Peerless Pump Company

SUBMERSIBLE TURBINEPUMP INSTALLATION AND

OPERATION INSTRUCTIONSFOR 4”, 6” & 8” SIZES

Pump No. __________________

Invoice No. _________________

P.O. No. ___________________

Item No. __________________

Bulletin B-2649804

Peerless Pump CompanyIndianapolis, IN 46207-7026

SUBMERSIBLE TURBINE PUMP INSTALLATION AND OPERATION INSTRUCTIONS1.0 PRE-INSTALLATION CHECK LIST

1.1 Inspection of Shipment

1.1.1 Motor

Standard Peerless Pump submersible pumpmotors are shipped assembled to their bowlunits.

Check the following:

a. Appropriate motor installation and operationmanual (provided by the motor manufacturer).

b. Motor must be free from evidence ofexternal damage.

c. Motor nameplate voltage, horsepower, etc.must be compatible with the ratings on thepumping plant panel, the power meter and onthe purchasing and shipping documents.

d. If the motor is equipped with a power cable,do not use it to support the weight of themotor.

e. Motor’s electrical connector or cable leads must be compatible with the drop cable.

f. Check the motor’s instruction tags or its installation manual to determine with whatliquid it is filled. Add liquid if necessary.

g. Record the motor serial number, installationdate and other pertinent information. Retainthis information in the pump’s permanent record file.

1.1.2 Bowl Unit

Examine the bowl unit and its strainer forevidence of external damage. Be sure that thecolumn adapter’s threads are clean and undamaged. Check to be sure that the largestoutside diameter of the motor/bowl unitassembly will fit inside the well. Record thebowl unit’s serial number, model number, etc. and retain this information in the pump’s permanent record file.

1.1.3 Drop Pipe (Column Pipe)

Examine the pipe to be sure that it is sound,with clean, well formed threads. Be sure thatenough pipe is on hand to reach the intendedsetting (depth).

1.1.4 Power Cable

The exact type of cable to be used is a matterfor the individual pump manufacturer orinstaller to decide. Several cablemanufacturers have cable designed for use

submerged in water. The insulation on theconductor should be Type RW, RUW, TW, orequivalent, specifically suitable for usesubmerged in water.

The cable may have three individualconductors twisted together, three conductorsmolded side by side in one flat cable, or threeconductors with a round external jacket. Useof solid or stranded conductor cable isoptional.

For information on cable selection, seeparagraph 4.1.

1.1.5 Connectors/Splicing Materials

Check to be sure that the connectors and/orsplicing materials are suitable. When making awaterproof cable splice, we recommend using:

1.1.5.1 Scotch Cast Splicing Kit No. 82-A1; one foreach lead. Each kit includes instructions foruse. (Peerless part 2615720)

1.1.5.2 Taped Type Splice (Peerless part 2615721).

The following tapes are used:

a. “Bi-Seal” tapeSupplier: Mitchell-Rand Insulation Co.

51 Murray StreetNew York, New York

or: “Scotchfil” electrical puttySupplier: Minnesota Mining & Mfg. Co.

b. “Scotch: #33 electrical tape and “Scotchkote”

Supplier: Minnesota Mining & Mfg. Co.

“Bi-Seal” tape is a self-bonding polyehtelenetape which has excellent electrical propertiesand extremely low water vapor transmission.“Scotchfil” electrical insulation putty has gooddielectric and excellent aging properties.

“Scotch” #33 tape, although a good insulating material, is used for mechanical protection dueto its superior abrasion resistance. Among themany effective methods of making waterproofsplices, those described in paragraph 2.6 areas effective as any.

1.1.6 Electrical Panel

Examine the pumping plant panel (starter) toestablish its compatibility with the motor, theelectric meter and the requirements of the

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application. For use with submersible motors,the panel must have ambient quick tripoverload relays instead of standard relays. Theuse of standard relays can void the motorwarranty. For additional information on motorprotection, see paragraph 4.3.

1.1.7 Airline

If an airline will be installed, check to ensurethat the material (plastic, copper, black pipe) isappropriate, that the quantity on hand issufficient, and that an exit opening is providedin the surface plate or through the pumpfoundation. See also paragraph 2.7.

1.2 Special Tools

Voltammeter for checking current

Sta-kon pliers or crimping tool for securingcable connectors to the cable

Banding tool for securing cable to the column

“Band-it” stainless steel band

“Band-it” buckles for use with bands

Rubber pads to protect cable under “Band-it” band

Cable: 3 parallel conductors #1 or #1/0 AWGapproximately 20 feet

1.3 Well Site

1.3.1 Size of Well and Straightness

Before attempting to install the pump, the wellshould be carefully checked to determine thatthe casing is of the proper diameter, depth andstraightness. If there is any doubt about thesize of accuracy of the well, consult your pumpdealer and, if necessary, have the wellsurveyed and plotted to determine that thepump can be installed properly and will operatenormally. Since the pump drop pipe can becurved, within limits, without detriment to pumpoperation, the well should be surveyed to findout in what direction and how sharply it curvesthroughout its length.

Wells for which the exact depth and diameterare not known should be checked even if theyare not crooked because the lower well casingsare frequently smaller in diameter than theupper casings.

If a well is crooked, surveying it is especiallyimportant when the pump outside diameter isclose to the well inside diameter.

Surveying involves lowering into the well to theproper depth a checking tool which is themaximum diameter and length of the pump.

together with a piece of drop pipe at least 50feet long.

In a crooked well a submersible pump will workmuch better than a line shaft pump which mighthave excessive friction and wear. Be sure thepump is not installed in a bend.

1.3.2 Condition of Water

1.3.2.1 Sand and Debris

Developing the well and freeing it from sandare part of the well driller’s job and should be done with a test pump reserved for thispurpose. However, if a test pump is notavailable and a new pump must be used,extreme care should be taken. Throttle thedischarge at least until the water becomesclear of excessive sand. Even then, in spite ofall precautions, the pump will probably be badlysand cut during the process. Peerless will notaccept the responsibility for a new pumpdamaged in this manner.

1.3.2.2 Gas

If air or other gas is present in the water, thepump will not perform as anticipated and, if gasis present in excessive quantities, pumpingmay stop altogether. The presence of gas maycause vibration and damage. If a gas ispresent, consult your dealer or the pumpmanufacturer for advice.

1.3.2.3 Temperature

Submersible motors which meet NEMAstandards are rated for full horsepower outputin water at temperatures up to about 25C (77F). If the water temperature exceeds 25C(77F), check with the pump manufacturer todetermine the maximum allowable motor load.

Some operating conditions do not ensureadequate flow past the motor. Examples are:

a. Top-feeding (cascading) wells can feed thewater directly into the pump without itsflowing past the motor if the well is notcased below the motor, or if the casing isperforated above the motor.

b. Flow may be inadequate if the motor is in alarge body of water, if the casing is muchlarger than the motor, or if delivery is verylow.

If either of these conditions exists, seeparagraph 4.2.

1.3.3 Installation Depth

Seasonal and pumping drawdown should be

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determined to prevent running dry withconsequent damage to the pump and motor. Ifthe seasonal or pumping drawdown levels arenot available, the use of a low water levelcontrol or a low water level alarm or indicatoris highly recommended. For best results thepump should be located below its lowestpumping level by at least the amount of itsNPSH required (NPSHr) value. The NPSHrvalue can be determined from the pumpperformance curve. If possible, the pumpshould also be located above its water bearingstratum.

Do not locate the pump so that it is buried insand or mud at the bottom of the well. Thebottom of the motor should be at least five feetabove the bottom of the well. If the motor orpump must be buried in mud at the bottom ofthe well, consult your pump dealer forrecommendations.

1.3.4 Power Supply

Verification of the electrical supply should bemade to ensure that its voltage, phase, andfrequency match that of the motor. Motorvoltage, phase, frequency, and full-loadcurrent information can be found on thenameplate attached to the motor. Mostsubmersible motors are designed to operatewith the normal NEMA input voltage range ofnameplate voltage 10%, plus an additional5% maximum drop in the supply cable.Voltages outside this range can causereduced pump output, produce overloadtripping, and cause failure to start.

