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Franklin Submersible Motors 2007 User's Manual

1. 41 Pump to Motor Coupling 41 Shaft Height and Free End Play 41 Submersible Leads and Cables 41 Maintenance all Motors System Troubleshooting 42 43 Preliminary Tests 44 Insulation Resistance 45 Resistance of Drop Cable 45 Maintenance Single Phase Motors amp Controls Identification of Cables 46 Single Phase Control 46 Ohmmeter Tests 47 QD Control BOX PariS L L uu 48 Integral hp Control Box 49 50 Control Box Wiring 51 54 Maintenance Electronic Products Pumptec Plus Troubleshooting During Installation 55 Pumptec Plus Troubleshooting After Installation 56 QD Pumptec and Pumptec Troubleshooting 57 SubDrive MonoDrive Troubleshooting 58 SubMonitor Troubleshooting 59 Subtrol Plus Troubleshooting
2. 4 Use of Engine Driven Generators 5 Use of Check Valves 5 Well Diameters Casing Top Feeding Screens 6 Water Temperature and Flow 6 Flow Inducer Sleeve 2 6 Head Loss Past Motor 7 Hot Water Applications 7 8 Drawdown Seals 9 Grounding Control Boxes and Panels 9 Grounding Surge Arrestors 9 Control Box and Panel Environment 9 Equipment Grounding 9 Application Single Phase Motors 3 Wire Control 10 2 Wire Motor Solid State Controls 10 QD Relays Solid 10 Cable Selection 2 Wire or 3 Wire 1j Two Different Cable Sizes 12 Single Phase Motor Specifications 19 Single Phase Motor Fuse Sizing 14 Auxiliary Running Capacitors 15 Buck Boost Transformers 15 Application Three Phase Moto
3. 60 61 li Storage Franklin Electric submersible motors are a water lubricated design The fill solution consists of a mixture of deionized water and Propylene Glycol a non toxic antifreeze The solution will prevent damage from freezing in temperatures to 40 F 40 C motors should be stored in areas that do not go below this temperature The solution will partially freeze below 27 F 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 3 Motors should run a minimum of one minute to dissipate heat build up from starting current 6 and larger motors should have a minimum of 15 m
4. Delay Sec Outlet Pressure Control Yes No If Yes Mfr Model Setting psi Delay Sec Outlet Flow Control Yes No If Yes Mfr Model Setting gom Delay Sec Water Temperature Control Yes No If Yes Mfr Model Delay Sec Set At F Or C Located Form No 3655 8 00 Insulation Check Initial Megs Motor amp Lead Only Black T1 U1 Yellow T2 V1 Hed T3 W1 Installed Megs Motor Lead amp Cable Black T1 U1 Yellow T2 V1 Red T3 W1 Voltage To Motor Non Operating B Y T1 U1 T2 V1 Y R T2 V1 T3 W1 R B TS W1 T1 U1 At Rated Flow of gpm B Y T1 U1 T2 V1 Y R T2 V1 T3 W1 R B T3 W1 T1 U1 At Open Flow gpm B Y T1 U1 T2 V1 Y R T2 V1 T3 W1 R B T3 W1 T1 U1 Amps To Motor At Rated Flow of gpm Black T1 U1 Yellow T2 V1 Hed T3 W1 At Open Flow gpm Black T1 U1 Yellow T2 V1 Red T3 W1 At Shut Off Black T1 U1 Yellow T2 V1 Hed T3 W1 Do NOT run at Shut Off more than two 2 minutes Inlet Pressure psi Outlet Pressure psi Water Temperature F or C If you have any questions or problems call the Franklin Electric Toll Free Hot Line 1 800 348 2420 Comments Please sketch the system li Recommended Adjustable Overload Relays Advance Controls MDR3 Overload AEG Series B17S B27S B27 2 ABB Type RVH 40 RVH65 RVP160 T25DU 25 TA25DU AGUT MT03 R1K1 110 R1L3 TE set Class 5 Allen Bradley Bulletin 193 SMP Class 10 only Automatic Switch Types D
5. 10 li Application Single Phase Motors 2 or 3 Wire Cable 60 Hz Service Entrance to Motor Maximum Length In Feet Table 11 MOTOR RATING VOUS WP KW 400 300 250 190 150 Table 11A MOTOR RATING vors KW 6 115 12 34 55 1 Foot 3048 Meter Lengths in BOLD only meet the US National Electrical Code ampacity requirements for individual conductors 60 C or 75 C in free air or water not in magnetic enclosures conduit or direct buried Lengths NOT in bold meet the NEC ampacity requirements for either individual conductors or jacketed 60 C or 75 C cable and can be in conduit or direct buried Flat molded and web ribbon cable are considered jacketed cable If any other cable is used the and local codes should be observed Cable lengths in tables 11 amp 11A allow for a 596 voltage drop running at maximum nameplate amperes If 396 voltage drop is desired multiply table 11 and 11A lengths by 0 6 to get maximum cable length 11 3 2 1 000 0000 3770 60 C INSULATION AWG COPPER WIRE SIZE 1760 1260 4 3 2 1 000 0000 75 C INSULATION AWG COPPER WIRE SIZE The portion of the total cable length which is between the supply and single phase control box with a line contactor should not exceed 25 of total maximum allowable to ensure reliable contactor operation Single phase control boxes without line contactors may be connected at any
6. For values over 10 ohms set the scale lever to R X 10 Zero the Ohmmeter On 3 wire motors measure the resistance of yellow to black Main winding and yellow to red Start winding On 2 wire motors measure the resistance from line to line Three phase motors measure the resistance line to line for all three combinations ATTACH THIS LEAD TO WELL CASING OR DISCHARGE PIPE CONNECT THIS LEAD TO GROUND POWER 4 L1 SUPPLY POWER MUST BE SHUT OFF FIG 13 TO GROUND TO POWER SUPPLY I MEGGER OR OHMMETER SET AT R X 100K POWER MUST BE SHUT OFF WHAT IT MEANS If the ohms value is normal table 45 the motor is not grounded and the cable insulation is not damaged If the ohms 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 If allohms values are normal tables 13 22 24 amp 26 the motor windings are neither shorted nor open and the cable colors are correct If any one value is less than normal the motor is shorted 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 If some ohms values are greater than normal and some less on single phase motors the leads are mixed See page 46 to verify cable colors OHMMETE
7. Submersible Niotors ATTENTION IMPORTANT INFORMATION FOR INSTALLERS OF THIS EQUIPMENT THIS EQUIPMENT IS INTENDED FOR INSTALLATION BY TECHNICALLY QUALIFIED PERSONNEL FAILURE TO INSTALL IT IN COMPLIANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES AND WITHIN FRANKLIN ELECTRIC RECOMMENDATIONS MAY RESULT IN ELECTRICAL SHOCK OR FIRE HAZARD UNSATISFACTORY PERFORMANCE AND EQUIPMENT FAILURE FRANKLIN INSTALLATION INFORMATION IS AVAILABLE FROM PUMP MANUFACTURERS AND DISTRIBUTORS AND DIRECTLY FROM FRANKLIN ELECTRIC CALL FRANKLIN TOLL FREE 800 348 2420 FOR INFORMATION 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 TO REDUCE RISK OF ELECTRICAL SHOCK DISCONNECT POWER BEFORE WORKING ON OR AROUND THE WATER SYSTEM DO NOT USE MOTOR IN SWIMMING AREAS ATTENTION INFORMATIONS IMPORTANTES POUR L INSTALLATEUR DE CET EQUIPEMENT CET EQUIPEMENT DOIT ETRE INTALLE PAR UN TECHNICIEN QUALIFIE SI LINSTALLATION N EST PAS CONFORME AUX LOIS NATIONALES OU LOCALES AINSI QU AUX RECOMMANDATIONS DE FRANKLIN ELECTRIC UN CHOC ELECTRIQUE LE FEU UNE PERFORMANCE NON ACCEPTABLE VOIRE MEME LE NON FONCTIONNEMENT PEUVENT SURVENIR UN GUIDE D INSTALLATION DE FRANKLIN ELECTRIC EST DISPONIBLE CHEZ LES MANUFACTURIERS DE POMPES LES DISTRIBUTEURS OU DIRECTEMENT CHEZ FRAN
8. 155 031 102 155 031 102 155 031 102 155 031 601 155 031 601 155 031 601 155 031 601 155 031 601 155 031 601 155 031 601 155 031 601 155 031 601 155 031 601 155 031 601 2 required 15525 102 202 155 326 101 L 155 326 102 L 155 326 102 L 155 326 102 L 155 429 101 L 155 429 1011 155 429 1011 3 For 208 volt systems or where line voltage is between 200 V and 210 V a low voltage relay is required 3 and smaller control boxes use relay part 155 031 103 in place of 155 031 102 and use the next larger cable size than specified in the 230 V table On 5 hp and larger use relay 155 031 602 in place of 155 031 601 and next larger wire Boost transformers per page 15 are an alternative to special relays and cable 4 Control box model 282 300 8610 is designed for use with motors having internal overload protectors If used with a 1 5 hp motor manufactured prior to date code 06H18 Overload Capacitor Kit 305 388 901 is required 49 f E Maintenance Single Phase Motors amp Controls Table 50 Integral hp Capacitor Replacement Kits CAPACITOR NUMBER 2 5 463 122 2 5 463 111 2 5 463 120 275 464 113 2 5 468 117 2 5 468 118 2 5 468 119 275 468 120 155 327 101 155 327 102 155 327 109 155 327 114 155 328 101 155325 102 155 328 103 Table 50A Integral hp Overload Replacement Kits OVERLOAD NUMBER 275 406 102 275 406 103 275 406 121 275 406 122 2 5 411 102 275
9. 9 34 25 95 45 170 90 340 140 530 200 760 280 1060 10 40 55 210 110 420 170 645 245 930 NOTCH OUT FOR CABLE GUARD LOCK NUTS INSIDE SLEEVE an 8 or smaller flow sleeve provides the required cooling FIG 1 SUBMERSIBLE MOTOR CENTERING BOLT CENTERING BOLTS MUST BE LOCATED ON MOTOR CASTING DO NOT LOCATE ON STATOR SHELL BOTTOM END VIEW CENTERING BOLT HOLE 3 REQUIRED f Application All Motors Head Loss From Flow Past Motor Table 7 lists the approximate head loss due to flow between an average length motor and smooth casing or flow inducer sleeve Table 7 Head Loss in Feet Meters at Various Flow Rates MOTOR DIAMETER CASING ID IN INCHES MM 25 95 50 189 100 378 150 568 200 757 7 178 8 203 0 3 09 1 2 37 4 7 1 4 102134 250 946 300 1136 Flow Rate in gpm 1000 3785 Hot Water Applications Standard Motors Franklin Electric offers a line of Hi Temp motors which are designed to operate in water with various temperatures up to 194 F 90 C without increased flow When a standard pump motor operates in water hotter than 86 F 30 C a flow rate of at least 3 ft s is required When selecting the motor to drive a pump in over 86 F 30 C water the motor horsepower must be de rated per the following procedure 3 ft s 91 m sec Flow Rate CAS
10. E o PF o 50 0 08 or 8 Bg 0 02 or 2 E 0 04 or 4 Phase designation of leads for CCW rotation viewing shaft end To reverse rotation interchange any two leads Phase 1 or A Black T1 or U1 Phase 2 or Yellow T2 or V1 Phase 3 or C Red T3 or W1 NOTICE Phase 1 2 and may not be L1 L2 and ft Application Three Phase Motors Three Phase Motor Lead Identification Line Connections Six Lead Motors T5 V2 YELLOW CHECK VALVE OR PIPE PLUG ON RIGHT SIDE FACING MOTOR WARNING When installing 1 i 6 lead motors extra care lt must be used to ensure lead identification at the surface T4 U2 Leads must be marked and BLACK connected per diagram Motor leads are not connected red to red yellow to yellow etc LEADS LOCATED HERE ONLY FOR 3 LEAD DOL MOTORS 90 Lead Spacing Connections for across the line starting running and any reduced voltage starting except WYE DELTA type starters L1 L2 L3 T1 T6 T2 T4 T3 5 U1 We V1 U2 W1 V2 WYE DELTA starters connect the motor as shown below during starting then change to the running connection shown at the left L1 L2 L3 T1 T2 T3 T4 I5 T6 U1 V1 W1 U2 V2 W2 Each motor lead is numbered with two markers one near each end To reverse rotation interchange any two line connections Phase Converters There are a number of different types of phase converters available Each generates three phase
11. 0 0 0 0 0 0 cM O gt c O fen RB O Fee O O c O O Lengths BOLD only meet the US National Electrical Code ampacity requirements for individual conductors free air or water Lengths NOT in bold meet NEC ampacity requirements for either individual conductors or jacketed cable See page 11 for additional details 19 Continued on page 20 Table 20 Three Phase 75 C Cable Continued MCM COPPER WIRE SIZE V 0175 Kw 14 12 6 4 3 2 4 o 00 000 250 300 350 400 500 TUB 3770 gt gt ENETN cs oy lt lt 75 gt mui 25 185 40 w 50 60 45 75 55 ETE ETE Application Three Phase Motors O e NM o Ng o NN O NN fen Oo EN o RR O E Fon O FS ood 8 e 150 0 37 A Q O EM Boe O O FSR O EM Boe Boe O c O EM O EM NN O FS Lengths in BOLD only meet the US National Electrical Code ampacity requirements for individual conductors in free air or water Lengths NOT in bold meet NEC ampacity requirements for either individual conductors or jacketed cable See page 11 for additional details Continued on page 21 20 f Application Three Phase Motors G T
