1Ø Service Manual Engineered for life
Contents
1. Table 3 Motor Resistance m Single Phase Motors Winding Resistance Motor Only Ohms 4 Motors CentriPro Franklin Electric e Winding Winding Resistance Resistance e V 115 1 3 1 8 K 1 0 1 3 R E 2 Wire V 230 4 5 5 2 K 4 2 5 2 R psc 230 3 048 J 3 0 3 6 N 1 230 4 2 5 2 F 2 2 2 7 N 2 1 230 1 9 2 3 H 1 5 1 9 M o Ld 4 Motors CentriPro Franklin Electric aq Resistance Resistance T KVA n KVA Type HP Volts Main Start coge Main Start Codel Pe BY RY BY RY m 3 Wire V 9 1 6 5 7 7 0 N 1 0 1 3 4 1 5 1 M w QD 145 42 49 174 187 M_ 4 2 5 2 16 7 20 5 M un Cap 34 2 6 3 6 11 8 13 L 4 3 033 6 0 7 13 1 M Les Start 1 22 32 113323 L 2 2 2 7 9 9 12 1 L bz 3 Wire 12 1 6 2 3 7 9 8 7 J 1 2 2 8 0 9 7 J a w CSCRI 2 1 6 2 2 10 8 12 0 G 1823 5872 G Pfs 73 Miral 2025 G 10 15 3544 H Bd Box 5 62 76 1 36 1 66 E 68 1 0 1 8 2 2 F e 6 Motors CentriPro Franklin Electric m 1 HP Volt Resistance KVA Resistance KVA e ype ofts R Y B Y R B Code BY RY Code 6 5 2 172 0 51212 627 G 55 68 1 3 1 7 E Single 2 5 545 401 0 4 1 774 F 36 50 8811 F DS Phase 10 1 052 0 316 1 31 E 27 33 80 99 E 15 0 678 0 23 0 85 D 17 22 68 93 E 4 RULE OF THUMB Add resistance of drop cable when checking2. 48 E Switch Does Not Cut Out 49 C E RULE OF THUMB Remember there may be other system problems caused by auxiliary controls not covered in this booklet 42 Troubleshooting x Pump Will Not Run 0000000 Uu PROBLEM ANSWER 1 Blown fuse or power Replace fuse close A turned off all switches 2 Broken or loose Examine all wiring e wiring connections and repair any bad connections 3 Motor overload Overload contacts protection contacts will close open automatically in a short time a Improper voltage See 1 Volt Ammeter b Pump bound Remove motor end mechanically will cap turn motor not turn freely shaft by hand Unit should rotate freely 4 Pressure switch faulty Adjust or replace or out of adjustment switch See I 5 Tubing or fittings on Remove switch pressure switch tubing and or all plugged fittings and clean 6 Faulty motor See 2 43 ui Q Lud Troubleshooting Little or no water delivered PROBLEM ANSWER 4 Pump or pipes not completely primed Fill pump completely with water through priming opening reprime pump a Deep Well system Control valve must be set properly or system will not pump See 4 2 Foot valveorend of a Shallow Well suction pipe either not system Install submerged or buried vacuum gauge See 3 b Deep Well system
3. n H Amperage Checkout ca Service Factor Amps w QD 7 1 HP or un CSCR 1 5 HP amp larger Control Boxes fa 4 CP FE CP FE Lu 18 3 Wire 3 Wire 2 Wire 2 Wire HP Volts Yel Black Red Yel Black Red Black Black Y2 115 12 6 12 6 0 12 0 12 0 O 95 12 0 v a7 6 3 63 0 160 60 0 47 60 Yq 8 3 83 O 8 0 8 0 O 64 80 1 9 7 9 7 0 98 9 8 0 9 1 9 8 1 2 230 11 1 11 0 1 3 11 5 11 0 1 3 11 0 13 1 2 12 2 11 7 2 6 13 2 11 9 2 6 3 16 5 13 9 5 6 17 0 12 6 6 0 N A 5 27 0 22 0 10 0 27 5 19 1 10 8 Service Factor Amps w Magnetic Contactor Control Boxes wm CentriPro 3 Wire Franklin Elec 3 Wire HP Volts Yel Black Red Yel Black Red 5 27 5 N A N A 27 5 17 4 10 5 7 5 230 41 0 N A N A 42 1 40 5 5 4 10 58 0 NA NA 51 0 47 5 8 9 15 85 0 NA NA 75 0 62 5 16 9 26 Control Box With Cover Attached Control Box With Cover Attached Ground Supply 2 Uy Amprobe P Meter set on jy L Ampere Scale LNONDAHD ADWYAdINIV H Pressure Switch Adjustment Checkout CentriPro and Square D Adjust in Proper Sequence 1 CUT IN Turn range nut big Spring down for higher cut in pressure or up for lower cut in 2 CUT OUT Turn differential nut small spring down for high cut out pressure or up for lower cut out 2
4. Horizontal Jet Vertical Jet SJ 37 SdINNd EET Typical Jet Pump System Shallow Well System illustrated is a Convertible jet pump with a shallow well adapter and a pressure tank JET PUMPS B RULES OF THUMB All jet pumps should be located at the highest point in the suction side of the system Distance from well head to pump If offset is greater than 20 increase horizontal pipes by one size each Never use pipes smaller than the pump suction tappings 38 TYPICAL JET PUMP SYSTEMS Typical Jet Pump System Deep Well Packer and twin pipe systems JET PUMPS 40 Improper Installations Trap air Hard to prime TRAPS AIR E A gt re m U Cc v un lt un j m wn Proper Installations Easy to prime 41 ui Q A Lud lum Troubleshooting An amprobe ohmmeter and vacuum pressure gauge are essential for properly checking a system Use of the amprobe is explained on page 10 Use of the ohmmeter is explained on page 11 Use of the compound vacuum pressure gauge is explained on page 66 Find the basic problem for which numerous symptoms are listed and possible solutions are given for each Page E Pump Will Not RUN eee 43 E Pump Runs But Little or No Water Delivered eae 44 45 E Pump Starts and Stops Too Often 46 47 B Insufficient Tank Pressure
