Franklin 2007 User Manual

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Submersible Motors

Application • Installation • Maintenance

60 Hz, Single-Phase and Three-Phase Motors

2007

ATTENTION!

IMPORTANT INFORMATION FOR INSTALLERS OF THIS EQUIPMENT!

THIS EQUIPMENT IS INTENDED FOR INSTALLATION BY TECHNICALLY QUALIFIED PERSONNEL. FAILURE TO INSTALL IT IN COMPLIANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES, AND WITHIN FRANKLIN ELECTRIC RECOMMENDATIONS, MAY RESULT IN ELECTRICAL SHOCK OR FIRE HAZARD, UNSATISFACTORY PERFORMANCE, AND EQUIPMENT FAILURE. FRANKLIN INSTALLATION INFORMATION IS AVAILABLE FROM PUMP MANUFACTURERS AND DISTRIBUTORS, AND DIRECTLY FROM FRANKLIN ELECTRIC. CALL FRANKLIN TOLL FREE 800-348-2420 FOR INFORMATION.

WARNING

SERIOUS OR FATAL ELECTRICAL SHOCK MAY RESULT FROM FAILURE TO CONNECT THE MOTOR, CONTROL ENCLOSURES, METAL PLUMBING, AND ALL OTHER METAL NEAR THE MOTOR OR CABLE, TO THE POWER SUPPLY GROUND TERMINAL USING WIRE NO SMALLER THAN MOTOR CABLE WIRES. TO REDUCE RISK OF ELECTRICAL SHOCK, DISCONNECT POWER BEFORE WORKING ON OR AROUND THE WATER SYSTEM. DO NOT USE MOTOR IN SWIMMING AREAS.

ATTENTION!

INFORMATIONS IMPORTANTES POUR L’INSTALLATEUR DE CET EQUIPEMENT.

CET EQUIPEMENT DOIT ETRE INTALLE PAR UN TECHNICIEN QUALIFIE. SI L’INSTALLATION N’EST PAS CONFORME AUX LOIS NATIONALES OU LOCALES AINSI QU’AUX RECOMMANDATIONS DE FRANKLIN ELECTRIC, UN CHOC ELECTRIQUE, LE FEU, UNE PERFORMANCE NON ACCEPTABLE, VOIRE MEME LE NON-FONCTIONNEMENT PEUVENT SURVENIR. UN GUIDE D’INSTALLATION DE FRANKLIN ELECTRIC EST DISPONIBLE CHEZ LES MANUFACTURIERS DE POMPES, LES DISTRIBUTEURS, OU DIRECTEMENT CHEZ FRANKLIN. POUR DE PLUS AMPLES RENSEIGNEMENTS, APPELEZ SANS FRAIS LE 800-348-2420.

AVERTISSEMENT

UN CHOC ELECTRIQUE SERIEUX OU MEME MORTEL EST POSSIBLE, SI L’ON NEGLIGE DE CONNECTER LE MOTEUR, LA PLOMBERIE METALLIQUE, BOITES DE CONTROLE ET TOUT METAL PROCHE DU MOTEUR A UN CABLE ALLANT VERS UNE ALIMENTATION D’ENERGIE AVEC BORNE DE MISE A LA TERRE UTILISANT AU MOINS LE MEME CALIBRE QUE LES FILS DU MOTEUR. POUR REDUIRE LE RISQUE DE CHOC ELECTRIQUE. COUPER LE COURANT AVANT DE TRAVAILLER PRES OU SUR LE SYSTEM D’EAU. NE PAS UTILISER CE MOTEUR DANS UNE ZONE DE BAIGNADE.

ATENCION!

INFORMACION PARA EL INSTALADOR DE ESTE EQUIPO.

PARA LA INSTALACION DE ESTE EQUIPO, SE REQUIERE DE PERSONAL TECNICO CALIFICADO. EL NO CUMPLIR CON LAS NORMAS ELECTRICAS NACIONALES Y LOCALES, ASI COMO CON LAS RECOMENDACIONES DE FRANKLIN ELECTRIC DURANTE SU INSTALACION, PUEDE OCASIONAR, UN CHOQUE ELECTRICO, PELIGRO DE UN INCENDIO, OPERACION DEFECTUOSA E INCLUSO LA DESCOMPOSTURA DEL EQUIPO. LOS MANUALES DE INSTALACION Y PUESTA EN MARCHA DE LOS EQUIPOS, ESTAN DISPONIBLES CON LOS DISTRIBUIDORES, FABRICANTES DE BOMBAS O DIRECTAMENTE CON FRANKLIN ELECTRIC. PUEDE LLAMAR GRATUITAMENTE PARA MAYOR INFORMACION AL TELEFONO 800-348-2420.

ADVERTENCIA

PUEDE OCURRIR UN CHOQUE ELECTRICO, SERIO O FATAL DEBIDO A UNA ERRONEA CONECCION DEL MOTOR, DE LOS TABLEROS ELECTRICOS, DE LA TUBERIA, DE CUALQUIER OTRA PARTE METALICA QUE ESTA CERCA DEL MOTOR O POR NO UTILIZAR UN CABLE PARA TIERRA DE CALIBRE IGUAL O MAYOR AL DE LA ALIMENTACION. PARA REDUCIR EL RIESGO DE CHOQUE ELECTRIC, DESCONECTAR LA ALIMENTACION ELECTRICA ANTES DE INICIAR A TRABAJAR EN EL SISTEMA HIDRAULICO. NO UTILIZAR ESTE MOTOR EN ALBERCAS O AREAS EN DONDE SE PRACTIQUE NATACION.

Commitment to Quality

Franklin Electric is committed to provide customers with defect free products through our program of continuous improvement. Quality shall, in every case, take precedence over quantity.

Submersible Motors

Application • Installation • Maintenance Manual

The submersible motor is a reliable, efﬁ cient and troublefree means of powering a pump. Its needs for a long operational life are simple. They are:

1. A suitable operating environment

2. An adequate supply of electricity

3. An adequate ﬂ ow of cooling water over the motor

4. An appropriate pump load

Contents

Application – All Motors

Storage ...........................................................................3

Frequency of Starts .........................................................3

Mounting Position ...........................................................3

Transformer Capacity .....................................................4

Effects of Torque .............................................................4

Use of Engine Driven Generators ................................... 5

Use of Check Valves .......................................................5

Well Diameters, Casing, Top Feeding, Screens ............. 6

Water Temperature and Flow .........................................6

Flow Inducer Sleeve .......................................................6

Head Loss Past Motor ....................................................7

Hot Water Applications ................................................7-8

Drawdown Seals ............................................................. 9

Grounding Control Boxes and Panels .............................9

Grounding Surge Arrestors ............................................. 9

Control Box and Panel Environment ...............................9

Equipment Grounding ..................................................... 9

All considerations of application, installation, and maintenance of submersible motors relating to these four areas are presented in this manual. Franklin Electric’s web page, www.franklin-electric.com, should be checked for the latest updates.

