Wayne CWS100, CWS75, CWS50 User Manual

4.5 (2)

Operating Instructions and Parts Manual

CWS50, CWS75 and CWS100

 

 

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

Convertible Well Jet

Pump Water Systems

Description

Jet pumps are single stage domestic water pumps designed for pumping potable water in applications where the water is up to 100 feet (deep well pump). A pressure switch is a standard feature. A built-in control valve is available on deep well pumps. Deep well pumps can be mounted to either a pre-charged, conventional type or free standing pressure tank.

Unpacking

After unpacking the jet pump, carefully inspect for any damage that may have occurred during transit. Check for loose, missing or damaged parts.

Safety Guidelines

This manual contains information that is very important to know and understand. This information is provided for SAFETY and to

PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.

Danger indicates an imminently

hazardous situation which, if not avoided, WILL result in death or serious injury.

Warning indicates a potentially

hazardous situation which, if not avoided, COULD result in death or serious injury.

Caution indicates a potentially

hazardous situation which, if not avoided, MAY result in minor or moderate injury.

Notice indicates important

information, that if not followed, may cause damage to equipment.

NOTE: Information that requires special attention.

General Safety

Information

CALIFORNIA PROPOSITION 65

This product contains chemicals,

including lead, known to the State of California to cause birth defects and other reproductive harm. Wash hands after handling.

GENERAL SAFETY

1.Read all manuals included with this product carefully. Be thoroughly familiar with the controls and the proper use of the equipment.

2. Know the pump application, limitations and potential hazards.

Always install a pressure relief valve

to match the system pressure rating and the maximum flow rate.

Do not use to pump flammable

or explosive fluids such as gasoline, fuel oil, kerosene, etc. Do not use in explosive atmospheres. Pump should only be used with liquids compatible with pump component materials.

Failure to follow this warning can result in personal injury and/or property damage.

Disconnect power and release all

pressure from the system before attempting to install, service, relocate or perform any maintenance. Lock the power disconnect in the open position. Tag the power disconnect to prevent unexpected application of power.

Install a screen around the inlet pipe

to prevent entrapment of swimmers.

3.Drain all liquids from the system before servicing.

4.Secure the discharge line before starting the pump. An unsecured discharge line will whip and possibly cause personal injury and/or property damage.

5.Check hoses for weak or worn condition before each use. Make certain all connections are secure.

6.Periodically inspect pump and system components. Perform routine maintenance as required (See Maintenance).

7.Personal Safety:

a.Wear safety glasses at all times when working with pumps.

b.Keep work area clean, uncluttered and properly lighted replace all unused tools and equipment.

c.Keep visitors at a safe distance from work area.

d.Make the workshop child proof: use padlocks, master switches and remove starter keys.

8.Do not pump chemicals or corrosive liquids. Pumping these liquids shortens the life of the pumps seals and moving parts and will void the warranty.

9.When installing pump, cover the well to prevent foreign matter from falling into well and contaminating the water and damaging internal mechanical pumping components.

10.Always test the water from the well for purity before use. Check with local health department for test procedure.

11.Complete pump and piping system MUST be protected against below freezing temperature. Freezing temperatures could cause severe damage and void the warranty.

REMINDER: Keep your dated proof of purchase for warranty purposes!

Attach it to this manual or file it for safekeeping.

© 2009 Wayne Water Systems

For parts, product & service information

340006-001 3/09

 

visit www.waynepumps.com

 

Operating Instructions & Parts Manual

CWS50, CWS75 and CWS100

General Safety

Information (Continued)

12.Do not run the pump dry or damage will occur and will void warranty.

This pump is designed for indoor

installation only. Failure to install indoors will significantly increase the risk of injury or death from electrical shock.

All wiring should be performed by a

licensed or certified electrician.

13.For maximum safety, the unit should be connected to a grounded circuit equipped with a ground fault interrupter device.

14.Before installing the pump, have the electrical outlet checked by a licensed or certified electrician to make sure the outlet is properly grounded.

15.Make sure the line voltage and frequency of electrical current supply agrees with the motor wiring.

16.Do not attempt repairs to the electric motor. All repairs to the motor must be completed at a licensed or certified electrical motor repair shop.

Do not touch an operating motor.

Modern motors are designed to operate at high temperatures.

17.Avoid kinking electrical cord and protect electrical cord from sharp objects, hot surfaces,

oil and chemicals. Replace or repair damaged or worn cords immediately.

18.Keep fingers and foreign objects away from ventilation and other openings. Do not insert any objects into the motor.

Risk of electric shock! Never

connect the green (or green and yellow wire) to a live terminal!

19.To reduce the risk of electrical shock, the pump should be plugged directly into a properly installed and grounded 3-prong grounding type receptacle, as shown in

Figure 1. The green (or green and yellow) conductor in the cord is the grounding wire. The motor must be securely and adequately grounded for protection against shock.