In the specific case of a 200 or 208 voltsupply, a 200 volt rated motor should be used.A 230 volt motor may be used with thefollowing limitations and conditions:

a. The power supply must be a good, stableone which will maintain 200 volts or higherunder running conditions.

b. Use the normal HP rated motor for thepump. Pump delivery and motor loadingwill be reduced slightly because the lowervoltage will reduce motor speed.

c. Use motor cable two sizes larger thanspecified, such as #8 where #12 wouldnormally be used.

d. If the control box for a single phase motorcontains 230 volt relays, change them to200-208 volt relays.

1.3.5 Pump Foundation

A substantial concrete foundation should bebuilt around the well before the pump is

installed. The top of the foundation should bea minimum of 3” above the top of the well casing and large enough so that a generousshoulder will extend beyond the base of thesurface plate. The foundation should slopeoutward and downward and be sufficientlydeep into the ground to provide the requiredthickness for strength as well as to secure afirm footing.

The thickness and the ground area for thefoundation will depend upon the firmness ofthe supporting earth around the well under theworst possible conditions (considering rain orflood effects) and the weight of the completepumping unit when full of water. If thetemperature drops below freezing, thefoundation must extend beyond the freezinglevel. The total load on the foundation equalsthe dead weight of all parts including theweight of the foundation itself plus the weightof water in the drop pipe. Tables 1, 2, 3, and 4may be used for reference when figuring thesize of the foundation.

A 2” pipe in one corner of the foundation (as shown in Figure 1) to accept a pipe extensionwill be convenient to anchor the chain tongswhen tightening the drop pipe joints. A 1-1/2” or 2” pipe through the foundation to permit passage of the sounding weight of anelectrical device to measure the distance tothe surface of the water (also shown in Figure1) is also recommended.

Properly constructed structural foundations orcombination structural and concretefoundations can be acceptable. However,wooden timbers in contact with the soil orfoundations resting on unstable soil areunsatisfactory.

2.0 INSTALLATION

2.1 Motor Leads Test

Test the motor leads and the motor connector(if used) as follows:

a. Check the winding resistance of the three-phase motor by touching the prongs of anohmmeter to the cable leads of any twowires. The readings must be equal in allthree legs; if otherwise, check with yourdealer or motor manufacturer.

b. Check the resistance of each lead to thewater or water container to measure theinsulation resistance. The readings shouldbe about 50,000,000 ohms (50 megohms)or more.

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FIGURE 12.2 Connect the Motor Leads to the Drop

Cable

Various motor connections to the drop cableare required depending upon the connectionconfiguration furnished by the motormanufacturer. If the motor connectionrequires a splice, the procedure described inparagraph 2.6 can be used.

2.3 Check Motor Rotation

Check the direction of the motor rotationbefore the motor is installed in the well.Temporarily splice the ends of the dropcable which extend from the hub of the cablereel to #1 or #1/0 AWG cable. Connect thiscable to the power supply. Momentarilyenergize the power supply (bump theswitch). Observe the direction of rotation(through the suction screen). The direction ofrotation must agree with the arrow fastenedto the unit. Mark the drop cable leadsextending from the cable reel hub for properrotation when the cable is permanentlyconnected. Disconnect and remove thetemporary conductors.

2.4 Place the Pump/Motor Assembly in the Well

Place timbers or equivalent supports on thefoundation around the well casing for use asresting blocks for the elevator clamps.

Fasten one pair of elevator clamps (seeFigure 2) to the top end of the bowlassembly. Make certain that the clamps arefastened securely around a smaller diameterso that a larger diameter cannot passthrough the clamps.

Caution: Never clamp or hold the bowl unit with aStillson type wrench or chain tongs.

Caution: Fasten the elevator clamps in a mannerwhich will not crush the motor cable or itsmetal guard.

Caution: The entire down thrust of the pump iscarried on a special thrust bearing. Thisbearing can be broken if the pump isdropped or jarred. PUMP FILURE WILLRESULT. The motor is enclosed in a metaltube. If this tube is damaged, motor failurecan follow.

Caution: Observe the instructions provided by themotor manufacturer. Failure to comply canshorten motor life and void the motorwarranty.

Note: If the motor/bowl unit assembly is longerthan six feet, do not remove the shippingskids until the bowl unit has been hoistedto the vertical position. This is also goodpractice for shorter bowl units.

Attach a sling to the elevator clamps andpass its looped end over the hoist hook.While a helper steadies the lower end of thepump, hoist the unit into position over thewell.

Slowly, carefully lower the unit into the wellunit the weight of the unit is supported by theelevator clamps on the support timbers.Remove the sling if possible. (If a secondsling is available, the first sling may beremoved later.)

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TABLE 1. PERMISSIBLE LOAD ON SOIL

Nature of SoilLbs. Per Sq.Ft. of Area

Packed GravelCompacted SandDry-Thick Clay BedMoist Thick Clay BedDry SandSoft, Wet ClayAlluvial Top Soil

16,0008,0008,0004,0004,0002,0001,000

TABLE 3. WEIGHT OF PUMP ANDINTERCONNECTOR-POUNDS

Type1st. Stage and

Inter-ConnectorEach

AdditionalStage

6LB6MA6HXB7LB7HXB8LB8MA8HXB9LA

808683

100102115123120144

141414191932323256

FIGURE 2

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TABLE 4. WEIGHT OF SUBMERSIBLE MOTOR

Horse-power Phase Size

ThrustRating

Weight,Pounds

57 ½105

7 ½1015202530405040506075

100

11133333333333333

6”6”6”6”6”6”6”6”6”6”6”6”8”8”8”8”8”

150015003500150015003500350035003500350035003500

1000010000100001000010000

10712314495

107128144168186190304355345375405460550

TABLE 2. WEIGHT OF PIPE AND WATER-POUNDS

Std.PipeSize

Wt. Per Ft.of pipe

Wt. ofWater PerFt. of Pipe

2 ½3456

5.797.58

10.7914.6218.97

2.13.05.08.0

12.0

2.5 Install the Drop Pipe

Securely fasten elevator clamps to a joint ofdrop pipe immediately below its pie coupling.With a sling on the ears of the elevator clampsand the hook of the hoist, lift the pipe into avertical position. A helper, with a “tail rope” on the pipe, should steady the pipe.

Slowly and carefully lower the drop pipe untilits threads enter the bowl unit’s column adapter.

Place chain tongs around the top end of thebowl unit to prevent its rotation.The pipe threads must be square, well formedand clean. Liberally apply a good quality pipesealant and joint compound. With chain tongs,thread the pipe into the column adapter. Ifcross threading has accidentally started,unthread the joint, file and clean the threads.Restart the threads, making sure that theyengage fully and squarely. If cross threadingdamage is extensive, remove and replace thepipe joint.

Make all pipe joints TIGHT.

With the hoist, lift the motor/bowl unit/pipe jointassembly about one inch. Remove the chaintongs, the (lower) elevator clamps, and thefirst sling, if it was not previously removed.Slowly and carefully lower the assembly intothe well until the elevator clamps are restingon the support timbers. Remove the sling, ifpossible.

Repeat this procedure (paragraph 2.5 –except that each pipe joint is threaded into thepipe joint below it instead of the bowl unit) untilthe desired setting (depth) is reached.

Caution: Refer also to paragraphs 2.6 through 2.9before proceeding with the installation.

2.6 Installing the Cable

2.6.1 Splices

2.6.1.1 If the cable furnished has three conductors ina single round jacket, snip the outer jacket intwo or three places with Sta-kon or similarpliers and remove it by peeling the jacket backapproximately one foot. Remove the cotton orany other tape from individual conductors inorder to expose the insulation from each wire.

Utmost care must be exercised to remove alltraces of tape from the insulation. Otherwise,through capillary action, water will enter thesplice and short out the motor.

Strip the insulation of each conductor backfar enough to allow the conductors to

extend half way through the connector.Crimp the connectors to the conductors.

