OWNERS MANUAL - Water Pumps Vancouver
Contents
1. 6 cable can be used for the 310 of cable in the well Any combination of sizes can be used provided that the total percentage of the length of the two sizes of cable does not exceed 100 of the total allowed lengths Metric Measurement Calculating cable size when two different sizes can be used Sometimes conditions make it desirable to use more than one cable size in an installation For example Replace a pump with a 3 HP 230 volt single phase motor with the motor setting at 94 5M down the well and with 48 8M of 4mm cable buried between the service entrance and the well head In order to avoid replacing the buried cable the question is What size cable is required in the well Calculate as follows 1 According to Table IV a total of 91 4M of 4mm cable is allowed to power the 3 HP motor The per cent of this total that has been used by the 48 8M of cable in the buried run is 48 8M 91 4M 534 53 4 2 With 53 4 of the allowable cable already used 46 6 of the total length is left for use in the well To avoid running a cable that is too long and lowering the voltage to the motor we have to find a cable size large enough so that 94 5M is less than 46 6 of the total length allowed for that size 3 Trying 6mm cable Table IV shows that the total allowable length for a 3 HP motor is 143M 143M x 46 6 143M x 466 66 60M This is not long enough 4 Trying 10mm cable Table IV shows that the total allowable l2. Low or high voltage Check that line voltage is within 10 of If voltage variation is greater than 10 call nameplate rated voltage while motor is power company to adjust voltage running Cable leads not correctly Check control box wiring diagram Reconnect leads to match wiring diagram in connected to control box against incoming power hookup control box cover Check drop cable color coding Reconnect drop cable so cable color code matches motor lead color code Broken wire in control Examine all connections and wiring in Disconnect power and repair or replace faulty box control box wire Pump or motor stuck or Check for locked rotor in pump If necessary pull pump make all possible binding above ground checks first If pump is locked replace it Clean well of all sand or lime before reinstalling pump Fuses blow or overload protector trips when motor is running Low or high voltage Check that line voltage is within 10 of If voltage variation is more than 10 call rated nameplate voltage while motor is power company to adjust voltage running High ambient Check temperature of control box Do not mount control box in direct sunlight atmospheric temperature Control box with wrong Compare voltage and horsepower on Replace control box if numbers do not match voltage or horsepower motor nameplate with those given on rating control box nameplate or on circuit diagram inside control box cover Wire size too small
3. provided use with an approved motor control that matches input in full load amperes ROTATION 3 PHASE ONLY To make sure motor is running in the right direction proceed carefully as follows After electrical connections have been made as outlined and with pump hanging in well supported from clamp on the discharge pipe momentarily close the switch con necting the motor to the power supply line Note direction of jerk as motor starts If connections are properly made pump will jerk clockwise when looking into the pump discharge when started If jerk is counter clockwise this means the motor is running in the wrong direction Interchange any two cable leads where they connect to the lead terminals in the magnetic starter With connections properly made and pump lowered into water throw the switch again and the pump should deliver water according to the performance charts Overload Protection of Three Phase Submersible Motors Submersible motors differ from standard motors and require the following for overload protection 1 Ambient compensation provides motor winding protection in low air temperatures avoids nuisance tripping in high air temperatures 2 Quick trip overloads To protect motor windings when motor stalls overloads must trip within approximately 10 seconds The following table lists correct ambient compensated quick trip overloads for several manufacturers Approval of other types may be requested f
