensor coil generates heat in the bi metal strip causing the bi metal strip to bend and open the
28. molded type Franklin Bold Meet and NEC Ampacity only For Individual 50HZ cable selections maintain motor voltage to at least Conductor Cables in air or water not in conduit 9596 of supply voltage with maximum rated running amps and maintain acceptable starting voltage and cable temperature Tables list the maximum recommended lengths in Meters for square millimeter copper cable sizes and in feet for AWG copper cable sizes The single phase Minimum Square Millimeter cable for each rating is tables apply to all three wire types and control boxes based on IEC Publication 364 5 523 1983 Edition where required may be at any point in the cable length Jacketed cable is based on Table 52 B1 Installation The portion of cable from service entrance to a three Method C In Table Using Column C in Table 52 C3 phase controller should not exceed 2596 of table 70 C Individual conductor is based on Table 52 B2 maximum length to assure reliable starter operation Installation Method G using Column 6 In Table 52 C10 70 TABLE 6 Single Phase Maximum Length of Copper Cable meters purum up ee 2 13 0 320 510 770 1260 1970 2960 3990 5340 6970 8750 120 210 330 500 820 1290 1950 2640 3560 4680 5910 55 3 4 gt 140 230 350 580 900 1360 1830 2450 3210 4020 75 1 0 o 110 180 270 440 690 1050 1430 1930 2550 3230 11 15 2 70 120 190 310 490 750 1020 1390
29. obtain at least 91 m sec flow rate 356 3860 406 5530 2 Determine pump KW HP required from the pump 4 5 6 Application All Motors EXAMPLE manufacturer s curve T 2 3 7 5 9 3 0 4 5 I 2 2 3 z o 1 5 2 x c 75 1 0 0 18 9 37 9 56 8 75 7 94 6 113 6 132 5 155 174 4 193 8 Liters Per Minute FIG 2 MANUFACTURER S PUMP CURVE TABLE 5 Heat Factor Multiplier at 91 m sec Flow Rate 3 Multiply the pump KW HP 1 3 5 7 1 2 30 HP Over 30HP required by the heat factor Water Temperature 25 3 7 KW 5 5 22 KW Over 22 KW 60 C multiplier from Table 5 1 25 1 62 2 00 55 C 1 11 1 32 1 62 50 C 1 00 1 14 1 32 45 C 1 00 1 00 1 14 40 C 1 00 1 00 1 00 35 C 1 00 1 00 1 00 4 Select a rated KW HP TABLE 5A Service Factor Horsepower hp kw sFnp Ezra EIE is at least the value 1 3 0 25 0 58 3 45 18 5 28 75 100 115 00 calculated in Item 3 1 2 037 5 37 575 22 0 34 50 125 93 143 75 3 4 0 55 1 12 7 5 55 8 62 40 30 0 46 00 150 110 172 50 1 0 75 140 10 7 5 11 50 50 37 0 57 50 175 130 201 25 15 140 195 15 11 0 17 25 60 45 0 69 00 200 150 230 00 2 150 2 50 20 15 0 23 00 75 55 0 86 25 Hot Water Applications Example EXAMPLE A 6 pump end requiring 29 1 KW 39 HP inpu
30. of the motor See table below Drop Cable Resistance Table 18 DC Resistance in Ohms per 100 ft of wire two conductors 10 0 544 0 338 0 214 0 135 0 082 0 052 0 041 0 032 0 026 0 021 0 017 0 013 0 010 0 0088 0 0073 0 0063 0 0056 0 0044 0 0037 0 0032 Drop Cable Resistance Table 18A DC Resistance Ohms 100 meters of wire two conductors 10 Square millimeter Copper o 1576 0977 0 651 0238 0 153 0 108 0 075 0 053 0 040 0 031 0 025 0 021 0 016 35 Identification 0f Cables When Color Code Is Unknown Single Phase 3 Wire Units If the colors on the individual drop cables cannot be found with an ohmmeter measure Cable 1 to Cable 2 Cable 2 to Cable 3 Cable 3 to Cable 1 Find the highest resistance reading The lead not used in the highest reading is the yellow lead Use the yellow lead and each of the other two leads to get two readings Highest is the red lead Lowest is the black lead Single Phase Control Boxes Checking and Repairing Procedures Power On WARNING Power must be on for these tests Do not touch any live parts A VOLTAGE MEASUREMENTS Step 1 Motor Off 1 Measure voltage at L1 and L2 of pressure switch or line contactor 2 Voltage Reading Should be 10 of motor rating Step 2 Motor Running 1 Measure voltage at load side of pressure switch or line contactor with pump running
31. sand may clog pump Replace damaged pipes or repair leaks Pull pump and replace worn parts Replace worn or damaged parts Clean screen and reset pump depth Replace if defective Repair or replace Possible Cause Checking Procedures Corrective Action A Contact power company if voltage is incorrect Shade box provide ventilation or move box away from source Repair or replace Repair or replace Replace pump and or motor TABLE 16 Preliminary Tests All Sizes Single Three Phase CHINE T TN RN Insulation Resistance Winding Resistance 1 Open master breaker and disconnect all leads from control box or pressure switch QD type control remove lid to avoid electric shock hazard and damage to the meter TO GROUND POWER SUPPLY POWER MUST BE SHUT OFF L1 12 Maintenance All Motors 1 If the ohms value is normal Table 17 the motor is not grounded and the cable insulation is not damaged 2 If the ohms value is below normal either the windings 2 Setthe scale lever to R X 100K and set the ohmmeter are grounded or the cable insulation is damaged on zero Check the cable at the well seal as the insulation is 3 Connect one ohmmeter lead to any one of the motor leads Sometimes damaged by being pinched and the other lead to the metal drop pipe If the
32. surge arrestor to be effective GROUNDING THE ARRESTOR TO THE SUPPLY GROUND OR TO A DRIVEN GROUND ROD PROVIDES LITTLE OR NO PROTECTION FOR THE MOTOR Control Box and Panel Environment Franklin Electric control boxes Pumptec products and three phase panels meet UL requirements for NEMA Type 3R enclosures They are suitable for indoor and outdoor applications within temperatures of 10 14 F to 50 122 F Operating control boxes below 14 can cause reduced starting torque and loss of overload protection when overloads are located in control boxes Control boxes Pumptec products and three phase panels should never be mounted in direct sunlight or Equipment Grounding WARNING Serious or fatal electrical shock may result from failure to connect the motor control enclosures metal plumbing and all other metal near the motor or cable to the power supply ground terminal using wire no smaller than motor cable wires The primary purpose of grounding the metal drop pipe and or metal well casing in an installation is safety It is done to limit the voltage between nonelectrical exposed metal parts of the system and ground thus minimizing dangerous shock hazards Using wire at least the size of the motor cable wires provides adequate current carrying capability for any ground fault that might occur It also provides a low resistance path to ground ensuring that the current to ground will be large enough to trip a
33. switch Ground Fault Check insulation resistance on motor and control box cable Low Line Voltage The line voltage is below 198 volts Pumptec Plus will try to restart the motor every two minutes until line voltage is normal Loose Connections Check for excessive voltage drops in the system electrical connections i e circuit breakers fuse clips pressure switch and Pumptec Plus L1 and L2 terminals Repair connections High Line Voltage The line voltage is over 242 volts Check line voltage Report high line voltage to the power company Rapid Cycle The most common cause for the rapid cycle condition is a waterlogged tank Check for a ruptured bladder in the water tank Check the air volume control or snifter valve for proper operation Check setting on the pressure switch and examine for defects Leaky Well System Stuck Check Valve Float Switch Replace damaged pipes or repair leaks Failed valve will not hold pressure Replace valve Press and release the reset button to restart the unit A bobbing float Switch may cause the unit to detect a rapid cycle condition on any motor or an overload condition on two wire motors Try to reduce water splashing or use a different switch v 43 itl Maintenance Electronic Products SubDrive2W 79 100 150 amp 300 SubDrive Troubleshooting Should an application or system problem occur built in diagnostics will protect the system T
34. switch circuit This removes the starting winding and the motor continues to run on the main winding alone Approximately 5 seconds after power is removed from the motor the bi metal strip cools sufficiently to return to its closed position and the motor is ready for the next start cycle If during operation the motor speed drops the lowered voltage in the sensor coil allows the bi metal contacts to close and bring the motor back to operating speed Rapid Cycling The BIAC starting switch will reset within approximately 5 seconds after the motor is stopped If an attempt is made to restart the motor before the starting switch has reset the motor may not start however there will be 10 H Application Single Phase Motors As the motor accelerates the increasing voltage across the start winding and the relay coil opens the relay contacts This opens the starting circuit and the motor continues to run on the main winding alone or the main plus run capacitor circuit After the motor is started the relay contacts remain open CAUTION The control box motor are two pieces of one assembly Be certain that the control box and motor hp and voltage match Since a motor is designed to operate with a control box from the same manufacturer we can promise warranty coverage only when a Franklin control box is used with a Franklin motor current in the main winding until the overload protector interrupts the circuit
35. 1860 2380 15 20 gt 60 100 150 250 400 620 850 1180 1590 2070 RAR gt 40 60 100 170 270 410 560 770 1030 1320 0 40 60 110 170 260 370 520 710 930 1 Meter 3 3 feet TABLE 6A Single Phase Motor Maximum Length of Copper Cable feet Motor Rating American Wire Guage 75 C Insulation AWG Cable in Feet EEE 1450 2310 3530 5480 8460 580 940 1500 2310 3600 5580 6830 8470 55 400 660 1050 1610 2510 3890 4750 5880 7150 8670 so soo 1240 1940 3690 4580 5610 6840 8350 EINEN gt 350 560 870 1360 2130 2620 3270 4020 4930 6060 KAEN 280 450 710 1120 1770 2180 2730 3390 4180 5160 AEN v 190 300 470 750 1170 1440 1800 2220 2730 3360 EARNE 120 190 300 480 760 940 1180 1480 1830 2280 Two different cable sizes can be used Depending on the installation any number of combinations of cable may be used For example in a replacement upgrade installation the well already has 40 meters of buried 4mm cable between the service entrance and the wellhead A new 2 2kW 230 volt single phase motor is being installed in a bore at 50 meters to replace a small motor The question is Since there is already 40M of 4mm installed what size cable is required in the well with a 2 2kW 230 volt single phase motor settin