2.6.1.2 Apply “Be-Seal” tape. First, stretch the tape 2-3 times its normal length. Start taping with aview of making a smooth contour across thelength of the splice. Use normal tension intaping. Continue taping until the thickest partof the splice is about 1-1/2” beyond the end of the wire insulation. When “Scotchfil” is used, make a smooth contour over the connectionby filling the voids and padding the sharpedges of the cable connectors. Extend thefilling at least 1” beyond the end of the wire insulation.

2.6.1.3 Apply four half lapped layers of “Scotch 33” tape going beyond the ends of the “Bi-Seal” tape.

2.6.1.4 Apply one coat of “Scotchkote” over the tape going beyond the end of the tape over thecable jacket.

2.6.1.5 Test the splice in accordance with theprocedure described in paragraph 2.1.

2.6.2 Feeding the Cable into the Well

As the motor/bowl unit/drop pipe assembly islowered into the well, extreme care must beexercised to avoid any nick or abrasion. Feedthe cable into the well CAREFULLY. Asubstantial proportion of submersible pumpfailures result from cable damage duringinstallation.

2.6.3 Banding the Cable to the Drop Pipe

At least once for every twenty feet of drop pipeband the cable to the drop pipe. Apply thebands in accordance with the proceduredescribed in Figure 3. See also Figure 4 for apictorial description of the banding at theupper end of the drop pipe and the route ofthe cable through the cable entrance fitting(cable entrance fitting is optional). Thefollowing recommendations will help to assurea satisfactory cable installation:

a. Slack in the cable, about one extra foot,should be provided at each band. Reason:Each band should support no more than theweight of twenty feet or cable.

b. Install a rubber block of appropriate height oneither side of the cable so that the band doesnot damage the cable.

c. It is good practice to install a rubber “boot” under the band, as shown in Figure 4. Thishelps to keep the bands in place.

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FIGURE 3. BANDING PROCEDURE

d. If airline is installed, band it to the drop pipeunder the same bands used to band the cableto the drop pipe; see paragraph 2.7

2.7 Airline

Installation of airline is strongly recommended.It will be used to determine the standing andpumping water levels in the well to facilitatetesting and monitoring changing wellconditions. Band the airline to the drop pipe

with the same bands used to secure the powercable.

Airline usually consists of ¼” black pipe or copper or plastic tubing. If copper or plastictubing is used, rubber standoff blocks arerecommended to prevent crushing.

The bottom end of the airline must remainopen. Locate the bottom end about two feetabove the top edge of the bowl unit’s suction screen. All joints except the opening at thebottom must be air tight.

The overall length of the airline must be knownto an accuracy of 2 or 3 inches. Normally thereference point for the top end of the airline isthe center of the discharge fitting of the surfaceplate. Record the overall length of the airline inthe pump’s permanent record file.

A tee with a water level gauge and an air valve(all optional) can be assembled to the surfaceplate. If the airline is tubing, use a compressionfitting where the airline passes through thebase of the surface plate. Locate the center ofthe water level gauge at about the same heightas the center of the discharge of the surfaceplate.

Adjust the movable gauge dial to reflect thelength of the airline. Loosen the screws on theface of the gauge and turn it until thegraduation corresponding to the vertical heightis opposite the pointer when the gauge is in a nupright position. Check the dial after tighteningthe screws.

To obtain readings, pump air into the airlineuntil the gauge needle ceases to rise. Note thegauge reading. This is the distance from thegauge center to the water level.

“Standing” or “static” water level readings are taken before starting the pump, or after ashutdown period long enough to allow the wellwater level to stabilize at its highest point. A“pumping level” reading is taken after the pump has been operating against normal head longenough for the water to stabilize at its lowestlevel. “Drawdown” is calculated by subtracting the standing water level from the pumpinglevel.

An ordinary pressure gauge could be usedinstead of a water level gauge. In this case thepressure indicated by the gauge must bemultiplied by 2.31 to get the water height in feetabove the bottom end of airline. The waterdepth in the well is airline length minus waterheight.

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FIGURE 4

Keep a record of all readings and the datestaken for a complete history of well and pumpperformance.

2.6 Installing the Surface Plate

The top joint of drop pipe will have no pipecoupling at its top end. It is inadvisable tosupport the weight of the pump/drop pipeassembly from the elevator clamps on the topassembly from the elevator clamps on the topjoint of drop pipe. Thread the top joint of droppipe into the surface plate; make the jointrelatively tight.

2.8.1 With the sling on the surface plate’s lifting lugs, lift the surface plate/drop pipe assemblyinto position over the well. If a well seal will beused, slip it into place. Thread the drop pipeinto its (lower) coupling tightly.

Lift the pump/drop pipe/surface plateassembly an inch or so. Remove the elevator

clamps, unused sling, resting blocks and cleanthe foundation. If a well seal is used, position iton the foundation. Lower the surface plate to a

Convenient working height and completetightening it onto the drop pipe. (A lever suchas a 2’ x 4” board or a 1-1/2” pipe inserted into the discharge will facilitate tightening.)

2.8.2 While the pump remains suspended, completethe airline assembly as described in paragraph2.7.

2.8.3 While the pump remains suspended, unrollenough electrical cable to reach the pumpingplant panel. Cut the cable. Test the cable asdescribed in paragraph 2.1. Pass the cablethrough the (optional) cable entrance fitting.Band the cable to the drop pipe as shown inFigure 4.

2.8.4 Turn the pump as it hangs from the hoist untilthe discharge connection points in the desireddirection. Slowly lower the pump and locatethe column pipe approximately concentric withthe well casing. If anchor bolts are used, theyshould be directly in line with the holes in thesurface plate. Continue to lower the pump untilthe bolts just enter the holes. Locate theleveling wedges, one on each side of thesurface plate where greatest support andrigidity are apparent. Lower the pump until thesurface plate rests firmly upon the wedgeswhile at the same time maintaining theconcentric position of the column within thewell casing. After carefully centering andaligning the surface plate and column, groutwith high strength non-shrink grout.

2.9 Wiring the Control Panel

Before making the final wiring connections ofthe drop cable to the control box terminal, it isgood practice to recheck the insulationresistance to ensure that the cable and spliceare still good. Measurement for a newinstallation must be 1,000,000 ohms or more.Do not start the pump if the measurement islower. If it is higher, finish the wiring and verifythat all electrical connections are made inaccordance with the wiring diagram and themotor rotation check in paragraph 2.3. Checkto be sure that the control box and the highvoltage surge arrestor (if used) have beengrounded.

2.9.1 Control Panel for Single Phase Three WireMotors

A Franklin Electric control box must be usedwith a Franklin motor. Each control box has anoverload protector, a capacitor or capacitors,and a starting relay, all of which are matched

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to the motor. Operation of a Franklin singlephase three wire motor without a Franklincontrol box or with an incorrect control box orwith an incorrect control box can result inimmediate or early failure of the motor, controlbox or both.

Control boxes for 1-1/2 HP and larger motorshave manual reset overload protectors orcircuit breakers, each made to match andprotect a motor with a specific horsepowerrating.

Control boxes for motors with ratings above 1HP, in addition to one or more electrolyticstarting capacitors, also have one or more oiltype running capacitors to provide a higherefficiency and power factor.

There are two types of starting relays generallyused with single phase submersible motorswhich do not have centrifugal switches. One iscalled a current relay because it operates fromthe current through the main winding. Theother is called a voltage or a potential relaysince it operates from the voltage across thestart winding. Each type will give satisfactoryservice. A different current relay is required foreach motor current rating. One voltage relay isused for all 115 volt motors and one for all 230volt motors.

For additional information relative to singlephase control panels see paragraph 4.3.1.

2.9.2 Controls and Protection for Three PhaseMotors

Caution: The normal thermal overload relays orheaters used for standard motors will not tripfast enough to protect a submersible motorand special quick trip protectors must beused.

WARRANTY OF THREE PHASESUBMERSIBLE MOTOR IS VOID IFPROPER QUICK TRIP PROTECTORS ARENOT USED IN ALL THREE MOTOR INPUTLINES.

If there is any question about the size/ratingsof the overload heaters or relays, check withthe motor manufacturer or the pump dealer.