SubMonitor .................................................................... 31

Power Factor Correction ............................................... 31

Three-Phase Starter Diagrams ..................................... 32

Three-Phase Power Unbalance ....................................33

Rotation and Current Unbalance ..................................33

Three-Phase Motor Lead Identiﬁ cation .........................34

Phase Converters .........................................................34

Reduced Voltage Starters .............................................35

Inline Booster Pump Systems ..................................35-38

Variable Speed Operation .............................................39

Installation – All Motors

Submersible Motors - Dimensions ................................ 40

Tightening Lead Connector Jam Nut ............................41

Pump to Motor Coupling ...............................................41

Shaft Height and Free End Play ...................................41

Submersible Leads and Cables .................................... 41

Application – Single-Phase Motors

3-Wire Control Boxes ....................................................10

2-Wire Motor Solid State Controls ................................10

QD Relays (Solid State) ................................................10

Cable Selection 2-Wire or 3-Wire .................................11

Two Different Cable Sizes ............................................12

Single-Phase Motor Speciﬁ cations ...............................13

Single-Phase Motor Fuse Sizing ...................................14

Auxiliary Running Capacitors ........................................15

Buck-Boost Transformers .............................................15

Application – Three-Phase Motors

Cable Selection - 60 °C Three-Wire .........................16-17

Cable Selection - 60 °C Six-Wire .................................. 18

Cable Selection - 75 °C Three-Wire .........................19-20

Cable Selection - 75 °C Six-Wire .................................. 21

Three-Phase Motor Speciﬁ cations ...........................22-26

Three-Phase Motor Fuse Sizing ...................................27

Overload Protection .................................................28-30

Submersible Pump Installation Checklist (No. 3656) Submersible Motor Installation Record (No. 2207) Submersible Booster Installation Record (No. 3655)

Maintenance – All Motors

System Troubleshooting ..........................................42-43

Preliminary Tests ..........................................................44

Insulation Resistance ....................................................45

Resistance of Drop Cable ............................................. 45

Maintenance – Single-Phase Motors & Controls

Identiﬁ cation of Cables ..................................................46

Single-Phase Control Boxes ......................................... 46

Ohmmeter Tests ...........................................................47

QD Control Box Parts ...................................................48

Integral hp Control Box Parts ...................................49-50

Control Box Wiring Diagrams ...................................51-54

Maintenance – Electronic Products

Pumptec-Plus Troubleshooting During Installation ....... 55

Pumptec-Plus Troubleshooting After Installation .......... 56

QD Pumptec and Pumptec Troubleshooting ................57

SubDrive/MonoDrive Troubleshooting .......................... 58

SubMonitor Troubleshooting .........................................59

Subtrol-Plus Troubleshooting ...................................60-61

Storage

Application – All Motors

Franklin Electric submersible motors are a waterlubricated design. The ﬁ ll solution consists of a mixture of deionized water and Propylene Glycol (a non-toxic antifreeze). The solution will prevent damage from freezing in temperatures to -40 °F (-40 °C); motors should be stored in areas that do not go below this temperature. The solution will partially freeze below 27 °F (-3 °C), but no damage occurs. Repeated freezing and thawing should be avoided to prevent possible loss of ﬁ ll solution.

There may be an interchange of ﬁ ll solution with well water during operation. Care must be taken with motors removed from wells during freezing conditions to prevent damage.

Frequency of Starts

The average number of starts per day over a period of months or years inﬂ uences the life of a submersible pumping system. Excessive cycling affects the life of control components such as pressure switches, starters, relays and capacitors. Rapid cycling can also cause motor spline damage, bearing damage, and motor overheating. All these conditions can lead to reduced motor life.

The pump size, tank size and other controls should be selected to keep the starts per day as low as practical for longest life. The maximum number of starts per 24-hour period is shown in table 3.

Motors should run a minimum of one minute to dissipate heat build up from starting current. 6" and larger motors should have a minimum of 15 minutes between starts or starting attempts.

When the storage temperature does not exceed 100 °F (37 °C), storage time should be limited to two years. Where temperatures reach 100° to 130 °F, storage time should be limited to one year.

Loss of a few drops of liquid will not damage the motor as an excess amount is provided, and the ﬁ lter check valve will allow lost liquid to be replaced by ﬁ ltered well water upon installation. If there is reason to believe there has been a considerable amount of leakage, consult the factory for checking procedures.

Table 3 Number of Starts

MOTOR RATING MAXIMUM STARTS PER 24 HR PERIOD

HP KW SINGLE-PHASE THREE-PHASE

Up to 0.75 Up to 0.55 300 300

1 thru 5.5 0.75 thru 4 100 300

7.5 thru 30 5.5 thru 22 50 100

40 and over 30 and over - 100

Mounting Position

Franklin submersible motors are designed primarily for operation in the vertical, shaft-up position.

During acceleration, the pump thrust increases as its output head increases. In cases where the pump head stays below its normal operating range during startup and full speed condition, the pump may create upward thrust. This creates upward thrust on the motor upthrust bearing. This is an acceptable operation for short periods at each start, but running continuously with upthrust will cause excessive wear on the upthrust bearing.

With certain additional restrictions as listed in this section and the Inline Booster Pump Systems sections of this manual, motors are also suitable for operation in positions

from shaft-up to shaft-horizontal. As the mounting position becomes further from vertical and closer to horizontal, the probability of shortened thrust bearing life increases. For normal motor life expectancy with motor positions other than shaft-up, follow these recommendations:

1. Minimize the frequency of starts, preferably to fewer than 10 per 24-hour period. 6” and 8” motors should have a minimum of 20 minutes between starts or starting attempts

2. Do not use in systems which can run even for short periods at full speed without thrust toward the motor.

Application – All Motors

Transformer Capacity - Single-Phase or Three-Phase

Distribution transformers must be adequately sized to satisfy the kVA requirements of the submersible motor. When transformers are too small to supply the load, there is a reduction in voltage to the motor.

Table 4 references the motor horsepower rating, singlephase and three-phase, total effective kVA required, and

Table 4 Transformer Capacity

MOTOR RATING

HP KW

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

40 30

50 37

60 45

75 55

100 75

125 90

150 110

175 130

200 150

TOTAL

EFFECTIVE

KVA

REQUIRED

32 1

4 2 1.5

53 2

7.5 5 3

10 7.5 5

15 10 5

20 15 7.5

25 15 10

30 20 10

40 25 15

50 30 20

60 35 20

75 40 25

90 50 30

120 65 40

150 85 50

175 100 60

200 115 70

230 130 75

SMALLEST KVA RATING-EACH TRANSFORMER

OPEN WYE

OR DELTA

2- TRANSFORMERS

the smallest transformer required for open or closed three-phase systems. Open systems require larger transformers since only two transformers are used.

Other loads would add directly to the kVA sizing requirements of the transformer bank.

NOTE: Standard kVA

CLOSED

WYE OR DELTA

3- TRANSFORMERS

ratings are shown. If power company experience and practice allows transformer loading higher than standard, higher loading values may be used to meet total effective kVA required, provided correct voltage and balance is maintained.

Effects of Torque

During starting of a submersible pump, the torque developed by the motor must be supported through the pump, delivery pipe or other supports. Most pumps rotate in the direction which causes unscrewing torque on right-handed threaded pipe or pump stages. All threaded joints, pumps and other parts of the pump support system must be capable of withstanding the maximum torque repeatedly without loosening or breaking. Unscrewing joints will break electrical cable and may cause loss of the pump-motor unit.

Table 4A Torque Required (Examples)

MOTOR RATING

HP KW

1 hp & Less 0.75 kW & Less

20 hp 15 kW

75 hp 55 kW

200 hp 150 kW

MINIMUM SAFE

TORQUE-LOAD

10 lb-ft

200 lb-ft

750 lb-ft

2000 lb-ft

To safely withstand maximum unscrewing torques with a minimum safety factor of 1.5, tightening all theaded joints to at least 10 lb-ft per motor horsepower is recommended (table 4A). It may be necessary to tack or strap weld pipe joints on high horsepower pumps, especially at shallower settings.

Application – All Motors

Use of Engine Driven Generators - Single-Phase or Three-Phase

Table 5 lists minimum generator sizes based on typical 80 °C rise continuous duty generators, with 35% maximum voltage dip during starting, for Franklin’s threewire motors, single- or three-phase.

This is a general chart. The generator manufacturer should be consulted whenever possible, especially on larger sizes.

There are two types of generators available: externally and internally regulated. Most are externally regulated. They use an external voltage regulator that senses the output voltage. As the voltage dips at motor start-up, the regulator increases the output voltage of the generator.