36. 2 Voltage Reading Should remain the same except for slight dip on starting Excessive voltage drop can be caused by loose connections bad contacts ground faults or inadequate power supply 3 Relay chatter is caused by low voltage or ground faults EXAMPLE The ohmmeter readings were Cable 1 to Cable 2 6 ohms Cable 2 to Cable 3 2 ohms Cable 3 to Cable 1 4 ohms The lead not used in the highest reading 6 ohms was Cable 3 Yellow From the yellow lead the highest reading 4 ohms was To Cable 1 Red From the yellow lead the lowest reading 2 ohms was To Cable 2 Black B CURRENT AMP MEASUREMENTS 1 Measure current on all motor leads 2 Amp Reading Current in red lead should momentarily be high then drop within one second to values on page 13 This verifies relay operation Current in black and yellow leads should not exceed values on page 13 3 Relay failures will cause red lead current to remain high and overload tripping 4 Openrun capacitor s will cause amps to be higher than normal in the black and yellow motor leads and lower than normal in the red motor lead 5 A bound pump will cause locked rotor amps overload tripping 6 Low amps may be caused by pump running at shutoff worn pump or stripped splines 7 Failed start capacitor or open relay are indicated if the red lead current is not momentarily high at starting CAUTION The tests this manual for components such
37. 34 BOSS HEIGHT lt 95 3 DIA gt jonas Standard Water Well 76 200 15 TOOTH 12 7 T6154 E ADU DIAMETRALPITCH gt 25387 0 23 9 MIN FULL SPLINE 73 03 72 87 6 35 6 10 1 2 20 UNF 2B CHECK MOUNTING HOLES VALVE L oA Nr N 138 2 DIA Dimensions mm unless otherwise noted 23 TOOTH 12 7000 DIAMETRAL PITCH SHAFT DIA 38 10 38 075 8 x 31 8 6G GROUND SCREW Installation All Motors 4 High Thrust Dimensions Standard Water Well 37 6 MA 12 7 MIN en FULL SPLINE 5 16 24 UNF 2B MOUNTING STUDS 4 09 MAX LEAD BOSS HEIGHT 95 3 DIA I H 8 Dimensions Standard Water Well 127 00 190 5 DIA MAX 40 to 100 HP 42 9 MIN FULL SPLINE 23 TOOTH 12 7000 DIAMETRAL PITCH 42 9 MIN FULL SPLINE 125 to 200 HP 1 T 101 60 SHAFT DIA 101 60 101 35 38 10 101 35 38 075 L 6 10 CHECK VALVE MOUNTING HOLES MODELS CLEARANCE FOR 1600 001175 PIPE PLUG STAINLESS STEEL MODELS x 31 8 6G L GROUND SCREW Motor lengths and shipping weights are available on Franklin Electric s web page www franklin electric com or by calling Franklin s submersible hotline 800 348 2420 29 H Installation All Motors Tightening Motor Lead Connector Jam Nut 4 Motors with Jam Nut
38. 47 9 22700 82 80 76 78 69 57 380 65 0 27800 80 79 76 88 83 76 276 616 380 415 400 64 5 27700 34 42 81 79 75 85 70 415 65 6 27800 80 79 74 82 76 65 380 65 5 35900 83 82 86 70 276 617 ri 380 415 400 64 5 35800 23 29 83 82 79 82 75 6 415 65 6 36000 83 81 77 78 58 380 66 8 37000 78 72 0 86 0 82 0 76 279 100 ri 380 415 400 65 5 37000 16 19 78 72 0 83 0 78 0 7 415 65 8 37000 77 71 0 8 0 74 0 65 380 80 7 45000 83 75 0 87 0 83 0 76 279101 YAN 380 415 400 79 6 45000 82 80 74 0 84 0 79 0 7 415 80 1 46000 82 79 73 0 81 0 75 0 65 g 380 94 3 53000 85 83 78 0 87 0 82 0 75 279 102 CIN 380 415 400 93 1 53000 09 11 84 82 o 84 1 78 0 69 415 93 53000 84 82 76 0 81 0 74 0 64 5 380 118 67000 84 82 0 87 0 84 77 L 279103 380 415 400 115 66000 07 09 84 82 0 85 0 81 0 72 415 113 66000 84 82 0 83 0 78 0 69 o 380 155 87000 85 84 81 o 87 0 83 0 76 279 104 380 415 400 151 87000 05 07 86 0 85 08 0 71 415 150 87000 85 84 0 82 0 78 0 66 380 191 109000 86 85 81 o 88 0 85 0 78 279 105 380 415 400 186 109000 04 06 86 84 81 0 86 0 8 0 73 415 184 109000 86
39. Drive Meter Output Amps Line 1 Line 2 Line 3 Test Ammeter Output Amps Line 1 Line 2 Line 3 Test Ammeter Make Model Submersible Motor Booster Installation Record Date Filled In By RMA No Installation Owner User Telephone Address City State Postal Code Zip Country Installation Site If Different Contact System Application Telephone System Manufactured By Model Serial No System Supplied By City State Postal Code Zip Country Motor Model No Serial No Date Code Horsepower kW Voltage Motor Diaphragm Height Yes No Does Motor Have a Deionized Fill Solution Slinger Removed Pump Manufacturer Model Qin mm Motor Shaft Height Check Valve Plug Removed Yes No Single Phase Three Phase Qin Motor Dia in DYes No Serial No Stages Diameter Flow Rate Of GPM At TDH Booster Case Internal Diameter Controis and Protective Devices Subtrol Yes If Yes Overload Set Underload Sets Reduced Voltage Starter Q Yes Mfr Starting Yes No Sec Max Freq Variable Frequency Drive Accel Time 0 to 30Hz Decel Time 30 to OHz Volt Hz Profile Sec Min Freq If Yes Warranty Registration No If Yes Type Full Voltage Ramp up to Full Voltage In If Yes Mfr Material Construction
40. Height and Free End Play TABLE 15 Dinonsien Free End Play If the m lt Shaft Height Shaft Height Pomp Chine SMS eine 3 8 motor is low and or end play 4472 en 1 508 38 30 mm 0 010 0 045 exceeds the limit the motor thrust i 1 498 38 05 0 25 mm 1 14 mm bearing is possibly damaged and m m 2 875 73 02 0 030 0 050 should be replaced 2 869 72 88 0 76 mm 1 27 4 000 101 60 0 008 0 032 _ mm 8 TYPE 1 4 101 6mm 3990 10135 0 20mm 0 81mm 4 000 101 60 0 030 0 080 8 2 1 8 101 6 3990 101 35 0 76mm 2 03 mm Submersible Leads and Cables A common question is why motor leads are smaller than specified in Franklin s cable charts CAUTION Lead assemblies on submersible motors are suitable only for use in water and may overheat and cause failure if operated in air The leads are considered a part of the motor and actually are a connection between the large supply wire and the motor winding The motor leads are short and there is virtually no voltage drop across the lead In addition the lead assemblies operate under water while at least part of the supply cable must operate in air Lead assemblies running under water operate cooler 30 Installation All Motors Splicing Submersible Cables When the drop cable must be spliced or connected 50 8 mm two inches beyond each end of the to t
41. ING FLOW REQUIREMENT IS NOT BEING MET FOR MORE THAN 10 SECONDS THE SYSTEM MUST BE SHUT DOWN IMMEDIATELY TO PREVENT PERMANENT MOTOR DAMAGE Discharge Pressure The discharge pressure must be monitored to ensure that a downthrust load toward the motor is present within 3 seconds after start up and continuously during operation IF THE MOTOR DISCHARGE PRESSURE IS NOT ADEQUATE TO MEET THIS REQUIREMENT THE SYSTEM MUST BE SHUT DOWN IMMEDIATELY TO PREVENT PERMANENT MOTOR DAMAGE H Application Three Phase Motors Variable Speed Submersible Pump Operation Inverter Drives Franklin three phase submersible motors are operable from variable frequency inverter drives when applied within guidelines shown below These guidelines are based on present Franklin information for inverter drives lab tests and actual installations and must be followed for warranty to apply to inverter drive installations Franklin two wire and three wire single phase submersible motors are not recommended for variable Speed operation WARNING There is a potential shock hazard from contact with insulated cables from a PWM drive to the motor This hazard is due to high frequency voltage content of a PWM drive output Load Capability Pump load should not exceed motor nameplate service factor amps at rated voltage and frequency Frequency Range Continuous between 30 Hz and rated frequency 50 or 60 Hz Operations above rated frequency require special co
42. R START 275464113 155328102 105 126 MFD ned p LT L BLK BLK RED ORG Bn YEL RELAY 282 350 8110 155031112 RED Hl 2H a s i 8 GROUND 7 LEAD L1 L2 YEL BLK RED YEL LINE POWER FROM TWO POLE Z FUSED SWITCH OR CIRCUIT BREAKER AND OTHER CONTROL gu IF USED 1 2 OVERLOAD GROUND TO 275411114 LEAD MOTOR 39 START CAPACITOR 275468115 189 227 MFD 220V LEAD LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER AND OTHER CONTROL IF USED GROUND RUN CAPACITOR 155328103 20 MFD 370V 5 RELAY 155031112 1 L1 GROUND MAIN START LEAD OVERLOAD OVERLOAD 219411102 275411106 TO MOTOR START CAPACITOR RUN 275468119 CAPACITOR 270 324 MFD 155327102 330V 35 370V BLK t RED ORG 5H YEL 155031112 1 2H gd B 5 GROUND L1 12 YEL BLK RED LEAD A FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER Y BLK AND OTHER CONTROL a A a IF USED START GROUND OVERLOAD OVERLOAD LEAD TO 275406107 275411107 MOTOR 3 HP 282 352 8110 40 2 HP 282 351 8110 Maintenance Single Phase Motors amp Controls
43. Smallest Rating Each Transformer Total Effective KVA Open WYE or DELTA Closed WYE or DELTA 2 Transformers 3 Transformers 1 Motor Rating Required and the smallest transformer required for open or closed three phase systems Open systems require larger transformers since only two transformers are used Other loads would add directly to the KVA sizing requirements of the transformer bank NOTE Standard KVA ratings are shown If power company experience and practice allows transformer loading higher than standard higher loading values may be used for transformer s to meet total effective KVA required provided correct voltage and balance is maintained 75 10 15 20 25 30 40 50 60 75 100 Effects of Torque During starting of a submersible pump the torque developed by the motor must be supported through the pump delivery pipe or other supports Most pumps rotate in the direction which causes unscrewing torque on right handed threaded pipe or pump stages All threaded joints pumps and other parts of the pump support system must be capable of withstanding the maximum torque repeatedly without loosening or breaking Unscrewing joints will break electrical cable and may cause loss of the pump motor unit TABLE 2A Torque Required Examples Motor Rating 13 57 1 13 57 20 13 57 75 x 13 57 200 x 13 57 1 amp Less 75 KW amp Less 13 57 N m 271 4 N
44. VAR required to increase the power factor of large Franklin three phase submersible motors to the approximate values shown at maximum input loading Capacitors must be connected on the line side of the overload relay or overload protection will be lost 20 TABLE 13 KVAR Required 50 Hz Cn 0c Cn oa wo Ww 18 18 13 10 1 5 2 1 2 2 3 3 4 3 6 5 7 5 10 12 18 15 18 35 38 37 37 KVAR Required for P F of 8 1 4 5 5 3 7 8 9 6 14 17 22 27 30 37 46 72 82 88 95 Values listed are total required per phase itl Three Phase Starter Diagrams Three phase combination magnetic starters have two distinct circuits a power circuit and a control circuit The power circuit consists of a circuit breaker or fused line switch contacts and overload heaters connecting incoming power lines L1 L2 L3 and the three phase motor The control circuit consists of the magnetic coil overload Line Voltage Control This is the most common type of control encountered Since the coil is connected directly across the power lines L1 and L2 the coil must match the line voltage Low Voltage Transformer Control This control is used when it is desirable to operate push buttons or other control devices at some voltage lower than the motor voltage The transformer primary must match the line voltage and the coil voltage must match the secondary voltage of the transformer External Voltage Contro