In all cases, three properly selected overloadprotectors in series with the lines of asubmersible motor will be needed to provideadequate motor protection. Two line protectionis not acceptable.

Submersible motors are different from above-ground motors. If a submersible motor is

stalled, the overload protector must trip withinapproximately 10 seconds to protect the motorwindings. In single phase submersible motors,this protection is provided by the speciallydesigned and selected protector in the controlbox, but in three phase submersible motorsprotection must be provided by the thermaloverload relays in the magnetic motor starter.

The ambient temperature at the magneticstarter affects the trip current and time of theprotector to a considerable degree unless theprotectors are ambient compensated. To affordmaximum motor protection and to avoidnuisance tripping, use ambient compensatedprotectors. If non-ambient compensatedprotectors are used, nuisance tripping may beexperienced, especially in warm weather,because as the ambient temperature rises, theprotectors’ safety margin is diminished. If non-compensated relays or heaters are used andnuisance tripping occurs, do not substitutelarger heaters. Instead, change to ambientcompensated relays or heaters.Compensated and non-compensated thermalrelays or heaters are interchangeable inmagnetic starters.

For additional information pertaining to controlsand protection for three phase motors, seeparagraph 4.3.2.

3.0 STARTING THE PUMP

3.1 General Review

Before starting the pump, it is good practice:

a. To review Section 2.0, the installationprocedure, to ensure that all installationrequirements have been met.

b. To clear the area surrounding the well oftools, equipment, discarded packaging, etc.

c. To review this complete Section 3.0 beforestarting the pump.

3.2 Energize the Pump

Turn the power switch to the “on” position. Stand by for several seconds to turn the switch“off” if anything should go wrong.

3.3 Check the Electrical Current

Using a snap-on voltammeter, measure thecurrent in each line without throttling the flow.The readings obtained should be within 15% ofnameplate rated full load amperage. Using thesame instrument check the voltage ineach line. The readings should be within

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10% of nameplate rated voltage. Any readingsoutside acceptable limits indicates that thepump should be turned off; the pump shouldnot be restarted until the problem is corrected.See paragraph 4.6.3 for additional information.

3.4 Check Motor Horsepower

Monitor motor horsepower at the power meter.(The power company can provide suitableinstructions.) If power consumption exceeds(nameplate rating) x (1.15) turn the pump offand correct the difficulty before the pump isrestarted. See also paragraph 4.6.3.

3.5 Throttle Valve Setting

Before the pump is started:

a. Attach a temporary horizontal length of pipeto the surface plate discharge.

b. Install a gate valve and another short lengthof pipe to the temporary pipe.

c. Adjust the gate valve one third of the wayopen.

When first starting the pump, determine thequantity of water the well can deliver to thepump and the quantity of water the pump candeliver to the system. The danger point isreached when the pup delivers water fasterthan it flows into the well. If this occurs thesupply of water in the well will be depletedbefore a pumping cycle is completed causingthe pup to run dry with consequent damage tothe pump and motor.

When the pump is turned on, the system hasno water pressure; the pump will deliver itsmaximum capacity until system pressure isdeveloped. The sudden rush of water in thewell may loosen sand, carry it into the waterlubricated bearings of the motor and thepump, causing serious damage. Prevent thiswith the following procedure:

a. Before the pump is started:

(1) Open the discharge throttling valve toabout 1/3 of full open.

(2) Determine the standing water level.Refer to paragraph 2.7.

b. Start the pump.

c. Determine the stabilized pumping level.

d. If the stabilized pumping level is above thelowest acceptable pumping level* thevalve may be opened in small increments(repeating steps c and d) until either:

(1) The valve is completely open, or

Caution: The pump should never be runin continuous upthrust. Seeparagraph 3.6.

(2) The lowest acceptable pumping level* isreached.

*e. The lowest acceptable pumping level isdefined as that water level above the bowlunit’s suction opening which equals the net positive suction head required(NPSHr) for that bowl unit. The NPSHrvalue can be determined from themanufacturer’s performance curve or from the dealer.

Caution: If the final pumping level iswithin 20 feet of the lowestacceptable pumping level,monitor the pumping levelfrequently, so that thelowest acceptable pumpinglevel will not be exceeding.or, install water levelcontrols.

3.6 Running in Continuous Upthrust

To insure that the pump is not running incontinuous upthrust, its flow must not exceedapproximately 120% of the capacity for whichthe pump was selected. If the capacity isgreater, throttle the flow until the limit is met.In seasons when the water level is high, thesame flow limit exists.

A flow measuring device (flow meter, pitottube, etc.) is recommended for installation inthe discharge pipe. However, if no flowmeasuring device is available, the followingprocedure will provide satisfactory results:

a. Install a pressure gauge in the dischargehead or discharge pipe between thedischarge head and the throttle valve.

b. Determine the distance to water level withthe pump running and the throttle valvepartially closed.

c. Multiply the pressure gauge reading by2.31, thus converting pressure to feet ofwater. Add this head to the distance towater which will then give the total headdeveloped by the pump.

d. Adjust the throttle valve so that the resultobtained in paragraph (c) corresponds tothe head (in feet) for which the pump isselected.

4.0 Other Considerations

4.1 Cable Selection

Tables 5 and 6 list the copper cable sizes10

recommended for various cable lengths. The tablescomply with National Electrical Code Table 310-16,Column 2 for 75C wire, with capacity divided by 1.25per N.E.C. article 430-22 for motor branch circuits,based on motor amperages at rated horse powers.

Maximum cable lengths are calculated to maintain 95%of service entrance voltages with motors running atmaximum nameplate amperes, and to maintainadequate starting torque. Calculations includeconsideration of basic cable resistance, reactance,power factor, and temperature rise. Cable larger thanspecified may always be used (if the well is largeenough) and will reduce power usage.

The portion of the total cable length which is betweenthe service entrance and a three phase motor startershould not exceed 25% of the maximum allowablelength to insure reliable starter operation. Single phasecontrol boxes may be connected at any point in thetotal cable length.

If aluminum conductors are used, they must be twosizes larger than the copper size specified, such as #0aluminum in place of #4 copper.

WARNING:Use of cable smaller than recommended voids thewarranty and can cause failure to start or operateproperly.

4.2 Cooling Flow Past the Motor

Check Figure 6 to determine if the expected deliveryproduces adequate flow past the motor. If necessary,use a flow inducer sleeve on the pump or provide flow.

A flow inducer’s sleeve is a tube over the motor, closedoff above the pump intake and

11

TABLE 6. CABLE SELECTION FOR THREE PHASE MOTORS

Motor Rating Maximum Cable Length (Feet) by Cable Size

Volts HP 14 12 10 8 6 4 2 0 00 000 0000

1.5 320 510 800 12602 250 390 610 960 15003 180 290 450 710 1110 16905 300 470 730 1110 16907.5 340 530 810 1230 1660

10 250 390 600 920 1240 154015 270 410 630 850 1060 127020 320 480 650 810 970 115025 390 530 660 790 930

200V

60 Hzor

50 Hz

30 430 540 640 7501.5 430 680 1070 16802 320 510 790 1250 19403 240 380 600 940 1470 22405 250 390 620 960 1470 22307.5 290 450 700 1070 1630 2200

10 340 520 800 1220 1640 205015 360 550 830 1130 1410 168020 420 640 860 1070 1280 151025 340 520 700 870 1040 1230

230 V60 Hz

and

220 V50 Hz

30 420 570 710 850 10001.5 17202 1280 20303 960 1530 24005 630 1000 1570 24707.5 460 730 1150 1800 2810

10 550 850 1340 2090 319015 590 920 1430 2190 334020 700 1100 1670 2550 344025 570 890 1360 2070 2800 350030 730 1110 1690 2280 2850 340040 850 1300 1750 2190 2610 307050 680 1040 1400 1750 2090 245060 870 1180 1470 1760 207075 950 1190 1420 1670

460 V60 Hz

and

380 Vthru

460 V50 Hz(Dividelengthsby 1.4

for 380 V60 Hz)

100 890 1060 12401.5 26402 18603 1490 23705 980 1560 24407.5 720 1150 1800 2820

10 540 850 1340 209015 590 920 1440 224520 700 1090 1700 260025 890 1390 2130 324030 730 1130 1730 2640 356040 870 1330 2030 2730 328050 1060 1620 2190 2620 312860 900 1360 1840 2210 2640 310075 1100 1490 1790 2130 2510

575 V

60 Hz

100 1110 1330 1590 1860

12

TABLE 5. CABLE SELECTION FOR SINGLE PHASE MOTORS(Two-Wire & Three-Wire)

Maximum Cable Length (Feet) by Cable Size

Volts HP 10 8 6 4 2 0 005 216 315 490 750 1142 15407 ½ 270 362 553 842 1136 1420220

10 250 425 650 875 1100

Example: Installation of a 5 HP 230 V single phase motor at 300 feet depth with 30 feet additional cable from well head toentrance totals 330 feet, and requires #6 or larger cable, since #8 is only suitable up to 315 feet.