Internally regulated (self-excited) generators have an extra winding in the generator stator. The extra winding senses the output current to automatically adjust the output voltage.

Generators must be sized to deliver at least 65% of the rated voltage during starting to ensure adequate starting torque. Besides sizing, generator frequency is important as the motor speed varies with the frequency (Hz). Due to pump afﬁ nity laws, a pump running at 1 to 2 Hz below motor nameplate frequency design will not meet its performance curve. Conversely, a pump running at 1 to 2 Hz above may trip overloads.

Generator Operation

Always start the generator before the motor is started and always stop the motor before the generator is shut down. The motor thrust bearing may be damaged if the generator is allowed to coast down with the motor running. This same condition occurs when the generator is allowed to run out of fuel.

Follow generator manufacturer’s recommendations for de-rating at higher elevations or using natural gas.

Table 5 Engine Driven Generators

NOTE: This chart applies to 3-wire or 3-phase motors. For best starting of 2-wire motors, the minimum generator rating is 50% higher than shown.

MOTOR RATING MINIMUM RATING OF GENERATOR

HP KW

1/3 0.25

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

40 30

50 37

60 45

75 55

100 75

125 90

150 110

175 130

200 150

EXTERNALLY REGULATED INTERNALLY REGULATED

KW KVA KW KVA

1.5 1.9 1.2 1.5 2 2.5 1.5 1.9 3 3.8 2 2.5 4 5.0 2.5 3.13 5 6.25 3 3.8

7.5 9.4 4 5

10 12.5 5 6.25 15 18.75 7.5 9.4 20 25.0 10 12.5 30 37.5 15 18.75 40 50 20 25 60 75 25 31

75 94 30 37.50 100 125 40 50 100 125 50 62.5 150 188 60 75 175 220 75 94 250 313 100 125 300 375 150 188 375 469 175 219 450 563 200 250 525 656 250 313 600 750 275 344

WARNING: To prevent accidental electrocution, automatic or manual transfer switches must be used any time a generator is used as standby or back up on power lines. Contact power company for use and approval.

Use of Check Valves

It is recommended that one or more check valves always be used in submersible pump installations. If the pump does not have a built-in check valve, a line check valve should be installed in the discharge line within 25 feet of the pump and below the draw down level of the water supply. For deeper settings, check valves should be installed per the manufacturer’s recommendations. More than one check valve may be required, but more than the recommended number of check valves should not be used.

Swing type check valves are not acceptable and should never be used with submersible motors/pumps. Swing type check valves have a slower reaction time which can cause water hammer (see next page). Internal pump check valves or spring loaded check valves close quickly and help eliminate water hammer.

Check valves are used to hold pressure in the system when the pump stops. They also prevent backspin, water

hammer and upthrust. Any of these can lead to early pump or motor failure.

NOTE: Only positive sealing check valves should be used in submersible installations. Although drilling the check valves or using drain-back check valves may prevent back spinning, they create upthrust and water hammer problems.

A. Backspin - With no check valve or a failed check

valve, the water in the drop pipe and the water in the system can ﬂ ow down the discharge pipe when the motor stops. This can cause the pump to rotate in a reverse direction. If the motor is started while it is backspinning, an excessive force is placed across the pump-motor assembly that can cause impeller damage, motor or pump shaft breakage, excessive bearing wear, etc.

B. Upthrust - With no check valve, a leaking check

valve, or drilled check valve, the unit starts under

Application – All Motors

a zero head condition. This causes an uplifting or upthrust on the impeller-shaft assembly in the pump. This upward movement carries across the pumpmotor coupling and creates an upthrust condition in the motor. Repeated upthrust can cause premature failure of both the pump and the motor.

C. Water Hammer - If the lowest check valve is more

than 30 feet above the standing (lowest static) water level, or a lower check valve leaks and the

the discharge piping. On the next pump start, water moving at very high velocity ﬁ lls the void and strikes the closed check valve and the stationary water in the pipe above it, causing a hydraulic shock. This shock can split pipes, break joints and damage the pump and/or motor. Water hammer can often be heard or felt. When discovered, the system should be shut down and the pump installer contacted to correct the problem.

check valve above holds, a vacuum is created in

Wells – Large Diameter, Uncased, Top Feeding and Screened Sections

Franklin Electric submersible motors are designed to operate with a cooling ﬂ ow of water over and around the full length of the motor.

If the pump installation does not provide the minimum ﬂ ow shown in table 6, a ﬂ ow inducer sleeve (ﬂ ow sleeve) must be used. The conditions requiring a ﬂ ow sleeve are:

• Well diameter is too large to meet table 6 ﬂ ow requirements.

• Pump is in an open body of water.

• Pump is in a rock well or below the well casing.

• The well is “top-feeding” (a.k.a. cascading)

• Pump is set in or below screens or perforations.

Water Temperature and Flow

Franklin Electric’s standard submersible motors, except Hi-Temp designs (see note below), are designed to operate up to maximum service factor horsepower in water up to 86 °F (30 °C). A ﬂ ow of 0.25 ft/s for 4" motors rated 3 hp and higher, and 0.5 ft/s for 6 and 8" motors is required for proper cooling. Table 6 shows minimum ﬂ ow rates, in gpm, for various well diameters and motor sizes.

If a standard motor is operated in water over 86 °F (30 °C), water ﬂ ow past the motor must be increased to maintain safe motor operating temperatures. See HOT WATER APPLICATIONS on page 7.

NOTE: Franklin Electric offers a line of Hi-Temp motors designed to operate in water at higher temperatures or lower ﬂ ow conditions. Consult factory for details.

Table 6 Required Cooling Flow

MINIMUM GPM REQUIRED FOR MOTOR COOLING IN WATER UP TO 86 °F (30 °C).

CASING OR

SLEEVE ID

INCHES (MM)

4 (102)

5 (127)

6 (152)

7 (178)

8 (203)

10 (254)

12 (305)

14 (356)

16 (406)

0.25 ft/s = 7.62 cm/sec 0.50 ft/s = 15.24 cm/sec 1 inch = 2.54 cm

4" MOTOR (3-10 HP)

0.25 FT/S

GPM (L/M)

1.2 (4.5) - -

7 (26.5) - -

13 (49) 9 (34) -

20 (76) 25 (95) -

30 (114) 45 (170) 10 (40)

50 (189) 90 (340) 55 (210)

80 (303) 140 (530) 110 (420)

110 (416) 200 (760) 170 (645)

150 (568) 280 (1060) 245 (930)

6" MOTOR

0.50 FT/S

GPM (L/M)

Flow Inducer Sleeve

If the ﬂ ow rate is less than speciﬁ ed, then a ﬂ ow inducer sleeve must be used. A ﬂ ow sleeve is always required in an open body of water. FIG. 1 shows a typical ﬂ ow inducer sleeve construction.

EXAMPLE: A 6" motor and pump that delivers 60 gpm will be installed in a 10" well.

From table 6, 90 gpm would be required to maintain proper cooling. In this case adding an 8" or smaller ﬂ ow sleeve provides the required cooling.

FIG. 1

WORM GEAR CLAMPS

INTAKE

FLOW INDUCER SLEEVE

SUBMERSIBLE MOTOR

CENTERING BOLT

CENTERING BOLTS MUST BE LOCATED ON MOTOR CASTING. DO NOT LOCATE ON STATOR SHELL.

SAW CUTS

NOTCH OUT FOR CABLE GUARD

BOTTOM END VIEW

CENTERING BOLT HOLE (3 REQUIRED)

8" MOTOR

0.50 FT/S

GPM (L/M)

LOCK NUTS INSIDE SLEEVE

Application – All Motors

Head Loss From Flow Past Motor

Table 7 lists the approximate head loss due to ﬂ ow between an average length motor and smooth casing or ﬂ ow inducer sleeve.