4. OVER SPLICE discharge pipe at 10 30 5M intervals with Scotch 33 electrical tape Take care not to damage pump cable NOTICE To avoid dropping the pump down the well or damaging cable or cable splices NEVER allow pump cable to support weight of pump 6 If a standard galvanized pressure tank is being used install two bleeder orifices about 2 6M apart as shown in Figure 16 Page 13 These orifices will automatically charge tank with air See Table lll to determine orifice location NOTICE If Pre charged bladder tank is used DO NOT install bleeder orifices If pump and pre charged tank are replacing a standard tank system remove bleeder orifices before installing pump in well INITIAL START UP NOTICE NEVER operate pump with discharge valve completely closed Pump can destroy itself if run with discharge shut off deadheaded and warranty will be void NOTICE To avoid sand locking pump follow procedure below when starting pump for the first time NEVER start a pump with discharge completely open unless you have done this procedure first 1 Connect a pipe elbow a short length of pipe and a gate valve to pump discharge at well head see Figure 14 2 Mount motor control box 3 wire pump or magnetic starter 3 phase pump in a permanently weather proofed place Make sure that controls will not be subjected to extreme heat or excess moisture 3 Make sure controls are in OFF position 4 Connect motor leads a
5. cap and a neoprene gasket sleeve on each wire end to be spliced see Figure 11 Slide insulator body onto one wire end Fig 11 6 Insert wire end into butt connector and crimp see Figure 12 Be sure to match cable and motor wire colors 7 Center insulator body over splice and slide neoprene sleeves into body as far as they will go Screw caps onto insulator body Figure 13 and tighten by hand for a strong waterproof splice 13mm from cable ends Oo To test submersible momentarily connect it to proper power supply Power supply frequency and voltage must match motor nameplate frequency and voltage to within 10 3 Phase pumps see Rotation Page 3 Fasten cable leads securely to pump discharge section leave 4 5 100 127mm of slack in leads at this point Securely fasten leads to plastic pipe within 6 150mm of the pump discharge section Use torque arresters to protect pump and pipe from twisting damage as pump starts and stops Connect copper ground wire to motor bracket Ground wire must be at least as large as wires supplying current to motor Consult local codes for grounding information Use only submersible cable supplied by pump manu facturer When lowering pump into well secure cable to INSULATOR BODY END CAP a 1 n q 2 2 i A 12 7mm GASKET BUTT CONNECTOR OR CRIMP OR SOLDER CAP SCREWED ON GASKET SLEEVE IN PLACE INSULATOR BODY CENTERED
6. 0mm 41 3 of Allowable Controls Service Entrance Main Fuse Box From Meter 3 HP 2 2 kw 230V 1Ph Motor 700 0294 FIGURE 3 English Measurement Calculating cable size when two different sizes can be used Sometimes conditions make it desirable to use more than one cable size in an installation For example Replace a pump with a 3 HP 230 volt single phase motor with the motor setting at 310 down the well and with 160 of 10 cable buried between the service entrance and the well head In order to avoid replacing the buried cable the question is What size cable is required in the well Calculate as follows 1 According to Table IV a total of 300 of 10 cable is allowed to power the 3 HP motor The per cent of this total that has been used by the 160 of cable in the buried run is 160 300 533 53 3 2 With 53 3 of the allowable cable already used 46 7 of the total length is left for use in the well To avoid running a cable that is too long and lowering the voltage to the motor we have to find a cable size large enough so that 310 is less than 46 7 of the total length allowed for that size 3 Trying 8 cable Table IV shows that the total allowable length for a 3 HP motor is 470 470 x 46 7 470 x 467 219 5 This is not long enough 4 Trying 6 cable Table IV shows that the total allowable length is 750 750 x 46 7 750 x 467 350 25 This is longer than needed Therefore
7. 60 3 6 3 2000 3 2 4 1 460 60 3 el 2000 11 3 15 0 575 60 3 270 2000 17 6 23 4 230 60 3 8 1 2580 2 4 3 0 460 60 3 4 1 2580 9 7 12 0 575 60 3 3 2 2690 15 1 18 7 230 60 3 10 9 3420 1 8 2 2 460 60 3 5 5 3420 7 0 8 7 575 60 3 4 4 3420 10 9 13 6 230 60 3 178 5810 460 60 3 8 9 5810 575 60 3 7 1 5810 230 60 3 460 60 3 575 60 3 15 12 NOTE 1 Maximum cable lengths shown maintain motor voltage at 95 of service entrance voltage running at maximum nameplate amperes If service entrance voltage will be at least motor nameplate voltage under normal load conditions 50 additional length is permissible for all sizes 2 Sizes given are for copper wire For aluminum wire go two sizes larger For example if table lists 12 3mm copper wire use 10 5mm aluminum wire 3 For reliable 3 Phase starter operation length of wire between starter and service entrance should be not more than 25 of total wire length Table IV Cable Length in Feet and Meters Service to Motor Copper Conductors Meets NEC for jacketed 75 C cable except lengths marked Lengths marked meet NEC for individual conductor 75 C cable 1 Phase 2 or 3 Wire 60 Hz 230 Volts a e 780 a ak oe e 37 90 a gt o jo a ji in Meters a saa ee T E NET sengt 213 267 Wire Size AWG ea wa es e 3 gt 670 1060 1670 2610 405 Cable 390 620 990 1540 2400 29 Length 230 370 590 920 1a30 1790 2190 in Fe