NOTE: For two-wire installations with known low line voltage or sandy well conditions, use the next larger cable size (such as #4 inplace of #6).

FIGURE 6. REQUIRED FLOW FORMOTOR COOLING

FIGURE 7. CONTROL BOX COMPONENTS ANDWIRING, 1 ½ HP AND LARGER MOTORS

TABLE 7. HEAD LOSS FROM FLOW PAST MOTOR

This table lists the approximate head loss in feet from flowbetween an average length motor and a smooth casing or sleeve.

Motor (Nominal) 4” 4” 4” 6” 6” 6” 8” 8”Casing I.D. 4 ¼” 5” 6” 6” 7” 8” 8.1” 10”

25 0.250 0.6

100 1.6 0.2 0.8150 4.8 0.5 .1 1.4200 0.9 .2 2.2 0.3 3250 1.3 .3 3.0 0.4 5300 1.8 .4 4.2 0.6 0.2 8400 7.4 1.0 0.3 12500 1.4 0.5 19 0.1600 2.0 0.7 27 0.2800 0.4

GPM

1000 0.7

13

FIGURE 8 CONTROL BOX CONNECTIONS

extending to the bottom of the motor orlower. It must be securely fastened to thepump and its top closed to make water flowcome in the bottom past the motor. Thesleeve material may be heavy plastic ormetal and it should resist corrosion. (SeeFigure 5.)

Figure 6 shows the delivery in gallons perminute required to provide minimumrecommended water flow past the motors indifferent sizes of casings or flow sleeves.Table 7 gives approximate head losses fromthe flows past the motor.

If a well feeds water from above the pump,has a casing too small to allow a flowinducer sleeve on the pump, or does nothave adequate level and flow to allow raisingthe pump above the inflow, it is difficult tocool the motor properly. When possible thecasing depth should be increased so thatflow must come from below the motor. If thisis not practical, some flow past the motorcan be attained by tapping a ¼” I.D. tube into the pump outlet, clamping it down past thepump and motor, and supporting it so that itsinlet is aimed upward about a foot below themotor. The tubing should be protectedagainst damage by the clamps or casingduring installation and by spacers alongsidethe tubing. See Figure 5.

4.3 Controls and Overload Protection

4.3.1 Controls for Single Phase Motors

The diagram in Figure 7 and the explanationwhich follows show the components, theiroperation and the wiring schemestypically in control panels for 1-1/2 HP andlarger single phase motors.

4.3.1.1 Operation of Voltage Relays

Before the power is applied the starting relaycontacts are closed. When the power isapplied, both start and main motor windingsare energized, and the motor starts. At thisinstant the voltage across the start winding isrelatively low. This low value of voltageacross the start winding is not enough topick up (open the contacts of) the startingrelay.

As the motor comes up to speed the voltageacross the start winding (and the startingrelay coil) increases. This higher voltage isenough to pick up the starting relay andopen its contacts. This removes the startwinding from the line and the motorcontinues to run on the main winding alone.Because of motor action when the motor isrunning, there is a voltage generated in thestart winding. This voltage is applied to thecoil of the starting relay. As long as themotor runs normally, this generated voltageis high enough to keep the starting relay“picked up” (contacts open) and keep the start winding circuit cut off from the linevoltage.

The voltage type relay is affected slightly byposition and for best operation the controlbox should be mounted vertically.

4.3.1.2 Operation of Current Relays

Before power is applied the starting relaycontacts are open. When power is appliedthe high main winding current through therelay coil immediately closes the contacts,energizing the start winding and starting themotor. As the motor comes up to runningspeed, the current through the relay coilgradually drops and allows the contacts toopen the start winding circuit; the motorcompletes its acceleration and runs on themain winding.

4.3.1.3 Mounting Control Box in ExtremeTemperatures

The control box should never be mounted indirect sunlight or in high temperaturelocations. This can cause unnecessarytripping of the overload protector.

When the control box is mounted inextremely cold locations, there will be areduction in the motor starting torquebecause of the action of the cold on theelectrolytic starting capacitor. At minus 25F, the starting torque is about 80% of normalimmediately and 90% after a few seconds.

14

at minus 40F, the starting torque is 33% ofnormal and at minus 80F there is nomeasurable torque. Therefore, where thetemperature may go below minus 25F, werecommend that a small enclosure be builtaround the control box and that a 25 watt orlarger light bulb be left burning inside theenclosure.

4.3.1.4 Single Phase Control Boxes

Figure 8 shows schematically the wiring,connections and approximate relativepositions of the components of the controlboxes for single phase motors. Other types ofcontrol boxes for different components andinternal arrangements, bat the wiring andmotor connections are essentially the same.Each type of control box should be connectedin strict accordance with the diagram furnishedwith the control box, usually attached inside itscover.

For both 115 and 230 volt installations, thetwo incoming line leads are connected toterminals L1 and L2. If the incoming leadsinclude a (third wire) ground conductor, it mustbe connected to the grounding terminal in thecontrol panel. If the circuit has no groundingconductor and metal conduit from the controlbox to the supply panel is not used, add a wireat least as large as the line conductors toconnect the grounding terminal to a metaldrop pipe, casing, water pipe, or driven groundrod. Failure to ground the box frame can resultin a serious electrical shock hazard if a circuitfault occurs.IMPORTANT: Boxes With Lighting ArrestersWhen the control box has a lighting arrester, itmust be grounded as described in paragraph4.5 for proper lightning protection of the motor.

4.3.2 Controls for Three Phase Motors

4.3.2.1 Motor Protection

All pumping plant panels are suitable forsubmersible motors by using ambientcompensated fast trip overload relays. Forassistance with the selection of appropriaterelays, contact the pump dealer or thesubmersible motor manufacturer.

Note: Overload protection is required on allthree motor input lines. FAILURE TOPROTECT ALL THREE MOTOR INPUTLINES WITH THE PROPER QUICKTRIP PROTECTORS WILL VOID THEMOTOR WARRANTY.

4.3.2.2 Phase Fault Protectors

Many devices are available to warn ordisconnect power if three phase lineimbalance exceeds a preset limit. Some sensevoltage imbalance, some current imbalance,and some even compensate to reduce currentimbalance, thus offering widely varyingdegrees of protection. While these devicescan be of value in detecting excessiveimbalance and in preventing damage to amotor which has improper overload protection,they are not required when the recommendedoverload protection is used.

4.3.2.3 Overload Protection with HeinemannCircuit Breakers

As an alternative to the use of extra-quick tripheaters in the thermal overload relays of motorstarters for protection of three phasesubmersible motors, as specified in paragraph4.3.2.1, Heinemann overload relays or circuitbreakers may also be used. These differ fromthe thermal overload relays in that they aremagnetic with a hydraulic time delay and thetripping characteristics are somewhat different.The ultimate trip current of the Heinemannrelays or breakers is completely unaffected bythe ambient temperature but their locked rotortrip time are faster than those of thermalprotectors.