45. as capacitors and relays should be regarded as indicative not as conclusive For example a capacitor may test good not open shorted but may have lost some its capacitance and may no longer be able to perform its function verify proper operation relays refer to operational test procedure described above Section 2 36 Ohmmeter Tests QD Control Box Power Off A START CAPACITOR 1 Meter Setting R x 1 000 2 Connections Capacitor terminals 3 Correct meter reading Pointer should swing toward zero then back to infinity B POTENTIAL VOLTAGE RELAY Step 1 Coil Test 1 Meter setting R x 1 000 Ohmmeter Tests Integral Horsepower Control Box Power Off A OVERLOADS Push Reset Buttons to make sure contacts are closed 1 Meter Setting R x 1 2 Connections Overload terminals 3 Correct meter reading Less than 0 5 ohms B CAPACITOR Disconnect leads from one side of each capacitor before checking 1 Meter Setting R x 1 000 2 Connections Capacitor terminals 3 Correct meter reading Pointer should swing toward zero then drift back to infinity except for capacitors with resistors which will drift back to 15 000 ohms 2 Connections 2 amp 5 3 Correct meter readings For 220 240 Volt Boxes 4 5 7 0 4 500 to 7 000 ohms Step 2 Contact Test 1 Meter setting x 1 2 Connections 1 amp 2 3 Correct meter reading Zero for all mo
46. asure 100 to 400 ohms Depress and hold in the reset button The resistance between the control terminals should measure close to infinity Check that coil voltage is within 10 of rated voltage If voltage is correct and matches line voltage turn off power and remove the contactor magnetic assembly and check for wear corrosion and dirt If voltage is erratic or lower than line voltage trace the control circuit for faults similar to the previous item but looking for a major drop in voltage rather than its complete loss Check that the small interlocks switch on the side of the contactor closes when the contactor closes If the switch or circuit is open the contactor will not stay closed when the selector switch is in HAND position Turn off power Check the contactor contacts for dirt corrosion and proper closing when the contactor is closed by hand With the Subtrol Plus receiver powered up and all leads disconnected from the signal terminals with an Ohmmeter set at RX10 measure the resistance between the signal terminals Resistance should measure close to infinite Depress and hold in the reset button The resistance between the signal terminals should measure 100 to 400 ohms 47 AWG BJT C CB CRC DI Dv dt EFF F FDA FL ft ft lb ft s kW L1 L2 L3 lb ft L min mA max Amp or amperage American Wire Gauge Bipolar Junction Transistor Degree Celsius Control Box
47. axial expansion of the motor without creating binding forces 3 Motor Support Points A minimum of two support points are required on the motor One in the motor pump flange connection area and one in the bottom end of the motor area The motor castings not the shell area are recommended as support points If the support is a full length support and or has bands in the shell area they must not restrict heat transfer or deform the shell 4 Motor Support Material and Design The support system shall not create any areas of cavitation or other areas of reduced flow less than the minimum rate required by this manual They should also be designed to minimize turbulence and vibration and provide stable alignment The support materials and locations must not inhibit the heat transfer away from the motor 5 Motor and Pump Alignment The maximum allowable misalignment between the motor pump and pump discharge is 2 mm per 1000 mm of length 0 025 inch per 12 inches This must be measured in both directions along the assembly using the motor pump flange connection as the starting point The booster sleeve and support system must be rigid enough to maintain this alignment during assembly shipping operation and maintenance 6 The best motor lubrication and heat resistance is obtained with the factory based propylene glycol fill solution Only when an application MUST HAVE deionized DI water should the factory fill solution be replaced
48. cate drive as necessary 8 SubDrive300 only Over Pressure Improper pre charge Valve closing too fast Pressure setting too close to relief valve rating Reset the pre charge pressure to 7096 of sensor setting Reduce pressure setting well below relief valve rating Use next size larger pressure tank Verify valve operation is within manufacturer s specifications Reduce system pressure setting to a value less than pressure relief rating RAPID Internal Fault A fault was found internal to drive Unit may require replacement Contact your supplier 9 SubDrive2W only Over Range Values Outside Normal Operating Range Wrong hp voltage Internal fault Verify motor hp and voltage Unit may require replacement Contact your supplier 44 SubMonitor SubMonitor Troubleshooting Maintenance Electronic Products Fault Message Problem Condition Possible Cause SF Amps Set Too High Phase Reversal Underload Overload Overheat Unbalance Overvoltage Undervoltage False Starts SF Amps setting above 359 Amps Reversed incoming voltage phase sequence Normal line current Motor SF Amps not entered Incoming power problem Wrong SF Max Amps setting Low line current Normal line current High line current Motor temperature sensor has detected excess motor temperature Current difference between any tw
49. cause problems such FIG 8 FULL THREE PHASE H Application Three Phase Motors as poor performance overload tripping or early motor failure due to current unbalance Transformer rating should be no smaller than listed in Table 2 for supply power to the motor alone EE Checking and Correcting Rotation and Current Unbalance 1 Established correct motor rotation by running in both directions Change rotation by exchanging any two of the three motor leads The rotation that gives the most water flow is always the correct rotation After correct rotation has been established check the current in each of the three motor leads and calculate the current unbalance as explained in 3 below If the current unbalance is 296 or less leave the leads as connected If the current unbalance is more than 296 current readings should be checked on each leg using each of three possible hook ups Roll the motor leads across the starter in the same direction to prevent motor reversal To calculate percent of current unbalance A Add the three line amps values together B Divide the sum by three yielding average current C Pick the amp value which is furthest from the average current either high or low D Determine the difference between this amp value furthest from average and the average E Divide the difference by the average Multiply the result b
50. cm sec 0 50 ft s 2 54 cm 1 inch SAW CUTS NOTCH OUT FOR CABLE GUARD LOCK NUTS INSIDE SLEEVE BOTTOM END VIEW CENTERING BOLT HOLE 8 REQUIRED STATOR SHELL FIG 1 3 Application All Motors Head Loss Past Motor Table 4 lists the approximate head loss due to flow between an average length motor and smooth casing or flow inducer sleeve TABLE 4 Head Loss in Meters at Various Flow Rates LLLI E 00 18 mp 95 0 09 189 0 37 378 14 0 09 0 52 E 568 8 1 0 18 0 06 14 757 0 34 0 12 1 9 0 15 2 1 5 946 0 55 0 21 29 0 24 8 2 E 1136 0 75 0 3 4 1 0 37 0 06 4 5 1514 72 0 61 0 12 7 5 1893 0 94 0 21 114 0 2 2271 13 0 3 15 9 0 3 3028 0 5 3785 0 7 Hot Water Applications Franklin Electric offers a line of Hi Temp motors TABLE 4A Minimum Required for 91 m sec Flow Rate various temperatures up to 194 F 90 C without Sleeve 1 0 Thrust Motor increased flow When a standard pump motor m operates water hotter than 86 30 a flow 102 57 rate of at least 3 ft s is required When selecting mm Em the motor to drive a pump in over 86 F 30 water the motor horsepower must be de rated 152 606 197 per the following procedure 178 568 1 Using Table 4A determine pump lpm ii 221 required for different well or sleeve 254 1970 1250 diameters If necessary add a flow sleeve 305 2460 to
51. ction 2 Wire or 3 Wire 11 Two Different Cable Sizes 12 Maintenance Single Phase Motors amp Controls Single Phase Motor Specifications 18 Identification of Cables 36 Single Phase Control 36 Application Three Phase Motors Ohmmeter Tests 37 QD Control Box Parts pp 38 Cable Selection 7 ms E 14 Integral HP Control Box 38 Cable Selection 75 C 3 6 Lead i HM 15 Control Box Wiring Diagrams 39 40 Three Phase Motor Specifications 16 18 Overload Protection pp 19 Maintenance Flectronic Products Submonitor Three Phase Protection 20 aintenance Hectronic Products Power Factor Correction ppp 20 Pumptec Troubleshooting eese 41 Three Phase Starter Diagrams 21 Pumptec Plus Troubleshooting During Installation 42 Three Phase Power Unbalance 22 Pumptec Plus Troubleshooting After Installation 43 Rotation Current 22 CP Water Troubleshooting pp 44 Submersible Pump Installation Check List 3656 Submonitor 45 S
52. d to operate in water at higher temperatures or lower flow conditions Consult factory for details Flow Inducer Sleeve If the flow rate is less than specified or coming from above the pump then a flow inducer sleeve must be used A flow sleeve is always required in an open body of water FIG 1 shows a typical flow inducer sleeve construction INTAKE EXAMPLE A six inch motor and pump that delivers 200 will be installed in 254 mm well From Table 6 340 I m would be required to maintain proper cooling In this case adding an 203 mm or smaller flow sleeve provides the required cooling SLEEVE CENTERING BOLT CENTERING BOLTS MUST BE LOCATED ON MOTOR CASTING DO NOT LOCATE ON WORM GEAR CLAMPS FLOW INDUCER SUBMERSIBLE MOTOR Pump is in an open body of water Pump is in a rock well or below the well casing The well is top feeding aka cascading Pump is set in or below screens or perforations TABLE 3 Required Cooling Flow Minimum gpm required for motor cooling in water up to 86 F 30 C 6 Motor 15 24 cm s gpm 8 Motor 15 24 cm s I m gpm Casing or Sleeve ID mm inches 4 Motor 2 2 7 5 KW 7 62 cm s gpm 4 5 1 2 26 5 7 49 13 34 9 76 20 95 25 114 30 170 45 40 10 189 50 340 90 210 55 303 80 530 140 420 110 416 110 760 200 645 170 568 150 1060 280 930 245 7 62 cm sec 0 25 ft s 15 24