5. MAIN TOYA WHITE Black Tracer is a black and white wire TO WIRE FOR 230 V BLACK TRACER TO B BLACK BLACK TO A TO WIRE FOR 115 V BLACK TRACER TO A BLACK TO L BLACK 61 DIIS Led Ee gt 9 un io e A wn Ohmmeter Checks Capacitor 62 1 Set ohmmeter to R x 1 000 adjust to 0 2 Disconnect leads on capacitor 3 Attach ohmmeter leads to each terminal Needle should swing to right and drift slowly to left To double check switch ohmmeter leads and repeat procedure If the needle will not move or moves toward 0 and stays there the capacitor is bad 4 If a digital meter is used readings should start low and rapidly increase to maximum value 63 ui A A Lud lm EJ Checking Suction Lift A vacuum gauge indicates total suction lift vertical lift friction loss total lift in inches of mercury 1 on the gauge 1 13 ft of total suction lift based on pump located at sea level RULE OF THUMB Practical suction lift at sea level is 25 ft Deduct 1 ft of suction lift for each 1 000 ft of elevation above sea level Shallow Well System Install vacuum gauge in shallow well adapter See opposite page When pump is running the gauge will show no vacuum if the end of suction pipe is not submerged or there is a suction leak If the gauge shows a very high vacuum 22 inches or more this indicates that the end of suction
6. If screws used tighten alternately and evenly Check by turning the motor shaft If binding occurs loosen screws readjust guide vane until impeller hub turns freely then tighten screws as before Some jets have snap in guide vane 11 12 13 14 Replace diaphragm gasket with opening in the upper position Replace guide vane seal ring on guide vane hub Make sure all gasket surfaces are clean Replace pump casing Tighten casing bolts alternately and evenly After reassembling pump check to be sure impeller rotates freely Reconnect tube between pressure switch and casing cover or control valve Close all drain openings using pipe joint compound or teflon tape on threads of plugs Prime according to Priming Instructions e RULE OF THUMB Do not start motor until pump and suction piping are filled with water 71 NOTES 73 NOTES itt Residential Water Systems GOULDS PUMPS Goulds Pumps CentriPro and the ITT Engineered Blocks Symbol are registered trademarks and tradenames of ITT Corporation SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE GSSINGLE May 2008 2008 ITT Corporation Engineered for life
7. a cost effective choice However if the outside metal parts such as the casing motor adapter and discharge head all require replacement due to extremely harsh water it may be less expensive to simply purchase a complete new water end A new casing or discharge head will require drilling and tapping for two new cable guard holes Pump Disassembly for Typical 4 Submersible Pumps 1 Remove 4 cable guard screws and remove cable guard 2 Reinstall top 2 screws so that discharge head and casing may be removed as one piece 3 Using two pipe wrenches or a vice and pipe wrench hold the motor adapter and turn the discharge head casing assembly clockwise it has left hand threads to loosen the assembly 32 10 Remove the casing assembly to expose the stages Remove the klip ring from the top of the shaft this will allow you to remove the stages from the shaft Note that on units which have operated in sandy water it may be hard to disassemble the stages The complete stages should be removed one at a time disassembled and inspected Replace worn parts as needed On most models the shaft and coupling assembly is replaceable without removing the motor adapter Lift the shaft off and inspect the coupling and motor splines for excessive wear If motor replacement is necessary remove the 4 nuts from the motor studs and separate the motor and motor adapter If motor is OK leave assembly intact The shaft sleeve is now
8. part of the shaft coupling assembly and will not have to be ordered as a replacement part Shaft couplings are not available alone as they are a pressed part Replace the entire shaft coupling assembly if either shows wear We use several check valve styles Some are built in and some screw in from the top outside of the discharge head Replace as necessary Replacement of a GS check valve will require separation of the discharge head and casing as it installs from inside the discharge head You may also replace it using a standard screw in line type check valve 33 v c v z 4 gt 4 4 m w lt Pump Reassembly 1 2 3 Clean all parts including the strainer Replace basket type internal strainer now Place shaft and coupling assembly and spacer where used onto motor spline Reattach the motor adapter to the motor Tighten the nuts in an alternating pattern Place straight edge across the rim of motor adapter If it fails to touch the shaft sleeve add one or more 010 shims repair part No 7K155 until they are either flush with motor adapter or slightly high never low Install first stage bowl first stage impeller and diffuser Stack up of the impeller hubs is checked by straight edge Install succeeding stages in the same manner as the first Check stack up at least every second or third stage If straight edge laid across the diffuser face fails to contact the impeller