8. Adequate Rated Pressure Switch ToLine Ground Disconnect Switch Pressure Switch 355 0893 NOTICE See Control box checking procedures Page 15 See Pressure Switch Wiring Information Page 7 Single Phase 1 2 HP thru 5 HP Standard Control Box with Pressure Switch One Pump for Two Houses with Adequate Rated Pressure Switch To Line To Line Ground Fused Disconnect Switch Pressure Switch 359 0893 Single Phase 1 2 thru 5 HP Standard Control Box with Liquid Level Control To Line AI Fused Disconnect Switch Liquid Level Control High Electrode Well Ground Casing 353 0893 Installation Wiring Diagrams Single Phase Follow color coding when connecting control box Yellow to Y Red to R Black to B For 1 1 2 HP 1 1 KW and larger install magnetic contactor when system includes a pressure switch Single Phase 1 2 thru 5 HP Standard Control Box with Pressure Switch amp Liquid Level Control Pressure Switch Box f LIL2R Y BK Y Fused nA A E Disconnect Switch BW Liquid Level Control High Electrode Low vell around 472 0893 Single Phase 2 3 amp 5 HP Deluxe Control Boxes Open System Ground 220V Line PEAN Control Box Fused Disconnect Switch Yellow o Well Ground 473 0893 Single Phase 2 3 5 HP Deluxe Control Boxes with Pressure Switch Ground Control O Pressure Yell
9. CE If surge arresters wired into the control box are against local electrical code contact power company or hydro authority for correct wiring information Liquid Level Pump Down Controls Use pump down controls on wells with low flow to prevent pumping well dry See Wiring diagrams Pages 8 through 10 for proper installation NOTICE Ground controls according to local code re quirements Surge Arrester Control Box L1 L2 RY B Q O O FIGURE 1 Typical 3 Wire Single Phase 230 Volt Surge Arrester Surge Arrester FIGURE 2 Three Phase Surge Arrester 650 Volt Maximum TABLE II Recommended Fusing Data 60 Hz Single Phase Franklin Submersible Pump Motors 3 Wire Application Capacitor Run Winding Max Locked Fuze Size Volts Hz Resistance Load Rotor Standard Phase R to Y B to Y Amps Amps Dual Element 1 1 2 230 60 1 62 120 1533 30 15 230 60 1 SAFA 1 6 2 3 30 15 230 60 1 3 0 4 9 0 9 1 5 45 20 230 60 1 2 1 28 0 68 1 0 118 0 70 30 2 Wire Application Induction Run 1 1 2 230 60 1 1 5 1 9 35 15 Red to Yellow start winding resistance Black to Yellow main winding resistance NOTE 2 Wire motor leads are not color coded Overload is located in motor and cannot be tested from above ground TABLE III Recommended Fusing Data 60 Hz 3 Phase Franklin Submersible Pump Motors Fuse Size Size Max Output Line to Volts E F Load Line Hz Ph Amps Resistance 230
10. Check wire size against chart Page 5 Install correct wire size Cable splices or motor Consult licensed electrician or qualified Do not attempt to disassemble pump or motor leads grounded shorted serviceman or open Pump starts too frequently Leaks in system Check all tank connections with System must be air and water tight soapsuds for air leaks Check plumbing for leaks Pressure switch Check for defective switch or switch out Re adjust or replace pressure switch of adjustment Tank waterlogged Pre charged tanks check tank pre Pre charge tanks adjust air pressure to 2 PSI charge air pressure check for leak in 13 8 kPa less than pump cut in pressure when bladder there is no water pressure on system Replace bladder if necessary Standard tanks check for air leaks Standard tanks repair or replace tanks Check Air Volume Control AVC replace snifter valves if necessary Check snifter valve operation Leak in drop pipe Raise drop pipe one length at a time Replace pipe above that point until water stands in pipe Pressure switch too far Measure distance from pressure switch Move switch to within one foot of tank from tank to tank 14 Little or no water delivered Bleeder orifice check valve stuck or installed back wards standard tank only Low water level Low voltage Plugged intake screen Check valve at pump discharge stuck Worn impellers and diffusers Air or milky wa