53. dels C RELAY COIL Disconnect lead from Terminal 5 1 Meter Setting R x 1 000 2 Connections 2 amp 5 3 Correct meter readings 4 5 7 0 4 500 to 7 000 ohms for all models D RELAY CONTACT Disconnect lead from Terminal 1 1 Meter Setting R x 1 2 Connections 1 amp 2 3 Correct meter reading Zero ohms for all models CAUTION The tests in this manual for components such as capacitors and relays should be regarded as indicative and as conclusive For example a capacitor may test good not open not shorted but may have lost some of its capacitance and may no longer be able to perform its function verify proper operation relays refer to operational test procedure described on page 36 Section B 2 37 Maintenance Single Phase Motors amp Controls it QD Control Box Parts List TABLE 19 Q D Control Box Components 50Hz Rating Dverood Pont dins 2803530115 155031112 275461128 43 53 Mfd 220v 151033957 155250101 2803550115 EJEN 220 155031112 275461123 43 53 Mfd 220v 151033957 155250101 2803570115 sro 220 155081112 275461108 59 71Mfd 220v 151033906 155250102 2803580115 220 155031112 275461106 86 103 Mfd 220v 151033918 155250103 Same parts used Suffix 101 Control Boxes The replacement kit for relay 155031112 is 305213912 Table 19A Capacitor Replacement Kit Tabl
54. drop pipe is plastic connect the ohmmeter lead to ground 1 Open master breaker and disconnect all leads from control 1 If all ohms values are normal Tables 7 amp 10 12 the box or pressure switch QD type control remove lid to motor windings are neither shorted nor open and the avoid electric shock hazard and damage to the meter cable colors are correct 2 Setthe scale lever to R X 1 for values under 10 ohms For 2 If any one value is less than normal the motor values over 10 ohms set the scale lever to X 10 Zero is shorted the ohmmeter 3 If any one ohm value is greater than normal the 3 On3 wire motors measure the resistance of yellow to black winding or the cable is open or there is a poor cable Main winding and yellow to red Start winding joint or connection 2 wire motors measure the resistance from line to line 4 some ohms values are greater than normal and Three ph WOO for some less single phase motors the leads are ne mixed See page 36 to verify cable colors all three combinations ATTACH THIS LEAD TO WELL CASING OR DISCHARGE PIPE CONNECT THIS LEAD B TO GROUND RED YELLOW YELLOW A BLACK 3 BLACK GROUND BLACK POWER 4 11 BLACK SUPPLY S 12 YELLOW RED gt gPUMP RED p UMP GROUND POWER MUST GROUND BE SHUT OFF OHMMETER OHMMETER
55. e 19B Cap Overload asm replacement Kit 275461106 305205906 151033906 305218906 275461108 305205908 151033918 305218918 275461123 305205923 151033957 305218957 Integral HP Control Box Parts List TABLE 20 Control Box Components 1 1 KW and larger 50Hz One 275464113 One 155328102 2823508110 275411114 275468115 155328103 275411102 run mcenia 220 155031112 189 227 Mfd 220v 20 Mfd 370v 275411106 start One 275468119 One 155327102 275406107 run cxi 220 195031112 570 824 Mfd 220v 85 Mfd 370v 275411117 start One 155327101 Two 275468115 30 Mfd 220v 275406102 run 220 155031112 189 227 Mfd 220v One 155327109 275411102 start 45 Mfd 220v 1 Relay Replacement Kit 305213912 20A Capacitor Replacement Kit 20B Overload Replacement Kit 155327101 305203901 275406102 305214902 155327102 305203902 275406107 305214907 155327109 305203909 275411102 305215902 155328102 305204902 275411106 305215906 275464113 305207913 275411117 305215917 275468115 305208915 275411114 305215914 275468119 305208919 38 Maintenance Single Phase Motors amp Controls Control Box Wiring Diagrams 1 3 1 HP 4 z 5 28035 0115 gt K B MAIN Y L2 MOTOR LEADS LINE LEADS RUN CAPACITO
56. en light will flash and not allow operation unless both sensor coils are plugged into the receiver If both are properly connected and it still flashes the sensor coil or the receiver is faulty An ohmmeter check between the two center terminals of each sensor coil connected should read less than 1 ohm or coil is faulty If both coils check good receiver is faulty The green light is on and the Subtrol Plus requires the specified off time before the pump can be restarted after having been turned off If the green light is on except as described the receiver is faulty Note that a power interruption when the motor is running will initiate the delay function This is a normal protective function which turns off the pump when the motor reaches maximum safe temperatures Check that amps are within the nameplate maximum on all three lines and that the motor has proper water flow past it If overheat trip occurs without apparent motor overheating it may be the result of an arcing connection somewhere in the circuit or extreme noise interference on the power lines Check with the power company or Franklin Electric A true motor overheat trip will require at least five minutes for a motor started cold If trips do not conform to this characteristic suspect arcing connections power line noise ground fault or SCR variable speed control equipment This is anormal protective function protecting against an overload or locked pump Check the amps in all
57. ensated to avoid nuisance tripping The specific information can be obtained directly from the manufacturer s catalog They are available from a Current Time curve as shown on the right For optimal protection a FE Subtrol Submonitor or adjustable overload recommended Overload setting DOL and YA start For DOL max at full current IN shown on nameplate For YA relay must be incorporated in the delta circuit for adequate protection Y start and set at IN x 0 58 Recommended setting for all applications is the measured current value at duty point Setting gt IN is not allowed 19 Time in sec 20 10 25 3 35 4 4 5 5 6 7 8 910 gt Multiple of IN name plate current FIG 4 3 Application Three Phase Motors SubMonitor Three Phase Protection Applications SubMonitor is designed to protect 3 phase pumps motors with service factor amp ratings SFA from 5 to 350 A approx 2 2 to 150 kW Current voltage and motor temperature are monitored using all three legs and allows the user to set up the SubMonitor quickly and easily Protects Against Under Overload Under Overvoltage Current Unbalance Overheated Motor if equipped with Subtrol Heat Sensor False Start Chattering Phase Reversal Power Factor Correction In some installations power supply limitations make it necessary or desirable to increase the power factor of a submersible motor The table lists the capacitive K
58. ents B Verify control box hp and voltage matches motor 3 only C Check that the electrical installation and controls meet all safety regulations and match the motor requirements including fuse or circuit breaker size and motor overload protection Connect all metal plumbing and electrical enclosures to the power supply ground to prevent shock hazard Comply with national and local codes 5 Lightning and Surge Protection A Use properly rated surge lightning arrestors on all submersible pump installations Motors 5 hp smaller which are marked Equipped with Lightning Arrestors contain internal arrestors B Ground all above ground arrestors with copper wire directly to the motor frame or to metal drop pipe casing which reaches below the well pumping level Connecting to a ground rod does not provide good surge protection 6 Electrical Drop Cable A Use submersible cable sized in accordance with local regulations and the cable charts See pages 11 16 21 Ground motor per national and local codes C B Include a ground wire to the motor and surge protection connected to the power supply ground if required by codes Always ground any pump operated outside a drilled well 7 Motor Cooling A Ensure at all times that the installation provides adequate motor cooling see page 6 for details Form No 3656 04 2013 2013 Franklin Electric Co Inc This mat
59. er with no water delivery C Check the valve settings The pump may be dead heading D Pump or motor shaft may be broken E Motor overload may be tripped Check the motor current amperage A Check switch position on the side of the circuit board in Pumptec Make Pumptec will not sure the switch is not set between settings time out and reset B If the reset time switch is set to manual reset position 0 Pumptec will not reset Turn power off for 5 sec then back on to reset A Check voltage B Check wiring The pump motor will not run at all C Bypass Pumptec by connecting L2 and the motor lead with a jumper If motor does not run the problem is not Pumptec D Check that Pumptec is installed between the control switch and motor A Be sure you have a Franklin motor B Check wiring connections Is power lead connected to the correct terminal Is motor lead connected to correct terminal C Check for ground fault in the motor and excessive friction in the pump Pumptec will not trip when D The well may be gulping enough water to keep Pumptec from tripping It the pump breaks suction may be necessary to adjust Pumptec for these extreme applications Call the Franklin Electric Submersible Service Hotline at 800 348 2420 for information E Does the control box have a run capacitor If so Pumptec will not trip except with Franklin 1 1 2 HP motors A Check for low voltage B Check for water logged tank Rapid cycling for an
60. erial may be reproduced in its entirety for personal and educational purposes including reproduction in technical specifications and manuals without prior permission provided that the above copyright notice is included in all copies or substantial portions of the material All other rights reserved Submersible Pump Installation Check List 8 Pump Motor Installation O LJ L Splice motor leads to supply cable using electrical grade solder or compression connectors carefully insulate each splice with watertight tape or adhesive lined shrink tubing as shown in motor or pump installation data Support the cable to the delivery pipe every 10 feet 3 meters with straps or tape strong enough to prevent sagging Use padding between cable and any metal straps A check valve in the delivery pipe is recommended More than one check valve may be required depending on valve rating and pump setting see page 5 for details Assemble all pipe joints as tightly as practical to prevent unscrewing from motor torque Torque should be at least 10 pound feet per hp 2 meter KG per kW Set the pump far enough below the lowest pumping level to assure the pump inlet will always have at least the Net Positive Suction Head NPSH specified by the pump manufacturer Pump should be at least 10 feet 3 meters from the bottom of the well to allow for sediment build up Check insulation resistance as pump motor assembly
61. g and provide immediate answers to your system application questions Technical support is also available online Visit our website at www franklinwater com Find knowledgeable real world business insights for ground water professionals at www franklininthefield com Franklin Electric The Company You Trust Deep Down M1339 08 13