12. 0 75 thru 4 300 5 5 thru 22 100 30 and over 100 1 thru 5 5 7 5 thru 30 40 and over 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 6 and 8 motors should have a minimum of 20 minutes between starts or starting attempts 2 Do not use in systems which can run even for short periods at full speed without thrust toward the motor li 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 4 references the motor horsepower rating single phase and three phase total effective kVA required and Table 4 Transformer Capacity MOTOR RATING TOTAL EFFECTIVE OPEN WYE KVA OR DELTA REQUIRED 2 TRANSFORMERS 3 4 5 7 5 5 5 Oon m N 150 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
13. 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 designed 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 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 EXAMPLE A 6 motor and pump that delivers 60 gpm will be installed in a 10 well From table 6 90 gpm would be required to maintain proper cooling In this case adding WORM GEAR CLAMPS INTAKE FLOW INDUCER SLEEVE Well diameter is too large to meet table 6 flow requirements e Pump is in an open body of water e Pump is in a rock well or below the well casing The well is top feeding a k a cascading e Pump is set in or below screens or perforations Table 6 Required Cooling Flow MINIMUM GPM REQUIRED FOR MOTOR COOLING IN WATER UP TO 86 F 30 C 8 MOTOR 0 50 FT S GPM L M CASING OR SLEEVE ID INCHES MM 4 102 5 127 6 MOTOR 0 50 FT S GPM L M 4 MOTOR 3 10 HP 0 25 FT S GPM L M 1 2 4 5 7 26 5 6 152 13 49 7 178 20 76 8 203 30 10 254 12 305 14 356 16 406 0 25 ft s 7 62 cm sec 0 50 ft s 15 24 cm sec 1 inch 2 54 cm
14. If a motor is overloaded with normal be mounted in an auxiliary box The values of additional capacitance it still will be overloaded with auxiliary running capacitors most likely to reduce noise are given run capacitance even though motor amps may be below The tabulation gives the max S F amps normally within nameplate values in each lead with the added capacitor Table 15 Auxiliary Capacitor Sizing NORMAL RUNNING AUXILIARY RUNNING CAPACITORS FOR MOTOR RATING CAPACITOR S NOISE REDUCTION S F AMPS WITH RUN CAP HP VOLTS MFD MIN VOLTS FRANKLIN PART YELLOW BLACK 1 2 ONE 155328101 3 4 ONE 155328103 1 155328101 155328102 155328103 155328102 155327101 155328101 155327101 1 Do not add running capacitors to 1 3 through 1 hp control boxes which use solid state switches relays Adding capacitors will cause switch failure If the control box is converted to use a voltage relay the specified running capacitance can be added Buck Boost Transformers When the available power supply voltage is not within wide range of voltage boost or buck are published by the proper range a buck boost transformer is often transformer manufacturers the following table shows used to adjust voltage to match the motor The most Franklin s recommendations The table based on common usage on submersible motors is boosting a boosting the voltage 10 shows the minimum rated 208 volt supp
15. lt 15 hp DELUXE 282 203 9330 or 282 203 9330 START CAPACITOR LINE POWER FROM TWO POLE TO FUSED PRESSURE SWITCH OR OTHER SEEN e OR CONTROL CIRCUIT SWITCH OVERLOAD BREAKER GROUND TO LEAD MOTOR 10 hp DELUXE 282 202 9230 or 282 202 9330 RUN CAPACITOR a START CAPACITOR SURG ARRESTOR 1 E L7T 17 BH GROUND LEAD LINE POWER FROM TWO POLE FUSED SWITCH R CIRCUIT PRESSURE OVERLOAD START BREAKER 1 OVERLOAD SWITCH 15 hp X LARGE 282 203 9621 54 Maintenance Electronic Products li Pumptec Plus Pumptec Plus is a pump motor protection device designed to work on any 230 V 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 Troubleshooting During Installation SYMPTOM POSSIBLE CAUSE SOLUTION Check wiring Power supply voltage should be applied to L1 and L2 terminals of the No Power to Unit Pumptec Plus In some installations the pressure switch or other control devices is wired to the input of the Pumptec Plus Make sure this switch is closed Unit Appears Dead No Lights Pumptec Plus is calibrated at the factory so that it will overload on most pump systems Unit
16. 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 f F Abbreviations A Amp or amperage MCM Thousand Circular Mils AWG American Wire Gauge mm Millimeter BJT Bipolar Junction Transistor MOV Metal Oxide Varister C Degree Celsius NEC National Electrical Code CB Control Box NEMA National Electrical Manufacturer CRC Capacitor Run Control Association DI Deionized Nm Newton Meter Dv dt Rise Time of the Voltage NPSH Net Positive Suction Head Efficiency OD Outside Diameter F Degree Fahrenheit OL Overload FDA Federal Drug Administration PF Power Factor FL Full Load psi Pounds per Square Inch ft Foot PWM Pulse Width Modulation ft Ib Foot Pound QD Quick Disconnect ft s Feet per Second R R
17. 0 467 of some other wire size to use in the remaining 310 feet down hole wire run The table shows 8 AWG copper wire is good for 470 feet Using the formula again 310 feet used 470 feet allowed 0 660 adding this to the 0 533 determined earlier 0 533 0 660 1 193 This combination is greater than 1 00 so the voltage drop will not meet US National Electrical Code recommendations Tables 11 amp 11A show 6 AWG copper wire is good for 750 feet Using the formula 310 750 0 413 and using these numbers 0 533 0 413 0 946 we find this is less than one and will meet the NEC 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 3 hp 230 Volt Single Phase Motor E SERVICE ENTRANCE MAIN FUSE BOX FROM METER x 160 ft 10 AWG 53 3 of allowable cable PUMP CONTROLS 3 hp 230 V Single Phase Motor CABLE 310 ft 6 AWG 41 3 of allowable cable 9 lt J Ox lt 757 H 12 li Table 13 Single Phase Motor Specifications 60 Hz 3450 rpm Application Single Phase Motors MAXIMUM WINDING 1 POWER MOTOR RATING je EIE p Sg SHE EFFICIENCY 96 eiit LOCKED TYPE MODEL 2 2 MAIN BES ROTOR Hei ESET amps A
18. 207 951 305 203 907 305 203 908 Table 48C QD Relay Replacement Kits QD RELAY NUMBER 305 101 901 305 101 902 305 101 903 305 101 904 305 101 905 305 101 906 305 105 901 305 105 902 305 105 903 f i Maintenance Single Phase Motors amp Controls 48 Maintenance Single Phase Motors amp Controls li Table 49 Integral Horsepower Control Box Parts 60 Hz CAPACITORS MFD VOLTS QTY MOTOR MOTOR SIZE RATING HP CONTROL BOX 1 MODEL NO PART NO PART NO PART NO OVERLOAD 2 PART NO 2 RELAY 3 x CONTACTOR 2 1 1 5 STANDARD 2 STANDARD 2 DELUXE 3 STANDARD 3 DELUXE 5 155 STANDARD 5 DELUXE 7 5 6 STANDARD 7 5 DELUXE 10 STANDARD 10 STANDARD 10 DELUXE 10 DELUXE 15 DELUXE 15 DELUXE 15 X LARGE FOOTNOTES 1 Lightning arrestors 150 814 902 are suitable for all control boxes 282 300 8110 282 300 8610 282 301 8110 282 301 8310 282 302 8110 282 302 8310 282 113 8110 ege 113 9310 282 201 9210 282 201 9310 282 202 9210 282 202 9230 282 202 9310 282 202 9330 282 203 9310 282 203 9330 282 203 9621 275 464 113 155 328 102 R 275464113S 155 323 101 R 275 464 113 155 328 103 R 275 464 1135 155 328 103 R 275 463 111 155 327 109 R 275 463 111 156 S27 100 IR 275 468 119 S 155 327 114 R 275 468 119 S 155 327 114 R 275 468 119 S 275 468 118 S 155 327 109 R 275
19. 411 107 2 5 411 108 275 411 113 2 5 411115 275 411 117 2 5 411 118 2S Ai TTE Table 50B Integral hp Voltage Relay Replacement Kits RELAY NUMBER 155 031 102 155 031 103 155 031 601 155 031 602 Table 50C Integral hp Contactor Replacement Kits CONTACTOR 155 325 102 155 326 101 155 326 102 155 429 101 305 206 912 305 206 911 305 206 920 305 207 913 305 208 917 305 208 918 305 208 919 305 208 920 305 203 901 305 203 902 305 203 909 305 203 914 305 204 901 305 204 902 305 204 903 305 214 902 305 214 903 305 214 921 305 214 922 305 215 902 305 215 907 305 215 908 305 215 913 305 215 915 eda 219 91 305 215 918 305 215 909 305 213 902 305 213 903 305 213 961 305 213 904 305 226 901 305 347 903 305 347 902 305 347 901 50 f 9 Maintenance Single Phase Motors amp Controls Control Box Wiring Diagrams ORANGE QDRELAY Ren 1 3 1 hp QD RELAY 280 10_ 4915 YELLOW sixth digit depends on hp MOTOR LEADS LINE LEADS ce ec LI E 1 2 1 hp CRC QD RELAY 28240 5015 YELLOW Sixth digit depends on hp L B MAIN Y R START L2 MOTOR LEADS LINE LEADS RUN CAPACITOR START CAPACITOR ART CAPACITOR RUN CAPACITOR ST TI T TI U E BLK ORG 5 RELAY 1 2 GROUND LEAD LI L2 BLK RED LINE POWER GROUND LEAD LINE POWER FROM TWO POLE FROM TWO POLE FUSED SWITCH OR FUSED SWITCH OR CIRCUIT BREAKER CIRCUIT BREAK
20. 468 119S 275 468 118 155 227 109 R 275 468 119 275468 120 155 327 102 R 275 463 120 S 275 468 118 S 275 468 119 S 155 327 1028 275 468 119 275468 120 155 327 102 R 275 463 120 S 275 468 118 S 275 468 119 S 158 S27 102 275 468 120 S 155 327 109 R 275 463 122 S 275 468 119 S 155 S27 109 IR 275 468 120 S 155 327 109 R 2 S Start M Main L Line R Run Deluxe Control box with line contactor 105 126 10 105 126 15 105 126 20 105 126 20 208 250 45 208 250 45 270 324 40 270 324 40 270 324 216 259 45 270 324 216 259 45 270 324 350 420 35 130 154 216 259 270 324 35 270 324 350 420 35 130 154 216 259 270 324 35 350 420 45 161 193 270 324 45 350 420 45 C5 G N C5 nO N N N LS 15 N N 275 411 107 None See Note 4 275 411 117 275 411 113 275 411 117 S 275 411 113 275 411 118 275 411 115 275 411 118 275 411 115 275 411 119 275 406 102 275 411 119 275 406 102 275 411 102 275 406 122 275 411 102 275 406 121 275 406 103 155 409 101 275 406 103 155 409 101 275 406 103 155 409 101 275 406 103 155 409 101 275 406 103 155 409 102 275 406 103 155 409 102 275 406 103 155 409 102 155 031 102 155 091 102 155 031 102
21. 5 100 100 150 175 250 300 Sys 450 525 600 WARNING To prevent accidental electrocution automatic or manual transfer switches must be used any time a generator is used as standby or back up on power lines Contact power company for use and approval 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 B Upthrust With no check valve a leaking check valve or drilled check valve the unit starts under li 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 C Water Hammer If the lowest check valve is more
22. MOUNTING HOLES Standard Water Well 1 48 MAX 0 50 MIN MAX FULL SPLINE 1 508 MOUNTING STUDS Y 0 161 MAX LEAD BOSS HEIGHT 3 75 DIA 8 Dimensions Standard Water Well 1 69 1 69 MIN FULL 5 000 5 000 009000 MIN FULL 23 TOOTH 16 32 SPLINE 23 TOOTH 16 32 4 997 SPLINE DIAMETRAL PITCH _ DIAMETRAL PITCH SHAFT DIA 4 000 SHAFT DIA 1 5000 3 990 1 5000 E 3 990 1 4990 1 4990 1 06 5 130 1 06 5 130 094 5 120 0 94 5 120 CHECK VALVE eG MOUNTING HOLES SCREW CLEARANCE FOR PIPE PLUG 5 8 BOLTS STAINLESS 7 70 DIA STEEL 7 70 DIA MAX MODELS L M8 x 1 25 6G MAX GROUND L SCREW 40 to 100 hp 125 to 200 hp Motor lengths and shipping weights are available on Franklin Electric s web site www franklin electric com or by calling Franklin s submersible hotline 800 348 2420 40 f Installation All Motors Tightening Motor Lead Connector Jam Nut 4 Motors first few hours after assembly may reduce the jam nut 15 to 20 ft lb 20 to 27 Nm torque This 1 normal condition which does not indicate 6 Motors reduced seal effectiveness Retightening is not required 50 to 60 ft lb 68 to 81 Nm but is permissible and recommended if original torque 8 Motors with 1 3 16 to 1 5 8 Jam Nut 50 to 60 ft
23. Needs to Be Calibrated 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 Flashing Yellow Light Pumptec Plus should be calibrated on a full recovery well with the maximum water flow Miscalibrated Flow restrictors are not recommended Step C of the calibration instructions indicate that a flashing green light condition will Flashing Yellow Light 2 Wire Motor occur 2 to 3 seconds after taking the SNAPSHOT of the motor load On some two wire During Calibration motors the yellow light will flash instead of the green light Press and release the reset button The green should start flashing During the installation of Pumptec Plus power may be switched on and off several times Power Interruption 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 Flashing Red and Yellow Lights A bobbing float switch may cause the unit to detect rapid cycle condition any motor Float Switch or an overload condition on two wire motors Try to reduce water splashing or use a different switch The line voltage is over 253 volts Check line voltage Report high line voltage to the High Line Voltage power company Flashing Red Light If you are using a generator the line voltage may become too high when the genera