11. OWNERS MANUAL INSTALLATION AND OPERATING INSTRUCTIONS REPAIR PARTS LIST 40 and 70 GPM Models 4 SUBMERSIBLE PUMPS 1 1 2 through 7 1 2 H P NOTICE Mount model and serial nameplate labels at well head or on control box Provide complete nameplate information with any service or part inquiries Record the following nameplate information here for future reference Pump Model No Pump Serial No Motor Model No Motor Serial No H P Volts Hz Ph Rated Amp Draw Printed in U S A 1995 Foreign Sales Corporation U49 Rev 2 20 95 Carefully read and follow all safety instructions in this manual or on pump This is the safety alert When you see this symbol on your pump or in this manual look for one of the following signal words and be alert to the potential for personal injury ADS warns about hazards that will cause serious personal injury death or major property damage if ignored AWARNING warns about hazards that can cause serious personal injury death or major property damage if ignored A CAUTION warns about hazards that will or can cause minor personal injury or property damage if ignored The word NOTICE indicates special instructions which are important but not related to hazards To avoid serious or fatal personal injury and possible property damage carefully read and follow the safety instructions 1 AWARNING Under certain conditions submersible Hazardous pumps can de
12. SI 193 kPa 40 276 kPa 60 414 kPa 38 PSI 262 kPa Pump FIGURE 16 Standard Pressure Tank Installation Control box Electrical disconnect 3 wire models AS 7 al Pressure gauge Ventilated i well cap X Air volume control Submersible Pressure switch cable Pitless adaptor dp o E ye caj SA NANI gt RES l a 2 I ae LS Gate valve Check valve Y See table Relief valve Bleeder orifice 691 0993 amp tee CHECK VALVE DISTANCE TO TOP BLEEDER ORIFICE TANK SIZE DISTANCE Pipe coupling 2 6M Tape cable to pipe 13 TROUBLESHOOTING GUIDE PROBLEM CHECK CORRECTIVE ACTION Motor will not start but fuses do not blow No voltage No voltage at fuse box Replace blown fuses No voltage at pressure switch Replace faulty pressure switch No voltage at control box Rewire supply to control box Cable or splices bad Consult licensed electrician or serviceman Control box incorrectly wired Reconnect control box correctly see wiring diagrams Pages 7 through 9 Fuses blow or overload protector trips when motor starts Wrong size fuse or wrong Check fuse size against chart Page 4 Install correct fuse or time delay fuse size time delay fuse Wire size too small Check wire size against chart Page 5 Install correct size wire Starting capacitor Check control box to see if starting Replace starting capacitor defective or blown capacitor has blown out
13. and control box A Taped splice Wire sizes No 8 7mm and larger 1 Cut off motor leads Stagger lead and wire length so that 2nd lead is 2 50mm longer than 1st lead and 3rd lead is 2 50mm longer than second Cut off cable ends Be sure to match colors and lengths of wires in drop cable to colors and lengths of motor leads Trim insulation back 1 2 13mm from cable ends and motor lead ends Insert motor lead ends and cable ends into butt connectors see Figure 5 Be sure to match wire colors between drop cable and motor leads Using crimping pliers Figure 8 indent butt connector lugs see Figure 6 to attach wires Cut Scotchfil electrical insulation putty into 3 equal parts and form tightly around butt con nectors Be sure scotchfil overlaps insulated part of wire Using 33 Scotch tape wrap each joint tightly cover wire for about 1 1 2 38mm on each side of joint Make four passes with the tape In other words when finished you should have four layers of tape tightly wrapped around the wire Press edges of tape firmly down against the wire see Figure 9 NOTICE Since the tightly wound tape is the only means of keeping water out of the splice the efficiency of the splice will depend on the care used in wrapping the tape NOTICE For wire sizes larger than 8 7mm use a soldered joint rather than Scotchfil putty see Figure 7 B Heat shrink splice For wir
14. ay to specified amps divided by transformer ratio Approved relays include AEG series b175 b27S 11 17A and 15 23A b27 2 11 17A and 15 23A ASEA type RVH40 Allen Bradley bulletin 193 Fanal types K7 or K7D through K400 General Electric CR4G1T CR4G1W CR4G2W CR4G3W Klockner Moeller types ZOO Z1 Z4 PKZM3 Lovato RC 22 to RC 80 RTE Delta types DQ LR1 D LR1 F Sprecher and Schuh types CT CT1 CTA1 Siemens types 3UA50 52 54 58 59 62 Square D Class 9065 types TUP MR TD TE TF TR TJE Telemecanique type LR1 D LR1 F Westinghouse types FT13 FT23 FT33 FT43 K7D K27D K67D Other relay types from these and other manufacturers should not be used without approval of Franklin Electric Surge Arresters in Control Box Grounding When the box has a surge arrester it MUST be grounded metal to metal all the way to the water strata for the arrester to be effective Grounding the arrester to a driven ground rod provides little or no protection for the motor NOTICE Surge arresters DO NOT protect against direct lightning strikes Install grounded surge arresters to protect pump from high voltage surges Install arrester on the incoming power line to control box or pressure switch as close to pump motor as possible See Figures 1 and 2 for installation wiring diagrams for arresters NOTICE Ground the arrester with a No 10 or larger bare wire Ground according to local code requirements NOTI