The locked rotor trip time of a Heinemannrelay of breaker depends upon the time delaycurve specified. To protect a stalledsubmersible motor time delay Curve No. 2must be specified. Curve No. 1 normallysupplied will not always trip quickly enough toprotect the motor. These ratings and timedelay curves apply whether the Heinemannequipment is the Type C overload relay (whichopens the control circuit of the motor contactoror starter) or the General Purpose of F Framecircuit directly). If the latter are used, the circuitbreaker, if mounted ahead of the motor starteror contactor, will serve as an overloadprotector for the motor as well as a safetyswitch to eliminate the need for a separatefused safety switch or combination starter.

Selection of the Heinemann equipmentdepends upon the type of mounting, terminals,connections, etc. For those who would likeadditional information or specific orderinginstructions, contact Heinemann ElectricCompany, Trenton, New Jersey.

15

4.4 Frequency of Starts

From the standpoint of motor temperatureand winding life, the starts per hour shouldnot exceed the rate indicated in Table 8.More rapid cycling can cause overheatingand possible failure, depending upon pumpinertia and other factors.

The average number of starts per day over aperiod of months or years influences the lifeof the motor and, even more, the life ofcontrol components such as starters, relays,and capacitors. The pump size, tank size,and controls should be selected to keep thestarts per day as low as practical formaximum life. Excessive cycling acceleratesmotor bearings and spline wear, pump wear,and control contact erosion.

4.5 Lightning Protection

Overhead power lines tend to draw lightningby a factor proportional to their height abovethe ground. Fortunately these lines areisolated from most residential equipment bytransformers. However, lightning strokes onpower lines can induce voltage surges in thesecondary lines and damage submersiblepump motors. These induced voltage surgescan be protected against through the use ofproperly selected and applied lightningarresters.

A high surge will travel over the power lineslooking for the best and closest connectionto ground. If it finds it in the submersiblemotor, the surge will leave the power lines atthe motor, jump across the motor windinginsulation to the motor frame, and dissipateitself to ground. A very small hole will havebeen punctured through the motor windinginsulation. If the motor is running at the time,the current of the normal voltage supply willfollow through this hole in the motor windinginsulation. It is this power follow currentwhich causes the damage; it will be high, inthe nature of a short circuit. Severe burningof the windings and insulation will result andthe motor windings will be ruined. All motorsare susceptible to this hazard. Thereplacement of a submersible pump motorwhich has been damaged by lightning ismore expensive than the replacement ofmost other pump motors. For this reason it ismost desirable to provide protection againstthese high voltage surges.

Protection consists of providing the best andshortest path to ground somewhere otherthan through the motor. Lightning arrestersare available which will provide such a path.

FIGURE 9. ARRANGEMENTS FOR GROUNDINGLIGHTENING ARRESTORS

These arresters are capable of conductingthe high voltage surge to ground (not a directlightning stroke) and will immediatelyextinguish the power follow current withoutdamage to themselves.

A lightning arrester installation is made byconnecting the arresters to the power linesand to a suitable ground. The suitability ofthe ground connection is all important.Ungrounded lightning arresters provide noprotection. A lightning arrester is merely adevice which will connect a surge ofelectricity from the power lines to a groundconnection. If this ground is better than theground afforded by the submersible motor,most of the high voltage surge will gothrough the lightning arrester to ground andprotection will have been provided to themotor. If the arrester ground is not as goodas that of the motor, most of the high voltagesurge will go to ground through the motorand damage the motor windings eventhough a lightning arrester is installed.

To provide motor surge protection, the highvoltage surge should be discharged throughan arrester to a true ground . True ground isa water bearing stratum below the earth’s surface.

Listed above are three acceptable ways ofgrounding an above ground lightningarrester.

16

a. The best possible protection is providedby a metal well casing which extends towithin 20 feet of the motor. In thisfortunate situation, the arrester should begrounded to the well casing by means of#12 or larger wire. (Refer to Figure 9A).

b. If the well casing is plastic or terminatesmore than 20 feet above the motor andmetal drop pipe is used, the best availableprotection is provided by grounding thearrester to the metal drop pipe. (Refer toFigure 9B).

c. If the well casing is plastic or terminatesmore than 20 feet above the motor andplastic drop pipe is used, then protection isonly provided when the arrester isgrounded to a #12 or larger bare copperwire run with the power cable to the motorand connected to a motor stud. This wireshould also connect to the top of the wellcasing. (Refer to Figure 9C).

The degree of protection afforded will be in theorder mentioned. Other factors affecting thedegree of protection, but over which there islittle control at the time of pump installationare:

a. Distance from bottom of well casing tomotor (only if casing ends above motor).

b. Distance from transformer to well casing.

The shorter these distances are, the better thedegree of protection.

The ground connection at the drop pipe and/orthe well casing must be a good, substantialelectrical connection. A bare wire wrappedaround the drop pipe or a band type connectorsimilar to a hose clamp is not adequate.Adequate ground connector fittings for use onmetal pipes from 3/4" to 12” are available at electrical supply houses; I is stronglyrecommended that these be used. Theconnection between the lightning arrester andthe drop pipe should be made with #12 orlarger copper wire. Stranded wire is preferableas it is less susceptible to breaking; a brokenground wire will render the lightning arresterinoperative.

The sketches in Figure 10 show the method ofattaching lightning arresters to thesubmersible motor power line.

4.6 Direction of Motor Rotation

4.6.1 Single Phase Motors

If the wiring connections are made inaccordance with the proper wiring diagram in

FIGURE 10. ATTACHMENT OF LIGHTNINGARRESTORS TO SUBMERSIBLE MOTOR

POWER LINE.

the control box, single phase motors shouldrotate in the correct direction.

4.6.2 Three Phase Motors

If the flow and pressure produced by the pumpare significantly lower than expected, it ispossible that the direction of motor rotation iswrong (in spite of the precautions described inparagraph 2.3).

If wrong motor rotation is suspected,interchange any two electrical cable leads inthe pump plant panel and try the pump again.If flow and pressure are reduced, switch theelectrical leads back to their originalterminals and look elsewhere for the problem.

4.6.3 Current Imbalance

Current imbalance causes the motor to havereduced starting torque, overload tripping,excessive vibration and poor performancewhich can result in early motor failure. It isvery important that current imbalance bechecked in all three phase systems. Currentimbalance between the legs should notexceed 5% under normal operating conditions.

Check the power supply service to determinewhether it is a two or a three transformersystem. The information can be obtained bycounting the transformers or by contactingyour power company. If two transformers are

17

TABLE 8. FREQUENCY OF STARTS

Average Number of Starts Per DayMotor Rating Maximum Frequency of

Starts Per Hour Single Phase Three PhaseLower than 1 HP1 HP thru 5 HP

7 ½ HP thru 30 HP40 HP and over

1501006020

30010050

300100100

present, the system is an “open delta” or “wye.” If there are three transformers, it is true three phase system. Make sure thetransformer rating in kilovolt amps (KVA) issufficient for the motor load. See table 9.

The percentage of current imbalance can becalculated as follows:

Greatest amp differencefrom the average% Current

Imbalance =Average current

X 100

Total of current values measuredon each legAverage current =

3

Determine the percentage of currentimbalance by:

Step 1. Measure and record current readings in ampsfor each leg (hookup). Disconnect the power.

FIGURE 11. TOTAL RESISTANCE OF DROP CABLE

18

TABLE 9. TRANSFORMER CAPACITY REQUIRED FORTHREE PHASE SUBMERSIBLE MOTORS

Minimum KVA Rating for Each TransformerThree PhaseMotor HP

Minimum TotalKVA Required* 2 Transformers

Open Delta or WYE3 TransformersDelta or WYE

57½101520253040506075100

7½10152025304050607590120

57½10151520253035405065

355

7½1010152020253040

*Pump motor KVA requirements only, and does not include allowances for other loads.

Step 2. Shift the motor leads from left to rightso the drop cable lead that was onterminal 1 is now on 2, lead on 2 isnow on 3, and lead on 3 is now on 1(Hookup 2). Changing the motor leadsin this manner will not reverse themotor rotation. Start the pump.Measure and record the currentreading on each leg. Disconnect thepower.