62. g at 50 meters From table 11 2 2kW motor can use up to 60 meters of 4mm cable The application has 40 meters of 4mm copper wire installed Using the formula below 40M actual 60M max allowable is equal to 0 666 This means 66 6 0 666 100 of the allowable voltage drop occurs in this wire This leaves us 33 4 1 00 0 666 0 334 of some other wire size to use in the remaining 50 meters down hole wire run Actual Length Allowed Formula Application Single Phase Motors FIRST EXAMPLE The table shows 6mm copper wire is good for 100 meters Using the formula again 50M used 100 feet allowed 0 5 adding this to the 0 666 determined earlier 0 666 0 5 1 16 This combination is greater than 1 00 so the voltage drop will not meet the ANSZ3000 recommendations SECOND EXAMPLE Tables 11 show 10mm copper wire is good for 170 meters Using the formula 50 170 0 294 and using these numbers 0 666 0 294 0 96 we find this is less than 1 00 and will meet the ANSZ3000 recommended voltage drop This works for two three or more combinations of wire and it does not matter which size wire comes first in the installation Actual Length Max Allowed EXAMPLE 2 2kW 230 Volt Single Phase Motor PUMP CONTROLS SERVICE ENTRANCE MAIN FUSE BOX FROM METER 40M 4mm 66 6 of allowable cable FIG 3 50M 10mm 29 495 of allowable cable
63. he FAULT light or digital display on the front of the SubDrive Controller will flash a given number of times or display a number indicating the nature of the fault In some cases the system will shut itself off until corrective action is taken Fault codes and their corrective actions are listed below See SubDrive Installation Manual for installation data Number Of Flashes Or Possible Cause Corrective Action Digital Display Motor Underload Overpumped well Broken shaft or coupling Blocked screen worn pump Air gas locked pump SubDrive not set properly for pump end Frequency near maximum with less than 65 of expected load 42 if DIP 3 is on System is drawing down to pump inlet out of water High static light loading pump reset DIP switch 3 to on for less sensitivity if not out of water Check pump rotation SubDrive only reconnect if necessary for proper rotation Air gas locked pump if possible set deeper in well to reduce Verify DIP switches are set properly Low line voltage Misconnected input leads Line voltage low less than approximately 150 VAC normal operating range 190 to 260 VAC Check incoming power connections and correct or tighten if necessary 2 Undervoltage Correct incoming voltage check circuit breaker or fuses contact power company Motor and or pump misalignment Amperage above SFL at 10 Hz 3 Tun Dragging motor a
64. he motor leads it is necessary that the splice be conductor insulation end and the second layer watertight This splice can be made with commercially extending 50 8 mm two inches beyond the ends of available potting heat shrink splicing kits or by careful the first layer Wrap tightly eliminating air spaces as tape splicing much as possible Tape splicing should use the following procedure C Tape over the rubber electrical tape with 33 Scotch electrical tape 3M or equivalent using two layers as in step B and making each layer overlap the end of the preceding layer by at least 50 8 mm two A Strip individual conductor of insulation only as far as necessary to provide room for a stake type connector Tubular connectors of the staked type are preferred If connector outside diameter OD is not inches as large as cable insulation build up this area with In the case of a cable with three conductors encased rubber electrical tape in a single outer sheath tape individual conductors as B Tape individual joints with rubber electrical tape described staggering joints using two layers with the first layer extending Total thickness of tape should be no less than the thickness of the conductor insulation STAKED CONNECTOR 50 8 mm 50 8 mm PVC ELECTRICAL TAPE FIG 12 Heat Shrink Splicing Pre place the heat shrinking tubes by sliding them over In case of a double jacketed lead heat shrink each the individ
65. ifications 50 Hz 2875 RPM 1 0 Service Factor Motor Model Prefix 236680 236610 236681 236611 236682 236612 236683 236613 236684 236614 236685 236615 236686 236616 236617 236618 276618 236619 276619 239600 239601 239602 239603 239604 239105 239106 239107 239108 Nameplate Rating Line Volts 220 380 380 380 380 380 380 380 380 380 380 220 380 400 415 220 380 400 415 220 380 400 415 220 380 400 415 220 380 400 415 220 380 400 415 220 380 400 400 415 15 4 8 9 31 3 31 0 69 1 40 0 38 5 38 5 82 9 47 0 45 3 Performance is typical not guaranteed at specified voltages Locked rotor amps for Wye start 6 lead motors is 3396 of value shown Performance also applies to 6 lead model numbers where not listed Six lead ind ividual phase resistance table X 1 5 54000 54000 54000 54000 54000 54000 34700 34700 34700 43000 43000 43000 51500 51500 51500 64000 64000 64000 85000 86000 86000 107000 107000 107000 127000 127000 127000 150000 148000 148000 170000 170000 170000 247 303 185 226 142 174 106 130 073 089 055 067 042 051 042 052 036 044 Line to Line 1 Resistance Ohms 3 9 4 8 79 97 2 4 2 9 63 77 1 9 2 4 38 47 1 1 1 4 26 33 83 1 0 20 25
66. ignal Circuit Terminals Do Not Energize Whenever the pump is off as a result of Subtrol Plus protective function the red tripped light is on A steady light indicates the Subtrol Plus will automatically allow the pump to restart as described and a flashing light indicates repeated trips requiring manual reset before the pump can be restarted Any other red light operation indicates a faulty receiver One half voltage on 460 V will cause tripped light on With power turned off check for a shorted contactor coil or a grounded control circuit lead The coil resistance should be at least 10 ohms and the circuit resistance to panel frame over 1 megohm A standard or delay type 2 amp fuse should be used If proper voltage is at the control coil terminals when controls are operated to turn the pump on but the contactor does not close turn off power and replace the coil If there is no voltage at the coil trace the control circuit to determine if the fault is in the Subtrol Plus receiver fuse wiring or panel operating switches This tracing can be done by first connecting a voltmeter at the coil terminals and then moving the meter connections step by step along each circuit to the power source to determine at which component the voltage is lost With the Subtrol Plus receiver powered up with all leads disconnected from the control terminals and with an ohmmeter set at RX10 measure the resistance between the control terminals It should me
67. ingle Phase Three Phase Up to 0 75 Up to 0 55 300 300 1 thru 5 5 0 75 thru 4 100 300 7 5 thru 30 5 5 thru 22 50 100 40 and over 30 and over 100 Keeping starts per day within the recommended numbers provides the best system life However when used with a properly configured Reduced Voltage Starter RVS or Variable Frequency Drive VFD 7 5 thru 30 hp three phase motors can be started up to 200 times per 24 hour period in positions from shaft up to shaft horizontal As the mounting position becomes further from vertical and closer to horizontal the probability of shortened thrust bearing life increases For normal motor life expectancy with motor positions other than shaft up follow these recommendations 1 Minimize the frequency of starts preferably to fewer than 10 per 24 hour period Six and eight inch motors should have a minimum of 20 minutes between starts or starting attempts 2 Donotusein systems which can run even for short periods at full speed without thrust toward the motor Application All Motors Transformer Capacity Single Phase or Three Phase Distribution transformers must be adequately sized to satisfy the KVA requirements of the submersible motor When transformers are too small to supply the load there is a reduction in voltage to the motor Table 2 references the motor horsepower rating single phase and three phase total effective KVA required TABLE 2 Transformer Capacity
68. is lowered into the well Resistance may drop gradually as more cable enters the water but any sudden drop indicates possible cable splice or motor lead damage see page 45 9 After Installation Date A B Check all electrical and water line connections and parts before starting the pump Start the pump and check motor amps and pump delivery If normal continue to run the pump until delivery is clear If three phase pump delivery is low it may be running backward Rotation may be reversed with power off by interchanging any two motor lead connections to the power supply Check three phase motors for current balance within 596 of average using motor manufacturer instructions Imbalance over 596 will cause higher motor temperatures and may cause overload trip vibration and reduced life Verify that starting running and stopping cause no significant vibration or hydraulic shocks After at least 15 minutes running time verify that pump output electrical input pumping level and other characteristics are stable and as specified Filled In By Notes Form 3656 04 2013 2013 Franklin Electric Co Inc This material may be reproduced in its entirety for personal and educational purposes including reproduction in technical specifications and manuals without prior permission provided that the above copyright notice is included in all copies or substantial po
69. lines through a complete pumping cycle and monitor whether low or unbalanced voltage may be causing high amps at particular times If overload trip occurs without high amps it may be caused by a faulty rating insert receiver or sensor coil Recheck that the insert rating matches the motor If it is correct carefully remove it from the receiver by alternately lifting sides with a knife blade or thin screwdriver and make sure it has no pins bent over If the insert is correct and its pins are okay replace receiver and or sensor coils This is a normal protective function A Make sure the rating insert is correct for the motor B Adjusting the underload setting as described to allow the desired range of operating conditions Note that a DECREASE in underload setting is required to allow loading without trip C Check for drop in amps and delivery just before trip indicating pump breaking suction and for unbalanced line current D With the power turned off recheck motor lead resistance to ground A grounded lead can cause underload trip 46 Maintenance Electronic Products Subtrol Plus Obsolete See SubMonitor Subtrol Plus Troubleshooting After Installation Continued Possible Cause or Solution Tripped Light On Control Circuit Fuse Blows Contactor Will Not Close Contactor Hums or Chatters Contactor Opens When Start Switch is Released Contactor Closes But Motor Doesn t Run S