Table 7 Head Loss in Feet (Meters) at Various Flow Rates

MOTOR DIAMETER 4" 4" 4" 6" 6" 6" 8" 8"

CASING ID IN INCHES (MM) 4 (102) 5 (127) 6 (152) 6 (152) 7 (178) 8 (203) 8.1 (206) 10 (254)

25 (95) 0.3 (.09)

50 (189) 1.2 (.37)

100 (378) 4.7 (1.4) 0.3 (.09) 1.7 (.52)

150 (568) 10.2 (3.1) 0.6 (.18) 0.2 (.06) 3.7 (1.1)

200 (757) 1.1 (.34) 0.4 (.12) 6.3 (1.9) 0.5 (.15) 6.8 (2.1)

250 (946) 1.8 (.55) 0.7 (.21) 9.6 (2.9) 0.8 (.24) 10.4 (3.2)

300 (1136) 2.5 (.75) 1.0 (.30) 13.6 (4.1) 1.2 (.37) 0.2 (.06) 14.6 (4.5)

Flow Rate in gpm (l/m)

400 (1514) 23.7 (7.2) 2.0 (.61) 0.4 (.12) 24.6 (7.5)

500 (1893) 3.1 (.94) 0.7 (.21) 37.3 (11.4) 0.6 (0.2)

600 (2271) 4.4 (1.3) 1.0 (.30) 52.2 (15.9) 0.8 (0.3)

800 (3028) 1.5 (0.5)

1000 (3785) 2.4 (0.7)

Hot Water Applications (Standard Motors)

Franklin Electric offers a line of Hi-Temp motors which are designed to operate in water with various temperatures up to 194 °F (90 °C) without increased ﬂ ow. When a standard pump-motor operates in water hotter than 86 °F (30 °C), a ﬂ ow rate of at least 3 ft/s is required. When selecting the motor to drive a pump in over 86 °F (30 °C) water, the motor horsepower must be de-rated per the following procedure.

1. Using table 7A, determine pump gpm required for different well or sleeve diameters. If necessary, add a ﬂ ow sleeve to obtain at least 3 ft/s ﬂ ow rate.

Table 7A Minimum gpm (l/m) Required for 3 ft/s (.91 m/sec) Flow Rate

INCHES (MM) GPM (L/M) GPM (L/M) GPM (L/M)

CASING OR SLEEVE ID

4 (102) 15 (57)

5 (127) 80 (303)

6 (152) 160 (606) 52 (197)

7 (178) 150 (568)

8 (203) 260 (984) 60 (227)

10 (254) 520 (1970) 330 (1250)

12 (305) 650 (2460)

14 (356) 1020 (3860)

16 (406) 1460 (5530)

4" HIGH

THRUST MOTOR

6" MOTOR 8" MOTOR

Application – All Motors

2. Determine pump horsepower required from the pump manufacturer’s curve.

3. Multiply the pump horsepower required by the heat factor multiplier from table 8.

EXAMPLE

Brake Horsepower

0 5 10 15 20 25 30 35 40 45 50

Gallons Per Minute

FIG. 2 MANUFACTURER’S PUMP CURVE

Table 8 Heat Factor Multiplier at 3 ft/s (.91 m/sec) Flow Rate

MAXIMUM

WATER TEMPERATURE

140 °F (60 °C) 1.25 1.62 2.00

131 °F (55 °C) 1.11 1.32 1.62

122 °F (50 °C) 1.00 1.14 1.32

113 °F (45 °C) 1.00 1.00 1.14

104 °F (40 °C) 1.00 1.00 1.00

95 °F (35 °C) 1.00 1.00 1.00

1/3 - 5 HP

.25 - 3.7 KW

7 1/2 - 30 HP

5.5 - 22 KW

OVER 30 HP

OVER 22 KW

Table 8A Service Factor Horsepower

4. Select a rated hp motor on table 8A whose Service Factor Horsepower is at least the value calculated in Item 3.

HP KW SFHP HP KW SFHP HP KW SFHP HP KW SFHP

1/3 0.25 0.58 3 2.2 3.45 25 18.5 28.75 100 75 115.00

1/2 0.37 0.80 5 3.7 5.75 30 22.0 34.50 125 90 143.75

3/4 0.55 1.12 7.5 5.5 8.62 40 30.0 46.00 150 110 172.50

1 0.75 1.40 10 7.5 11.50 50 37.0 57.50 175 130 201.25

1.5 1.10 1.95 15 11.0 17.25 60 45.0 69.00 200 150 230.00

2 1.50 2.50 20 15.0 23.00 75 55.0 86.25

Hot Water Applications - Example

EXAMPLE: A 6" pump end requiring 39 hp input will pump 124 °F water in an 8" well at a delivery rate of 140 gpm. From table 7A, a 6" ﬂ ow sleeve will be required to increase the ﬂ ow rate to at least 3 ft/s

Using table 8, the 1.62 heat factor multiplier is selected because the hp required is over 30 hp and water

temperature is above 122 °F. Multiply 39 hp x 1.62 (multiplier), which equals 63.2 hp. This is the minimum rated service factor horsepower usable at 39 hp in 124 °F. Using table 8A, select a motor with a rated service factor horsepower above 63.2 hp. A 60 hp motor has a service factor horsepower of 69, so a 60 hp motor may be used.

Application – All Motors

Drawdown Seals

Allowable motor temperature is based on atmospheric pressure or higher surrounding the motor. “Drawdown seals,” which seal the well to the pump above its intake

Grounding Control Boxes and Panels

The National Electrical Code requires that the control box or panel-grounding terminal always be connected to supply ground. If the circuit has no grounding conductor and no metal conduit from the box to supply panel, use a wire at least as large as line conductors and connect as required by the National Electrical Code, from the grounding terminal to the electrical supply ground.

Grounding Surge Arrestors

An above ground surge arrestor must be grounded, metal to metal, all the way to the lowest draw down water strata for the surge arrestor to be effective. GROUNDING THE ARRESTOR TO THE SUPPLY GROUND OR TO A DRIVEN GROUND ROD PROVIDES LITTLE OR NO SURGE PROTECTION FOR THE MOTOR.

Control Box and Panel Environment

Franklin Electric control boxes meet UL requirements for NEMA Type 3R enclosures. They are suitable for indoor and outdoor applications within temperatures of +14 °F (-10 °C) to 122 °F (50 °C). Operating control boxes below +14 °F can cause reduced starting torque and loss of overload protection when overloads are located in control boxes.

Control boxes and panels should never be mounted in direct sunlight or high temperature locations. This will cause shortened capacitor life and unnecessary tripping

to maximize delivery, are not recommended, since the suction created can be lower than atmospheric pressure.

WARNING: Failure to ground the control frame can result in a serious or fatal electrical shock hazard.

of overload protectors. A ventilated enclosure painted white to reﬂ ect heat is recommended for an outdoor, high temperature location.

A damp well pit, or other humid location, accelerates component failure from corrosion.

Control boxes with voltage relays are designed for vertical upright mounting only. Mounting in other positions will affect the operation of the relay.

Equipment Grounding

WARNING: Serious or fatal electrical shock may result from failure to connect the motor, control enclosures, metal plumbing and all other metal near the motor or cable to the power supply ground terminal using wire no smaller than motor cable wires.

The primary purpose of grounding the metal drop pipe and/or metal well casing in an installation is safety. It is done to limit the voltage between nonelectrical (exposed metal) parts of the system and ground, thus minimizing dangerous shock hazards. Using wire at least the size of the motor cable wires provides adequate current-carrying capability for any ground fault that might occur. It also provides a low resistance path to ground, ensuring that the current to ground will be large enough to trip any overcurrent device designed to detect faults (such as a ground fault circuit interrupter, or GFCI).