9. pipe is buried in mud the foot valve or check valve is stuck closed or the suction lift exceeds capability of pump High Vacuum 22 inches or more Suction pipe end buried in mud Foot valve or check valve stuck closed Suction lift exceeds capability of the pump Low Vacuum or 0 vacuum Suction pipe not submerged Suction leak NN N NN 2 Compound Vacuum Pressure Gauge This gauge will show the pressure or vacuum at any position in a pump or system where it is installed A reading of 20 on a vacuum gauge placed on the suction side of the pump would tell you that you have a vacuum or suction lift of 22 6 ft 20 x 1 13 22 6 ft Vacuum Vertical Lift Plus Friction 14 NOILINS DNDIO3HD E ui A 2 A Lud E Pressure Control Valves When pump is first started or under maximum flow condition pressure control should be immediately adjusted to the pressure corresponding to H P and jet assembly used See rating tables in catalog for proper pressure setting 1 Turn left to reduce pressure 2 Turn right to increase pressure amp RULE OF THUMB If pressure control valve is set too high the air volume control will not function If pressure control valve is set too low the pump may not shut off To Adjust Pressure Control Valve 1 Close pressure control valve 2 Open faucet in house 3 Turn pump on 4 As pump picks up its prime the pressure wil
10. 1 Meter Setting RX 1 2 Connections L1 amp T1 or L2 amp T2 3 Manually close contacts 4 Correct meter reading Zero ohms Additional information on troubleshooting and replacement parts for Single Phase Control Boxes is available in the ITT MAID Motor Application Installation Manual and in the FE AIM It is available online at www goulds com and www franklin electric com Overload Checkout For 112 HP and Larger Control Box 1 Set Ohmmeter at R x 1 2 Connect the Ohmmeter leads to Terminal 1 and 3 on each Overload Protector 3 Reading should be not more than 0 5 Ohms maximum on the scale CSCR or Mag Contactor Control Box v uu Pr c m t n DJ Voltage Checkout To Check Voltage with Q D Type Control Box 1 Remove cover to break all motor connections 2 To check VOLTAGE Use voltmeter on L1 and L2 as shown 3 When checking voltage all other major electrical appliances that could be in use at the same time should be running 4 If readings are not within the limits see chart call your power supplier Voltage Limits Measured Volts Nameplate V Min Max 115V 19 105 125 208V 19 188 228 230V 19 210 250 Voltage Checkout E Electrical Short Checkout Measuring Insulation Resistance 1 Set the scale lever to R x 100K and adjust to 0 v uu n m t m 2 Connect an ohmmeter lead to any one of the m
11. 8 FURNAS j 1 MAIN SPRING ADJUSTMENT Turn clockwise to increase both Cut Out and Cut In pressure 2 PSI turn 2 DIFFERENTIAL ADJUSTMENT Turn differential nut clockwise to increase Cut Out pressure without affecting Cut In 3 PSI turn 29 Hn Pressure Tank Checkout Procedure 1 To check Shut off power supply and drain system to 0 pressure 2 Air pre charge in tank should be 2 psi less than the cut in pressure of the pressure switch Example If pressure switch setting is 30 50 psi tank should be pre charged with 28 lbs air 3 If water at valve replace tank e RULE OF THUMB Improper tank sizing may cause motor damage 1 2 to 172 HP pumps Tank draw down should be equal to the pump capacity in GPM or greater v uu Pr ce m t n Example 3 4 HP pump capacity 12 GPM pressure switch setting 30 50 PSI correct tank V140 2 HP and larger pumps tank drawdown should be double the pump capacity in GPM Example 3 HP pump capacity 30 GPM pressure switch setting 40 60 PSI correct tank selection 2 V350 tanks 30 HydroPro Water System Tank Shown with base extension 31 Repair or Replace Some Considerations While our pumps are designed for ease of repair it is important to compare the cost of repair versus the cost of water end replacement Replacing typical wear parts such as impellers and diffusers is