70. load requirement times the pump load multiplier number indicated on the vertical axis to determine the minimum motor nameplate rating Fourth Select a motor with a nameplate equal or higher than the above calculated value Motor Alterations Sand Slinger amp Check Valve Plug On 6 and 8 motors the rubber sand slinger located on the shaft must be removed If a pipe plug is covering the check valve it must be removed The special booster motor already has these modifications Frequency of Starts Fewer than 10 starts per 24 hour period are recommended Allow at least 20 minutes between shutdown and start up of the motor Inline Booster Pump Systems continued 9 Controls Soft Starters and VFDs Reduced voltage starters and variable speed drives inverter drives may be used with Franklin three phase submersible motors to reduce starting current upthrust and mechanical stress during start up The guidelines for their use with submersible motors are different than with normal air cooled motor applications Refer to the Franklin Electric Application Installation and Maintenance AIM Manual Reduced Voltage Starters section or Variable Speed Submersible Pump Operation Inverter Drives sections for specific details including required filtering 10 Motor Overload Protection Submersible motors require properly sized ambient compensated Class 10 quick trip overloads per Franklin s AIM Manual guidelines to protect the mot
71. ls Control of a power circuit by a lower circuit voltage can also be obtained by connecting to a separate control voltage source The coil rating must match the control voltage source such as 115 or 24 volts 21 Application Three Phase Motors contacts and a control device such as a pressure switch When the control device contacts are closed current flows through the magnetic contactor coil the contacts close and power is applied to the motor Hands Off Auto switches start timers level controls and other control devices may also be in series in the control circuit L1 12 13 3388 PRESSURE SWITCH OR OTHER CONTROL DEVICE O L CONTACTS M _ OVERLOAD HEATERS AND OR SUBTROL PLUS FUSES CONTACTS FIG 5 L1 L2 L3 PRESSURE SWITCH OR OTHER CONTROL DEVICE FUSES O L CONTACTS TRANSFORMER 8 CONTACTS OVERLOAD 8 HEATERS AND OR SUBTROL PLUS FIG 6 1 5 L3 PRESSURE SWITCH OR OTHER CONTROL DEVICE O L CONTACTS TO SEPARATE CONTROL VOLTAGE SOURCE OVERLOAD HEATER AND OR SUBTROL DEVICE 3 33 FIG 7 Three Phase Power Unbalance A full three phase supply is recommended for all three phase motors consisting of three individual transformers or one three phase transformer So called open delta or wye connections using only two transformers can be used but are more likely to
72. m 1017 8 N m 2714 N m To safely withstand maximum unscrewing torques with a minimum safety factor of 1 5 tightening all threaded joints to at least 13 57 N m per motor horsepower is recommended Table 2A It may be necessary to tack or strap weld pipe joints on high horsepower pumps especially at shallower settings Minimum Safe Torque Load Engine Driven Generators Refer to generator manufacturer s recommendations and locked rotor amps listed on page 13 single phase and pages 16 18 three phase Use of Check Valves It is recommended that one or more check valves always be used in submersible pump installations If the pump does not have a built in check valve a line check valve should be installed in the discharge line within 7 6 m 25 feet of the pump and below the draw down level of the water supply For deeper settings check valves should be installed per the manufacturer s recommendations More than one check valve may be required but more than the recommended number of check valves should not be used Swing type check valves are not acceptable and should never be used with submersible motors pumps Swing type check valves have a slower reaction time which can cause water hammer see next page Internal pump check valves or spring loaded check valves close quickly and help eliminate water hammer Check valves are used to hold pressure in the system when the pump stops They also prevent backspin water
73. m starting current Six inch and larger motors should have a minimum of 15 minutes between starts or starting attempts Mounting Position Franklin submersible motors are designed primarily for operation in the vertical shaft up position During acceleration the pump thrust increases as its output head increases In cases where the pump head stays below its normal operating range during startup and full speed condition the pump may create upward thrust This creates upward thrust on the motor upthrust bearing This is an acceptable operation for short periods at each start but running continuously with upthrust will cause excessive wear on the upthrust bearing With certain additional restrictions as listed in this section and the Inline Booster Pump Systems sections of this manual motors are also suitable for operation H Application All Motors When the storage temperature does not exceed 37 C storage time should be limited to two years Where temperatures reach 37 to 54 C storage time should be limited to one year Loss of a few drops of liquid will not damage the motor as an excess amount is provided and the filter check valve will allow lost liquid to be replaced by filtered well water upon installation If there is reason to believe there has been a considerable amount of leakage consult the factory for checking procedures Table 1 Number of Starts Motor Rating Maximum Starts 24 hr Period KW S
74. mptec Plus should be calibrated on a full recovery well with the maximum water flow Flow restrictors are not recommended Two Wire Motor Step C of the calibration instructions indicate that a flashing green light condition will occur 2 to 3 seconds after taking the SNAPSHOT of the motor load On some two wire motors the yellow light will flash instead of the green light Press and release the reset button The green should start flashing Power Interruption During the installation of Pumptec Plus power may be switched on and off several times If power is cycled more than four times within a minute Pumptec Plus will trip on rapid cycle Press and release the reset button to restart the unit Float Switch A bobbing float switch may cause the unit to detect a rapid cycle condition on any motor or an overload condition on two wire motors Try to reduce water splashing or use a different switch High Line Voltage The line voltage is over 242 volts Check line voltage Report high line voltage to the power company Unloaded Generator If you are using a generator the line voltage may become too high when the generator unloads Pumptec Plus will not allow the motor to turn on again until the line voltage returns to normal Over voltage trips will also occur if line frequency drops too far below 50 Hz Low Line Voltage The line voltage is below 198 volts Check line voltage Loose Connections Check for loo
75. nd or pump Remove and repair or replace as required Abrasives in pump Incorrectly Wired MonoDrive only Wrong resistance values on main and start Wrong resistance on DC test at start Check wiring check motor size and DIP switch setting adjust or repair as needed 7 Circuit Short Circuit Loose connection Defective motor or drop cable Wrong motor When fault is indicated immediately after power up short circuit due to loose connection defective cable splice or motor Open reading on DC test at start Check drop cable and motor resistance tighten output connections repair or replace as necessary use dry motor to check drive functions if drive will not run and exhibits underload fault replace drive Amperage exceeded 50 amps on DC test at start or max amps during running Incorrect output wiring phase to phase short phase to ground short in wiring or motor If fault is present after resetting and removing motor leads replace drive Over Current Overheated Drive When fault is indicated while motor is running over current due to loose debris trapped in pump High ambient temperature Direct sunlight Obstruction of airflow Check pump Drive heat sink has exceeded max rated temperature needs to drop below 85 to restart Fan blocked or inoperable ambient above 125 F direct sunlight air flow blocked Replace fan or relo
76. nsiderations consult factory for details Volts Hz Use motor nameplate volts and frequency for the drive base settings Many drives have means to increase efficiency at reduced pump speeds by lowering motor voltage This is the preferred operating mode Voltage Rise time or dV dt Limit the peak voltage to the motor to 1000V and keep the rise time greater than 2 usec Alternately stated keep dV dt lt 500V usec See Filters or Reactors Motor Current Limits Load no higher than motor nameplate service factor amps For 50 Hz ratings nameplate maximum amps are rated amps See Overload Protection below Motor Overload Protection Protection in the drive or separately furnished must be set to trip within 10 seconds at 5 times motor maximum nameplate amps in any line and ultimately trip within 11596 of nameplate maximum amps in any line 28 Subtrol Plus Franklin s Subtrol Plus protection systems ARE NOT USABLE on VFD installations Start and Stop One second maximum ramp up and ramp down times between stopped and 30 Hz Stopping by coast down is preferable Successive Starts Allow 60 seconds before restarting Filters or Reactors Required if all three of the following conditions are met 1 Voltage is 380 or greater and 2 Drive uses IGBT or BJT switches rise times lt 2 usec and 3 Cable from drive to motor is more than 15 2 m A low pass filter is preferable Filters or reactors should be selected in conjunction
77. ntenance All Motors Checking Procedures Check voltage at line terminals The voltage must be 10 of rated voltage Check fuses for recommended size and check for loose dirty or corroded connections in fuse receptacle Check for tripped circuit breakers Check voltage at contact points Improper contact of switch points can cause voltage less than line voltage For detailed procedure see pages 34 35 Check for loose or corroded connections or defective wiring Check for misalignment between pump and motor or a sand bound pump Amp readings will be 3 to 6 times higher than normal until the overload trips For detailed procedure see pages 34 35 Checking Procedures Check setting on pressure switch and examine for defects Damaged or defective check valve will not hold pressure Check air charge Check system for leaks 32 Corrective Action Contact power company if voltage is incorrect Replace with proper fuse or reset circuit breakers Replace pressure switch or clean points Repair or replace Correct faulty wiring or connections Pull pump and correct problem Run new installation until the water clears Repair or replace Corrective Action Reset limit or replace switch Replace if defective Repair or replace Replace damaged pipes or repair leaks System Troubleshooting Motor Runs Continuously Possible Cause Checking Procedures Corrective Action