Grounded Pin

TEST RESET

Figure 1

Grounded Outlet

 

20.Where a 2-prong is encountered, replace the plug with a properly grounded 3-prong receptacle in accordance with the National Electrical Code, local codes and ordinances. To ensure a proper ground, the grounding means must be tested by a licensed or certified electrician.

21.Use only 3-wire extension cords that have a 3-prong, ground type plug, and 3-pole receptacles that accept the equipment plug.

22.Use wire of adequate size to minimize voltage drop at the motor.

Do not handle pump or pump motor with

wet hands, when standing on a wet or damp surface or when standing in

water. Fatal electrical shock could occur.

Pump motor is equipped with an

automatic resetting thermal protector and may restart unexpectedly. Protector tripping is an indication of motor overloading because of operating pump at low heads (low discharge restriction), excessively high or low voltage, inadequate wiring, incorrect motor connections or defective motor or pump.

Pre-Installation

WATER SUPPLIES

The water supplies illustrated in Figure 26 are possible sources for water. These water supplies can be divided into two categories:

SURFACE WATER

Water from a lake, stream, pond and cistern. This water is usually not fit for human consumption, but may be

suitable for washing, irrigation or other household uses.

GROUND WATER

Water found in the water bearing stratum at various levels beneath the earth. Of all the fresh water found on earth only 3 percent is found on the surface and 97 percent is underground.

TANKS - CONVENTIONAL STORAGE

The function of the tank is to store a quantity of water under pressure. When full, the tank contains approximately 2/3 water and 1/3 compressed air. The compressed air forces the water out

of the tank when a faucet is opened. An air volume control automatically replaces air lost or absorbed into the water. The usable water, or draw-down capacity, of the tank is approximately 1/6 of the tanks total volume when operated on a “20-40” pressure setting (Figure 2).

Air Volume

Control

 

Bladder

Conventional

Pre-charged

Tank

Tank

Figure 2 - Conventional and

Pre-charged Storage Tanks

TANKS - PRE-CHARGED STORAGE

A pre-charged storage tank has a flexible bladder or diaphragm that acts as a barrier between the compressed air and water. This barrier prevents the air from being absorbed into the water and allows the water to be acted on by compressed air at initially higher than atmospheric pressures (pre-charged). More usable water is provided than with a conventional type tank. Precharged tanks are specified in terms

of a conventional tank. For example, a 20 gallon pre-charged tank will have the same usable water or draw-down capacity as a 40 gallon conventional tank, but the tank is smaller in size (Figure 2).

PRESSURE SWITCH

The pressure switch provides for automatic operation. The pump starts when pressure drops to a cut-in setting. The pump stops when pressure reaches a cut-out setting.

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Operating Instructions & Parts Manual

CWS50, CWS75 and CWS100

Pre-Installation

(Continued)

PACKAGE SYSTEMS

There are four jet pump/tank assemblies sold as packages (Chart 1).

WELLS

A new well should be pumped clear of sand before installing the pump. Sand will damage the pumping parts and seal. The draw-down level of the well should not exceed the maximum rated depth for the pump. The capacity of the pump will be reduced and a loss of prime may occur.

Installation

LOCATION

Select a location as close to the water supply as possible.

Be sure to comply with any state or local codes regarding the placement of the pump. The equipment must be protected from the elements. A basement or heated pump house is a

good location. Make sure the pump has proper ventilation. The temperature surrounding the pump is not to exceed 100° F (40°C) or nuisance tripping of the motor overload may occur.

This pump is designed for indoor

installation only. Failure to install indoors will significantly increase the risk of injury or death from electrical shock.

PIPING

Piping may be copper, steel, rigid PVC plastic or flexible polyethylene plastic.

Flexible pipe is not recommended on

suction pipe (inlet pipe).

The pipe must be clean and free of rust or scale. Use a pipe joint compound on the male threads of the metal pipe. Teflon® tape should be used with

plastic threads. All connections must be air tight to insure normal operation.

Slope all inlet piping upwards towards the pump to prevent trapping air. Unions or hose couplings can be installed near pump to facilitate removal for servicing or storage. A rubber hose installed between the water system and the house piping will reduce the noise transmitted to the house.

Plastic pipe can be used on all installations except 2 in. deep well jet. The 2 in. deep well jet requires 1-1/4 in. galvanized steel pipe and special machined couplings (1-13/16 in. O. D.).

The galvanized steel pipe and the couplings restrict the flow of return water back to the jet unless the couplings are machined.

PIPE SIZES

Long horizontal pipe runs and an abundance of fittings and couplers decrease water pressure due to friction loss. See Chart 2 to determine the proper pipe size.

SHALLOW WELL INSTALLATION

A shallow well jet assembly can be used with the deep well pump when the pump is located 25 feet vertically of the water level. Shallow well installations have only one pipe between the pump and water supply (Figure 3).