Normally, the ground wire to the motor would provide the

primary path back to the power supply ground for any ground fault. There are conditions, however, where the ground wire connection could become compromised. One such example would be the case where the water in the well is abnormally corrosive or aggressive. In this example, a grounded metal drop pipe or casing would then become the primary path to ground. However, the many installations that now use plastic drop pipes and/or casings require further steps to be taken for safety purposes, so that the water column itself does not become the conductive path to ground.

When an installation has abnormally corrosive water AND the drop pipe or casing is plastic, Franklin Electric recommends the use of a GFCI with a 10 mA set-point. In this case, the motor ground wire should be routed through the current-sensing device along with the motor power leads. Wired this way, the GFCI will trip only when a ground fault has occurred AND the motor ground wire is no longer functional.

Application – Single-Phase Motors

3-Wire Control Boxes

Single-phase three-wire submersible motors require the use of control boxes. Operation of motors without control boxes or with incorrect boxes can result in motor failure and voids warranty.

Control boxes contain starting capacitors, a starting relay, and, in some sizes, overload protectors, running capacitors and contactors.

Ratings through 1 hp may use either a Franklin Electric solid state QD or a potential (voltage) type starting relay, while larger ratings use potential relays.

Potential (Voltage) Relays

Potential relays have normally closed contacts. When power is applied, both start and main motor windings are energized, and the motor starts. At this instant, the voltage across the start winding is relatively low and not

2-Wire Motor Solid State Controls

BIAC Switch Operation

When power is applied the bi-metal switch contacts are closed, so the triac is conducting and energizes the start winding. As rpm increases, the voltage in the sensor coil generates heat in the bi-metal strip, causing the bi-metal strip to bend and open the switch circuit. This removes the starting winding and the motor continues to run on the main winding alone.

Approximately 5 seconds after power is removed from the motor, the bi-metal strip cools sufﬁ ciently to return to its closed position and the motor is ready for the next start cycle.

enough to open the contacts of the relay.

As the motor accelerates, the increasing voltage across the start winding (and the relay coil) opens the relay contacts. This opens the starting circuit and the motor continues to run on the main winding alone, or the main plus run capacitor circuit. After the motor is started the relay contacts remain open.

CAUTION: The control box and motor are two pieces

of one assembly. Be certain that the control box and motor hp and voltage match. Since a motor is designed to operate with a control box from the same manufacturer, we can promise warranty coverage only when a Franklin control box is used with a Franklin motor.

to restart the motor before the starting switch has reset, the motor may not start; however, there will be current in the main winding until the overload protector interrupts the circuit. The time for the protector to reset is longer than the reset of the starting switch. Therefore, the start switch will have closed and the motor will operate.

A waterlogged tank will cause fast cycling. When a waterlogged condition does occur, the user will be alerted to the problem during the off time (overload reset time) since the pressure will drop drastically. When the waterlogged tank condition is detected, the condition should be corrected to prevent nuisance tripping of the overload protector.

Rapid Cycling

The BIAC starting switch will reset within approximately 5 seconds after the motor is stopped. If an attempt is made

CAUTION: Restarting the motor within 5 seconds after power is removed may cause the motor overload to trip.

QD Relays (Solid State)

There are two elements in the relay: a reed switch and a triac. The reed switch consists of two tiny rectangular blade-type contacts, which bend under magnetic ﬂ ux. It is hermetically sealed in glass and is located within a coil, which conducts line current. When power is supplied to the control box, the main winding current passing through the coil immediately closes the reed switch contacts. This turns on the triac, which supplies voltage to the start winding, thus starting the motor.

Once the motor is started, the operation of the QD relay is an interaction between the triac, the reed switch and

Bound Pump (Sandlocked)

When the motor is not free to turn, as with a sandlocked pump, the BIAC switch creates a “reverse impact torque” in the motor in either direction. When the sand is dislodged, the motor will start and operate in the correct direction.

the motor windings. The solid state switch senses motor speed through the changing phase relationship between start winding current and line current. As the motor approaches running speed, the phase angle between the start current and the line current becomes nearly in phase. At this point, the reed switch contacts open, turning off the triac. This removes voltage from the start winding and the motor continues to run on the main winding only. With the reed switch contacts open and the triac turned off, the QD relay is ready for the next starting cycle.

Application – Single-Phase Motors

2 or 3-Wire Cable, 60 Hz (Service Entrance to Motor - Maximum Length In Feet)

Table 11

MOTOR RATING 60 °C INSULATION - AWG COPPER WIRE SIZE

VOLTSHPKW1412108643210000000000

115 1/2 .37

1/2 .37

3/4 .55

1 .75

1.5 1.1

230

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

100 160 250 390 620 960 1190 1460 1780 2160 2630 3140 3770

400 650 1020 1610 2510 3880 4810 5880 7170 8720

300 480 760 1200 1870 2890 3580 4370 5330 6470 7870

250 400 630 990 1540 2380 2960 3610 4410 5360 6520

190 310 480 770 1200 1870 2320 2850 3500 4280 5240

150 250 390 620 970 1530 1910 2360 2930 3620 4480

120

190 300 470 750 1190 1490 1850 2320 2890 3610

000

0000

180

280 450 710 890 1110 1390 1740 2170 2680

200

310 490 610 750 930 1140 1410 1720

250

170 270

390 490 600 750 930 1160 1430 1760

340 430 530 660 820 1020 1260

Table 11A

MOTOR RATING 75 °C INSULATION - AWG COPPER WIRE SIZE

VOLTSHPKW1412108643210000000000

115 1/2 .37

1/2 .37

3/4 .55

1 .75

1.5 1.1

230

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

100 160 250 390 620 960 1190 1460 1780 2160 2630 3140 3770

400 650 1020 1610 2510 3880 4810 5880 7170 8720

300 480 760 1200 1870 2890 3580 4370 5330 6470 7870 9380

250 400 630 990 1540 2380 2960 3610 4410 5360 6520 7780 9350

190 310 480 770 1200 1870 2320 2850 3500 4280 5240 6300 7620

150 250 390 620 970 1530 1910 2360 2930 3620 4480 5470 6700

120

190 300 470 750 1190 1490 1850 2320 2890 3610 4470 5550

110

000

0000

180 280 450 710 890 1110 1390 1740 2170 2680 3330

120

200 310 490 610 750 930 1140 1410 1720 2100

160

250 390 490 600 750 930 1160 1430 1760

170

270 340 430 530 660 820 1020 1260

60 °C

75 °C

1 Foot = .3048 Meter

Lengths in BOLD only meet the US National Electrical Code ampacity requirements for individual conductors 60 °C or 75 °C in free air or water, not in magnetic enclosures, conduit or direct buried.

Lengths NOT in bold meet the NEC ampacity requirements for either individual conductors or jacketed 60 °C or 75 °C cable and can be in conduit or direct buried. Flat molded and web/ribbon cable are considered jacketed cable.

If any other cable is used, the NEC and local codes should be observed.

Cable lengths in tables 11 & 11A allow for a 5% voltage drop running at maximum nameplate amperes. If 3% voltage drop is desired, multiply table 11 and 11A lengths by 0.6 to get maximum cable length.

The portion of the total cable length, which is between the supply and single-phase control box with a line contactor, should not exceed 25% of total maximum allowable to ensure reliable contactor operation. Singlephase control boxes without line contactors may be connected at any point in the total cable length.

Tables 11 & 11A are based on copper wire. If aluminum wire is used, it must be two sizes larger than copper wire and oxidation inhibitors must be used on connections.

EXAMPLE: If tables 11 & 11A call for #12 copper wire, #10 aluminum wire would be required.

Contact Franklin Electric for 90 °C cable lengths. See pages 15, 48, and 49 for applications using 230 V motors on 208 V power systems.

Application – Single-Phase Motors

Two or More Different Cable Sizes Can Be Used

Depending on the installation, any number of combinations of cable may be used.