24. Pump Installation Check List 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 A If not yet assembled check that pump and motor mounting faces are free from dirt debris and uneven paint thickness B Pumps and motors over 5 hp should be assembled in 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 C If accessible check that the pump shaft turns freely D Assemble the pump lead guard over the motor leads Do not cut or pinch lead wires during assembly installation 4 Power Supply and Controls A Verify that the power supply voltage hertz and kVA capacity match motor requirements B Verify control box hp and voltage matches motor 3 wire 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 and sm
25. STANDARD DUAL ELEMENT CIRCUIT STANDARD DUAL ELEMENT TIME CIRCUIT FUSE TIME DELAY FUSE BREAKER FUSE DELAY FUSE BREAKER 239660 239600 239610 239661 239601 239611 239662 239602 239612 239663 239603 239613 239664 239604 239614 239165 239105 29915 239166 239106 239116 239167 239107 299117 239168 380 239108 460 239118 575 380 460 575 380 460 575 380 460 575 380 460 575 380 460 575 380 460 51 5 380 460 575 380 460 575 w w ey EN EN EN EN EN EN Bunu 27 Application Three Phase Motors li Overload Protection of Three Phase Submersible Motors The characteristics of submersible motors are different All heaters and amp settings shown are based on total than standard motors and special overload protection line amps When determining amperage settings or is required making heater selections for a six lead motor with a If the motor is locked the overload protection must trip Wye Delta starter divide motor amps by 1 732 within 10 seconds to protect the motor windings Subtrol pages 28 29 and 30 list the correct selection and SubMonitor a Franklin approved adjustable overload settings for some manufacturers Approval for other relay or a Franklin approved fixed heater must be used manufacturers types not
26. between any two legs Unbalance Unbalanced power supply exceeds programmed setting Open delta transformer Overvoltage Line voltage exceeds programmed setting Unstable power supply Poor connection in motor power circuit Undervoltage Line voltage below programmed setting Unstable or weak power supply Chattering contacts Power has been interrupted too many times T Loose connections in motor power circuit 10 second period I Arcing contacts 59 li Maintenance Electronic Products Subtrol Plus Obsolete See SubMonitor Subtrol Plus Troubleshooting After Installation SYMPTOM Subtrol Plus Dead Green Off Time Light Flashes Green Off Time Light On Overheat Light On Overload Light On Underload Light On POSSIBLE CAUSE OR SOLUTION 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 green 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 ligh
27. coil rating must match the control SOURCE voltage source such as 115 or 24 volts CONTACTS 3 OVERLOAD HEATER AND OR SUBTROL DEVICE FIG 9 32 pe 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 cause problems such as FIG 10 FULL THREE PHASE poor performance overload tripping or early motor failure due to current unbalance Transformer rating should be no smaller than listed in table 4 for supply power to the motor alone FIG 11 OPEN DELTA 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 2 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 2 or less leave the leads as connected If the current unbalance is more than 2 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 3 To calculate per
28. 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 OF FLASHES Motor Underload Locked Pump Incorrectly Wired MonoDrive Only EN un Short Circuit Overheated Controller 4 POSSIBLE CAUSE Air locked pump Overpumped or dry well Worn pump Damaged shaft or coupling Blocked pump or screen Low line voltage Misconnected input leads Motor pump misaligned Abrasive sand bound pump Dragging pump or motor Start winding resistance too low Loose connections Defective motor or cable When fault is indicated immediately after power up short circuit due to loose connection defective cable splice or motor When fault is indicated while motor is running over current due to loose debris trapped in pump High ambient temperature Direct sunlight Obstruction of air flow CORRECTIVE ACTION Wait for well to recover and automatic restart timer to time out If the problem does not correct check motor and pump See description on smart reset at the end of the installation manual Check for loose connections Check line voltage Report low voltage to the power company Unit will start automatically when proper power is supplied Unit will attempt to free a locked pump If unsuccessful check the motor and pump Check if ma
29. point in the total cable length Tables 11 amp 11 are based on copper wire If aluminum wire is used it must be two sizes larger than copper wire and oxidation inhibitors must be used on connections EXAMPLE If tables 11 amp 11A call for 12 copper wire 10 aluminum wire would be required Contact Franklin Electric for 90 C cable lengths See pages 15 48 and 49 for applications using 230 V motors on 208 V power systems p Two or More Different Cable Sizes Can 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 160 feet of buried 10 cable between the service entrance and the wellhead A new 3 hp 230 volt single phase motor is being installed to replace a smaller motor The question is Since there is already 160 feet of 10 AWG installed what size cable is required in the well with a 3 hp 230 volt single phase motor setting at 310 feet From tables 11 amp 11A a 3 hp motor can use up to 300 feet of 10 AWG cable The application has 160 feet of 10 AWG copper wire installed Using the formula below 160 feet actual 300 feet max allowable is equal to 0 533 This means 53 396 0 533 x 100 of the allowable voltage drop or loss which is allowed between the service entrance and the motor Actual Length F la cat Max Allowed occurs in this wire This leaves us 46 7 1 00 0 533
30. power from a single phase power line In all phase converters the voltage balance is critical to current balance Although some phase converters may be well balanced at one point on the system operating curve submersible pumping systems often operate at differing points on the curve as water levels and operating pressures fluctuate Other converters may be well balanced at varying loads but their output may vary widely with fluctuations in the input voltage The following guidelines have been established for submersible installations to be warrantable when used with a phase converter Limit pump loading to rated horsepower Do not load into motor service factor Maintain at least 3 ft s flow past the motor Use a flow sleeve when necessary Use time delay fuses or circuit breakers in pump panel Standard fuses or circuit breakers do not provide secondary motor protection SubMonitor may be used with electro mechanical type phase converters however special connections are required Consult SubMonitor Manual for connections of receiver and lightning arrestor SubMonitor will not work with electronic solid state phase converters Current unbalance must not exceed 10 34 pe 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 half second or less The motor current goes from zero to
31. than 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 Application All Motors the discharge piping On the next pump start water moving at very high velocity fills the void and strikes 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 Wells Large Diameter Uncased Top Feeding and Screened Sections Franklin Electric submersible motors are designed to operate with a cooling flow of water over and around the full length of the motor If the pump installation does not provide the minimum flow shown in table 6 a flow inducer sleeve flow sleeve must be used The conditions requiring a flow sleeve are 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 and higher and 0 5 ft s for 6 and 8 motors is required for proper cooling Table 6 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
32. to the reactor impedance 102 voltage for 2 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 0 25 ft s 7 26 cm sec and for 6 and 8 motors 0 5 ft s 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 Electric three phase motors are not declared Inverter Duty motors per NEMA 1 standards The reason is Part 31 of NEMA standard MG1 does not include a section covering encapsulated winding designs However Franklin submersible motors can be used with VFDs without problems and or warranty concerns provided these guidelines are followed f Installation All Motors 4 Super Stainless Dimensions 4 High Thrust Dimensions Standard Water Well 1 48 MAX 0 030 R 0 50 MIN MAX FULL SPLINE 1 508 5 16 24 UNF 2A MOUNTING STUDS i 0 161 MAX LEAD BOSS HEIGHT 3 75 DIA 6 Dimensions Standard Water Well 15 TOOTH 16 32 DIAMETRAL PITCH 94 MIN FULL SPLINE 4 1 2 20 UNF 2B
33. 126A Association of Railroads 320A 219A ae 112 76 152 104 194 132A 263A 180A 98A 320A RP 585 Based on 30 C maximum ambient with cable length of 100 feet or less 37 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 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 2 Inlet Pressure The inlet pressure on each booster module must be continuously monitored It must always be positive and higher th
34. 230 i 22500 236665 380 22500 236615 460 22500 236625 575 22500 236656 200 26900 236606 230 26900 236666 380 i 26900 236616 460 26900 236626 575 26900 236667 380 35600 236617 460 35600 236627 575 35600 236668 380 45100 236618 460 45100 236628 575 i 45100 236669 380 53500 236619 460 53500 236629 575 53500 I I T T T I LX E LE E C C T T I IL T T T T T T T T T T T T T T I I Model numbers above are for three lead motors Six lead motors with different model numbers have the same running performance but when wye connected for starting have locked rotor amps 33 of the values shown Six lead individual phase resistance table X 1 5 24 Application Three Phase Motors f Table 25 Three Phase Motor Fuse Sizing CIRCUIT BREAKERS OR FUSE AMPS CIRCUIT BREAKERS OR FUSE AMPS MOTOR RATING MAXIMUM PER NEC TYPICAL SUBMERSIBLE STANDARD DUAL ELEMENT TIME CIRCUIT STANDARD DUAL ELEMENT TIME CIRCUIT VOLTS FUSE DELAY FUSE BREAKER FUSE DELAY FUSE BREAKER 236650 ae 200 6 il 236600 230 236660 380 236610 460 236620 575 236651 200 236601 230 236661 380 236611 460 236621 575 236652 200 236602 230 236662 380 236612 460 236622 575 236653 200 236603 230 236663 380 236613 460 236623 575 236654 200 236604 230 236664 380 236614 460 236624 575 236655 200 236605 230 236665 380 236615 460 236625
35. 575 236656 200 236606 230 236666 380 236616 460 236626 575 236667 380 236617 460 236627 575 236668 380 236618 460 236628 575 236669 380 236619 460 236629 575 25 Application Three Phase Motors li Table 26 Three Phase Motor Specifications 60 Hz MOTOR RATING FULL LOAD MAXIMUM LINE TO LINE EFFICIENCY LOCKED TYPE MODEL S F LOAD RESISTANCE ROTOR PREFIX VOLTS AMPS KILOWATTS AMPS KILOWATTS OHMS FL AMPS 380 460 575 380 460 575 380 460 575 380 460 575 380 460 575 380 460 575 380 460 575 380 460 575 KVA CODE 239660 8 II 239600 239610 239661 239601 239611 239662 239602 239612 239663 239603 239613 239664 239604 239614 239165 239105 239115 239166 239106 239116 239167 239107 239117 239168 380 239108 460 239118 575 w w w SN NTN k EE EM NEM B lt lt Model numbers above are for three lead motors Six lead motors with different model numbers have the same running performance but when wye connected for starting have locked rotor amps 33 of the values shown Six lead individual phase resistance table X 1 5 26 Application Three Phase Motors li Table 27 Three Phase Motor Fuse Sizing CIRCUIT BREAKERS OR FUSE AMPS CIRCUIT BREAKERS OR FUSE AMPS MOTOR RATING MODEL MAXIMUM PER NEC TYPICAL SUBMERSIBLE PREFIX VOLTS