12. Physically check well conditions Foot valve in well or Replace foot valve if line check valve stuck necessary Very closed high vacuum 22 inches or more see 3 3 Leaks on suction side Pressurize system of pump Very common problem and inspect 44 Troubleshooting PROBLEM ANSWER 4 Jet assembly plugged A Shallow Well system Clean if necessary Insert wire through 1 plug in shallow well adapter b Deep Well system Pull jet assembly and clean 5 Punctured diaphragm Disconnect the J Oo w nd m 4 o io Z 2 in air control tubing and plug Galvanized tanks the connection in pump If this corrects the trouble the air control must be replaced 6 Original installation Check rating in incorrect nozzle or product catalog diffuser combination 45 4 A 2 gt A Lu Lm Troubleshooting Pump starts and stops too often POSSIBLE CAUSE ANSWER 1 Leaks in piping system Pressurize piping system and inspect Repair or replace 2 Faulty pressure switch Check contact points Adjust or replace switch See I 3 Waterlogged galvanized tank faulty air control Pumps using Brady control Test by holding your ear on air control If control is operating air can be heard passing from control into tank when pump stops If no air movement is heard air control should be replaced 4 Lea
13. V rT Residential Water Systems 19 Service Manual GOULDS PUMPS Goulds Pumps is a brand of ITT Corporation www goulds com Engineered for life wn E Ld a o U U le ud l lt E Table of Contents This manual covers single phase 4 submersible pumps and jet pumps Submersibles Pages 1 35 Page Typical Systems 1 3 Troubleshooting rcs crea toe etta eie rhe 4 9 Amprobe Instructions seessseseeeee 10 Ohmmeter Instructions 11 A Capacitor Checkout 12 13 B Relay Checkout ecceeseesseeeeseeeseeeeeneeesneeeeaes 14 16 C Overload Checkout 17 D Voltage Checkout 18 19 E Electrical Short Checkout 20 21 F Motor Winding Resistance Checkout ie G Cable Checkout eeeeeeee H Amperage Checkout sssr I Pressure Switch Adjustment J Pressure Tank Checkout Submersible Pump Disassembly Submersible Pump Reassembly Jet Pumps Pages 36 71 Typical SySterfis icon meer erri rhe eges Troubleshooting siisii 1 Voltage Checkout 2 Amperage Checks Ohmmeter Checks Wiring Diagrams ccccceceeeeeeeeeeteeeeeseeeeees 3 Checking Suction Lift ssusssssse 64 65 4 Pressure Control Valves seee 66 67 Jet Pump Disassembly sese 68 69 Jet Pump Reassembly sesseeeee 70 71 Goul
14. chanical seal assembly 11 Motor adapter can be unbolted from the motor for motor replacement 68 JET PUMP DISASSEMBLY ui Q 2 A E uu Jet Pump Reassembly 1 70 Be sure that recess for seal seat and surface where guide vane mounts on motor adapter are entirely free of all scale and dirt Clean motor shaft Apply film of light oil such as vegetable oil to the recess of the motor adapter and the neoprene bushing before installing the new seal seat This is a tight fit but it must go in all the way evenly or a leak will result Do not mar lapped face of this seal The slightest scar or particle of dirt will cause a leak Bolt motor adapter to motor making sure the motor shaft does not dislocate the stationary seal member Assemble rotating member of seal on motor shaft Rotating seal face must fit snugly against lapped seal face of stationary member in casing cover This is accomplished by pushing with a piece of tube against back end of neoprene washer after oiling sleeve and shaft Be sure rotating seal face does not drop out of holding collar while sliding the rotating members of the seal on the shaft Also take extra care that the rotating seal face is not marred during handling While holding the shaft against rotating screw impeller on shaft by hand until tight against shoulder of motor shaft Replace guide vane making sure that bore of guide vane does not bind impeller hub
15. d back to the pitless b Q On installations with well seals or well pits it is allowable to locate the top check valve near the tank Three wire Single Phase Wiring Diagram L1 L2 3 A gt r n lt 4 M m N Ground Breaker Control or Fuse Box Ground To Well Pressure Switch v uu Pr ce m t n Troubleshooting An amprobe and ohmmeter are essential for properly checking a system Use of the amprobe is explained on page 10 Use of the ohmmeter is explained on page 11 Find the basic problem for which numerous symptoms are listed and possible solutions are given for each Page E Pump Will Not Start ee 5 E Pump Will Not RUN eee 6 E Pump Runs But Little or No Water Delivered 7 B Insufficient Tank Pressure 8 E Pump Starts Too Frequently 9 RULE OF THUMB Remember there may be other system problems caused by auxiliary controls not covered in this booklet Letters and Numbers in chart ex See A refer to sections in the Manual Submersible sections use letters and Jet sections are numbered Troubleshooting If fuses and overload check okay PROBLEM ANSWER 1 No power or See D incorrect voltage 2 Defective pressure Inspect points and switch replace switch if necessary 3 Loose connection SeeE EG in control box cable or motor J O