DRILLED WELL (FIGURE 17)

1.Install a foot valve on the first section of pipe (Figure 3, Illustration A).

2.Lower the pipe into the well.

3.Add pipe until the foot valve is 5 feet below the lowest anticipated water level.

The foot valve should be at least 18

in. from the bottom of the well or sand or sediment could be drawn into the system.

4.After proper depth is reached, install a well seal or pitless adapter to support pipe and prevent surface. water and other contaminants from entering well.

CHART 1 - JET PUMP/TANK ASSEMBLIES

 

 

Air Volume

 

 

Control

 

Type

Required

Well X

Pre-charged

No

 

 

 

PCA

Pre-charged

No

 

 

 

12 P & 30 P Horizontal

Conventional

Yes

 

 

 

FX Horizontal

Pre-charged

No

To Pump

Well

Seal

Well

Casing

Foot

Valve

Illustration A

To

Pump

Packer

Type Foot

Valve

Drive

Point

Illustration B

To

Pump

Incline

Check

Valve

Drive

Point

Figure 3

Illustration C

 

5.Slope the horizontal pipe upward toward the pump to eliminate trapping air. Sloping the pipe will also aid in priming the pump.

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Operating Instructions & Parts Manual

CWS50, CWS75 and CWS100

Installation (Continued)

DRIVEN WELL

Drive the point several feet below the water table.

NOTE: A packer type foot valve can be installed in the well (Figure 3, Illustration B). This type of foot valve allows the well to be filled with water

when priming and makes the inlet pipe much easier to test for leaks. Follow the manufacturer’s instructions when installing the packer type foot valve.

As an alternative, an in-line check valve can be used with a driven well (Figure 3, Illustration C). The pipe between the check valve and the water level will always be under a vacuum.

Leaking joints or couplings will allow air to leak into the pipe and cause abnormal pump operation. Make sure to use pipe joint compound on all male pipe threads.

DUG WELL, CISTERN, LAKE AND SPRING INSTALLATION (FIGURE 17)

Install a foot valve on inlet pipe and lower into water.

The foot valve should be at least 18

in. from the bottom of the well or sand or sediment could be drawn into the system.

NOTE: When a lake is used as a water supply, make sure the inlet pipe is deep enough to be submerged at all times. Protect the pipe from damage from swimmers and boats.

Slope the horizontal piping upward toward the pump to prevent trapping air. The pipe must be removed during winter months or protected against freezing.

Protect the pipe from damage from swimmers and boats.

Install a screen around the inlet

pipe to prevent the entrapment of swimmers.

DEEP WELL INSTALLATION

DRILLED WELL (4 IN. OR LARGER) WITH TWO PIPE JET (FIGURES 17 AND 4)

1.Assemble a 1-1/4 in. foot valve (not included) to the jet body. A 1-1/4 in. coupling is required to connect the larger pipe to the jet assembly.

2.Connect the 1 in. pipe threads into the smaller opening in the jet body.

 

 

CHART 2 - PIPE SIZING

 

 

 

Horizontal Distance

 

 

Pump

(Feet)

 

 

 

 

 

 

 

 

 

Pump Model

Opening

0-25

 

26-100

Deep Well

Inlet:

1-1/4 in.

1-1/2 in.

 

Suction

 

 

 

 

Inlet: Drive

1 in.

1-1/4 in.

 

 

 

 

 

Outlet

3/4 in.

1 in.

 

 

 

 

 

1-1/4 in. Pipe

Jet Body

 

1 in. Foot Valve Pipe

Figure 4 - Two Pipe Jet

Install a screen around the inlet

pipe to prevent the entrapment of swimmers.

5.Slope the horizontal pipes upward toward the pump to prevent trapping air. If horizontal distance exceeds 25 feet, see Chart 2 for recommended pipe sizes.

3. Lower the jet into the well. Add pipe

DRILLED WELL (2 IN.) WITH SINGLE PIPE

as needed. Be sure to use pipe joint

PACKER (FIGURES 17 AND 5)

compound on all male threads.

 

4. Position the jet 10 - 20 feet below

1-1/4 in. Pipe

Foot Valve

the lowest anticipated water level,

Packer

but never closer than 5 feet from the

 

 

bottom of the well, if possible.

 

 

5. Install a well seal to support the pipe

 

 

and prevent surface water and other

 

Cups

contaminants from entering the

 

Figure 5 - Single Pipe Jet

well.

 

 

6.Install the horizontal pipe from the well to the pump. Piping from the vertical well pipe to the pump should never be smaller than the well pipes.

7.Slope both pipes upward toward the pump to prevent trapping air. If the horizontal distance exceeds 25 feet, see Chart 2 (on page 5) for the recommended pipe sizes.

DUG WELL, CISTERN, LAKE AND SPRING WITH TWO PIPE JET (FIGURE 17)

1.Install a 1-1/4 in. foot valve (not included) to the jet body. A 1-1/4 in. coupling is required to connect the larger pipe to the jet assembly.