36. AWG MCM Copper Aluminum Jacketed Individual Conductors PUMP 0 PANEL P SERVICE lt ENTRANCE Transformers 2 1 2 3 z Initial Megs dc motor amp lead T1 T2 T3 Control Panel Final Megs motor lead amp cable T1 T2 T3 Panel Manufacturer Short Circuit Device Incoming Voltage Circuit Breaker Rating Setting Fuses Rating Type No Load L1 L2 L2 L3 L1 L3 Standard Delay Full Load L1 L2 L2 L3 L1 L3 Starter Manufacturer Running AMPS Starter Size Type of Starter Full Voltage Autotransformer HOOKUP 1 Other Full Voltage in Full Load L1 L2 L3 Unbalance Heater Manufacturer HOOKUP 2 Number Adjustable Set at amps Full Load L1 L2 SubMonitor Subtrol Plus No Yes Unbalance Registration No HOOKUP 3 If yes Full Load L1 L2 1 Overload Set No Yes Set at amps Unbalance Underload Set No Yes Set at amps Ground Wire Size AWG 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 Mode U Coast sec Ramp Sec Output filter Reactor Model None Maximum Load AMPS Driv
37. AYOR AL DE LA ALIMENTACION PARA REDUCIR EL RIESGO DE CHOQUE ELECTRIC DESCONECTAR LA ALIMENTACION ELECTRICA ANTES DE INICIAR A TRABAJAR EN EL SISTEMA HIDRAULICO NO UTILIZAR ESTE MOTOR EN ALBERCAS O AREAS EN DONDE SE PRACTIQUE NATACION Commitment to 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 li Submersible Motors Application Installation Maintenance Manual The submersible motor is a reliable efficient and trouble free means of powering a pump Its needs for a long operational life are simple They are 1 A suitable operating environment 2 An adequate supply of electricity 3 An adequate flow of cooling water over the motor 4 An appropriate pump load All considerations of application installation and maintenance of submersible motors relating to these four areas are presented in this manual Franklin Electric s web page www franklin electric com should be checked for the latest updates Contents Application Motors 18 22 2 A EEE 9 Frequency of Starts 3 Mounting FOS 3 Transformer Capacity 4 Effects of Torque
38. Class 10 SR Class 10 and 63 A LB Series Integral 18 32 63 GV2 L GV2 M GV2 P GV3 M 1 6 10 amp only LR9D SF Class 10 ST Class 10 LT6 Class 5 or 10 LRD Class 10 Motor Logic Class10 Application Three Phase Motors Table 30 60 Hz Motors HEATERS FOR ADJUSTABLE VOLTS OVERLOAD RELAYS RELAYS SIZE FURNAS NOTE 3 NOTE 1 NOTE 2 SET MAX 3 K78 L866B 68 73 3 K73 L520B 45 48 380 3 K86 L107C 81 87 575 3 K77 L710B 56 60 380 1 K89 L126C 101 108 460 1 K86 Loe 83 89 380 4 K92 L142C 121 130 575 1 85 L950C 79 85 380 1 K28 L100B 168 181 575 4 K90 L142C 108 116 380 5 K32 L135B 207 223 575 1 K26 L825A 140 150 380 5 L147B 248 267 575 1 28 L100B 165 177 380 6 K26 270 290 575 2 K31 L111B 186 200 380 6 K27 316 340 460 5 K33 L165B 266 286 Toshiba Type 2E RC820 set at 8 sec max WEG RW2 Westinghouse Types FT13 FT23 FT33 FT43 K7D K27D K67D Advantage Class 10 MOR 10500 Class 5 Westmaster OLWROO and OLWTOO suffix D thru P Other relay types from these and other manufacturers may or may not provide acceptable protection and they should not be used without approval of Franklin Electric Some approved types may only be available for part of the listed motor ratings When relays are used with current transformers relay setting is the specified amps divided by the transformer ratio 30 li SubiVionitor Three Phase Protection Application Th
39. ER AND OTHER CONTROL 1 AND OTHER CONTROL IF USED L IF USED OVERLOAD GROUND TO GROUND TO LEAD MOTOR LEAD MOTOR 1 1 5 hp 1 1 5 hp 282 300 8110 282 300 8610 51 li Maintenance Single Phase Motors amp Controls RUN CAPACITOR START CAPACITOR RUN CAPACITOR START CAPACITOR E E BLK BLK a BLK deu kas LINE CONTACTOR COIL GROUND LEAD TE LINE POWER LINE FROM TWO POLE POWER FUSED SWITCH OR FROM CIRCUIT BREAKER TWO POLE TO gt AND OTHER CONTROL ea N FUSED PRESSURE BO UND IF USED BLK SWITCH OR OTHER LEAD MAIN START OR CONTROL LEA CIRCUIT SWITCH MAIN OVERLOAD START TO AER 6 BREAKER PUE OVERLOAD MOTOR MOTOR 2 hp STANDARD 282 301 8110 RUN CAPACITOR START CAPACITOR GROUND LEAD LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER 2 AND OTHER CONTROL N IF USED START GROUND OVERLOAD OVERLOAD LEAD 3 hp STANDARD 282 302 8110 2 hp DELUXE 282 301 8310 RUN CAPACITOR T Lu JI Lu gt 11 L2 LINE CONTACTOR GROUND LEAD LINE POWER FROM TWO POLE TO FUSED PRESSURE SWITCH OR OTHER OR CONTROL CIRCUIT SWITCH BREAKER OVERLOAD 3 hp DELUXE 282 302 8310 START CAPACITOR BLK TO MOTOR 52 li START CAPACITOR BLK RUN CAPACITOR G LEAD LINE POWER FROM TWO POLE FUSED SWITCH OR l CIRCUIT BREAKER u BLK AND OTHER CONTROL IF USED START OVERL
40. ER WIRE SIZE volts HP 14 10 6 4 3 2 1 250 300 350 400 500 160 7540 3 7 200 V 7 5 55 110 5340 75 4080 Three 2770 Phase 2160 6 Lead 1750 Y D 1450 3 230 V 60 Hz Three Phase 6 Lead Y D N NJN N N N ol 41 N e m lt OOOO O O O O O O cM Ss O 9 O O gt 0 0 0 0 0 0 0 0 0 0 175 130 5 37 75 55 N e N Q 2885568558 O EM EE O fe 9 O O KI O es N N E 51 o o J 51 m OOo OOO O Oo O i Lengths in BOLD only meet the US National Electrical Code ampacity requirements for individual conductors in free air or water Lengths NOT in bold meet NEC ampacity requirements for either individual conductors or jacketed cable See page 11 for additional details 18 Application Three Phase Motors f Table 19 Three Phase 75 C Cable 60 Hz Service Entrance to Motor Maximum Length in Feet MOTOR RATING 75 C INSULATION AWG COPPER WIRE SIZE MCM COPPER WIRE SIZE voLTs Kw 14 12 W NET ENE 00 000 0000 250 300 350 400 500 710 4420 3 4 0 55 so 3160 EEA 430 2670 1960 gt lt 1520 3 22 o 1160 WIIIIII NIISI 110 690 490 RM m aed N N 0 0 0 0 0 0 0
41. F THE MOTOR DISCHARGE PRESSURE IS NOT ADEQUATE TO MEET THIS REQUIREMENT THE SYSTEM MUST BE SHUT DOWN IMMEDIATELY TO PREVENT PERMANENT MOTOR DAMAGE 38 pe Variable Speed Submersible Pump Operation Inverter Drives Franklin three phase submersible motors are operable from variable frequency inverter drives when applied within guidelines 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 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 considerations 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 1000 V and keep the rise time greater than 2 usec Alternately stat
42. ING OR SLEEVE ID 4 HIGH THRUST MOTOR 1 Using table 7A determine pump gpm required for different well or sleeve diameters If necessary add a flow sleeve to obtain at least 3 ft s flow rate 8 1 206 6 8 2 1 10 4 3 2 14 6 4 5 24 6 7 5 37 3 11 4 52 2 15 9 6 10 254 Table 7A Minimum gpm l m Required for 8 MOTOR li 2 Determine pump horsepower required from the pump manufacturer s curve Application All Motors Brake Horsepower 5 10 15 20 25 30 35 40 45 50 Gallons Per Minute FIG 2 MANUFACTURER S PUMP CURVE Table 8 Heat Factor Multiplier at 3 ft s 91 m sec Flow Rate 3 Multiply the pump horsepower required by MAXIMUM 1 3 5 HP 7 1 2 30 HP OVER 30 HP the heat factor multiplier from table 8 WATER TEMPERATURE 25 3 7 KW 5 5 22 KW OVER 22 KW 140 F 60 C 4 Select a rated hp motor on table 8A whose Service Factor Horsepower is at least the value calculated in Item 3 Hot Water Applications Example EXAMPLE A 6 pump end requiring 39 hp input will pump 124 F water in an 8 well at a delivery rate of 140 gpm From table 7A a 6 flow sleeve will be required to increase the flow rate to at least 3 ft s Using table 8 the 1 62 heat factor multiplier is selected because the hp required is over 30 hp and water 559 0 temperature is above 122 F Multiply 39 hp x 1 62 multiplier wh
43. KLIN POUR DE PLUS AMPLES RENSEIGNEMENTS APPELEZ SANS FRAIS LE 800 348 2420 AVERTISSEMENT UN CHOC ELECTRIQUE SERIEUX OU MEME MORTEL EST POSSIBLE SI L ON NEGLIGE DE CONNECTER LE MOTEUR LA PLOMBERIE METALLIQUE BOITES DE CONTROLE ET TOUT METAL PROCHE DU MOTEUR AUN CABLE ALLANT VERS UNE ALIMENTATION D ENERGIE AVEC BORNE DE MISEALA TERRE UTILISANT AU MOINS LE MEME CALIBRE QUE LES FILS DU MOTEUR POUR REDUIRE LE RISQUE DE CHOC ELECTRIQUE COUPER LE COURANT AVANT DE TRAVAILLER PRES OU SUR LE SYSTEM D EAU NE PAS UTILISER CE MOTEUR DANS UNE ZONE DE BAIGNADE ATENCION INFORMACION PARA EL INSTALADOR DE ESTE EQUIPO PARALA INSTALACION DE ESTE EQUIPO SE REQUIERE DE PERSONAL TECNICO CALIFICADO EL NO CUMPLIR CON LAS NORMAS ELECTRICAS NACIONALES Y LOCALES ASI COMO CON LAS RECOMENDACIONES DE FRANKLIN ELECTRIC DURANTE SU INSTALACION PUEDE OCASIONAR UN CHOQUE ELECTRICO PELIGRO DE UN INCENDIO OPERACION DEFECTUOSA E INCLUSO LA DESCOMPOSTURA DEL EQUIPO LOS MANUALES DE INSTALACION Y PUESTA EN MARCHA DE LOS EQUIPOS ESTAN DISPONIBLES CON LOS DISTRIBUIDORES FABRICANTES DE BOMBAS O DIRECTAMENTE CON FRANKLIN ELECTRIC PUEDE LLAMAR GRATUITAMENTE PARA MAYOR INFORMACION AL TELEFONO 800 348 2420 ADVERTENCIA PUEDE OCURRIR UN CHOQUE ELECTRICO SERIO O FATAL DEBIDO A UNA ERRONEA CONECCION DEL MOTOR DE LOS TABLEROS ELECTRICOS DE LA TUBERIA DE CUALQUIER OTRA PARTE METALICA QUE ESTA CERCA DEL MOTOR O POR NO UTILIZAR UN CABLE PARA TIERRA DE CALIBRE IGUAL O M
44. LEMENT TIME CIRCUIT FUSE DELAY FUSE BREAKER FUSE DELAY FUSE BREAKER 234501 4 gt e 234541 234521 1 2 234502 234512 234542 234522 234503 234513 234543 234523 234504 234514 234544 234524 234534 234305 234315 234345 234325 234335 234306 234316 234346 234326 234336 234307 234317 234347 234327 234337 234308 234318 234348 234328 234338 234349 234329 234339 234549 234595 234598 Ol Oo 4 Ol A O C A O Q N N o p 23 Application Three Phase Motors f Table 24 Three Phase Motor Specifications 60 Hz MOTOR RATING FULL LOAD LINETOLINE EFFICIENCY LOCKED kva TYPE MODEL S F LOAD RESISTANCE ROTOR CODE PREFIX Hp KW VOLTS AMPS WATTS AMPS WATTS OHMS 1 AMPS 236650 200 5 4700 20 0 6 236600 230 4700 17 6 236660 gt 4700 10 7 236610 co 4700 8 8 236620 LM 575 4700 7 1 236651 200 7000 28 3 236601 230 7000 24 6 236661 380 7000 5 236611 5 460 7000 12 3 236621 575 7000 9 8 236652 200 9400 3 236602 230 9400 236662 380 9400 236612 460 9400 236622 575 9400 236653 200 13700 236603 230 13700 236663 380 13700 236613 460 13700 236623 SS 13700 236654 200 18100 236604 230 18100 236664 380 18100 236614 460 18100 236624 575 18100 236655 200 22500 236605
45. N Lengths BOLD only meet the US National Electrical Code ampacity requirements for individual conductors in free air or water Lengths NOT in bold meet NEC ampacity requirements for either individual conductors or jacketed cable See page 11 for additional details Continued on page 17 16 f Application Three Phase Motors Table 17 Three Phase 60 C Cable Continued 60 C MOTOR RATING 60 C INSULATION AWG COPPER WIRE SIZE MCM COPPER WIRE SIZE V 0175 Kw 14 12 6 4 3 2 4 o 00 000 250 300 350 400 500 3770 2 5 22 cs oy fe gt ms EXE 25 iss Po Z Q A o o EM o EN E o E BO o EM o EN EN o E BO EN o EN EN E o O O O O O O O Q Q o o e hh hk 0 A c fen Fen O O Bon NM c fen NONO Lengths in BOLD only meet the US National Electrical Code ampacity requirements for individual conductors in free air or water Lengths NOT in bold meet NEC ampacity requirements for either individual conductors or jacketed cable See 11 for additional details 17 Continued on page 18 f Application Three Phase Motors Table 18 Three Phase 60 C Cable Continued 60 C MOTOR RATING 60 C INSULATION AWG COPPER WIRE SIZE MCM COPP
46. OAD GROUND TO MAIN OVERLOAD LEAD MOTOR 5 hp STANDARD 282 113 8110 START CAPACITOR START CAPACITOR RUN CAPACITOR YEL GROUND LEAD FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER AND OTHER CONTROL IF USED LINE POWER START MAIN OVERLOAD OVERLOAD 53 7 5 hp STANDARD 282 201 9210 Maintenance Single Phase Motors amp Controls START CAPACITOR 3m E 3 2 RUN CAPACITOR LINE cor CONTACTOR GROUND LEAD LINE POWER FROM TWO POLE TO 2 2 FUSED PRESSURE e SWITCH OR OTHER OR CONTROL START CIRCUIT SWITCH MAIN OVERLOAD OVERLOAD GROUND To BREAKER LEAD MOTOR 5 hp DELUXE 282 113 8310 or 282 113 9310 RUN CAPACITOR GROUND LEAD POWER FROM TWO POLE TO FUSED PRESSURE SWITCH OR OTHER OR CONTROL MAIN START LINE BLK CIRCUIT SWITCH OVERLOAD OVERLOAD GROUND TO BREAKER LEAD MOTOR 7 5 hp DELUXE 282 201 9310 Maintenance Single Phase Motors amp Controls START CAPACITOR START CAPACITOR ea 5 D e i LINE POWER FROM TWO POLE FUSED SWITCH OR EN E BLK CIRCUIT BREAKER RA OTHER CONTROL MAIN GROUND SED OVERLOAD Sum LEAD OVERLOAD 10 hp STANDARD 282 202 9210 or 282 202 9230 TO MOTOR GROUND LEAD LINE POWER FROM TWO POLE FUSED TO SWITCH PRESSURE OR OR OTHER CIRCUIT CONTROL OVERLOAD OVERLOAD GROUND TO BREAKER SWITCH LEAD MOTOR RUN CAPACITOR START CAPACITOR go