16. ds Pumps CentriPro and the ITT Engineered Blocks symbol are registered trademarks and tradenames of ITT Corporation Typical Submersible System Three wire system illustrated using galvanized tank 7 RULE OF THUMB 1 Use same size or larger pipe as discharge on pump 2 Always use a check valve for every 200 ft of vertical pipe v uu 2 Pr ce m t m To House Piping Shut off e Valve 3 Drain Tap Pressure Relief Valve Air Escape Control Pressure Switch Line Check Valve with Snifter Union NOTE Piping below the frost line is common in colder climate areas In warm climates the piping is often above ground and tank placement is often outside the house and or inside a separate cover or housing Typical Submersible System Two wire system illustrated using diaphragm type tank RULE OF THUMB 1 Use same size or larger pipe as discharge on pump 2 Always use a check valve for every 200 ft of vertical pipe m Lu Z n c m t n To House Piping Protected Power Supply x F ee Prem Disconnect us Switch Valve W Union Pressure Switch Relief Valve ue Drain Tap Pitless Adapter Tank Tee Frost Level Check Valve Check Valve On installations with a pitless adapter Li the top check valve should be below the pitless not at the tank as the discharge line should be pressurize
17. hub a shim should be added underneath the impeller This will keep the bottom of the impeller from dragging on the bowl Longer units have one intermediate bearing spider and sleeve which should be placed to divide the stages evenly 10 11 12 13 When all stages are in place replace klip ring on shaft Check upper bearing for wear and replace if loose on shaft Replace bearing spider on stack Replace casing discharge head assembly turning counterclockwise left hand threads Turn it all the way down so that the casing bottoms against the flange on the motor adapter Using a pipe wrench on the motor adapter and one on the discharge head tighten to approximately 85 Ibs ft This will be approximately s to 1 4 turn from the hand tight position Remove the upper cable guard screws and replace the cable guard using all 4 screws The cable guard should be straight up and down if the casing is properly tightened If you installed a new casing or discharge head they will have to be drilled and tapped to provide holes for the cable guard screws Use a 4 drill and an 8 32 NC tap Replace the external wrap around strainer where used New part number is 7K2242 35 v v JJ m D wn 4 m w lt ui Q 2 A Lu lum Jet Pumps Since these are the basic types that have been used for many years the vast majority of jet pump service work will be on these types
18. king tank or air valve Use soapy water to find leaks Repair or replace 46 Troubleshooting POSSIBLE CAUSE ANSWER 5 Not enough suction Throttle suction line lift on shallow well with partially closed system water flows valve into pump flooded suction 6 Insufficient vacuum or Pump requires vacuum does not exist minimum 3 for long enough time vacuum for to operate air control 15 seconds J Oo w md m 4 o io Z 2 7 Improper air change See J in in captive air tank submersible section 8 Tank too small Replace with for pump proper size storage tank 47 ui Q 2 A uu lm Troubleshooting Pumps water but does not develop 40 Ibs tank pressure PROBLEM ANSWER 1 Leaks in well piping Pressurize piping or discharge pipe system and inspect 2 Jet or screen on foot valve partially plugged Clean if necessary 3 Improper pressure control valve setting deep well only See 4 4 Suction lift too high for shallow well system a Jet set too deep for deep well system Use vacuum gauge on shallow well systems Vacuum should not exceed 22 inches at sea level On deep well system check ratings tables in catalog for maximum jet depth 5 Faulty air charger Disconnect the tubing and plug the hole If this corrects the trouble the air control must be replaced 6 Worn impe
19. l begin to rise on the gauge 5 Turn adjusting screw to set pressure control valve to pressure recommended in catalog 66 Use with 1 2 and 3 4 HP pumps requiring control valve settings up to 35 PSI Use with pumps requiring 35 PSI or higher control valve setting Typically all multi stage units and single stage pumps 1 HP and larger Use with deep well multi stage and high pressure units 67 ui Q 2 E uu Jet Pump Disassembly 1 Turn off power to motor Disconnect service wires from pressure switch 2 Drain system to relieve pressure 3 Disconnect motor cord from pressure switch when used 4 Remove casing bolts If pump is mounted on top of tank remove bolt holding motor adapter to mounting pad 5 Disconnect tubing between casing or pressure control valve and pressure switch 6 Remove motor motor adapter casing and rotating element Casing remains attached to piping 7 Remove guide vane seal ring and diaphragm gasket ring 8 Remove guide vane from motor adapter via 4 bolts or may be snap in type 9 A O Smith Motors Remove motor end cover Insert 7 6 open end wrench under switch mechanism or behind overload protector onto flats on motor shaft While holding the shaft against rotating turn the impeller counterclockwise The impeller should turn completely off the shaft in this manner 10 Using two screwdrivers pry out holding collar of me