For example, in a replacement/upgrade installation, the well already has 160 feet of buried #10 cable between the service entrance and the wellhead. A new 3 hp, 230-volt, single-phase motor is being installed to replace a smaller motor. The question is: Since there is already 160 feet of #10 AWG installed, what size cable is required in the well with a 3 hp, 230-volt, single-phase motor setting at 310 feet?

From tables 11 & 11A, a 3 hp motor can use up to 300 feet of #10 AWG cable.

The application has 160 feet of #10 AWG copper wire installed.

Using the formula below, 160 feet (actual) ÷ 300 feet (max allowable) is equal to 0.533. This means 53.3% (0.533 x 100) of the allowable voltage drop or loss, which is allowed between the service entrance and the motor,

Formula:

Actual Length

Max Allowed

occurs in this wire. This leaves us 46.7% (1.00 - 0.533 = 0.467) of some other wire size to use in the remaining 310 feet “down hole” wire run.

The table shows #8 AWG copper wire is good for 470 feet. Using the formula again, 310 feet (used) ÷ 470 feet (allowed) = 0.660; adding this to the 0.533 determined earlier; 0.533 + 0.660 = 1.193. This combination is greater than 1.00, so the voltage drop will not meet US National Electrical Code recommendations.

Tables 11 & 11A show #6 AWG copper wire is good for 750 feet. Using the formula, 310 ÷ 750 = 0.413, and using these numbers, 0.533 + 0.413 = 0.946, we ﬁ nd this is less than one and will meet the NEC recommended voltage drop.

This works for two, three or more combinations of wire and it does not matter which size wire comes ﬁ rst in the installation.

Actual Length

Max Allowed

1.00

EXAMPLE: 3 hp, 230-Volt, Single-Phase Motor

160 ft #10 AWG

(53.3% of allowable cable)

FIG. 3

310 ft #6 AWG

(41.3% of allowable cable)

3 hp, 230 V Single-Phase Motor

Application – Single-Phase Motors

Table 13 Single-Phase Motor Speciﬁ cations (60 Hz) 3450 rpm

FULL

LOAD

(2)

WATTS

AMPS

Y10.0 B10.0R0670

Y5.0 B5.0R0670

Y6.8 B6.8R0940

Y8.2 B8.2R01210

Y3.6 B3.7 R2.0

Y4.9 B5.0 R3.2

Y6.0 B5.7 R3.4

Y6.6 B6.6 R1.3

Y10.0

B9.9 R1.3

Y10.0

B9.3

R2.6 Y14.0 B11.2

R6.1 Y23.0 B15.9 R11.0 Y23.0 B14.3 R10.8 Y36.5 B34.4

R5.5 Y44.0 B39.5

R9.3 Y62.0 B52.0 R17.5

655

925

1160

1130

1660

2060

2940

4920

4910

7300

9800

13900

TYPE

MOTOR MODEL PREFIX

244504 244505 244507 244508

4" 2-WIRE

244309

214504

214505

4" 3-WIRE

214507

214508

214505

214507

4" 3-WIRE W/CRC CB

214508

W/1-

1.5 CB

224300

224301

4" 3-WIRE

224302

(3)

224303

(4)

226110

(5)

226111

226112

226113

RATING

HP KW VOLTS HZ S.F.

1/2 0.37 1/2 0.37 3/4 0.55

1 0.75

1.5 1.1

1/2 0.37

3/4 0.55

1 0.75

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

115 60 1.6 10.0 670 12.0 960 1.0-1.3 62 56 73 58 64.4 R 230 60 1.6 5.0 670 6.0 960 4.2-5.2 62 56 73 58 32.2 R 230 60 1.5 6.8 940 8.0 1310 3.0-3.6 64 59 74 62 40.7 N 230 60 1.4 8.2 1210 9.8 1600 2.2-2.7 65 62 74 63 48.7 N 230 60 1.3 10.6 1700 13.1 2180 1.5-1.9 67 66 80 73 66.6 M

115 60 1.6

230 60 1.6

230 60 1.5

230 60 1.4

230 60 1.6

230 60 1.5

230 60 1.4

230 60 1.3

230 60 1.25

230 60 1.15

(1) Main winding - yellow to black Start winding - yellow to red

(2) Y = Yellow lead - line amps B = Black lead - main winding amps R = Red lead - start or auxiliary winding amps

(3) Control Boxes date coded 02C and older have 35 MFD run capacitors. Current values should be Y14.0 @ FL and Y17.0 @ SF Load. B12.2 B14.5 R4.7 R4.5

Performance is typical, not guaranteed, at speciﬁ ed voltages and speciﬁ ed capacitor values. Performance at voltage ratings not shown is similar, except amps vary inversely with voltage.

MAXIMUM

(S.F. LOAD)

(2)

WATTS

AMPS

Y12.0 B12.0R0960

Y6.0 B6.0R0960

Y8.0 B8.0R01310

Y9.8 B9.8R01600

Y4.3 B4.0 R2.0

Y5.7 B5.2 R3.1

Y7.1 B6.2 R3.3

Y8.0 B7.9

R1.3 Y11.5 B11.0

R1.3 Y13.2 B11.9

R2.6 Y17.0 B12.6

R6.0 Y27.5 B19.1 R10.8 Y27.5 B17.4 R10.5 Y42.1 B40.5

R5.4 Y51.0 B47.5

R8.9 Y75.0 B62.5 R16.9

890

1220

1490

1500

2100

2610

3350

5620

5570

8800

11300

16200

WINDING (1) RES. IN OHMS M=MAIN RES.

S=START RES.

M1.0-1.3 S4.1-5.1

M4.2-5.2

S16.7-20.5

M3.0-3.6

S10.7-13.1

M2.2-2.7

S9.9-12.1

M4.2-5.2

S16.7-20.5

M3.0-3.6

S10.7-13.1

M2.2-2.7

S9.9-12.1

M2.2-2.7

S9.9-12.1

M1.7-2.2 S8.0-9.7

M1.8-2.3 S5.8-7.2

M1.0-1.5 S3.5-4.4

M.68-1.0 S1.8-2.2

M.55-.68 S1.3-1.7

M.36-.50 S.88-1.1

M.27-.33 S.80-.99

M.17-.22 S.68-.93

EFFICIENCY %

S.F. F.L. S.F. F.L.

62 56 73 58 50.5 M

62 56 73 58 23 M

64 59 74 62 34.2 M

65 62 74 63 41.8 L

67 57 90 81 23 M

69 60 92 84 34.2 M

70 64 92 86 41.8 L

70 66 82 72 43 L

69 67 82 74 52 J

71 73 95 93 51 G

77 76 97 97 83.5 H

76 76 100 100 121 F

77 76 100 99 99 E

73 74 91 90 165 F

76 77 96 96 204 E

79 80 97 98 303 E

POWER

FACTOR %

(4) Control Boxes date coded 01M and older have 60 MFD run capacitors and the current values on a 4" motor will be Y23.0 @ FL - Y27.5 @ SF Load. B19.1 B23.2 R8.0 R7.8

(5) Control Boxes date coded 01M and older have 60 MFD run capacitors and the current values on a 6" motor will be Y23.0 @ FL -Y27.5 @ SF Load. B18.2 B23.2 R8.0 R7.8

LOCKED

ROTOR

AMPS

KVA

CODE

Application – Single-Phase Motors

Table 14 Single-Phase Motor Fuse Sizing

RATING

HP KW VOLTS

STANDARD

FUSE

TYPE

MOTOR MODEL PREFIX

CIRCUIT BREAKERS OR FUSE AMPS CIRCUIT BREAKERS OR FUSE AMPS

(MAXIMUM PER NEC) (TYPICAL SUBMERSIBLE)