Step 3. Again shift drop cable leads from leftto right so the lead on terminal 1 nowgoes to 2, 2 to 3, and 3 to 1 (Hookup3). Start the pump. Measure andrecord the current readings on eachleg. Disconnect the power.

Step 4. Add together the values for eachhookup.

Step 5. Divide the total by 3 to obtain theaverage.

Step 6. Compare each single leg reading withthe average to obtain the greatestamperage difference from theaverage.

Step 7. Divide this difference by the averageto obtain the percentage of imbalance.Use the wiring hookup which providesthe lowest percentage of imbalance.See Table 10 for a specific example ofcorrecting for three phase powerimbalance.

5.0 TROUBLE SHOOTING

Many of the problems which develop withsubmersible pumps are electrical; mostproblems can be serviced without pullingthe pumps from their wells. The followingcharts cover most of the submersible pumpservice work. As with any trouble shootingprocedure, start with the simplest solution first;always make all the above ground checksbefore considering pulling the pump from thewell.

WARNINGWHEN WORKING WITH ELECTRICALCIRCUITS, USE CAUTION TO AVOIDELECTRICAL SHOCK.

It is recommended that rubber gloves andboots be worn and that care be taken to havemetal control boxes and motors grounded topower supply grounds or steel drop pipes orcasings extended into the wells.

Basically, only two instruments are needed –acombination voltmeter/ammeter and anohmmeter. These are relatively inexpensiveand can be obtained from most water systemssuppliers.

WARNING:A SUBMERSIBLE MOTOR IS INTENDEDFOR OPERATION IN A WELL. WHENNOT OPERATED IN A WELL, FAILURETO CONNECT THE MOTOR FRAME TOTHE POWER SUPPLY WITH ANEUTRAL GROUND MAY RESULT INSERIOUS ELECTRICAL SHOCK.

19

TABLE 10. CORRECTING FOR THREE PHASE POWER IMBALANCE

Example: Check for current imbalance for a 230 volt, 3 phase, 60 Hz submersible pump motor, 18.6 full load amps.

Solution: Steps 1 to 3 measure and record amperages on each motor drop lead for Hookups 1, 2, & 3.Step 1 (Hookup 1) Step 2 (Hookup 2) Step 3 (Hookup 3)

(T1) DL1 = 19 amps DL3 = 17 amps DL2 = 17 amps(T2) DL2 = 14 DL1 = 15 DL3 = 14(T3) DL3 = 15 DL2 = 16 DL1 = 17Step 4 Total = 48 amps Total = 48 amps Total = 48 amps

Total current 48Step 5 Average Current = 3 Readings = 3 = 16 Amps

(Hookup 1) = 19 –16 = 3(Hookup 2) = 16 –15 = 1Step 6 Greatest difference from

the average amperage (Hookup 3) = 16 –14 = 2

3(Hookup 1) = 48x 100 = 6.25

1 x 100 = 2.08(Hookup 2) = 482 x 100 = 4.17

Step 7 % Imbalance

(Hookup 3) = 48

Hookup 2 should be used since it shows the least amount of current imbalance. Therefore, the motor will operate atmaximum efficiency and reliability.By comparing the current values recorded on each leg, note that the highest value was always on the same leg, L1.This indicates the imbalance is in the power source. If the high current values were on a different leg each time theleads were changed, the imbalance would be caused by the motor or a poor connection. If the current imbalance isgreater than 5%, contact your power company for help.

20

TABLE 11. TYPICAL ELECTRICAL DATA FOR6” 60 HERTZ SUBMERSIBLE MOTORS

Rated HP Input MaximumInput

(S.F. Load)

RatedHP

Volts Ph. ServiceFactor

Amps Watts Amps Watts

MaximumThrustLoad

Pounds

CircuitBreakerOr Std.Fuse

DuelElement

Fuse

LockedRotorAmps

5

7.5

10

230

230

230

1

1

1

1.15

1.15

1.15

26.0

34.5

45.0

5070

7300

9800

29.5

40.0

52.0

5820

8500

11500

1500

1500

3500

35

45

60

35

45

60

95

145

223

5 200230460575

3333

1.151.151.151.15

17.014.87.25.9

4800480048004800

19.116.68.36.6

5600560056005600

1500150015001500

50452520

2520108

103904536

7.5 200230460575

3333

1.151.151.151.15

24.221.010.58.4

7000700070007000

27.523.911.99.5

8200820082008200

1500150015001500

70703025

30301512

1561366854

10 200230460575

3333

1.151.151.151.15

32.127.913.911.1

9600960096009600

36.832.016.012.8

11100111001110011100

3500350035003500

100804035

40352015

23520410282

15 200230460575

3333

1.151.151.151.15

47.241.020.516.0

13900139001390013900

53.646.623.318.6

16100161001610016100

3500350035003500

1501256050

60603025

306266133106

20 200230460575

3333

1.151.151.151.15

60.352.426.221.0

1830183018301830

70.261.030.524.4

21600216002160021600

3500350035003500

2001758070

80703530

430374187150

25 200230460575

3333

1.151.151.151.15

74.865.032.526.0

22600226002260022600

86.375.037.530.0

26100261002610026100

3500350035003500

22520010080

100904535

598520260208

30 200230460575

3333

1.151.151.151.15

92.080.040.032.0

27000270002700027000

105.892.046.036.8

31500315003150031500

3500350035003500

300250125100

1251105040

662576288230

40 460575

33

1.151.15

51.541.0

3600036000

60.048.0

4200042000

35003500

150125

7060

400320

50 460575

33

1.151.15

64.053.5

4400044000

75.060.0

5200052000

35003500

200150

9070

520416

TABLE 12. TYPICAL ELECTRICAL DATA FOR8” 60 HERTZ SUBMERSIBLE MOTORS

RatedHP

Input

MaximumInput

(S.F. Load)

RatedHP

Volts ServiceFactor

Amps KW Amps KW

MaximumThrustLoad

Pounds

Circuit.Breaker

OrStd.Fuse

DualElement

Fuse

LockedRotorAmps

40

50

60

75

100

460

460

460

460

460

1.15

1.15

1.15

1.15

1.15

53

66

77

97

128

37

44

53

66

87

60

75

89

110

148

42

51

61

76

102

10,000

10,000

10,000

10,000

10,000

175

200

225

300

400

70

90

100

125

175

342

433

560

750

1000

21

TABLE 14. INSULATION RESISTANCE VALUES FOR MOTOR AND CABLE

Condition of Motor and Leads OHM Value MEGOHM Value

New motor.2,000,000 (or more) 2.0

Used motor which can be reinstalled in the well. 1,000,000 (or more) 1.0

Motor in the well in reasonably good condition. 500,000 –1,000,000 0.5 –1.0

Motor which may have been damaged by lightning orwithdamaged leads. Do not pull the pump for this reason.

20,000 –500,000 0.02 –0.5

Motor or cable with damaged insulation. The pumpshould be pulled and repair made to the cable or themotor replaced. The motor will not fail for this reasonalone, but it will probably not operate for long.

10,000 –20,000 0.01 –0.02

Motor or cable insulation has failed. The pump must bepulled and the cable repaired or the motor replaced. Themotor will not run in this condition.

Less than 10,000 0 –0.01

22

TABLE 13. TYPICAL MOTOR WINDING RESISTANCE

Single Phase Motors

Resistance –OHMS

HP Motor VoltsMain WindingBlack-Yellow

Start WindingRed-Yellow

57 ½

10

6”6”6”

230230230

.55-.68

.40-.50

.27-.33

1.30-1.6.98-1.2.80-.98

Three Phase Motors

Resistance –OHMSHP

MotorSize 200V 230V 460V 575V

57 ½

1015202530405040506075

100

6”6”6”6”6”6”6”6”6”8”8”8”8”8”

.70-.88

.48-.59

.28-.46

.19-.24

.15-.22

.10-.19

.08-.14

.87-1.1.56- .71.35- .55.27- .37.19- .27.13- .21.11- .15

3.1 –4.12.1 –2.91.5 –2.11.1 –1.4

.77-1.1

.53- .81

.40- .59

.38- .54

.28- .40

.264-.282

.184-.216

.150-.166

.114-.126

.078-.090

5.7- 7.04.0- 4.82.5- 3.21.7- 2.21.2- 1.6.91-1.3.70-9.5.64- .80.47- .65

5.1 Preliminary Test

5.1.1 Supply Voltage

HOW TO MEASURE

By means of a volt meter which has been setto the proper scale, measure the voltage atthe control box or starter. On single phaseunits measure between line and neutral.On three phase units measure between thelegs (phases).