20. lace or coupling v lu Pr c m t m Troubleshooting PROBLEM ANSWER 1 Improper pressure See switch setting 2 Incorrect voltage See D Repair or replace 3 Excessive pump wear Repair or replace 4 Leaks in piping system Repair or replace Troubleshooting PROBLEM ANSWER 1 Waterlogged tank a Galvanized b Captive air type Check tank for leaks Check drain and Y fittings snifter valve for proper operation See J 2 Check valve stuck open Replace if necessary 3 Improper pressure switch setting See 4 Leaks in piping system Repair or replace 5 Pressure tank improperly sized RULE OF THUMB Must be sized to allow a minimum run time per cycle as follows Ys 1 HP 1 minute run time 2 HP amp larger 2 minute run time J Oo w rm m 4 o io Z 2 Amprobe Instructions The Amprobe is a multi range combination ammeter and voltmeter Voltmeter Scales 150 VOLTS 600 VOLTS Ammeter Scales 5 AMPS 40 AMPS 15 AMPS 100 AMPS 1 When used as an ammeter the tongs are placed around the wire being measured with the rotary scale on the 100 amp range Then rotate the scale back to the smaller ranges until an exact reading is indicated 2 When used as a voltmeter the two leads are clipped into the bottom of the instrument with the rotary scale on the 600
21. ller hub and or guide vane bore Replace if necessary Clearance should not exceed 012 on a side or 025 diametrically 7 Overpumping the well 48 Throttle a valve on the pump suction do not exceed 22 Hg Troubleshooting Pump develops 40 Ibs pressure but switch does not cut out J Oo w r m 4 o io Z 2 PROBLEM ANSWER 1 Pressure switch See I in incorrectly set submersible section 2 Tubing or fittings Remove switch between switch and tubing and or all pump plugged fittings and clean 3 Faulty switch or Replace if necessary corroded contact points 49 a How to Use Volt Ammeter For Voltage Check ui A A uu Attach leads to volt ammeter and select proper voltage scale for voltage to be tested 2 Place leads in A position to test for presence of incoming voltage Voltage should be within 10 of the design voltage specified on the motor nameplate in A B and C test positions 3 With disconnect switch in ON position move leads to B position and test voltage flow through fuse s 4 The C position tests voltage at pressure switch terminals The voltage should be within limits with the motor operating Voltage Limits Nameplate V Measured Volts Min Max 115V 1g 105 125 208V 16 188 228 230V 16 210 250 50 x I o e Cc 4 m lt o x P m
22. lt Boxes 7 1 8 700 to 1 800 ohms For 230 Volt Boxes 4 5 7 0 4 500 to 7 000 ohms Step 2 Contact Test 1 Meter setting R x 1 2 Connections 1 amp 2 3 Correct meter reading Zero for all models L v uu n ce m t n B FE Blue Relay Solid State 5 1 HP QD Control Boxes Used from 1994 until present time Step 1 Triac Test Step 2 Coil Test 1 Meter setting 1 Meter setting Rx 1 000 Rx 1 2 Connections Cap 2 Connections and B terminal L1 and B 3 Correct meter 3 Correct meter reading Infinity reading Zero for all models ohms for all models C FE Black Solid State Switch 74 1 HP QD Control Boxes Used from 1985 until 1994 Step 1 Triac Test Step 2 Coil Test m 2 Z 2 m a I P 4 m A o A oO n O X A gt lt e I m A e c 1 Meter setting 1 Meter setting R x 1 000 Rx1 2 Connections 2 Connections R Start terminal Y Common and orange lead and L2 on start switch 3 Correct meter 3 Correct meter reading Zero reading Infinity ohms for all for all models models v uu n c m t n B Relay Checkout Continued Contactor Checkout Checkout procedure for magnetic and other Contactors Contactor Coil Test Disconnect lead from one side of coil 1 Meter setting R X 100 2 Connections Coil terminals 3 Correct meter reading 180 to 1 400 ohms Contactor Contact Test
23. m J ui Q A uu A How to Check Amperage 1 52 If attached remove leads from volt ammeter Select lowest reading amperage scale according to motor nameplate rating With disconnect switch in OFF position clamp instrument around one incoming lead at pressure switch Turn switch ON and observe amperage as motor runs With proper voltage reading should not exceed the MAXIMUM LOAD AMPERAGE of motor Excessive amps means an overloaded condition or incorrect voltage applied Problem could also be in motor Take readings with pump running at normal system pressure At open discharge zero pressure the pump may exceed maximum amps due to no discharge head 2 HOW TO CHECK AMPERAGE AT PRESSURE SWITCH Ohmmeter Checks Power supply OFF Disconnect motor leads L1 and L2 On dual voltage motors motor must be wired 230V for the checks listed below and illustrated on the page indicated for each check Rewire for 230V if necessary CHECK Page a Ground sseeeeseeeeee een 55 b Winding Continuity 56 57 c Contact Points Switch 58 59 d Overload Protector 60 61 e Capacitor osi E 62 63 54 o Ground Check Set ohmmeter to R x 1 000 Attach one probe to ground screw and touch other probe to all terminals on terminal board switch capacitor and protector any oh