DUAL ELEMENT

TIME DELAY

FUSE

CIRCUIT

BREAKER

STANDARD

FUSE

DUAL ELEMENT

TIME DELAY

FUSE

CIRCUIT

BREAKER

4" 2-WIRE

4" 3-WIRE

4" 3-WIRE W/CRC CB

244504

244505

244507

244508

244309

214504

214505

214507

214508

214505

214507

214508

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

1/2 0.37

3/4 0.55

1 0.75

1/2 0.37

3/4 0.55

1 0.75

115 35 20 30 30 15 30

230 20 10 15 15 8 15

230 25 15 20 20 10 20

230 30 20 25 25 11 25

230 35 20 30 35 15 30

115 35 20 30 30 15 30

230 20 10 15 15 8 15

230 25 15 20 20 10 20

230 30 20 25 25 11 25

230 20 10 15 15 8 15

230 25 15 20 20 10 20

230 30 20 25 25 11 25

W/ 1-1.5 CB

4" 3-WIRE

214508

224300

224301

224302

224303

226110

226111

226112

226113

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

230 30 20 25 25 11 25

230 35 20 30 30 15 30

230 30 20 25 30 15 25

230 45 30 40 45 20 40

230 80 45 60 70 30 60

230 125 70 100 110 50 100

230 150 80 125 150 60 125

230 200 125 175 200 90 175

Application – Single-Phase Motors

Auxiliary Running Capacitors

Added capacitors must be connected across “Red” and “Black” control box terminals, in parallel with any existing running capacitors. The additional capacitor(s) should be mounted in an auxiliary box. The values of additional running capacitors most likely to reduce noise are given below. The tabulation gives the max S.F. amps normally

Although motor amps decrease when auxiliary run capacitance is added, the load on the motor does not. If a motor is overloaded with normal capacitance, it still will be overloaded with auxiliary run capacitance, even though motor amps may be within nameplate values.

in each lead with the added capacitor.

Table 15 Auxiliary Capacitor Sizing

MOTOR RATING

HP VOLTS MFD MFD MIN VOLTS FRANKLIN PART YELLOW BLACK RED

1/2 115

1/2

3/4

1.5

7.5

230

NORMAL RUNNING

CAPACITOR(S)

0 60(1) 370 TWO 155327101 8.4 7.0 4.0

0 15(1) 370 ONE 155328101 4.2 3.5 2.0

0 20(1) 370 ONE 155328103 5.8 5.0 2.5

0 25(1) 370

10 20 370 ONE 155328103 9.3 7.5 4.4

20 10 370 ONE 155328102 11.2 9.2 3.8

45 NONE 370 17.0 12.6 6.0

80 NONE 370 27.5 19.1 10.8

45 45 370

70 30 370 ONE 155327101 49.0 42.0 13.0

135 NONE 75.0 62.5 16.9

AUXILIARY RUNNING CAPACITORS FOR

NOISE REDUCTION

ONE EA. 155328101

155328102

ONE EA. 155327101

155328101

S.F. AMPS WITH RUN CAP

7.1 5.6 3.4

37.0 32.0 11.3

(1) Do not add running capacitors to 1/3 through 1 hp control boxes, which use solid state switches or QD relays. Adding capacitors will cause switch failure. If the control box is converted to use a voltage relay, the speciﬁ ed running capacitance can be added.

Buck-Boost Transformers

When the available power supply voltage is not within the proper range, a buck-boost transformer is often used to adjust voltage to match the motor. The most common usage on submersible motors is boosting a 208 volt supply to use a standard 230 volt single-phase submersible motor and control. While tables to give a

Table 15A Buck-Boost Transformer Sizing

MOTOR HP 1/3 1/2 3/4 1 1.5 2 3 5 7.5 10 15

LOAD KVA

MINIMUM XFMR KVA

STANDARD XFMR KVA

1.02 1.36 1.84 2.21 2.65 3.04 3.91 6.33 9.66 11.70 16.60

0.11 0.14 0.19 0.22 0.27 0.31 0.40 0.64 0.97 1.20 1.70

0.25 0.25 0.25 0.25 0.50 0.50 0.50 0.75 1.00 1.50 2.00

Buck-Boost transformers are power transformers, not control transformers. They may also be used to lower voltage when the available power supply voltage is too high.

wide range of voltage boost or buck are published by transformer manufacturers, the following table shows Franklin’s recommendations. The table, based on boosting the voltage 10%, shows the minimum rated transformer kVA needed and the common standard transformer kVA.

Application – Three-Phase Motors

Table 16 Three-Phase 60 °C Cable, 60 Hz (Service Entrance to Motor) Maximum Length in Feet

60 °C

MOTOR RATING 60 °C INSULATION - AWG COPPER WIRE SIZE MCM COPPER WIRE SIZE

VOLTSHPKW1412108643210000000000 250 300 350 400 500

710 1140 1800 2840 4420

510 810 1280 2030 3160

430 690 1080 1710 2670 4140 5140

310 500 790 1260 1960 3050 3780

240 390 610 970 1520 2360 2940 3610 4430 5420

180 290 470 740 1160 1810 2250 2760 3390 4130

170 280 440 690 1080 1350 1660 2040 2490 3050 3670 4440 5030

110

0 0 200 310 490 770 960 1180 1450 1770 2170 2600 3150 3560

000

0000

00000

000000

930 1490 2350 3700 5760 8910

670 1080 1700 2580 4190 6490 8060 9860

560 910 1430 2260 3520 5460 6780 8290

420 670 1060 1670 2610 4050 5030 6160 7530 9170

320 510 810 1280 2010 3130 3890 4770 5860 7170 8780

240 390 620 990 1540 2400 2980 3660 4480 5470 6690 8020 9680

230 370 590 920 1430 1790 2190 2690 3290 4030 4850 5870 6650 7560 8460 9220

140

000

0000

00000

2690 4290 6730

2000 3190 5010 7860

1620 2580 4060 6390 9980

1230 1970 3100 4890 7630

870 1390 2180 3450 5400 8380

680 1090 1710 2690 4200 6500 8020 9830

400 640 1010 1590 2490 3870 4780 5870 7230 8830

270 440 690 1090 1710 2640 3260 4000 4930 6010 7290 8780

200 320

000

0000

00000

000000

0000000

00000000

000000000

00000000000

000000000000

0000000000000

0000000000000 0

260 420 650 1020 1270 1560 1920 2340 2870 3440 4160 4710 5340 5970 6500 7510

160

190

510 800 1250 1930 2380 2910 3570 4330 5230 6260 7390 8280 9340

370

370 570 720 880 1090 1330 1640 1970 2390 2720 3100 3480 3800 4420

230

160 250

310 490 760 950 1170 1440 1760 2160 2610 3160 3590 4100 4600 5020 5840

210

590 920 1430 1770 2170 2690 3290 4000 4840 5770 6520 7430 8250 8990

440

360

390 490 600 740 910 1110 1340 1630 1850 2100 2350 2570 2980

300 380 460 570 700 860 1050 1270 1440 1650 1850 2020 2360

190

240 300 370

250 310 380

330 520 650 800 980 1200 1470 1780 2150 2440 2780 3110 3400 3940

400 500 610 760 930 1140 1380 1680 1910 2180 2450 2680 3120

250

400 500 610 750 920 1120 1360 1540 1760 1980 2160 2520

320

260 330 410

700 1090 1350 1670 2060 2530 3090 3760 4500 5110 5840 6510 7120 8190

570 880 1100 1350 1670 2050 2510 3040 3640 4130 4720 5250 5740 6590

730 910 1120 1380 1700 2080 2520 3020 3430 3920 4360 4770 5490

470

660 820 1010 1240 1520 1840 2200 2500 2850 3170 3470 3990

530

540 660

460 570 700 840 1030 1170 1330 1500 1640 1900

470 580 700 850 970 1110 1250 1360 1590

510 620 760 930 1130 1280 1470 1650 1800 2110

820 1000 1220 1480 1770 2010 2290 2550 2780 3190

560 690

850 1030 1250 1500 1700 1940 2150 2350 2700

570 700 860

510 630 760

1050 1270 1440 1660 1850 2030 2350

910 1030 1180 1310 1430 1650

620 740 840 950

620 700 790 880 960

650 750 840 920

630 700 760 880

1060 1160 1330

1090

1070

200 V

60 Hz ThreePhase

3 - Lead

230 V

60 Hz ThreePhase

3 - Lead

380 V

60 Hz ThreePhase

3 - Lead

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

40 30

50 37

60 45

75 55

100 75

125 90

150 110

175 130

200 150

Lengths in BOLD only meet the US National Electrical Code ampacity requirements for individual conductors in free air or water. Lengths NOT in bold meet NEC ampacity requirements for either individual conductors or jacketed cable. See page 11 for additional details.