47. OR RATING FULL LOAD LINETOLINE Efficiency LOCKED TYPE MODEL S F LOAD RESISTANCE ROTOR PER amps watts amps WATTS Mie F Es oem 234501 U 2 8 6 6 8 4 4 il 234511 2 4 9 5 10 9 234541 1 4 23 2 28 6 234521 2 38 4 44 1 234502 3 6 4 6 5 9 234512 055 3 1 6 8 7 8 234542 1 9 16 6 20 3 234522 1 6 27 2 30 9 234503 4 5 3 8 4 5 234513 3 9 4 9 5 6 234543 23 12 2 14 9 234523 2 19 9 23 0 234504 5 8 2 5 3 0 234514 5 3 2 4 0 234544 x 3 8 5 10 4 234524 ER 13 0 16 0 234534 20 3 25 0 234305 1 8 2 4 234315 2 3 3 0 234345 6 6 8 2 234325 9 2 12 0 234335 14 6 18 7 234306 13 1 234316 guae 234346 4 7 6 0 234326 234336 11 4 13 9 234307 MERITI 74 91 234317 1 0 1 2 234347 2 9 3 6 234327 4 0 4 9 234337 6 4 7 8 234308 46 57 234318 MR aoe 234348 1 6 2 0 234328 2 5 3 1 234338 4 0 5 0 234549 1 2 1 6 234595 MMR 1 8 2 3 75 234598 10 DON KVA mE EM PSG BE LC BEN BEN X NEM o EM lt BM lt EM 2 EM lt BM Z ES 22 Application Three Phase Motors f Table 23 Three Phase Motor Fuse Sizing CIRCUIT BREAKERS OR FUSE AMPS CIRCUIT BREAKERS OR FUSE AMPS MOTOR RATING MAXIMUM PER NEC TYPICAL SUBMERSIBLE MODEL PREFIX STANDARD DUAL ELEMENT TIME CIRCUIT STANDARD DUAL E
48. Q LR1 D LR1 F LR2 Class 10 Benshaw RSD6 Class 10 Soft Start Bharita C H MC 305 ANA 3 Clipsal 6CTR 6MTR Cutler Hammer C316F C316P 3165 C310 set at 6 sec max Advantage Class10 Fanal Types K7 or K7D through K400 Franklin Electric Subtrol Plus SubMonitor Fuji Types TR OQ TR OQH TR 2NQ TR 3NQ TR 4NQ TR 6NQ RCa 3737 ICQ amp ICQH Furnas Types US15 48AG amp 48BG 958L ESP100 Class 10 only 3RB10 Class 10 General Electric CR4G CR7G RT 1 RT 2 RTF3 RT 4 CR324X Class 10 only Kasuga RU Set Operating Time Code 10 amp time setting 6 sec max Klockner Moeller Types ZOO Z1 Z4 PKZM1 PKZM3 amp PKZ2 Lovato RC9 RC22 RC80 RF9 RF25 amp RF95 Matsushita FKT 15N 15GN 15E 15GE FT 15N FHT 15N Mitsubishi ET TH K12ABKP TH K20KF TH K20KP TH K20TAKF TH K60KF TH K60TAKF Omron K2CM Set Operating Timing Code 10 amp time setting 6 sec max SE KP24E time setting 6 sec max Riken PM1 PM3 Samwha EOCRS Set for Class 5 EOCR ST EOCR SE EOCR AT time setting 6 sec max Siemens Types 3UA50 52 54 55 58 59 60 61 62 66 68 70 3VUI3 Class 5 Sprecher and Schuh Types CT CT1 CTA 1 CT3K CT3 12 thru CT3 42 KTAS amp CET3 set at 6 sec max CEP 7 Class 10 CT4 6 amp 7 CT3 KT7 Square D Telemecanique Class 9065 Types TD TE TF TG TJ TK TR TJE amp TJF Class 10 LR1 D LR1 F LR2 Class 10 Types 18A 32A SS
49. R SET AT RX 1 FIG 14 44 f F 4 Maintenance All Motors Insulation Resistance Readings Table 45 Normal ohm and Megohm Values Between All Leads and Ground CONDITION OF MOTOR AND LEADS OHMS VALUE MEGOHM VALUE A new motor without drop cable 200 000 000 or more 200 0 or more A used motor which can be reinstalled in well 10 000 000 or more 10 0 or more MOTOR IN WELL READINGS ARE FOR DROP CABLE PLUS MOTOR 2 000 000 or more 2 0 or more New motor 7 500 000 2 000 000 0 50 2 0 Motor in good condition Less than 500 000 Less than 50 Insulation damage locate and repair Insulation resistance varies very little with rating Motors of all hp voltage and phase rating have similar values of insulation resistance The table above is based on readings taken with a megohm meter with a 500 VDC output Readings may vary 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 13 22 24 amp 26 When measured through the dro
50. TIS amps WATTS S START RES 244504 115 60 244505 230 60 244507 ETE 230 60 244508 230 60 244309 230 60 214504 115 1 He i i M4 2 5 2 214505 1 230 60 16 25 5 214507 PPM 230 60 Spend 214508 UNE 230 60 d M4 2 5 2 214505 230 60 e c e M3 0 3 6 214507 230 60 S107 1J Ml 214508 230 60 1 dod 214508 W 1 230 60 22 1 5 224300 230 60 lh se 224301 230 60 1 E 2 224302 1 0 1 5 3 r 53 5 4 4 224303 68 1 0 4 Pe OS s 51 8 2 2 226110 230 60 5 226111 230 60 226112 230 60 226113 230 60 1 Main winding yellow to black 4 Control Boxes date coded 01M and older have Start winding yellow to red 60 MFD run capacitors and the current values on a 4 motor will Y23 0 FL Y27 5 SF Load 2 Y Yellow lead line aMps 19 1 23 2 Black lead winding amps R80 R78 R Red lead start or auxiliary winding amps 5 Control Boxes date coded 01M and older have 3 a 77 60 MFD run capacitors and the current values bo Fl and Y17 0 SF cae 6 motor will be 23 0 FL Y27 5 SF Load B12 2 14 5 18 2 23 2 RA 7 R4 5 R8 0 R7 8 Performance is typical not guaranteed at specified voltages and specified capacitor values Performance at voltage ratings not shown is similar except amps vary inversely with volta
51. This same condition occurs when the generator is allowed to run out of fuel Follow generator manufacturer s recommendations for de rating at higher elevations or using natural gas 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 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 owing 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 5 Table 5 Engine Driven Generators NOTE This chart applies to 3 wire or 3 phase motors For best starting of 2 wire motors the minimum generator rating is 50 higher than shown MOTOR RATING MINIMUM RATING OF GENERATOR HP KVA 1 9 1 2 1 5 25 IES 1 9 3 8 2 2 5 2 9 3 EXTERNALLY REGULATED INTERNALLY REGULATED
52. able 21 Three Phase 75 C Cable Continued MOTOR RATING 75 C INSULATION AWG COPPER WIRE SIZE MCM COPPER WIRE SIZE VOLTS HP KW 14 6 4 3 2 1 250 300 350 400 500 dE 75 55 _ 49 75 Three We m Y D 22 37 7 5 230 60 Hz Three Phase 6 Lead Y D EN 5 N ol N O 9 35 O 9 O o EE oo 5 Jt c 51 ol N lt o O S amp S o gt N Jt c 51 ol o EN EUN 20 _ EN 100 EUN 175 EN EN NN ETE EUN 5 EN 100 EUN 175 O O O O O O 175 200 150 Lengths in BOLD only meet the US National Electrical Code ampacity requirements for individual conductors in free air or water Lengths NOT in bold meet NEC ampacity requirements for either individual conductors or jacketed cable See page 11 for additional details O O O O O O O 21 Application Three Phase Motors li Table 22 Three Phase Motor Specifications 60 Hz MOT
53. after power is removed may cause the motor overload to trip QD Relays Solid State There are two elements in the relay a reed switch and a triac The reed switch consists of two tiny rectangular blade type contacts which bend under magnetic flux It is hermetically sealed in glass and 1 located within a coil which conducts line current When power is supplied to the control box the main winding current passing through the coil immediately closes the reed switch contacts This turns on the triac which supplies voltage to the start winding thus starting the motor Once the motor is started the operation of the QD relay is an interaction between the triac the reed switch and Application Single Phase Motors enough to open the contacts of the relay 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 and 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 to restart the motor before the starting switch has
54. al until the overload trips G Defective cable or motor For detailed procedure see pages 44 amp 45 Repair or replace Motor Starts Too Often A Pressure switch Setting on pressure switeh Reset limit or replace switch examine for defects B Check valve stuck open Replace if defective not hold pressure F Bound pump C Waterlogged tank Check air charge Clean or replace D Leak in system Check system for leaks Replace damaged pipes or repair leaks 42 Maintenance All Motors li System Troubleshooting Motor Runs Continuously POSSIBLE CAUSE CHECKING PROCEDURES CORRECTIVE ACTION heck switch for wel n I A Pressure switch Chee Swie ii e ded contacts Clean contacts replace switch or adjust setting Check switch adjustments Pump may exceed well capacity Shut off B Low water level in well pump wait for well to recover Check static and drawdown level from well head C Leak in system Check system for leaks Replace damaged pipes or repair leaks Throttle pump output or reset pump to lower level Do not lower if sand may clog pump 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 Motor Runs But Overload Protector Trips A Incorrect voltage Using volimeier check the line terminals Contact power company if voltage is incorrect 99 Voltage m
55. aller 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 or 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 and 16 21 Ground motor per national and local codes 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 8 Pump Motor Installation A Splice motor leads to supply cable using electrical grade solder or compression connectors and carefully insulate each splice with watertight tape or adhesive lined shrink tubing as shown in motor or pump installation data B 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 C 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 D Assemble all pipe joints as tightly as practical to preve
56. an 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 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 COOLING 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 I
57. c and Pumptec are load sensing devices that monitor the load on submersible pumps motors If the load drops below a preset level for a minimum of 4 seconds the QD Pumptec or the Pumptec will shut off the motor The QD Pumptec is designed and calibrated expressly for use on Franklin Electric 230 V 3 wire motors 1 3 to 1 hp The QD Pumptec must be installed in QD relay boxes The Pumptec is designed for use on Franklin Electric 2 and 3 wire motors 1 3 to 1 5 hp 115 and 230 V The Pumptec is not designed for jet pumps QD Pumptec amp Pumptec Troubleshooting 57 SYMPTOM If the QD Pumptec or Pumptec trips in about 4 seconds with some water delivery If the QD Pumptec or Pumptec trips in about 4 seconds with no water delivery If the QD Pumptec or Pumptec will not timeout and reset If your pump motor will not run at all If your QD Pumptec or Pumptec will not trip when the pump breaks suction If your QD Pumptec or Pumptec chatters when running CHECKS OR SOLUTION Is the voltage less than 90 of nameplate rating Are the pump and motor correctly matched Is the QD Pumptec Pumptec wired correctly For the Pumptec check the wiring diagram and pay special attention to the positioning of the power lead 230 V or 115 V For QD Pumptec is your system 230 V 60 Hz or 220 V 50 Hz The pump may be airlocked If there ia a check valve on top of the pump put another section of pipe between the pump a
58. cent 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 by 100 to determine percent of unbalance 4 Current unbalance should not exceed 5 at service factor load or 10 at rated input 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 33 1st Hook Up 2nd Hook Up 3rd Hook Up L1 8 413 L1 12 L3 L1 12 13 FOE 19 fat 4p oP T T T TJ t starter motor EXAMPLE T1 51 amps T3 50 amps T2 50 amps T2 46 amps T1 49 amps T3 48 amps T3 53 amps 12 51 amps 11 52 amps Total 150 amps Total 150 amps Total 150 amps 190 _sSoamps 99 59amps 120 50 amps 3 3 3 50 46 4 amps 50 49 1 50 48 2 amps
59. e 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 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 Table 37 Franklin Cable chart See 12 Wiring CABLE TEMP RATING CC MOTOR NAME PLATE RATED AMPS FULL LOAD 3 LEAD DOL 6 LEAD Y A 3 LEAD DOL 6 LEAD Y A 3 LEAD DOL 10 AWG 8 AWG IN AIR IN AIR IN CONDUIT 40A 69A 44 76 51 IN CONDUIT 28A 48A 32A 55A 46A 40 69A 44A 76A 63A 56A 97A 64A 111A 74A 76A 84A 6 LEAD Y A 109A 80 127A 88A IN AIR 132A 145A 104A 74A 145A 180A 129A 251A 15 6 AWG IN CONDUIT 52A 90A 60A 104A Application Three Phase Motors Franklin Cable Chart tables 16 21 Notice wire size wire rating and insulation temperature rating must be 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 conduit also increases Check Valves Spring loaded check valves must be used on start up to minimize mot
60. e Meter Input Amps Line 1 Line 2 Line 3 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 Zip Installation Site If Different Contact Telephone System Application System Manufactured By Model Serial No System Supplied By City State Zip Is this a HERO system 10 0 10 5 PH Yes No Motor Model No Serial No Date Code Horsepower Voltage Single Phase Three Phase Diameter in Slinger Removed Yes No Check Valve Plug Removed Yes No Motor Fill Solution C Standard DI Water Pump Manufacturer Model Serial No Stages Diameter Flow Rate Of gpm At TDH Booster Case Internal Diameter Material Controls and Protective Devices SubMonitor Yes If Yes Warranty Registration No If Yes Overload Set Q Yes No Set At Underload Sets Yes No Set At VFD or Reduced Voltage Starter Yes No If Yes Type Mfr Setting Full Voltage In Sec Pump Panel Yes No If Yes Mfr Size Magnetic Starter Contactor Mfr Model Size Heaters Mfr No If Adjustable Set At Fuses Mfr Size Type Lightning Surge Arrestor Mfr Model Controls Are Grounded to with No Wire Inlet Pressure Control Yes No If Yes Mfr Model Setting psi Delay Sec Inlet Flow Control Yes No If Yes Mfr Model Setting