15. distance of bleeder orifices from pressure tank Pre charged Pressure Tank Hookup See Figure 15 Page 13 for piping connections to pre charged pressure tank NOTICE Check air pre charge in tank before starting pump Adjust pre charge to 2 PSI 13 8kPa below pump cut in setting For example a pre charge tank used with a 30 50 switch should be pre charged with air to 28 PSI 193kPa Adjust pre charge by either adding or bleeding air through tire valve located on top of tank Check pre charge annually and adjust as needed Control center or SS electrical disconnect box Temporary wiring to control center or electrical disconnect box Temporary piping Gate valve Pump installation Pump in well for developing a well FIGURE 14 689 0993 FIGURE 15 Typical Submersible Installation with Pre charged Tank Electrical disconnect Control box 3 wire L E S Ventilated well cap BEANA ZII AS LOZA EES gt VERS Pre charged tank Submersible a AS Pressure switch cable Pressure gauge Union Relief valve EE ry a Z Pitless Bel pa A OA A adaptor BS F um MS Vel ll ZU gt To house service Bel Pep 2 M5 a YA efai AL O E A a Aa Check gt ti pR PERRERA a valve A ATA REA TIES NAY all OS Gate valve i 690 0993 Tape cable io iss Cut In PSI Cut Off PSI Pre charge Pressure A 20 138 kPa 40 276 kPa 18 PSI 124 kPa 30 207 kPa 50 345 kPa 28 P
16. e sizes 14 12 and 10 AWG or 2 3 and 5mm 1 Remove 3 8 10mm insulation from ends of motor leads and drop cable wires 2 Put plastic heat shrink tubing over motor leads 3 Match wire colors and lengths in drop cable to wire colors and lengths of motor leads 4 Insert cable and motor wire ends into butt connectors and crimp See Figures 5 and 6 BE SURE to match wire colors between drop cable and motor leads Pull leads to check connections 5 Center tubing over butt connector and apply heat evenly with a torch a match or lighter will not supply enough heat 1 2 1d 7mm lt gt a_i y BUTT CONNECTOR Cos FIGURE 5 e INDENT HERE FIGURE 6 ALTERNATE METHOD Y TWIST AND SOLDER FIGURE 7 FIGURE 8 SS GLN A COMPLETED SPLICE FIGURE 9 CONNECTOR HEAT SHRINK TUBING FIGURE 10 476 0893 11 FIGURE 11 FIGURE 13 NOTICE Keep torch moving Too much con centrated heat may damage tubing see Figure 10 C Butt Connectors with plastic insulators for 14 12 and 10 Gauge AWG Wire or 2 3 and 5mm wire 1 Cut off motor leads Stagger lead and wire length so that 2nd lead is 4 100mm longer than 1st lead and 3rd lead is 4 100mm longer than second 2 Cut off cable ends Be sure to match colors and lengths of wires in drop cable to colors and lengths of motor leads 3 Trim insulation back 1 2 and motor lead ends 4 Unscrew plastic caps from insulators Place a
17. embly other than the pump bond together all metal parts accessible at the well head including metal discharge pipe metal well casing and the like Use a metal bonding conductor at least as large as the power cable conductors running down the well to the pump s motor Clamp or weld or both if necessary this bonding conductor to the grounding means provided with the pump which will be the equipment grounding terminal the grounding conductor on the pump housing or an equipment grounding lead The equipment grounding lead when provided will be the conductor having green insulation it may also have one or more yellow stripes Ground the pump motor and any metallic conduit that carries power cable conductors Ground these back to the service by connecting a copper conductor from the pump motor and conduit to the grounding screw provided within the supply connection box wiring compartment This conductor must be at least as large as the circuit conductors supplying the pump Save these instructions Installation Wiring Diagrams Single Phase Follow color coding when connecting control box Yellow to Y Red to R Black to B For 1 1 2 HP 1 1 KW and larger install magnetic contactor when system includes a pressure switch Open System Single Phase 1 2 HP thru 5 HP Standard Control Box Disconnect Switch ae Well Ground 357 0893 Single Phase 1 2 thru 5 HP Standard Control Box with