2.Connect the 1 in. pipe threads into the smaller opening in the jet body.

3.Lower the jet into the water below the lowest anticipated water level, but never closer than 18 in. from the bottom. Sand or debris may be drawn into the system if the jet is too close to the bottom.

4.Provide protection for the jet and pipes against damage from boats or swimmers if a lake is used for the water supply.

NOTE: Single pipe packer jets rely on the space between single pipe and inside of well casing for return water to operate jet. Two inch installations must use 1-1/4 in. galvanized steel pipe with special turned couplings (1-13/16 in. O.D.) to avoid restricting flow of return water back to jet.

1.Assemble the foot valve and packer to the jet body.

2.Lubricate the rubber cups with petroleum jelly.

3.Attach the first section of pipe and lower jet into well.

4.Add pipe until the jet is positioned 5 - 15 feet below the lowest anticipated water level. The jet should never be closer than 5 feet from the bottom of the well or sand and sediment may be drawn into the system.

5.With the jet in position, fill the pipes with water to make sure the rubber cups are sealed against inside of the well casing. It may be necessary to move the jet up and down to seat the cups.

6.Install the casing adapter and the horizontal pipes.

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Operating Instructions & Parts Manual CWS50, CWS75 and CWS100

Installation (Continued)

Pressure

Outlet

Prime

 

Electrical

7. Slope both pipes upward toward

Plug

To

 

 

Risk of electrical

Switch

 

 

 

Suction

the pump to eliminate trapping

 

 

shock. This pump is

 

 

 

 

air. If the horizontal distance

 

 

 

To Jet

designed for indoor installation only.

exceeds 25 feet, see Chart 2 for the

 

 

Select the proper size wire and

recommended pipe sizes.

 

 

 

To Drive

fuse (Chart 3). Time delay fuses are

DEEP WELL PUMP WITH HORIZONTAL

 

 

recommended over standard fuses

AND VERTICAL STORAGE TANK

 

 

28-30 psi

 

 

for motor circuit protection. All pump

(FIGURES 6 AND 7)

 

 

 

 

 

motors have built-in automatic overload

 

 

 

3/4 HP an 1 HP

 

Prime

 

 

 

 

 

protection that will prevent damage to

 

To Suction

 

 

 

 

 

 

To Jet

 

 

 

 

the motor due to overheating.

Plug

 

 

 

 

 

 

Pressure

 

 

 

Figure 8 - Pre-charged Storage Tank

 

Do not connect to

 

 

Air

 

 

 

 

electric power supply

Switch

 

 

2. Check the pressure with the power

 

 

Volume

until unit is permanently grounded.

 

 

 

off, faucets open and no water

 

 

 

 

Control

 

Connect ground wire to approved ground

 

 

 

Tubing

flowing (zero water pressure).

 

then connect terminal provided.

 

 

 

 

3. Install a valve and isolator hose between

A metal underground water pipe or

 

 

 

Air

the system and the house plumbing to

well casing at least 10 feet long makes

 

 

 

aid in pump removal for servicing and

the best ground electrode. If plastic

To Drive

 

Volume

for reducing noise transmitted to the

pipe or insulated fittings are used, run

 

Outlet Control

 

house through the piping.

 

a wire directly to the metal well casing

Figure 6 - Horizontal Tank

 

 

 

4. Provide a hose bib (faucet) at the

 

or use a ground electrode furnished by

 

 

 

 

 

 

 

Air Volume

lowest point in the system to drain

the power company.

Air Volume Control

for service or storage.

 

 

 

Control Tubing

 

 

There is only one proper ground

 

Hose

 

CONVERTING THE DEEP WELL PUMP TO

terminal on the unit. The terminal(s) is

Outlet

To

SHALLOW WELL OPERATION (FIGURE 9)

located under the pressure switch cover,

Coupling

Suction

 

 

To Air Volume

is painted green and is identified as

 

 

 

 

 

 

 

 

 

 

 

Control

 

GRD. The ground connection must be

 

 

 

 

 

 

 

 

made at this terminal (Figure 10).

 

 

 

 

Ground

Motor

 

 

 

Jet

Screw

 

 

 

 

Prime To Suction

To Drive

To Jet

Figure 9 - Shallow Well Jet

 

 

 

L1

 

 

For shallow wells (25 feet or less), a

1

Figure 7 - Vertical Tank

 

 

 

 

bolt-on shallow well jet is available

 

 

1. Install the air volume control on the

 

 

as an accessory for deep well pumps.

L2

3

tank as shown.

 

 

The jet attaches to the front of the

 

 

2. Connect the copper tube from the

pump with the two bolts provided and

 

 

air volume control to the 1/8 in. NPT

converts the deep well pump into a

Line

 

opening directly above the 1-1/4 in.

shallow well pump. The shallow well

 

Figure 10 - Electrical Connections

opening on the front of the pump.

jet has a 1 in. NPT inlet and a 1/8 in.