24. mmeter reading indicates ground If digital meter is used the reading should be at least one megohm If grounded check all external leads for cuts breaks frayed wires etc Replace damaged leads and recheck for grounds and proper lead routings Make sure replaced leads are not pinched between canopy and end bell If ground is in stator replacement of motor is recommended 55 2 Ohmmeter Checks 4 Q ii Winding Continuity Q Lu 1 Terminal board connected for 230 V 2 Set ohmmeter to R x 1 adjust to 0 3 Slip a heavy piece of paper between motor switch points discharge the capacitor and take the following ohm readings a Resistance between L1 and A must be the same as between A and yellow b Yellow to red winding side of switch must be the same as L1 to same red terminal OVERLOAD PROTECTOR GOVERNOR 115 230 VOLT VOLTAGE SELECTOR SWITCH PRESSURE SWITCH WIRING TERMINAL BOARD START SWITCH L1 Blue wire L2 White wire A Purple wire 56 Ohmmeter tests on the new style terminal board with the quick change voltage terminal plug see picture on pg 60 Black plastic part with 2 wires in it is simplified if your ohmmeter is equipped with the sharp pointed probes rather than alligator clips With the voltage change plug on the 230 volt terminal the Black wire in the plug is positioned on Terminal A Simply touch one ohmmeter probe on the Black
25. o w und m 4 o io Z 2 m uu z Pr ce m t m Troubleshooting If motor overload trips or fuses blow PROBLEM 1 Improper size fuses ANSWER Replace with correct 2 Wrong control box Replace with correct 3 Incorrect voltage See D 4 Defective control box See A B C 5 Loose connections See E in control box cable or motor Condition causes improper resistance readings Cable insulation damaged or splice may be open or shorted Defective pressure switch or plugged tubing Control box in hot environment See G Condition causes improper resistance readings Inspect points and or replace switch if necessary Temperature not to exceed 122 F 50 C Pump bound by abrasives Pull pump and clean See H Condition causes high amperage Troubleshooting Pump Runs But 000000000 E Little or no water delivered PROBLEM ANSWER m 1 Line check valve stuck Replace if defective o or installed backwards 2 Connections loose See wiring diagram or misconnected in in control box Z control box 2 3 Incorrect voltage See D 4 Pump not submerged Check water level in well 5 Leak in piping system Replace if necessary 6 Worn pump Repair or replace water end 7 Worn motor Replace motor 8 Suction screen or Pull pump and impeller clogged clean 9 Broken pump shaft Rep
26. otor leads and the other to the metal drop pipe If the drop pipe is plastic connect the ohmmeter lead to the metal well casing or ground wire Rx 100 OHMS px 1000 Rx 10 Rx 100K Ja Table 1 Normal Ohm and Megohm Values Insulation Resistance Between All Leads and Ground Insulation resistance does not vary with rating All motors of all HP voltage and phase rating have similar values of insulation resistance Condition of Motor and Leads Ohm Megohm Value Value A new motor without drop cable 20 000 000 20 0 or more A used motor which can be 10 000 000 10 0 reinstalled in the well or more Motor in Well Ohm readings are 2 000 000 2 0 for drop cable plus motor or more A new motor in the well A motor in the well in reasonably 500 000 good condition 2 000 000 0 5 2 0 A motor which may have been damaged 20 000 0 02 0 5 by lightning or with damaged leads Do 500 000 not pull the pump for this reason A motor which definitely has been 10 000 0 01 damaged or with damaged cable The 20 000 0 02 pump should be pulled and repairs made to the cable or the motor replaced The motor will not fail for this reason alone but it will probably not operate for long A motor which has failed or with Less than 0 0 01 completely destroyed cable insulation The 10 000 pump must be pulled and the cable repaired or the motor replaced What It Means 1 If the ohm value is no