61. e 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 41 Maintenance All Motors li System Troubleshooting Motor Does Not Start POSSIBLE CAUSE CHECKING PROCEDURES CORRECTIVE ACTION A No power or incorrect voltage Check voltage at line terminals Contact power company if voltage is incorrect 99 The voltage must be 10 of rated voltage 9 Check fuses for recommended size and check for loose dirty or corroded Replace with proper fuse or reset connections in fuse receptacle Check circuit breakers for tripped circuit breakers B Fuses blown or circuit breakers tripped Check voltage at contact points Improper C Defective pressure switch contact of switch points can cause voltage Replace pressure switch or clean points less than line voltage D Control box malfunction For detailed procedure see pages 46 54 Repair or replace Check for loose or corroded connections E Defective wiring mes Correct faulty wiring or connections or defective wiring Check for misalignment between pump and motor or a sand bound pump Pull pump and correct problem Run new Amp readings will be 3 to 6 times higher installation until the water clears than norm
62. e 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 0 025 inch per 12 inches of length 2 mm per 1000 mm of length 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 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 Pump Load Multiplier Application Three Phase Motors 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 motor shell then must be permanently stamped with a D closely be
63. e 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 open atmosphere applications such as lakes ponds etc 3 The Standard Vertical Water Well 40 125 hp 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 S
64. ed keep dV dt lt 500 V usec See Filters or Reactors below 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 115 of nameplate maximum amps in any line Subtrol Plus and SubMonitor Franklin s Subtrol Plus and SubMonitor protection systems ARE NOT USABLE on VFD installations 39 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 BUT switches rise times lt 2 usec and 3 Cable from drive to motor is more than 50 ft 15 2 m A low pass filter is preferable Filters or reactors should be selected in conjunction 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
65. ee Phase Table 5 lists minimum generator sizes based on typical 80 C rise continuous duty generators with 35 maximum voltage dip during starting for Franklin s three wire motors single or three phase This is a general chart The generator manufacturer should be consulted whenever possible especially on larger sizes There are two types of generators available externally and internally regulated Most are externally regulated They use an external voltage regulator that senses the output voltage As the voltage dips at motor start up the regulator increases the output voltage of the generator Internally regulated self excited generators have an extra winding in the generator stator The extra winding senses the output current to automatically adjust the output voltage Generators must be sized to deliver at least 65 of the rated voltage during starting to ensure adequate starting torque Besides sizing generator frequency is important as the motor speed varies with the frequency Hz Due to pump affinity laws a pump running at 1 to 2 Hz below motor nameplate frequency design will not meet its performance curve Conversely a pump running at 1 to 2 Hz above may trip overloads Generator Operation Always start the generator before the motor is started and always stop the motor before the generator is shut down The motor thrust bearing may be damaged if the generator is allowed to coast down with the motor running
66. es 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 measure 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
67. es or relays refer to operational test procedure described on page 46 Section B 2 47 Table 48 QD Control Box Parts 60 Hz CONTROL BOX MODEL NUMBER x QD BLUE RELAY x 280 104 4915 223 415 906 230 280 105 4915 223 415 902 282 405 5015 CRC 223 415 912 NOTE 1 Control boxes supplied with QD Relays are designed to operate on 230 volt systems For 208 volt systems or where line voltage is between 200 volts and 210 volts use the next larger cable size or use a boost transformer to raise the voltage NOTE 2 Voltage relays kits for 115 volts 305102901 and 230 volts 305102902 will replace current voltage or QD Relays and solid state switches Table 48B Overload Kits 60 Hz KIT 1 305 100 901 305 100 902 305 100 903 305 100 904 305 100 905 305 100 906 1 For Control Boxes with model numbers that end with 4915 275 464 105 275 464 113 275 464 118 275 464 125 275 464 126 275 464 201 156 362 101 155 962 102 223 415 901 223 415 902 223 415 903 223 415 904 223 415 905 223 415 906 223 415 912 223 415 913 223 415 914 MFD VOLTS 280 102 4915 223 415 905 275464125 159 191 110 250 300 125 TEN 230 43 53 156 362 101 230 280 107 4915 223 415 903 275 464 118 86 103 EN 230 280 108 4915 223 415 904 275 464 113 105 126 Table 48 QD Capacitor Replacement Kits CAPACITOR NUMBER 305 207 905 305 207 913 305 207 918 305 207 925 305 207 926 305
68. esistance Ground Fault Circuit Interrupter RMA Return Material Authorization gom Gallon per Minute RMS Root Mean Squared HERO High Efficiency Reverse Osmosis rpm Revolutions per Minute hp Horsepower SF Service Factor Hz Hertz SFhp Service Factor Horsepower ID Inside Diameter S N Serial Number IGBT Insulated Gate Bipolar Transistor TDR Total Dynamic Head n inch UNF Fine Thread kVA Kilovolt Amp V Voltage kVAR Kilovolt Amp Rating VAC Voltage Alternating Current kW Kilowatt 1000 watts VDC Voltage Direct Current L1 L2 L3 Line One Line Two Line Three VFD Variable Frequency Drive Ib ft Pound Feet W Watts L min Liter per Minute XFMR Transformer mA Milliamp Y D Wye Delta Q ohms max Maximum ii notes M1311 03 07 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 and motor installation questions When you call a Franklin expert will offer assistance in troubleshooting and provide immediate answers to your system application questions Technical support is also available online Visit our website at www ftranklin electric com Franklin Electric The Company You Trust Deep Down
69. f 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 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 li 3 Wire Control Boxes Single phase three wire submersible motors require the use of control boxe
70. ge 13 Application Single Phase Motors li Table 14 Single Phase Motor Fuse Sizing CIRCUIT BREAKERS OR FUSE AMPS CIRCUIT BREAKERS OR FUSE AMPS Aun iss TYPICAL SUBMERSIBLE iuis DUAL ELEMENT DUAL ELEMENT yours 800880 sn ss sasay FUSE FUSE 244504 115 35 30 30 15 30 244505 1 2 0 37 230 20 10 15 15 8 19 244507 3 4 230 25 15 20 20 10 20 244508 a 0 75 230 30 20 29 25 15 25 244309 1 5 1 1 230 35 20 30 35 15 30 214504 118 35 20 30 30 16 30 1 2 0 37 214507 230 25 15 20 20 10 20 214508 1 0 75 230 30 20 25 25 11 25 214505 214505 230 20 10 18 15 8 115 214507 230 25 15 20 20 10 20 4 3 WIRE W CRC CB 214508 230 30 20 25 25 14 25 214508 1 0 75 230 30 20 25 25 11 25 W 1 1 5 CB 224300 ie 230 35 20 30 30 15 30 224301 230 30 20 20 30 15 25 224302 230 45 30 40 45 20 40 5 3 7 224303 230 80 45 60 70 30 60 226110 230 80 45 60 70 30 60 5 3 7 wo so 226112 EFMES 230 150 80 125 150 60 125 226113 15 11 230 200 125 175 200 90 175 226111 Application Single Phase Motors li Auxiliary Running Capacitors Added capacitors must be connected across Red and Although motor amps decrease when auxiliary Black control box terminals in parallel with any existing run capacitance is added the load on the motor running capacitors The additional capacitor s should does not
71. hind 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 00 Service Factor 50 2 1 15 Service Factor 60Hz 40 35 30 25 20 15 10 Feed Water Temperature FIG 12 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 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 T 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 The pipe plug covering the check valve must be removed from Ni resist and 316 SS motors The special Booster motor already has these alterations made Frequency of Star
72. ich equals 63 2 hp This is the minimum rated service factor horsepower usable at 39 hp in 124 F Using table 8A select a motor with a rated service factor horsepower above 63 2 hp A 60 hp motor has a service factor horsepower of 69 so a 60 hp motor may be used li Allowable motor temperature is based on atmospheric pressure or higher surrounding the motor Drawdown seals which seal the well to the pump above its intake Grounding Control Boxes and Panels Application All Motors to maximize delivery are not recommended since the suction created can be lower than atmospheric pressure The 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 surge arrestor to be effective GROUNDING THE ARRESTOR TO THE SUPPLY GROUND OH TO A DRIVEN GROUND ROD PROVIDES LITTLE OR NO SURGE PROTECTION FOR THE MOTOR Control Box and Panel Environment Franklin Electric control boxes meet UL requirements for NEMA Type 3R enclosures They are suitable for indoo
73. id splashing water Replace float switch Ground Fault Check insulation resistance on motor and control box cable The line voltage is below 207 volts Pumptec Plus will try to restart the motor every two minutes until line voltage is normal Yellow Flashing Light Float Switch Low Line Voltage Solid Red Light a Check for excessive voltage drops in the system electrical connections i e circuit breakers Loose Connections fuse clips pressure switch and Pumptec Plus L1 and L2 terminals Repair connections The line voltage is over 253 volts Check line voltage Report high line voltage to the Flashing Red Light High Line Voltage power company 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 Replace damaged pipes or repair leaks Stuck Check Valve 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 Rapid Cycle Flashing Red and Yellow Lights Float Switch unit to detect a rapid cycle condition on any motor or an overload condition on 2 wire motors Try to reduce water splashing or use a different switch 56 li QD Pumptec and Pumptec Maintenance Electronic Products QD Pumpte
74. ife 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 Make sure the rating insert is correct for the motor 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 Check for drop in amps and delivery just before trip indicating pump breaking suction and for unbalanced line current With the power turned off recheck motor lead resistance to ground A grounded lead can cause underload trip 60 f Maintenance Electronic Products Subtrol Plus Obsolete See SubMonitor Subtrol Plus Troubleshooting After Installation Continued SYMPTOM 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 Signal Circuit Terminals Do Not Energize 61 POSSIBLE CAUSE OR SOLUTION 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 indicat
75. in and start wires are swapped Make certain proper motor is installed Check motor wiring Make certain all connections are tight Make certain proper motor is installed input power to reset Check motor wiring Cycle input power to reset Check pump This fault automatically resets when temperature returns to a safe level Cycle input power means turn the power off until both lights fade off and apply power again 58 Maintenance Electronic Products f SubiVionitor SubMonitor Troubleshooting FAULT MESSAGE PROBLEM CONDITION POSSIBLE CAUSE SF Amps Set Too High SF setting above 359 Amps Motor SF Amps not entered Phase Reversal Reversed incoming Fw s phase sequence Incoming power problem line current Wrong SF Max Amps setting Over pumping well nderload Clogged pump intake Closed valve Low line current Loose pump impeller Broken shaft or coupling Phase loss 000000002 line current Wrong SF Max Amps setting Overiosa High or low line voltage d Ground fault High line current Pump motor dragging Motor stalled or bound pump High or low line voltage Motor is overloaded Excessive current unbalance Motor temperature sensor has detected excess Overheat Poor motor cooling motor temperature High water temperature Excessive electrical noise in close proximity Phase loss Current difference