3. Install a valve and isolating hose

 

NPT opening for an air volume control.

The ground conductor must not be

between the system and the house

For optimum performance, an incline

smaller than the circuit conductors

plumbing to aid in pump removal

check valve on the inlet side of the

supplying the motor.

 

for servicing and for reducing noise

shallow well jet is recommended.

 

 

transmitted through the house piping.

CHART 3 - RECOMMENDED FUSE AND WIRING DATA - 60 HZ MOTORS

 

 

 

4. Provide a hose bib (faucet) at the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Distance in Feet

 

 

lowest point in the system to drain

 

 

 

 

 

 

 

 

 

 

 

 

From Meter to Motor

 

 

for service or storage.

 

 

 

 

 

 

 

 

 

Dual

0

 

51

 

101

 

201

 

 

 

 

 

DEEP WELL PUMP WITH PRE-CHARGED

 

 

 

 

 

 

 

to

 

to

 

to

 

to

STORAGE TANK (FIGURE 8)

 

 

Element

 

 

 

 

 

50

 

100

 

200

 

300

 

 

Fuse

 

 

 

1. Check tank pre-charge using a tire

 

 

 

 

 

 

 

 

 

HP

Volt

250V

 

 

 

Wire Size

 

 

pressure gauge. Set air pressure in

1/2

115

15

14

14

12

10

tank to 28 psi which is 2 psi below

 

 

 

 

 

 

 

 

 

230

10

14

14

14

14

pressure switch cut-in level. An air

 

 

115

15

14

14

10

8

valve is located on the side and will

3/4

230

10

14

14

14

14

accept a standard fitting from a

 

 

115

20

12

12

10

8

bicycle pump or air line.

1

 

230

10

14

14

14

14

 

 

 

 

 

 

 

 

 

 

 

 

 

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5

Operating Instructions & Parts Manual

CWS50, CWS75 and CWS100

Electrical (Continued)

Check selector to voltage supply. They must match change if needed.

The voltage of power supply must match the voltage of the pump. The unit has dual voltage motors preset at the factory to 115 volts. The motors can be converted to 230 volts by turning the voltage selector to the desired voltage (see Figure 11). Use needle nose pliers to pull the selector out approximately 1/4 in., rotate and then reinsert in correct position.

230 V

115 V

230 V

115 V

Figure 11 - Voltage Selector

Disconnect power and release all

pressure from the system before attempting to install, service, relocate or perform any maintenance.

Operation

PRIMING THE SHALLOW WELL PUMP

To prevent damage to the pump, do not

start motor until pump has been filled with water.

NOTE: When the deep well pump is used with the bolt-on shallow well jet, be sure the control valve slot (Figure 12) is in the vertical (open) position at all times.

Control Valve Slot

Open 1/4 in.

Turn

Closed

Figure 12 - Control Valve

1.Remove prime plug.

2.Fill pump and piping completely full of water.

3.Replace the prime plug.

4.Open a faucet to vent the system.

5.Start the motor. Water will pump in a few minutes. If pump fails to prime in 5 minutes, stop motor and refill pump with water. Priming time is proportional to the amount of air in inlet pipe. Do not allow pump to get hot.

6.Let the system operate for several minutes to flush all pipes.

7.Close faucet and allow pump to build pressure in tank. When the pressure reaches the cut-out setting, the motor will stop.

The system is now in operation and will automatically cycle on demand.

PRIMING THE DEEP WELL PUMP

To prevent damage to the pump, do not

start motor until pump has been filled with water.

1.Remove prime plug.

2.Fill pump and piping completely full of water.

3.Replace the prime plug.

4.Close the control valve (Figure 12) and open a nearby faucet.

5.Start the motor. The pressure inside the pump body will build almost

immediately as the pump, jet and piping become completely filled with water.

6.Slowly open the control valve. Water will begin to flow. Continue to open the control valve until maximum flow is achieved. Opening the valve too far will cause the water to stop flowing.

7.Adjust the valve until there is a steady flow of water. The valve should be opened as much as possible without losing pressure.

8.Let the system operate for several minutes to flush all piping.

9.Close the faucets and allow the pump to build pressure in the tank. When the pressure reaches the cutout setting, the motor will stop.

The system is now in operation and will automatically cycle upon demand.

Maintenance

Disconnect power and release all

pressure from the system before attempting to install, service, relocate or perform any maintenance. Lock the power disconnect in the open position. Tag the power disconnect to prevent unexpected application of power.

Protect the pump from freezing during

winter conditions.

DRAINING THE PUMP

Drain openings are provided on all models. To drain the pump:

1.Remove drain plug and prime plug to vent the system.

2.Drain all piping to a point below the freeze line.

DRAINING THE TANK

Conventional tanks can be drained by opening an outlet at the lowest point in the system. Remove plug or the air volume control to vent the tank.