78. ny overcurrent device designed to detect faults such as a ground fault circuit interrupter or GFCI Normally the ground wire to the motor would provide the 3 Application All Motors to maximize delivery are not recommended since the suction created can be lower than atmospheric pressure Connect earth grounds to control boxes and panels per local and national codes or regulations WARNING Failure to ground the control frame can result in a serious or fatal electrical shock high temperature locations This will cause shortened capacitor life where applicable and unnecessary tripping of overload protectors A ventilated enclosure painted white to reflect heat is recommended for an outdoor high temperature location A damp well pit or other humid location accelerates component failure from corrosion Control boxes with voltage relays are designed for vertical upright mounting only Mounting in other positions will affect the operation of the relay primary path back to the power supply ground for any ground fault There are conditions however where the ground wire connection could become compromised One such example would be the case where the water in the well is abnormally corrosive or aggressive In this example a grounded metal drop pipe or casing would then become the primary path to ground However the many installations that now use plastic drop pipes and or casings require further steps to be taken
79. o legs exceeds programmed setting Line voltage exceeds programmed setting Line voltage below programmed setting Power has been interrupted too many times ina 10 second period 45 Over pumping well Clogged pump intake Closed valve Loose pump impeller Broken shaft or coupling Phase loss Wrong SF Max Amps setting High or low line voltage Ground fault Pump or motor dragging Motor stalled or bound pump High or low line voltage Motor is overloaded Excessive current unbalance Poor motor cooling High water temperature Excessive electrical noise VFD in close proximity Phase loss Unbalanced power supply Open Delta transformer Unstable power supply Poor connection in motor power circuit Unstable or weak power supply Chattering contacts Loose connections in motor power circuit Arcing contacts itl Maintenance Electronic Products Subtrol Plus Obsolete See SubMonitor Subtrol Plus Troubleshooting After Installation symptom Possible Cause or Solution Subtrol Plus Dead Green Off Time Light Flashes Green Off Time Light On Overheat Light On Overload Light On Underload Light On When the Subtrol Plus reset button is depressed and released all indicator lights should flash If line voltage is correct at the Subtrol Plus L1 L2 L3 terminals and the reset button does not cause lights to flash Subtrol Plus receiver is malfunctioning The gre
80. open atmosphere applications such as lakes ponds etc 3 The Standard Vertical Water Well 30 93 kW motors can be adapted to non vertical applications when applied per the below guidelines However they will be more sensitive to application variances than the other two designs All of the above motors must be applied per the guidelines listed below In addition for all applications where the motor is applied in a sealed system a Submersible Motor Booster Installation Record Form 3655 or its equivalent must be completed at startup and received by Franklin Electric within 60 days A sealed system is one where the motor and pump intake are mounted in a sleeve and the water feeding the pump intake is not open to the atmosphere Inline Booster Pump Systems continued Design And Operational Requirements 1 Non Vertical Operation Vertical Shaft up 0 to Horizontal 90 operation is acceptable as long as the pump transmits down thrust to the motor within 3 seconds after start up and continuously during operation However it is best practice to provide a positive slope whenever it is possible even if it is only a few degrees 2 Motor Sleeve and Pump Support System The booster sleeve ID must be sized according to the motor cooling and pump NPSHR requirements The support system must support the motor s weight prevent motor rotation and keep the motor and pump aligned The support system must also allow for thermal
81. or Class 20 or higher overloads are NOT acceptable Franklin s SubMonitor is strongly recommended for all large submersibles since it is capable of sensing motor heat without any additional wiring to the motor Applications using soft starters with a SubMonitor require a start up bypass consult the factory for details SubMonitor can not be used in applications using a VFD control 11 Motor Surge Protection Properly sized grounded and dedicated motor surge arrestors must be installed in the supply line of the booster module as close to the motor as possible This is required on all systems including those using soft starters and variable speed drives inverter drives 12 Wiring Franklin s lead assemblies are only sized for submerged operation in water to the motor nameplate maximum ambient temperature and may overheat and cause failure or serious injury if operated in air Any wiring not submerged must meet applicable national and local wiring codes and Franklin cable chart tables 8 9 Notice wire size wire rating and insulation temperature rating must be Table 14 Franklin Cable chart See 12 Wiring Motor Nameplate Rated Amps Full Load Cable Temp Rating C 13 14 15 16 H Application Three Phase Motors known when determining its suitability to operate in air or conduit Typically for a given size and rating as the insulation temperature rating increases its ability to operate in air or
82. otor Rating AWG Wire Size T Wire 75 C Rated Insulation 9230 7310 6160 4530 3610 3030 2620 1970 1500 1270 1120 990 F250 200 aso a0 220v 50Hz 30 6 Lead x EN i 380v 50Hz 30 6 Lead 400V may use 11096 of table 415V may use 11996 of table N E 1 Meter 3 3 feet 280 o 240 Lengths in BOLD meet the ampacity only for indivi Ampacities are determined from motor full load curren 450 370 600 960 15 4140 3300 2760 2370 1780 1380 1150 1000 900 4750 3790 3180 2730 2050 1570 1330 1170 1030 5470 4360 3660 3150 2370 1810 1530 1350 1180 6180 4930 4120 3570 2680 2040 1740 1530 1350 7840 5950 4630 3670 3090 6790 5410 4540 3930 2950 2250 1900 1680 1480 idual conductor cable in free air or water not in conduit Table 430 150 in the National Electrical Code Circuit Breakers or Fuse Amps Power Line to Line 1 Efficiency Factor Typical Submersible 234551 220 18 560 18 3 22 4 7 3 15 4 37 1 2 Inch 234561 380 1 1 560 56 8 69 4 66 82 4 3 15 234552 220 26 810 12 3 15 0 69 83 10 15 3 4 234562 380 16 810 38 6 47 2 69 86 5 9 15 234553 220 3 5 1055 8 4 10 3 71 83 15 15 0 75 234563 380 2 1
83. r Aluminum Jacketed Individual Conductors SERVICE ENTRANCE Transformers KVA 1 2 3 Initial Megs motor amp lead T2 T3 Final Megs CONTROL PANEL motor lead amp cable 1 T2 Panel Manufacturer Incoming Voltage Short Circuit Device Circuit Breaker Rating Setting No Load L1 L2 L2 L3 L1 L3 Fuses Rating Type Full Load L1 L2 L2 L3 L1 L3 Standard Delay Running Amps Starter Manufacturer HOOKUP 1 Starter Size Full Load 11 12 13 Type Starter Full Voltage Autotransformer 96Unbalance Other Full Voltage in sec HOOKUP 2 Heater Manufacturer Full Load L1 L2 L3 Number Adjustable Set at amps 96Unbalance HOOKUP 3 Subtrol Plus Yes Registration No Full Load L1 L2 L3 If yes Overload Set Yes Set at amps Unbalance Underload Set Q No Yes Set at amps Ground Wire Size mm MCM Controls are Grounded to Motor Surge Protection Yes No Well Head Motor Rod Power Supply Variable Frequency Drives Manufacturer Model Output Frequency Hz Min Hz Max Cooling Flow at Min Freq Cooling Flow at Max Freq Approved Overload Built in External Model per above Cables per above Set Amps Start Time sec Stop Coast sec Ramp sec Output filter Reactor 96 Make Model None Maximum Load Amps Drive Meter Input Amps Line 1 Line 2 Line 3
84. rikes the closed check valve and the stationary water in the pipe above it causing a hydraulic shock This shock can split pipes break joints and damage the pump and or motor Water hammer can often be heard or felt When discovered the system should be shut down and the pump installer contacted to correct the problem H Application All Motors Wells Large Diameter Uncased Top Feeding amp Screened Sections Franklin Electric submersible motors are designed to operate with a cooling flow of water over the motor If the pump installation does not provide the minimum flow shown in Table 3 a flow inducer sleeve flow sleeve must be used The conditions requiring a flow sleeve are Well diameter is too large to meet Table 3 flow requirements Water Temperature and Flow Franklin Electric s standard submersible motors except Hi Temp designs see note below are designed to operate up to maximum service factor horsepower in water up to 86 F 30 C A flow of 0 25 ft s for 4 motors rated 3 hp 2 2 KW and higher and 0 5 ft s for 6 and 8 motors is required for proper cooling Table 3 shows minimum flow rates in gom for various well diameters and motor sizes If a standard motor is operated in water over 86 F 30 C water flow past the motor must be increased to maintain safe motor operating temperatures See HOT WATER APPLICATIONS on page 7 NOTE Franklin Electric offers a line of Hi Temp motors designe
85. rtions of the material All other rights reserved Submersible Motor Installation Record RMA No INSTALLER S NAME OWNER S NAME ADDRESS ADDRESS CITY STATE ZIP CITY STATE ZIP PHONE FAX PHONE WELL DATE INSTALLED DATE FAILED WATER TEMPERATURE C Motor Motor No Date Code KW Voltage Phase Pump Manufacturer Model No Curve No Rating m NPSH Required m NPSH Available m Actual Pump Delivery PSI Operating Cycle ON Min Hr OFF Min Hr Circle Min or Hr as appropriate YOUR NAME DATE TOP PLUMBING Total Dynamic Head m Please sketch the plumbing after the well head check valves throttling valves pressure tank etc Casing Diameter mm and indicate the setting of each device EN Drop Pipe Diameter mm Ne Static Water Level m Drawdown pumping Water Level Checkvalves at amp amp amp m e Solid Drilled Pump Inlet Setting m Flow Sleeve No Yes Dia mm Casing Depth m Well Screen Perforated Casing From to ft amp to m Well Depth m Form No 2207 10 03 3 Submersible Motor Installation Record Power Supply Cable Service Entrance to Control m mm2 MCM Copper Aluminum Jacketed Individual Conductors Cable Control to Motor m mm MCM Coppe