18. ength is 225M 225M x 46 6 225M x 466 105M This is longer than needed Therefore 10mm cable can be used for the 94 5M of cable in the well Any combination of sizes can be used provided that the total percentage of the length of the two sizes of cable does not exceed 100 of the total allowed lengths Installation Wiring Diagrams Single Phase 3 Wire Hazardous voltage Can shock burn or kill Ground control box all metal plumbing and motor frame with copper wire in compliance with local codes Use a ground wire at least as large as the wires supplying power to motor Permanently close all unused openings in this and other equipment Disconnect power to control box before working on or around control box pipes cable pump or motor To be sure that starting relay will function and that overload will not nuisance trip install control box vertically with top side up Wire control box as shown on pages 8 through 10 Pump will not operate without control box and deluxe boxes require a switch or a jumper lead between SW and L2 terminals Operation without control box will burn out motor Installation must include circuit and component protection which meet local code requirements If main overload trips look for 1 Shorted Capacitor 2 Voltage Problems 3 Overloaded or locked pump If start overload or both overloads trip s replace start relay Reset and analyze for tripping cause To a
19. et a CA E EE A A E ea AA Ha sass ef 153 248 384 603 039 1107 1931 1758 2151 Cable Ce pr 186 297 462 720 008 1008 1504 160 Length a am 657 in Meters 00 7816 195 306 381 468 576 707 3 Phase 3 Wire Cable 60 Hz 460 Volt Wire Size AWG CA A is vo 2710 2270 65860 2 1300 2070 3270 5150 8050 Cable 31000 1600 2520 3970 6200 Length 3 390 oso 1500 2360 3700 570 in Feet z5 a0 650 1070 1690 2640 4100 Wire Size Millimeters Squared cs 2 4 6 Jope s so es ar 197 gt o fso om 1545 amis Cable s so ze 1191 1860 Length 7 2s o 7 mo 7 in Meters 3 Phase 3 Wire Cable 60 Hz 575 Volt Wire Size AWG WieSize AWG O OO SSS O AFAFA wo foe fe fo 15 220 4180 6730 0 93050 000 3 1580 2530 3980 6270 Wire Size Millimeters Squared as 25 4 6 786 154 2019 gt 609 975 1533 24018 aa 7 94 188 oz 444 699 1104 1735 How to size Wire Cable correctly when using more than one gauge of wire ee 160 Ft AWG 10 gt 53 3 of Allowable Cable 310 Ft AWG 6 41 3 of Allowable Cable p Controls 3 HP 2 2 kw 230V 1Ph Motor Service Entrance Main Fuse Box From Meter ai ses fe 48 8m 4mm gt 53 3 of Allowable Cable 94 5m 1
20. ground wire to a copper conductor that matches motor wire size specified in Table IV Page 5 See Pages 10 to 12 for cable splicing instructions Permanently ground pump motor and control box before connecting power cable to power supply Connect ground wire to approved ground first and then connect to equipment being installed Do not ground to a gas supply line AA WARNING Fire and electrical shock hazard If using a drop cable larger than No 10 5mm for example No 8 7mm wire between pump and control box run cable to a separate junction box Connect junction box to control box with a No 10 5mm or smaller wire depending on amp rating of pump see Table Il and III For more information contact your local code officials Wiring Connections All wiring must meet local code requirements Use only copper wire when making connections to pump and control box To avoid over heating wire and excessive voltage drop at motor be sure that wire size is at least as large as size listed in Table IV for your horsepower pump and length of wire run NOTICE See Pages 8 through 10 for typical wiring hookups and control box identification A WARNING When built in overheating protection is not provided use with an approved overload equipped motor control that matches motor input in full load amps Select or adjust overload element s in accordance with control instructions When built in overheating protection is
21. ity except back to 15 000 ohms on any start capacitor with a resistor on terminals AMS Hazardous voltage Can shock burn or cause death Disconnect power to control box before doing these check procedures A Overloads push reset buttons to make sure contacts C Relay coil disconnect lead from terminal 5 are closed 1 Ohmmeter setting R x 1 2 Terminal connections ohmmeter leads to overload terminals 3 Ohmmeter reading should not be over 0 5 ohms B Capacitor disconnect one lead from each capacitor prior to checking 1 Ohmmeter setting R x 1000 2 Terminal connections individual capacitor terminals 3 1 1 2 through 3 HP ohmmeter reading pointer should swing toward zero then drift back toward infinity 4 5 HP only ohmmeter reading pointer should ES 1 Ohmmeter setting R x 1000 2 Terminal connections 5 and 2 on relay 3 Ohmmeter reading 4500 7000 ohms Relay contact disconnect lead from terminal 1 1 Ohmmeter setting R x 1 2 Terminal connections 1 and 2 on relay 3 Ohmmeter reading should be zero Deluxe Boxes ONLY Capacitor disconnect 1 coil lead 1 Ohmmeter setting R x 100 2 Check coil resistance 180 1400 ohms 3 Remove contact cover and inspect contacts 16