Pre-charged tanks force virtually all the water from the tank when system pressure is released. No draining is necessary.

RESTARTING PUMP

If the pump has been serviced, drained or has not been used for some time, be sure there is water in the pump housing (volute) and the piping to the well. There must be water in the pump housing (volute) at all times when

the pump is running to avoid internal damage of seal members (See Priming the Shallow Well or Priming the Deep Well Sections).

WATERLOGGED TANKS:

CONVENTIONAL

When a tank system has an inadequate ratio of air and water, the pump will start and stop often and erratically.

1.Disconnect the power to the pump.

2.Open the lowest faucet in the system to release all pressurized water in the system.

3.Prime the pump (See Priming the Shallow Well or Priming the Deep Well Sections).

4.Reconnect the power to the pump.

NOTE: As the pump refills the tank with water, the air volume control supplies the tank with the correct air to water ratio for the system to operate. If the air volume control is good, the pump will shut off at the desired cut-off and will be adjusted correctly.

WATERLOGGED TANKS: PRECHARGED

If a pre-charged tank becomes waterlogged, the bladder is normally leaking or broken.

1.Test the tank by depressing the air valve. The air valve will expel water if the bladder is broken.

2.Replace the tank.

NOTE: Once a bladder is leaking or broken, the bladder cannot be repaired. The tank must be replaced.

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Operating Instructions & Parts Manual

CWS50, CWS75 and CWS100

Maintenance (Continued)

PRE-CHARGED TANK

Some air is lost through the bladder in any tank. To prevent tank failure, check the tank pre-charge on a yearly basis.

1.Disconnect power to the pump

2.Open a faucet nearest the tank and allow all water to drain from the tank.

3.Measure the tank pre-charge at the valve stem using a tire gauge.

4.If necessary, adjust the pre-charge with an air pump 28 - 30 psi on 1/2, 3/4 and 1 HP pumps.

LUBRICATION

The bearing used in the pumps are lifetime lubricated at the factory and require no additional lubrication.

REMOVING OLD SHAFT SEAL

Turn disconnect switch to “off”

position.

1.Disconnect power to the pump

2.Open a faucet nearest the tank and allow all water to drain from the tank.

3.Remove the four cap screws holding the pump housing (volute) to the motor (Figure 13).

Cap

Seal

Pump

Screws

Plate

Housing

 

 

(Volute)

 

 

Diffuser

Motor Impeller

Drain Plug

Figure 13 - Convertible Well Pump

4.Separate the pump housing (volute) from the motor to expose the diffuser and the seal plate.

5.Remove the two cap screws and diffuser from the seal plate to expose the impeller.

6.Remove the small end cap on the end of the motor opposite the impeller.

7.With a large screwdriver or adjustable wrench, keep the shaft from rotating and remove the impeller with hand (standard right hand thread). Be sure to hold onto the cast iron seal plate when removing the impeller from the shaft.

8.Remove the seal plate.

9.Pry the rotating shaft seal member from the impeller (Figure 14).

Rotating

Impeller

Seal

Shaft Seal

Plate

 

Member

 

 

Rubber

Seat

Ring

Ceramic Seat

Figure 14 - Removing Shaft Seal and

Ceramic Seat

10.Push or pry the ceramic seat free from the seal plate (Figure 14).

11.Remove loose particles from impeller hub and seal plate.

INSTALLING NEW SHAFT SEAL

Before handling shaft seal parts wipe

hands clean. Dirt or grease can damage the seal.

1.Wet the inside of the seal cavity on seal plate and the rubber cup enclosing the new ceramic seat with cooking oil. Be careful not to scratch the ceramic surface of the seal seat and push seat enclosed in

rubber into seal cavity on seal plate. Use a cardboard washer to protect polished surface when pushing against ceramic seat with any object. Be sure to remove cardboard washer.

Screw

Holes

Motor

Shaft

Figure 15 - Seal Plate Replacement

2.Carefully slip seal plate over shaft so as not to disturb seal position in seal plate. The seal plate must be orientated during assembly so that the two holes are on a horizontal line across the motor shaft and the

(4) locating pins on the back of the seal plate line up with the tabs on the motor housing (Figure 15). This placement should be done to ensure proper draining and priming.

3.Place rotating shaft seal member in position on impeller and press into place. Take care not to press against polished seal surface.

4.Position impeller on shaft and tighten securely (Figure 16).

Seal Plate

Motor

 

 

 

 

Impeller

Seal

 

 

Plate

Seal

 

Seal

Seat

 

Facing

 

 

Must

 

 

Be Clean For

Figure 16 - Motor Shaft

Proper Seal

 

5.Secure diffuser to seal plate using the two cap screws. Be sure the screws are orientated on a

horizontal line as described in Step 2.

6.Carefully position pump housing (volute) gasket over the diffuser onto the seal plate. In all convertible applications the seal ring must also be positioned on the diffuser. In all shallow well applications care must be taken that the o-ring is clean and properly positioned on the venturi. Cleaning and positioning makes a good seal inside the diffuser when assembled.