86. se connections which may cause voltage drops Loaded Generator If you are using a generator the line voltage may become too low when the generator loads Pumptec Plus will trip on undervoltage if the generator voltage drops below 198 volts for more than 2 5 seconds Undervoltage trips will also occur if the line frequency rises too far above 50 Hz 42 Pumptec Plus Pumptec Plus Troubleshooting After Installation Solid Yellow Light Yellow Flashing Light Solid Red Light Flashing Red Light Flashing Red and Yellow Lights Dry Well Maintenance Electronic Products Wait for the automatic restart timer to time out During the time out period the well should recover and fill with water If the automatic reset timer is set to the manual position then the reset button must be pressed to reactivate the unit Blocked Intake Clear or replace pump intake screen Blocked Discharge Remove blockage in plumbing Check Valve Stuck Replace check valve Broken Shaft Replace broken parts Severe Rapid Cycling Machine gun rapid cycling can cause an underload condition See flashing red and yellow lights section below Worn Pump Replace worn pump parts and recalibrate Stalled Motor Repair or replace motor Pump may be sand or mud locked Float Switch A bobbing float switch can cause two wire motors to stall Arrange plumbing to avoid splashing water Replace float
87. t will pump 51 C water in an 203 mm well at a delivery rate of 530 I m From table 4A a 152 mm flow sleeve will be required to increase the flow rate to at least 91 m sec Using table 5 the 1 62 heat factor multiplier is selected because the KW HP required is over 22 KW 30 HP and water temperature is above 50 Multiply 29 1 KW x 1 62 multiplier which equals 47 1 KW 63 2 HP This is the minimum rated full load horsepower usable at 21 9 KW 39 HP in 51 C Using table 5A select a motor with a rated service factor above 47 1 KW 63 2 HP A 45 KW 60 HP motor has a service factor kilowatt of 51 4 69 HP so a 45 kw 60 HP motor may be used Drawdown Seals Allowable motor temperature is based on atmospheric pressure or higher surrounding the motor Drawdown seals which seal the well to the pump above it s intake Grounding Control Boxes and Panels The United States National Electrical Code requires that the control box or panel grounding terminal always be connected to supply ground If the circuit has no grounding conductor and no metal conduit from the box to supply panel use a wire at least as large as line conductors and connect as required by the National Electrical Code from the grounding terminal to the electrical supply ground Grounding Surge Arrestors An above ground surge arrestor must be grounded metal to metal all the way to the lowest draw down water strata for the
88. tage starters may be used for soft starting standard three phase motors When autotransformer starters are used the motor should be supplied with at least 55 of rated voltage to ensure adequate starting torque Most autotransformer starters have 65 and 80 taps Setting the taps on these starters depends on the percentage of the maximum allowable cable length used in the system Inline Booster Pump Systems Franklin Electric offers three different types of motors for non vertical applications 1 The booster motors are specifically designed for booster applications They are the Best Choice for sealed reverse osmosis applications These motors are the result of two years of focused development and bring additional value and durability to booster module systems These motors are only available to OEMs or distributors who have demonstrated capability in booster module systems design and operation and adhere to Franklin s Application Manual requirements 2 The Hi Temp motors have many of the internal design features of the booster motor It s additional length allows for higher temperature handling and the Sand Fighter sealing system provides greater abrasion resistance One or both of these conditions Continued on next page 3 Application Three Phase Motors If the cable length is less than 50 of the maximum allowable either the 65 or the 80 taps may be used When the cable length is more than 50 of allowable the 80
89. ual lead wires using a stake type connector individual lead wire staggering the joints After all Once the connection is complete slide the heat shrink individual lead wires have been prepared with the heat tube over the splice area and center it so that the tube shrink tubing repeat the process to include a heat shrink extends between one and two inches beyond each tube over the jacket of the cables insulated edge of the lead wires Note Use only heat shrink tubing with an inner sealant Use either a heat gun or propane torch with a diffusing which will melt when heated and ooze out the ends of tip to evenly distribute heat to the shrinking tubing Begin the tube applying heat to the middle of the shrink tube and work outward to avoid trapping air within the tube Rotate the cable while heating to evenly shrink the tubing Avoid over heating as this may make tubing brittle Complete this same process for the remaining lead wires 25 4 50 8 mm HEAT SHRINK TUBING 1 to 2 Inches FIG 13 31 System Troubleshooting Motor Does Not Start Possible Cause A No power or incorrect voltage B Fuses blown or circuit breakers tripped C Defective pressure switch D Control box malfunction E Defective wiring F Bound pump G Defective cable or motor Motor Starts Too Often Possible Cause A Pressure switch B Check valve stuck open C Waterlogged tank D Leakin system 3 Mai
90. ubmersible Motor Installation Record 2207 Subtrol Plus Troubleshooting 46 47 Storage Franklin Electric submersible motors are a water lubricated design The fill solution consists of a mixture of de ionized water and Propylene Glycol a non toxic antifreeze The solution will prevent damage from freezing in temperatures to 40 C motors should be stored in areas that do not go below this temperature The solution will partially freeze below 3 C but no damage occurs Repeated freezing and thawing should be avoided to prevent possible loss of fill solution There may be an interchange of fill solution with well water during operation Care must be taken with motors removed from wells during freezing conditions to prevent damage Frequency of Starts The average number of starts per day over a period of months or years influences the life of a submersible pumping system Excessive cycling affects the life of control components such as pressure switches starters relays and capacitors Rapid cycling can also cause motor spline damage bearing damage and motor overheating All these conditions can lead to reduced motor life The pump size tank size and other controls should be selected to keep the starts per day as low as practical for longest life The maximum number of starts per 24 hour period is shown in Table 1 Motors should run a minimum of one minute to dissipate heat build up fro
91. with the drive manufacturer and must be specifically designed for VFD operation Cable Lengths Per Franklin s cable tables unless a reactor is used If a long cable is used with a reactor additional voltage drop will occur between the VFD and the motor To compensate set the VFD output voltage higher than the motor rating in proportion to the reactor impedance 10296 voltage for 296 impedance etc Motor Cooling Flow For installations that are variable flow variable pressure minimum flow rates must be maintained at nameplate frequency In variable flow constant pressure installations minimum flow rates must be maintained at the lowest flow condition Franklin s minimum flow requirements for 4 motors 7 26 cm sec for 6 and 8 motors 15 24 cm sec Carrier Frequency Applicable to PWM drives only These drives often allow selection of the carrier frequency Use a carrier frequency at the low end of the available range Miscellaneous Franklin three phase motors are not declared Inverter Duty motors per NEMA MG1 Part 31 standards However Franklin s submersible motors can be used with VFDs without problems and or warranty concerns provided these guidelines are followed 4 Super Stainless Dimensions Standard Water Well 37 6 76R 12 7 MIN 7 MIN MAX FULL SPLINE 5 16 24 UNF 2B MOUNTING STUDS Y 38 30 38 05 277 4 09 MAX LEAD 2
92. y 100 to determine percent of unbalance Current unbalance should not exceed 5 at full load If the unbalance cannot be corrected by rolling leads the source of the unbalance must be located and corrected If on the three possible hookups the leg farthest from the average stays on the same power lead most of the unbalance is coming from the power source However if the reading farthest from average moves with the same motor lead the primary source of unbalance is on the motor side of the starter In this instance consider a damaged cable leaking splice poor connection or faulty motor winding 22 1st Hook Up 2nd Hook Up 3rd Hook Up 11 02 B U 12 B L1 2 supply ea Ti CUN T1 T3 T3 T2 0 EXAMPLE T1 251 amps 50 amps T2 2 50 amps T2 46 amps T1 2 49 amps 48 amps T3 2 58 amps T2251amps T1 52 amps Total 150 amps Total 150 amps Total 150 amps 150 E 50 amps 150 50 50 3 P 3 50 46 4amps 50 49 1 50 48 2 amps 4 08 l 020r294 04 4 50 50 50 Phase designation of leads for CCW rotation viewing shaft end To reverse rotation interchange any two leads Phase 1 or Black T1 or U1 Phase 2 or B Yellow T2 or V1 Phase 3 or Red W1 NOTICE Phase 1 2 and 3 may not be L1 L2 and L3 Submersible Pump Installation Check List
93. y reason can cause the Pumptec chatters when running Pumptec relay to chatter C Make sure the L2 and motor wires are installed correctly If they are reversed the unit can chatter 41 Pumptec Plus 3 Maintenance Electronic Products Pumptec Plus is a pump motor protection device designed to work on any 220V single phase induction motor PSC CSCR CSIR and split phase ranging in size from 1 2 to 5 horsepower Pumptec Plus uses a micro computer to continuously monitor motor power and line voltage to provide protection against dry well water logged tank high and low voltage and mud or sand clogging Pumptec Plus Trouble During Installation Symptom Unit Appears Dead No Lights Flashing Yellow Light Flashing Yellow Light During Calibration Flashing Red and Yellow Lights Flashing Red Light Solid Red Light Possible Cause No Power to Unit Check wiring Power supply voltage should be applied to L1 and L2 terminals of the Pumptec Plus In some installations the pressure switch or other control device is wired to the input of the Pumptec Plus Make sure this switch is closed Unit Needs To Be Calibrated Pumptec Plus is calibrated at the factory so that it will overload on most pump systems when the unit is first installed This overload condition is a reminder that the Pumptec Plus unit requires calibration before use See step 7 of the installation instructions Miscalibrated Pu

50 Hz AIM Manual - Franklin Electric

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