5.1.2 Current Measurement

HOW TO MEASURE

By use of an ammeter set to the properscale, measure the current on each powerlead at the control box or starter. See theElectric Data, Tables 11 and 12, for motoramperage draw information. Current shouldbe measured when the pump is operating atconstant discharge pressure with the motorfully loaded.

5.1.3 Winding Resistance

HOW TO MEASURE

Turn off power and disconnect the dropcable leads in the control box or starter.Using an ohmmeter, set the scale selectorsto R x 1 for values under 10 ohms and R x10 values for over 10 ohms. Zero adjust themeter and measure the resistance betweenloads. Record the values. Motor resistancevalues can be found in Table 13, Cableresistance values in Table 14.

5.1.4 Insulation Resistance

HOW TO MEASURE

Turn off power and disconnect the dropcable leads in the control box or starter.Using an ohm or megohmmeter, set thescale selector to R x 100K and zero adjustthe meter. Measure the resistance betweenthe lead and ground. (A steel well casing ordischarge pipe is an acceptable ground.)

WHAT IT MEANS

When the motor is under load, the voltage should bewithin 10% of the nameplate voltage. Largervariations may cause winding damage. Largevariations in the voltage indicate a poor electricalsupply and the pump should not be operated untilthese variations have been corrected. If the voltageconstantly remains high or low the motor should bechanged to the correct supply voltage.

WHAT IT MEANS

If the amperage drawn exceeds the listed servicefactor amps (SFA) or if the current imbalance is greaterthan 5% between each leg on three phase units, checkthe following:1. Burned contacts in motor starter.2. Loose terminal in starter or control box or possible

cable defect. Check winding and insulationresistance.

3. Supply voltage too high or low.4. Motor windings are shorted.5. Pump is damaged causing a motor overload.

WHAT IT MEANS

If all the ohm values are normal, and the cable colorsare correct, the motor windings are not damaged. Ifany one ohm value is less than normal the motor maybe shorted. If any one ohm value is greater thannormal, there is a poor cable connection or thewindings or cable may be open.If some of the ohm values are greater than normal andsome less, the drop cable leads are mixed. To verifylead colors, see resistance values in Electrical Data,Table 13.

WHAT IT MEANS

For ohm values, refer to Table 14. Regardless ofhorsepower, phase, voltage or Hertz, all insulation hasthe same resistance values.

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5.2 TROUBLE SHOOTING CHART

5.2.1 Pump Does Not Run

1. No electricity at pump panel.Check for voltage at pump panel.

Check for voltage on line and load.

4. Starter does not energize.Energize control circuit and check forvoltage at the holding coil.

5. Defective controls.Check all safety and pressure switchesfor operation. Inspect contacts in controldevices.

6. Motor and/or cable are defective.Turn off voltage, disconnect drop leadsfrom control box to the motor. Measurethe lead to ground values with ohmmeter(R x1). Measure the lead to groundvalues with ohmmeter (R x 100K).Record measured values.

7. Defective capacitor.Turn off voltage, discharge capacitor.Check with ohmmeter (R x 100K).

5.2.2 Motor Runs but Pump Does Not DeliverWater

Check well drawdown.

2. Pump check valve is blocked.Install pressure gauge, start pump,gradually close the discharge valve andread pressure at shut-off.

3. Inlet strainer is clogged.Same as number 2 above.

Check for very low motor amperage.

Correction

If no voltage at pump panel, check house or feederpanel for tripped circuits.

Replace blown fuses or reset circuit breaker. If newfuses blow or circuit breaker trips, the electricalinstallation, motor and cable must be checked.

Replace burned heaters or reset. Inspect starter forother damage. If heater trips again, check the supplyvoltage and starter holding coil.

If no voltage, check control circuit. If voltage, checkholding coil for short. Replace bad coil.

Replace worn or defective parts.

If open winding or ground is found, remove pump andrecheck values at the surface. Repair or replace motoror cable.

Replace if defective.

Correction

Submergence required varies with the particular pumpmodel installed. Contact your dealer.

Remove pump and inspect discharge section. Removeblockage, repair valve and valve seat, if necessary.Check for other damage. Rinse out pump and reinstall.

Remove and inspect pump. Clean strainer, check thecheck valve for blockage. Rinse out pump and reinstall.

Pull pump and repair.

2. Fuses are blown or circuit breakers are tripped.Remove fuses and check for continuity with ohmmeter.

1. Water level in well is too low or well is collapsed.

4. Coupling or shaft sheared between motor and pump.

3. Motor starter overloads are burned or have tripped.

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5. Pump is defective.Same as number 2 above.

5.2.3 Pump Runs but at Reduced Capacity

1. Wrong rotation.Check for proper electrical connection incontrol box.

2. Drawdown is larger than anticipated.Check drawdown during pump

operation.

3. Discharge piping or valve leaking.Examine system for leaks.

Remove pump and inspect.

5. Pump worn.Install pressure gauge, start pump,gradually close the discharge valve andread pressure at shut-off.

6. Pump may be airlocked.

5.2.4 Pump Cycles Too Much

1. Pressure switch is defective.Check pressure setting on switch andoperation. Check voltage across closedcontacts.

Check setting and operation.

4. Plugged snifter valve or bleed orifice.Examine valve and orifice for dirt orcorrosion.

5. Tank is too small.Check tank size.

5.2.5 Fuses Blow or Circuit Breakers Trip

1. High or low voltage.Check voltage at pump panel.

Convert PSI to feet (PSI x 2.31 ft/PSI = _____ft), addelevation from top of well to water level to the pressurereading. Refer to the specific pump curve for shutoffhead for that pump model. If head is close to curve,pump is probably OK. If not, remove pump and inspect.

Correction

Correct wiring and change leads as required.

Lower pump if possible. If not, throttle discharge valveand install water level control.

Repair leaks.

Clean, repair, rinse pump and reinstall.

Convert PSI to feet (PSI x 2.31 ft/PSI = _____ft), addelevation from top of well to water level to the pressurereading. Refer to the specific pump curve for shutoffhead for that pump model. If head is close to curve,pump is probably OK. If not, remove pump and inspect.

Stop and start several times, waiting about one minutebetween cycles.

Correction

Readjust switch or replace if defective.

Readjust setting (refer to manufacturer’s data). Replace if defective.

Check diaphragm for leak. Check tank and piping forleaks with soap and water solution. Check air to watervolume.

Clean and/or replace if defective.

Tank volume should be approximately 10 gallons foreach gpm of pump capacity.

Correction

If not within 10%, check wire size and length of run topump panel.

4. Pump strainer or check valve are clogged.

2. Level control is not properly set or is defective.

3. Insufficient air charging or leaking tank or piping.Pump air into tank or diaphragm chamber.

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1. Three phase current imbalance.Check current draw on each lead.

Check that control parts match parts list.Check wiring matches wiring diagram.Check for loose or broken wires orterminals.

4. Bad capacitor.Discharge capacitor. Check using anohmmeter (R x 100K).

Check resistance of relay coil with anohmmeter (R x 1000). Check contactsfor wear.

Check current draw. See Tables 9 and

10.

Must be within 5%; if not contact power company.

Correct as required.

When meter is connected, the ohmmeter needleshould jump forward and slowly drift back. If no needlemovement, replace the capacitor.

Replace defective relay.

Pull pump and clean or repair.

3. Wrong control box wiring or components.

5. Starting relay defective (single phase motors only).

6. Pump is sand locked or otherwise jammed.

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NOTES

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Peerless Pump CompanyP.O. Box 7026 –Indianapolis, IN 46207-7026Phone: (317) 925-9661 –Fax: (317) 924-7388

Bulletin B-2649804