7.Assemble the pump housing (volute) to the motor using the four cap screws. Be sure the pump

housing (volute) gasket is positioned correctly and tighten the screws securely.

NOTE: Shaft must rotate freely and motor end cap should be secured before operation.

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7

Wayne CWS100, CWS75, CWS50 User Manual

CWS50, CWS75 and CWS100

Operating Instructions & Parts Manual

Water Supplies

(C) DUG WELL

 

(E) DRILLED WELL

(F) CISTERN

 

(D) DRIVEN WELL

 

 

 

TOP SOIL

 

 

(A) SPRING

CLAY

 

 

 

 

 

 

PERMEABLE

 

 

(B) LAKE,

MATERIAL

 

 

STREAM, POND

 

 

 

 

WATER

WATER TABLE

 

BEARING

 

 

 

SAND

 

 

SHALE

(A) SPRING:

A spring that emerges from the ground. Occurs when water in permeable materials is trapped between impermeable

material as rock or clay.

(B) LAKE, STREAM or POND: Surface water, unless treated, is usually not safe for human consumption. It may be used for purposes such as washing or irrigation.

(C) DUG WELL:

A hole is excavated several feet in diameter to a fairly shallow depth. It is then lined with brick, stone or concrete to prevent cave-in.

(D) DRIVEN WELL: Pipe with a pointed screen is driven into the ground below the water table. The depth is usually less than 50 feet. Available diameters are

1" through 2".

(E) DRILLED WELL:

A hole bored into the earth with machinery and lined with pipe. Depths range from a few feet

to over 1000 feet. Common well diameters are 2", 3", 4" and 6" for domestic water wells.

(F) CISTERN:

An underground tank built to collect rain water from rooftops. The water is not fit

for human consumption.

Figure 17 - Water Supplies

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8

Operating Instructions & Parts Manual CWS50, CWS75 and CWS100

Troubleshooting Chart

Symptom

Possible Cause(s)

Corrective Action

Pump will not run

1.

Power off

1. Turn power on or call power company

 

2.

Blown fuse or tripped breaker

2.

Replace fuse or reset circuit breaker

 

3.

Faulty pressure switch

3.

Replace switch

 

4.

Motor overload tripped

4.

Let cool. Overload will automatically reset

 

 

 

 

 

Motor hums but will not run

1.

Voltage does not match selector switch

1.

Check voltage

 

2.

Wiring too small

2.

Rewire. See Chart 4*

 

3.

Damage or misalignment causing rotating

3.

Replace or take to service shop for repair

 

 

parts to bind

 

 

 

 

 

 

 

Overload trips

1.

Incorrect line voltage

1.

Rewire. See Chart 4*

 

2.

Damage or misalignment causing rotating

2.

Take to motor repair shop or locate and repair

 

 

parts to bind

 

mechanical binding

 

3.

High surrounding temperature

3.

Provide a shaded, well-ventilated area for pump

 

4.

Rapid cycling

4.

Pump starts and stops too often section

 

 

 

 

 

Pump runs but delivers little or

1.

Water level below pump intake

1.

Lower suction pipe further into well

no water

2.

Control valve open too far (deep well)

2.

Adjust control valve or repeat priming

 

 

 

 

 

procedure.

 

3.

Discharge not vented while priming

3.

Open faucet, repeat priming procedure

 

4.

Leaking in piping on well side of pump

4.

Repair piping as needed

 

5.

Well screen or inlet strainer clogged

5.

Clean or replace as necessary

 

6.

Clogged nozzle (deep well)

6.

Pull jet and clear obstruction

 

7.

Air volume control diaphragm ruptured

7.

Repair or replace air volume control

 

8.

Foot valve may be clogged or stuck closed

8.

Clean or replace as needed

 

9.

Pump not fully primed

9.

Continue priming, pausing every 5 minutes to

 

 

 

 

cool pump body. Refill pump as needed

 

10.

Control valve completely closed (deep well)

10.

Adjust control valve per deep well priming

 

 

 

 

procedure

 

11.

Water level below maximum lift specification

11.

Select applicable pump and/or jet assembly

 

12.

Undersized piping

12.

Replace as needed

 

13.

Gaseous well

13.

Install baffle on pump intake to prevent gas from

 

 

 

 

entering system

 

14.

Distorted venturi

14.

Inspect and replace

 

15.

Incorrect jet for application

15.

Purchase a jet matched to your system when

 

 

 

 

replacing another brand pump

 

16.

Undersized pump

16.

Increase horsepower of pump

 

17.

Pump cavitates, sounds like pumping gravel

17.

Increase suction plumbing diameter or decrease

 

 

 

 

pipe friction

 

 

 

 

 

Pump starts and stops too often

1.

Water logged tank (conventional tank)

1.