76. inutes 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 in positions Application All Motors When the storage temperature does not exceed 100 F 37 C storage time should be limited to two years Where temperatures reach 100 to 130 F 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 3 Number of Starts MOTOR RATING HP KW Up to 0 75 MAXIMUM STARTS PER 24 HR PERIOD SINGLE PHASE THREE PHASE Up to 0 55 300 300
77. lb 68 to 81 Nm A motor lead assembly should not be reused A new lead assembly should be used whenever one is removed from Apply increasing torque to the screws equally Because pner set and possible damage criss cross pattern until 80 to 90 in lb 9 0 to 10 2 9 Nm is reached All motors returned for warranty consideration must have the lead returned with the motor 8 Motors with 4 Screw Clamp Plate Jam nut tightening torques recommended for field assembly are shown Rubber compression set within the Pump to Motor Coupling Assemble coupling with non toxic FDA approved waterproof grease such as Mobile FM102 Texaco CYGNUS2661 or approved equivalent This prevents abrasives from entering the spline area and prolongs Spline life Shaft Height and Free End Play Table 41 If the height measured from the NORMAL DIMENSION FREE END PLAY A mp mountin rf f th SHAFT HEIGHT SHAFT HEIGHT p UE saat US o p s 383mm 508 exceeds the limit the motor thrust bearing is possibly damaged and 73 0 should be replaced 101 6 mm 8 TYPE 2 1 101 6 mm Submersible Leads and Cables A common question is why motor leads are smaller than specified in Franklin s cable charts CAUTION Lead assemblies submersible motors are suitable only for use in water and may overheat The leads are considered a part of the motor and actually and cause failure if operated in air are a connection between th
78. listed may be requested by Fixed heater overloads must be the ambient compensated calling Franklin s Submersible Service Hotline at quick trip type to maintain protection at high and low 800 348 2420 air temperatures Refer to notes on page 29 Table 28 60 Hz Motors HEATERS FOR ADJUSTABLE ine oat OVERLOAD RELAYS RELAYS SIZE FURNAS G E NOTE 5 NOTE 1 NOTE 2 200 K31 230 K28 380 460 575 200 230 3 4 380 460 575 0 0 0 00 00 0 0 0 0 0 1 1 0 0 0 1 1 1 1 1 1 1 1 28 li Table 29 60 Hz J Motors HEATERS FOR NEMA OVERLOAD RELAYS VOLTS STARTER FURNAS G E NOTE 1 NOTE 2 L220B L199B L122B L100B L825A 29 ADJUSTABLE RELAYS NOTE 3 Application Three Phase Motors Footnotes for Tables 28 29 and 30 NOTE 1 Furnas intermediate sizes between NEMA starter sizes apply where 1 is shown in tables size 1 75 replacing 2 2 5 replacing 3 3 5 replacing 4 and 4 5 replacing 5 Heaters were selected from Catalog 294 table 332 and table 632 starter size 00 size B Size 4 starters are heater type 4 JG Starters using these heater tables include classes 14 17 and 18 inNOVA classes 36 and 37 reduced voltage and classes 87 88 and 89 pump and motor control centers Overload relay adjustments should be set no higher than 100 unless necessary to stop nuisance tripping with measured amps in all lines below nameplate maximum Heater selections fo
79. 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 voltage 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 Inline Booster Pump Systems Franklin Electric offer
80. ly to use a standard 230 volt single phase transformer kVA needed and the common submersible motor and control While tables to give a standard transformer kVA Table 15A Buck Boost Transformer Sizing MOTOR HP LOAD KVA MINIMUM XFMR KVA STANDARD XFMR KVA Buck Boost transformers are power transformers not control transformers They may also be used to lower voltage when the available power supply voltage is too high 15 Application Three Phase Motors Table 16 Three Phase 60 C Cable 60 Hz Service Entrance to Motor Maximum Length in Feet 60 C MOTOR RATING MCM COPPER WIRE SIZE vors HP kw 14 12 10 6 4 3 2 1 o oo o0 000 250 300 350 400 500 710 ENT o EHE rs ss gt 75 0 0 0 0 0 N o o N Q o o o JS I o EMEN 25 185 30 22 34 055 1 07s 15 ad 5 75 55 ESEN EMEN 25 185 30 2 0 37 34 0 55 WS 228 ERR 75 55 10 75 15 20 15 25 185 28 50 37 60 45 75 5 100 75 _ 125 90 150 110 175 130 0 0 0 0 0 0 0 0 0 0 0 0 0 fon NEM FSO c fon O O c Foe O o NM O FSO c fon O O
81. nd QD switches should be regarded as indicative and not conclusive For example 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 To verify proper operation of QD switches or relays refer to operational test procedure described above Section 2 Abound pump will cause locked rotor amps 46 li Ohmmeter Tests QD Solid State Control Box Power Off A START CAPACITOR AND RUN CAPACITOR IF APPLICABLE CRC 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 Q D BLUE RELAY Step 1 Triac Test 1 Meter setting R x 1 000 2 Connections Cap and B terminal 3 Correct meter reading Infinity for all models Step 2 Coil Test 1 Meter Setting R x 1 2 Connections L1 and B 3 Correct meter reading Zero ohms for all models 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 excep
82. nd the check valve The pump may be out of water Check the valve settings The pump may be dead heading Pump or motor shaft may be broken Motor overload may be tripped Check the motor current amperage Check switch position on side of circuit board on Pumptec QD Pumptec check timer position on top front of unit Make sure the switch is not between settings If the reset time switch is set to manual reset position 0 QD Pumptec and Pumptec will not reset turn power off for 5 sec then back on to reset Check voltage Check wiring Remove the QD Pumptec from the control box Reconnect wires in box to original state If motor does not run the problem is not QD Pumptec Bypass Pumptec by connecting L2 and motor lead with jumper Motor should run If not the problem is not Pumptec On Pumptec only check that Pumptec is installed between the control switch and the motor A Be sure you have a Franklin motor Check wiring connections On Pumptec is lead power 230 V or 115 V connected to correct terminal 15 motor lead connected to correct terminal C Check for ground fault in the motor and excessive friction in the pump The well may be gulping enough water to keep QD Pumptec or Pumptec from tripping It may be necessary to adjust the QD Pumptec or the Pumptec for these extreme applications Call the Franklin Electric Service Hotline at 800 348 2420 for information On Pumptec ap
83. ng time verify that pump output electrical input pumping level and other characteristics are stable and as specified Date Filled In By Notes INSTALLER S NAME ADDRESS CITY STATE ZIP PHONE FAX CONTACT NAME WELL NAME ID WATER TEMPERATURE F or C IViotor Motor No Date Code Manufacturer Model No NPSH Required ft NPSH Available Operating Cycle ON Min h YOUR NAME WELL DATA Total Dynamic Head Casing Diameter oe Pipe Diameter Drawdown pumping Water Level Check Valves at amp amp Solid Drilled Pump Inlet Setting Flow Sleeve No Yes Dia Casing Depth Well Screen Perforated Casing From to ft amp to Well Depth Form No 2207 8 00 A N Submersible Motor Installation Record RMA No OWNER S NAME ADDRESS CITY STATE PHONE FAX CONTACT NAME DATE INSTALLED DATE FAILED hp Voltage Phase Curve No Rating _ ft Actual Pump Delivery gom psi OFF min h Circle Min or h as appropriate TOP PLUMBING Please sketch the plumbing after the well head ft check valves throttling valves pressure tank etc and indicate the setting of each device ft ft amp ft ft in ft ft ft ft TDH it submersbte motor mstanation Record Power Supply Cable Service Entrance to Control ft AWG MCM Copper Aluminum Jacketed Individual Conductors Cable Control to Motor ft
84. nt unscrewing from motor torque Torque should be at least 10 pound feet per hp 2 meter KG per kW E 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 Form No 3656 02 07 Submersible Pump Installation Check List F Check insulation resistance as pump motor assembly 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 44 9 After Installation A Check all electrical and water line connections and parts before starting the pump B 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 C Check three phase motors for current balance within 5 of average using motor manufacturer instructions Imbalance over 5 will cause higher motor temperatures and may cause overload trip vibration and reduced life D Verify that starting running and stopping cause no significant vibration or hydraulic shocks E After at least 15 minutes runni
85. or 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 4 AWG 2 AWG SOURCE OF CABLE IN AIR AMPACITY 100A 173A IN AIR 136A 236A IN CONDUIT 92A 19A IN CONDUIT 68A 118A US N E C 2002 edition tables 310 16 amp 310 17 US N E C 2002 edition tables 310 16 amp 310 17 Standard AAR American 185A
86. p cable the resistance of the drop cable must be subtracted from the Ohmmeter readings to get the winding resistance of the motor See table below Table 45A DC Resistance in ohms per 100 ft of Wire Two conductors 50 F AWG OR MCM WIRE SIZE COPPER 14 12 10 8 6 4 3 2 OHMS 0 544 0 338 0 214 0 135 0 082 0 052 0 041 0 032 1 1 0 2 0 3 0 4 0 250 300 350 400 500 600 700 0 026 0 021 0 017 0 013 0 010 0 0088 0 0073 0 0063 0 0056 0 0044 0 0037 0 0032 45 f f Maintenance Single Phase Motors amp Controls identification Of 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 1 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 2 Voltage Reading Should remain the
87. plications does the control box have a run capacitor If so Pumptec will not trip Except for Franklin 1 5 hp motors Check for low voltage Check for waterlogged tank Rapid cycling for any reason can cause the QD Pumptec or the Pumptec relay to chatter On Pumptec make sure the L2 and motor wires are installed correctly If they are reversed the unit can chatter li Maintenance Electronic Products SubDrive75 150 300 MonoDrive amp MonoDrive XT The Franklin Electric SubDrive MonoDrive Constant Pressure controller is a variable speed drive that delivers water at a constant pressure WARNING Serious or fatal electrical shock may result from failure to connect the motor SubDrive MonoDrive Controller 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 To reduce the risk of electrical shock disconnect power before working on or around the water system Capacitors inside the SubDrive MonoDrive Controller can still hold a lethal voltage even after power has been removed Allow 10 minutes for dangerous internal voltage to discharge Do not use motor in swimming areas SubDrive MonoDrive Troubleshooting Should an application or system problem occur a built in diagnostics will protect the system The FAULT light on the front of the SubDrive MonoDrive Controller will flash a given number of times indicating the
88. r and outdoor applications within temperatures of 14 F 10 C to 122 F 50 C Operating control boxes below 14 F can cause reduced starting torque and loss of overload protection when overloads are located in control boxes Control boxes and panels should never be mounted in direct sunlight or high temperature locations This will cause shortened capacitor life and unnecessary tripping 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 any 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 9 WARNING Failure to ground the control frame can result in a serious or fatal electrical shock hazard o