22. nd power supply to motor control box or magnetic starter see Wiring Diagrams Pages 8 through 10 DO NOT START PUMP YET 5 Set gate valve on discharge 1 3 open start pump see Figure 14 6 Keep gate valve at this setting while water pumps out on ground Let it run until water is clear of sand or silt To check solids in water fill a glass from pump and let solids settle out 7 When water is completely clear at 1 3 setting open gate valve to approximately two thirds open and repeat process 8 When water is completely clear at 2 3 setting open gate valve completely and run pump until water is completely clear 9 Remove gate valve for permanent installation near tank see Figures 15 and 16 Page 13 Install sanitary well seal or pitless adapter unit well unit electrical conduit and surface piping according to local code requirements 10 12 CONNECTING TO TANK WATER SYSTEM A WARNING Hazardous pressure Submersible pumps can develop very high pressure in some situations To prevent tank blowup install a pressure relief valve able to pass full pump flow at 100 PSI 690kPa Install this relief valve between pump and tank NOTICE Allowing pump or piping system to freeze may severely damage pump and will void warranty Protect pump and entire piping system including pressure tank from freezing Standard Tank Hookup See Figure 16 Page 13 for piping connections to standard pressure tank and for correct
23. ow Pump Sc Well Ground 356 0893 Single Phase 2 3 amp 5 HP Deluxe Control Boxes with Liquid Level Control Fused Disconnect Switch BW Liquid Level Control High Electrode Low Well Ground Electrode 354 0893 NOTICE See Control box checking procedures Page 15 See Pressure Switch Wiring Information Page 7 Installation Wiring Diagrams Single and Three Phase Follow color coding when connecting control box Yellow to Y Red to R Black to B For 1 1 2 HP 1 1 KW and larger install magnetic contactor when system includes a pressure switch Single Phase 2 3 amp 5 HP Deluxe Control Boxes with Pressure Switch and Liquid Level Control Ground Pressure Switch Fused Disconnect Switch BW Liquid Level Control High Electrode 358 0893 Three Phase 1 HP amp Larger with Pressure Switch amp Liquid Level Control Pressure Switch Disconnect Switch Magnetic Starter Liquid Level Control High Electrode Low Electrode 361 0893 NOTICE See Control box checking procedures Page 15 See Pressure Switch Wiring Information Page 7 Three Phase 1 HP amp Larger with Pressure Switch Pressure Switch Fused Disconnect Switch Magnetic 362 0893 Cable Splicing 1 Splice cable to motor leads Use one of the three methods outlined below Use only copper wire for connections to pump motor
24. rom motor manufacturer NOTICE Warranty on three phase submersible motors is void unless proper quick trip protection in all three motor lines is used TABLE I Overloads for 3 Phase 60 Hertz 4 Franklin Electric Motors Heaters for Adjustable NEMA Overload ays Relays Starter Furnas Allen Note 3 Size Note 1 Bradley Set Max J22 J15 J13 J25 J18 J15 Note 2 J32 J25 J23 J36 J29 J27 J28 J20 J18 FOOTNOTES NOTE 1 Heaters listed apply to Innova 45 designs and Definite Purpose Class 16 starters through their available range and to standard starters in larger sizes Set overload relay adjustments no higher than 100 unless necessary to stop nuisance tripping with measured amps in all lines below nameplate maximum NOTE 2 General Electric heaters are type CR123 usable only on type CR124 overload relays Adjustment should be set no higher than 100 unless necessary to stop nuisance tripping with measured amps in all lines below nameplate maximum NOTE 3 Adjustable overload relay amp settings apply to approved types listed below Request approval of other types from Franklin Electric Set relay adjustment at specified SET amps do not increase setting unless motor trips with measured amps in all lines within nameplate maximum amps Do not increase setting past MAX value shown Some approved types may not be available for all listed motor ratings When using relays with current transformers set rel
25. speeemmn cea 12 Connecting to Tank Water SysteM ooooonccnnnccnonncnnns 12 13 Troubleshooting GIO sia 14 15 NY PAIN RENEI AE E E easiso 16 PRE INSTALLATION Inspect pump and motor for delivery damage Report any damage immediately to the shipping carrier or to your dealer The well driller should thoroughly develop the well that is pump out all fine sand and foreign matter before pump is installed Pump performance is based on pumping clear cold solid water Warranty is void in the following conditions e If pump has pumped excessive sand excessive sand can cause premature wear to pump e If water is corrosive e If entrained gas or air are present in the water being pumped these can reduce flow and cause cavitation which can damage pump e If pump has been operated with discharge valve closed severe internal damage will result Install pump at least 15 to 20 4 5 to 6M below the lowest water level reached with pump running lowest draw down water level and at least 5 1 5M above the bottom of the well Wiring Grounding 4AWARNING Can shock burn or cause death Perma nently ground pump motor and control box before connecting power supply to motor Hazardous voltage Ground pump and motor in accordance with all codes and ordinances that apply Use a copper ground wire at least as large as wires carrying current to motor Motor is supplied with a copper ground wire Splice this