Replace tank or air volume control

 

2.

Air volume control tubing kinked or clogged

2.

Clean or replace as needed

 

3.

Air volume control tubing connected to

3.

Move to correct pump opening

 

 

wrong opening on pump

 

 

 

4.

Incorrect tank pre-charged (pre-charged

4.

Add or release air as needed

 

 

tank)

 

 

 

5.

Ruptured diaphragm/bladder (pre-charged

5.

Replace tank

 

 

tank)

 

 

 

6.

Leak in house piping

6.

Locate and repair leak

 

7.

Foot valve or check valve stuck open

7.

Remove and replace

 

8.

Motor overload tripping

8.

See overload trips section

 

9.

Improperly adjusted pressure switch

9.

Readjust or replace switch

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9

Operating Instructions & Parts Manual

CWS50, CWS75 and CWS100

 

 

For Replacement Parts or Technical Assistance, Call 1-800-237-0987

Please provide following information:

Address any correspondence to:

- Model number

Wayne Water Systems

- Serial number (if any)

101 Production Drive

- Part description and number as shown in parts list

Harrison, OH 45030 U.S.A.

1 2

3

5

6 7

4

8

14

10

9

11

12

13

Replacement Parts List

Ref.

 

 

Part Number for Models

 

 

 

 

 

 

 

No.

 

Description

CWS50-1/2 HP

CWS75-3/4 HP

CWS100-1 HP

Qty.

1

 

Motor

32059-001

32015-001

32015-001

1

2

 

Screw

16636-002

16636-002

16636-002

4

3

 

Seal plate

4372-001

4372-001

4372-001

1

4

Shaft seal assembly

56393

56393

56393

1

5

Square ring rubber gasket

17150-001

17150-001

17150-001

1

6

 

Impeller

23285-002

23285-001

23285-001

1

7

 

Diffuser

17148-001

17148-001

17148-001

1

8

Rubber seal ring

17149-001

17149-001

17149-001

1

9

 

Volute

56870-001

56870-001

56870-001

1

10

 

Pressure switch

30010-001

30010-001

30010-001

 

11

 

O-ring

15592

15592

15592

1

12

 

Control valve (includes #11)

56883-001

56883-001

56883-001

1

13

 

Pipe plug 1/8 in.

15766-002

15766-002

15766-002

2

14

 

Base

23029-001

23029-001

23029-001

1

 

Repair kit (includes #4, 5 & 8)

56874-001

56874-001

56874-001

1

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10

Operating Instructions & Parts Manual CWS50, CWS75 and CWS100

Performance

 

 

Suction

 

Discharge Pressure psi

 

 

 

 

20

30

40

50

 

Model No.

Motor HP

Lift (Feet)

 

 

 

 

 

Output in Gallons Per Hour (GPH)

 

 

 

 

 

 

 

 

 

 

 

 

5

910

850

590

366

 

 

 

10

780

720

520

324

 

CWS50

1/2

15

690

660

480

270

 

 

 

20

580

580

410

228

 

 

 

25

390

390

325

174

 

 

 

 

 

 

 

 

 

 

 

5

1140

1140

858

600

 

 

 

10

1014

1014

800

520

 

CWS75

3/4

15

900

900

756

456

 

 

 

20

702

702

690

390

 

 

 

25

558

558

558

318

 

 

 

 

 

 

 

 

 

 

 

5

1260

1218

930

618

 

 

 

10

1140

1140

858

600

 

CWS100

1

15

990

990

786

480

 

 

 

20

828

828

720

400

 

 

 

25

630

630

630

340

 

 

 

 

 

 

 

 

 

 

Pump Model

Jet Assembly

 

 

Vertical Distance to Pumping Level

 

 

 

 

 

 

 

 

 

 

 

 

Jet Diameter

No.

No.

30'

40'

50'

60'

70'

80'

90'

100'

 

 

 

 

 

 

Output in Gallons Per Hour (GPH)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CWS50

56319

620

590

500

 

 

 

 

 

 

 

CWS50

55462

 

 

400

335

260

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2 in.

CWS75

56322

840

740

615

 

 

 

 

 

 

CWS75

55462

 

 

 

390

360

290

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CWS100

56322

890

780

650

 

 

 

 

 

 

 

CWS100

58319

 

 

 

520

420

330

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CWS50

56324

900

750

 

 

 

 

 

 

 

 

CWS50

56317

 

690

580

540

390

 

 

 

 

 

CWS50

55465

 

 

 

415

335

275

210

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4 in.

CWS75

56324

900

800

675

 

 

 

 

 

 

CWS75

55465

 

 

 

470

420

340

280

200

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CWS100

56324

950

840

706

 

 

 

 

 

 

 

CWS100

56317

 

 

 

585

490

390

 

 

 

 

CWS100

55465

 

 

 

 

 

 

315

230

 

 

 

 

 

 

 

 

 

 

 

 

 

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11

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