89. r class 16 starters Magnetic Definite Purpose will be furnished upon request NOTE 2 General Electric heaters are type CR123 usable only on type CR124 overload relays and were selected from Catalog GEP 1260OJ page 184 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 Relay adjustment should be set at the specified SET amps Only if tripping occurs with amps in all lines measured to be within nameplate maximum amps should the setting be increased not to exceed the MAX value shown NOTE 4 Heaters shown for ratings requiring NEMA size 5 or 6 starters are all used with current transformers per manufacturer standards Adjustable relays may or may not use current transformers depending on design fr 1 Motor Inspection A Verify that the model hp or kW voltage phase and hertz on the motor nameplate match the installation requirements L B Check that the motor lead assembly is not damaged Measure insulation resistance using a 500 1000 volt DC megohmmeter from each lead wire to the motor frame Resistance should be at least 200 megohms without drop cable 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 Submersible
90. ree Phase Motors Applications SubMonitor is designed to protect 3 phase pumps motors with service factor amp ratings SFA from 5 to 350 A approx 3 to 200 hp 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 e Under Overload Under Overvoltage Current Unbalance Overheated Motor if equipped with Subtrol Heat Sensor False Start Chattering e Phase Reversal Power Factor Correction In some installations power supply limitations make it Table 31 kVAR Required 60 Hz necessary or desirable to increase the power factor of a submersible motor The table lists the capacitive required to increase the power factor of large Franklin three phase submersible motors to the approximate values shown at maximum input loading KVAR REQUIRED FOR PF OF 0 95 Capacitors must be connected on the line side of the overload relay or overload protection will be lost ol er N eo N 150 Values listed are total required not per phase 31 li Three Phase Starter Diagrams Application Three Phase Motors Three phase combination magnetic starters have two The control circuit consists of the magnetic coil overload distinct circuits a power circuit and a control circuit contacts and a control device such as a pressure switch When the control device con
91. reset the motor may not start however there will be current in the main winding until the overload protector interrupts the circuit 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 the motor windings The solid state switch senses motor speed through the changing phase relationship between start winding current and line current As the motor approaches running speed the phase angle between the start current and the line current becomes nearly in phase At this point the reed switch contacts open turning off the triac This removes voltage from the start winding and the motor continues to run on the main winding only With the reed switch contacts open and the triac turned off the QD relay is ready for the next starting cycle
92. rs Cable Selection 60 C Three Wire 16 17 Cable Selection 60 C Six Wire 18 Cable Selection 75 C Three Wire 19 20 Cable Selection 75 C Six Wire 21 Three Phase Motor Specifications 22 26 Three Phase Motor Fuse Sizing 27 Overload Protection 28 30 Submersible Pump Installation Checklist No 3656 Submersible Motor Installation Record No 2207 Submersible Booster Installation Record No 3655 SubMonitor a a 31 Power Factor Correction 31 Three Phase Starter Diagrams 32 Three Phase Power Unbalance 39 Rotation and Current Unbalance 33 Three Phase Motor Lead Identification 34 Phase Converters 0 7 34 Reduced Voltage Starters 35 Inline Booster Pump Systems 35 38 Variable Speed 39 Installation Motors Submersible Motors Dimensions 40 Tightening Lead Connector Jam Nut
93. s 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 and in some sizes overload protectors running capacitors and contactors Ratings through 1 hp may use either a Franklin Electric solid state QD or a potential voltage type starting relay while larger ratings use potential relays 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 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 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 Rapid Cycling The BIAC starting switch will reset within approximately 5 seconds after the motor is stopped If an attempt is made CAUTION Restarting the motor within 5 seconds
94. s 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 35 maximum allowable cable length used in the system 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 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 in 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 th
95. 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 The lead not used in the highest reading 6 ohms was Cable 1 to Cable 2 6 ohms Cable 2 to Cable 3 2 ohms Cable 3 to Cable 1 4 ohms Cable 3 Yellow From the yellow lead the highest reading 4 ohms was From the yellow lead the lowest reading 2 ohms was To Cable 1 Red To Cable 2 Black B CURRENT AMP MEASUREMENTS 1 2 Measure current on all motor leads Amp Reading Current in red lead should momentarily be high then drop within one second to values in table 13 This verifies relay or solid state relay operation Current in black and yellow leads should not exceed values in table 13 Relay or switch failures will cause red lead current to remain high and overload tripping Open run 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 overloading tripping Low amps may be caused by pump running at shutoff worn pump or stripped splines Failed start capacitor or open switch relay are indicated if the red lead current is not momentarily high at starting CAUTION The tests in this manual for components such as capacitors relays a
96. t for capacitors with resistors which will drift back to 15 000 ohms C POTENTIAL VOLTAGE RELAY Step 1 Coil Test 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 Maintenance Single Phase Motors amp Controls C POTENTIAL VOLTAGE RELAY Step 1 Coil Test 1 Meter setting R x 1 000 2 Connections 2 amp 5 3 Correct meter readings For 115 Volt Boxes 0 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 Step 2 Contact Test 1 Meter Setting R x 1 2 Connections 1 amp 2 3 Correct meter reading Zero ohms for all models CONTACTOR Step 1 Coil 1 Meter setting R x 100 2 Connections Coil terminals 3 Correct meter reading 1 8 14 0 180 to 1 400 ohms Step 2 Contacts 1 Meter Setting R X 1 2 Connections L1 amp T1 or L2 amp T2 3 Manually close contacts 4 Correct meter reading Zero ohms CAUTION The tests in this manual for components such as capacitors relays and QD switches should be regarded as indicative and not as conclusive example 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 To verify proper operation of QD switch
97. t 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 lf 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 a normal protective function protecting against an overload or locked pump Check the amps all 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 kn
98. tacts are closed current The power circuit consists of a circuit breaker or flows through the magnetic contactor coil the contacts fused line switch contacts and overload heaters close and power is applied to the motor Hand Off Auto connecting incoming power lines L1 L2 L3 and the switches start timers level controls and other control three phase motor devices may also be in series in the control circuit Li L2 Line Voltage Control This is the most common type of control encountered Since the coil is connected directly across the power FUSES lines L1 and L2 the coil must match the line voltage PRESSURE SWITCH OR OTHER CONTROL DEVICE CONTACTS CONTACTS OVERLOAD HEATERS AND OR SUBTROL PLUS gt FIG 7 L1 L2 L3 Low Voltage Transformer Control This control is used when it is desirable to operate push buttons or other control devices at some voltage lower FUSES than the motor voltage The transformer primary must match the line voltage and the coil voltage must match the secondary voltage of the transformer PRESSURE SWITCH OR OTHER CONTROL DEVICE O L CONTACTS m TRANSFORMER CONTACTS OVERLOAD HEATERS AND OR SUBTROL PLUS FIG 8 L1 L2 External Voltage Controls FUSES OTHER CONTROL DEVICE Control of a power circuit by a lower circuit voltage can O L CONTACTS also be obtained by connecting to a separate control CONTROL VOLTAGE voltage source The
99. 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 4A Torque Required Examples MOTOR RATING MINIMUM SAFE 1 hp amp Less 0 75 kW amp Less 10 Ib ft 200 Ib ft 750 2000 Ib ft SMALLEST KVA RATING EACH TRANSFORMER 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 CLOSED ratings are shown If power WYE OR DELTA company experience and 3 TRANSFORMERS practice allows transformer loading higher than standard higher loading values may be used to meet total effective kVA required provided correct voltage and balance is maintained To safely withstand maximum unscrewing torques with a minimum safety factor of 1 5 tightening all theaded joints to at least 10 lb ft per motor horsepower is recommended table 4A It may be necessary to tack or strap weld pipe joints on high horsepower pumps especially at shallower settings li Application All Motors Use of Engine Driven Generators Single Phase or Thr
100. tor 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 60 Hz Unloaded Generator Low Line Voltage The line voltage is below 207 volts Check line voltage Check for loose connections which may cause voltage drops 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 207 volts for more than 2 5 seconds Undervoltage trips will also occur if the line frequency rises too far above 60 Hz Solid Red Light Loaded Generator 55 Maintenance Electronic Products li Pumptec Plus Pumptec Plus Troubleshooting After Installation SYMPTOM POSSIBLE CAUSE SOLUTION 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 Dry Well Solid Yellow Light Machine gun rapid cycling can cause an underload condition See flashing red and yellow Severe Rapid Cycling lights section below Worn Pump Replace worn pump parts and recalibrate Stalled Motor Repair or replace motor Pump may be sand or mud locked A bobbing float switch can cause two wire motors to stall Arrange plumbing to avo
101. ts Fewer than 10 starts per 24 hour period are recommended Allow at least 20 minutes between shutdown and start up of the motor 36 li Inline Booster Pump Systems continued 9 10 11 12 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 Motor Overload Protection Submersible motors require properly sized ambient compensated Class 10 quick trip overloads per Franklin s AIM Manual guidelines to protect the motor 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 Motor Surge Protection Properly sized grounded and dedicated motor surge arrestors must b
102. ubmersible 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 1 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 li 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 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 th
103. ust be within 10 of rated voltage p pany g Direct sunlight other heat source can raise control B Overheated protectors box temperature causing protectors to trip The box D Worn pump Pull pump and replace worn parts Shade box provide ventilation or move box away from source must not be hot to touch C Defective control box For detailed procedures see pages 46 54 Repair or replace D Defective motor or cable For detailed procedures see pages 44 amp 45 Repair or replace E Worn pump or motor Check running current see tables 13 22 24 amp 26 Replace pump and or motor 43 f Maintenance All Motors Table 44 Preliminary Tests All Sizes Single and Three Phase TEST Insulation Resistance Winding Resistance PROCEDURE 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 Use a megohmmeter or set the scale lever to R X 100K on an Ohmmeter Zero the meter Connect one meter lead to any one of the motor leads and the other lead to the metal drop pipe If the drop pipe is plastic connect the meter lead to ground 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 Set the scale lever to R X 1 for values under 10 ohms

Franklin Submersible Motors 2007 User's Manual

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