26. ter discharge from faucets Gas in well water Air volume control not working standard tanks only TROUBLESHOOTING GUIDE PROBLEM CHECK CORRECTIVE ACTION Examine valve Determine lowest water level in well while pump is running and compare to pump depth setting Check voltage at control box with pump running Check incoming wire size and drop cable size against chart Page 5 Pull pump and check condition of screen Pull pump and examine check valve Make sure system is clear of obstructions and pump is in solid water and operation normally Check for presence of gas in well water Make sure ports and ball check valves are clear If stuck free valve if installed backwards reverse it Lower pump further into well but it must be at least 5 1 6M above bottom of well Throttle pump discharge until discharge equals recovery rate of well NOTICE Running pump while airlocked can cause loss of prime and seriously damage pump Install larger wire from meter to control box Install larger wire from control box to pump If necessary have power company raise supply voltage Clean or replace as necessary Free check valve Replace pump Remove bleeder orifices plug tees Be sure plugged tees do not leak If necessary separate gas from air before it enters pressure tank Replace control if necessary CONTROL BOX CHECKING PROCEDURE ALL BOXES swing toward zero then drift back toward infin
27. velop extremely high pressure e pressure Install a pressure relief valve capable of passing entire pump flow at 75 PSI 517 kPa Do not allow pump pressure tank piping or any other system component containing water to freeze Freezing may damage system leading to injury or flooding Allowing pump or system components to freeze will void warranty 2 AWARNING Can shock burn or cause death To avoid Hazardous dangerous or fatal electric shock hazard use pump only in a water well voltage Install ground and wire pump according to local code requirements Disconnect electrical power supply before in stalling or servicing pump Make sure line voltage and frequency of power supply match motor nameplate voltage and frequency 3 Install pump according to all plumbing pump and well code requirements 4 Test well water for purity before using well Call your local health department for testing procedure 5 During installation keep well covered as much as possible to prevent leaves and foreign matter from falling into well Foreign objects in well can contaminate the water and cause serious mechanical damage to the pump TABLE OF CONTENTS Satety WISH MIC HONG iran 2 Pra TIO ih esses i 2 Electrical A sesisessiersteni sirrien in 2 3 Surge Arresters Fusing Data oocccccccnoonccnnnnnnoonccnnnnnnanonoss 4 Eo E e rio 5 6 WARE ANS e E 7 10 Cable SUCIAS etica 10 12 a T a neeeeacasneosesancses wesunee
28. void motor burnout do not remove or short circuit overload protection Single Phase 2 Wire 2 Wire pumps have two power supply wires Red Black and one ground wire Green Control box is not required See Figure 4 for correct hook up information for 230 Volt 2 Wire motors only Ground To Line Fused Disconnect Switch Pressure Switch ES g Ground M Well Green Casing 336 1093 Figure 4 Single Phase 2 Wire Connections NOTICE Match motor to control box as shown below Franklin motor and control box model numbers may include additional suffix numbers to the right of the numbers shown here These additional numbers are not important for control box selection TABLE V Control Box Selection e a No No ie 330224300 o o gt w m o IEC Pressure Switch Wiring Information NOTICE Starting current inrush current from large motors may damage pressure switch Pressure switches installed with motors of 1 1 2 HP 1 1 KW or larger should be wired through a magnetic contactor to avoid burning out pressure switch Consult factory for further information NOTICE See Control box checking procedures Page 15 Important Electrical Grounding Information A WARNING Hazardous voltage Can shock burn or kill To reduced the risk of electrical shock during pump operation ground and bond the pump and motor as follows A To reduce risk of electrical shock from metal parts of the ass
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