27. pump in well See Table 2 page 22 what it Means If all ohm values are normal the motor windings are neither shorted nor open and the cable colors are correct 2 If any one ohm value is less than normal the motor is shorted 3 If any one ohm value is greater than normal the winding or the cable is open or there is a poor cable joint or connection 4 If some ohm values are greater than normal and some less the leads are mixed 23 v uu Pr c m t n d Cable Checkout Checking Cable and Splice 24 Submerge cable and splice in steel barrel of water with both ends out of water Set ohmmeter selector on RX100K and adjust needle to zero 0 by clipping ohmmeter leads together After adjusting ohmmeter clip one ohmmeter lead to barrel and the other to each cable lead individually as shown If the needle deflects to zero 0 on any of the cable leads pull the splice up out of the water If the needle falls back to oc no reading the leak is in the splice If leak is not in the splice pull the cable out of the water slowly until needle falls back to c no reading When the needle falls back the leak is at that point If the cable or splice is bad it should be repaired or replaced Checking Cable and Splice Test Ohmmeter Set at R x 100K Rx 1000 m Rx 10K x 100K Attach this lead to Metal Tank 1n0 23HD J14V 5
28. rmal the motor windings are not grounded and the cable insulation is not damaged 2 If the ohm value is below normal either the windings are grounded or the cable insulation is damaged Check the cable at the well seal as the insulation is sometimes damaged by being pinched Winding Resistance Measuring When measured as shown on page 22 motor resistance only should fall within the values in Table 3 page 23 When measured through the drop cable the size and length of the cable must be known and the correct cable resistance from Table 2 subtracted from the ohmmeter reading to get the winding resistance for comparison with Table 3 21 m m m e j m A B und un I je ad e I m A oO F Motor Winding Resistance Checkout Measuring Winding Resistance 1 Set the scale lever to R x 1 for values under 10 ohms For values over 10 ohms set the scale lever to R x 10 Zero balance the 4 Lu mi E 4 ce Lu 2 a 2 i 7 ohmmeter as described earlier on page 11 2 Connect the ohmmeter leads as shown below Table 2 Cable Resistance Copper Size Cable DC Resistance of Cable per 100 Foot Length Ohms per Pair of Leads 14 544 12 338 10 214 8 135 6 082 4 052 2 032 If aluminum cable is used the readings will be higher Divide the ohm readings on this chart by 0 61 to determine the actual resistance of aluminum cable 22
29. volt range If the reading is less than 150 volts rotate the scale to the 150 volt range to get a more exact reading Ohmmeter Instructions The Ohmmeter is used for measuring the electrical resistance of a wire circuit The unit of measurement is called an Ohm 1 The knob at the bottom of the Ohmmeter is adjustable through six ranges Rx1 Rx10 Rx100 Rx1 000 Rx10 000 Rx100 000 1000 10K 100K EEEE Hon Hn n og x If your ohmmeter is digital readout type refer to the instructions that came with it 2 The round center knob is for the purpose of adjusting the instrument to zero 0 after clipping the two ohmmeter leads together This must be done every time the range selection is changed v uu zi Pr m t m AN Capacitor Checkout Capacitor with Ohmmeter 1 Disconnect leads to capacitor post 2 Setting R x 1 000 3 Connect ohmmeter leads to capacitor posts 4 Reading Pointer should swing toward zero then back toward infinity Capacitor Checkout Juick Disconnect Control Box RULE OF THUMB To recheck reverse the OHMMETER LEADS B Relay Checkout voltage Relay Control Boxes CentriPro or F E Checking Relay with Ohmmeter A Voltage Relay 5 1 HP CP QD 1 15 HP CSCR Control Boxes Step 1 Coil Test 1 Meter setting R x 1 000 2 Connections 2 amp 5 3 Correct meter readings For 115 Vo
30. wire in the voltage change plug to get the A terminal reading Another method is to remove the terminal board screws and place the alligator clip on the wire on the bottom side of Terminal A Old Style Brown Terminal Board Wiring A O SMITH MOTOR WIRING 115 VOLT 230 VOLT Black from motor Black from motor on L1 onA Black White Black White Black tracer from Black tracer from overload on A overload on B 57 m oO Ss m m A A I m e 4 l gt 9 a I io o A 4 2 Ohmmeter Checks 4 Q Contact Points switch 9 L 1 Set ohmmeter to R x 1 adjust to 0 2 Remove leads from switch 3 Attach ohmmeter leads to each side of switch reading should be 0 4 Flip governor weight to run position Reading should be infinity 2 Ohmmeter Checks O Smith Motor Overload Protector 1 Set ohmmeter to R x 1 adjust to 0 2 Disconnect the overload leads 3 Check resistance between terminals 1 and 2 then 2 and 3 If either reading is higher than 1 replace the overload 1 Blue wire 2 Black white wire 3 Yellow wire 58 Motor Terminal Board and Voltage Change Plug WHITE STATOR LEADS JET PUMPS RED TRACER Black Tracer is a black and white wire 60 Motor Terminal Board and Voltage Change Wiring OLD STYLE UP TO APRIL 1999 PURPLE
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