Continued on page 17

Application – Three-Phase Motors

Table 17 Three-Phase 60 °C Cable (Continued)

60 °C

MOTOR RATING 60 °C INSULATION - AWG COPPER WIRE SIZE MCM COPPER WIRE SIZE

VOLTSHPKW1412108643210000000000 250 300 350 400 500

3770 6020 9460

2730 4350 6850

2300 3670 5770 9070

1700 2710 4270 6730

1300 2070 3270 5150 8050

1000 1600 2520 3970 6200

590 950 1500 2360 3700 5750

420 680 1070 1690 2640 4100 5100 6260 7680

310 500 790 1250 1960 3050 3800 4680 5750 7050

000

0000

00000

0000000

00000000

0000000000

00000000000

000000000000

0000000000000

5900 9410

4270 6810

3630 5800 9120

2620 4180 6580

2030 3250 5110 8060

1580 2530 3980 6270

920 1480 2330 3680 5750

660 1060 1680 2650 4150

490 780 1240 1950 3060 4770 5940

330

000

0000

00000

0000000

00000000

000000000

0000000000

00000000000

540 850 1340 2090 2600 3200 3930 4810 5900 7110

340

650 1030 1610 2000 2470 3040 3730 4580 5530

410

830 1300 1620 1990 2450 3010 3700 4470 5430

530

680 1070 1330 1640 2030 2490 3060 3700 4500 5130 5860

430

790 980 1210 1490 1830 2250 2710 3290 3730 4250

500

800 980 1210 1480 1810 2190 2650 3010 3420 3830 4180 4850

640

540 670 830

530 850 1340 2090 3260 4060

650 1030 1610 2520 3140 3860 4760 5830

410

830 1300 2030 2530 3110 3840 4710

520

680 1070 1670 2080 2560 3160 3880 4770 5780 7030 8000

430

790 1240 1540 1900 2330 2860 3510 4230 5140 5830

500

1000 1250 1540 1890 2310 2840 3420 4140 4700 5340 5990 6530 7580

640

1060 1300 1600 1960 2400 2890 3500 3970 4520 5070 5530 6410

850

690 860 1060

1020 1250 1540 1850 2240 2540 2890 3240 3540 4100

680 840

790 970 1190

1030 1260 1520 1850 2100 2400 2700 2950 3440

620 760 940

1310 1600 1970 2380 2890 3290 3750 5220 4610 5370

770 950 1160

800 990 1190

1130 1380 1560 1790 2010 2190 2550

740 890 1000

760 920 1050 1190

810 930 1060 1190

1460 1770 2150 2440 2790 3140 3430 3990

1400 1690 1920 2180 2440 2650 3070

1440 1630 1860 2080 2270 2640

870 1050 1270 1450

920 1110 1260 1440

1220 1390 1560 1700 1960

1340 1460 1690

1300 1510

810 920 1030 1130

1650 1860 2030 2360

1620 1760 2050

1310

460 V

60 Hz ThreePhase

3 - Lead

575 V

60 Hz ThreePhase

3 - Lead

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

40 30

50 37

60 45

75 55

100 75

125 90

150 110

175 130

200 150

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

40 30

50 37

60 45

75 55

100 75

125 90

150 110

175 130

200 150

Continued on page 18

Application – Three-Phase Motors

Table 18 Three-Phase 60 °C Cable (Continued)

60 °C

MOTOR RATING 60 °C INSULATION - AWG COPPER WIRE SIZE MCM COPPER WIRE SIZE

VOLTSHPKW1412108643210000000000 250 300 350 400 500

200 V

60 Hz ThreePhase

6 - Lead

Y-D

230 V

60 Hz ThreePhase

6 - Lead

Y-D

380 V

60 Hz ThreePhase

6 - Lead

Y-D

460 V

60 Hz ThreePhase

6 - Lead

Y-D

575 V

60 Hz ThreePhase

6 - Lead

Y-D

5 3.7

7.5 5.5 10 7.5 15 11 20 15 25 18.5 30 22

5 3.7

7.5 5.5 10 7.5 15 11 20 15 25 18.5 30 22

5 3.7

7.5 5.5 10 7.5 15 11 20 15 25 18.5 30 22 40 30 50 37 60 45 75 55

100 75 125 90 150 110 175 130 200 150

5 3.7

7.5 5.5 10 7.5 15 11 20 15 25 18.5 30 22 40 30 50 37 60 45 75 55

100 75 125 90 150 110 175 130 200 150

5 3.7

7.5 5.5 10 7.5 15 11 20 15 25 18.5 30 22 40 30 50 37 60 45 75 55

100 75 125 90 150 110 175 130 200 150

160 250 420 660 1030 1620 2020 2490 3060 3730 4570 5500 6660 7540 110 180 300 460 730 1150 1440 1770 2170 2650 3250 3900 4720 5340

130 210 340 550 850 1080 1320 1630 1990 2460 2950 3580 4080 4650 5220 5700 6630

00 000 000

0000 210 340 550 880 1380 2140 2680 3280 4030 4930 6040 7270 8800 9970 150 240 390 630 970 1530 1900 2340 2880 3510 4300 5160 6240 7060 8010 8950 9750

180 280 460 730 1140 1420 1750 2160 2640 3240 3910 4740 5380 6150 6900 7530 8760

110

000

000 600 960 1510 2380 3730 5800 7170 8800 400 660 1030 1630 2560 3960 4890 6000 7390 9010 300 480 760 1200 1870 2890 3570 4360 5350 6490 7840 9390 210 340 550 880 1380 2140 2650 3250 4030 4930 6000 7260 8650 9780

260 410 660 1050 1630 2020 2500 3090 3790 4630 5640 6750 7660 4260 9760

160

210

000

0000

00000

000000

0000000

00000000

0000000000 880 1420 2250 3540 5550 8620 630 1020 1600 2530 3960 6150 7650 9390 460 750 1180 1870 2940 4570 5700 7020 8620 310 510 810 1270 2010 3130 3900 4800 5890 7210 8850

380 610 970 1540 2410 3000 3700 4560 5590 6870 8290

230

310 490 790 1240 1950 2430 2980 3670 4510 5550 6700 8140

190

250

000

0000

00000

000000

0000000

00000000

000000000

1380 2220 3490 5520 8620

990 1590 2520 3970 6220 730 1170 1860 2920 4590 7150 8910 490 790 1270 2010 3130 4890 6090 370 610 970 1540 2410 3780 4710 5790 7140 8740

490 780 1240 1950 3040 3790 4660 5760 7060

300

400 645 1020 1600 2500 3120 3840 4740 5820 7150 8670

240

300

000

0000

00000

000000

0000000

00000000

240 370 580 730 900 1110 1360 1660 2010 2440 2770 3150 3520 3850 4470

140

190

140

330 540 850 1320 1650 2020 2500 3070 3760 4560 5460 6190 7080 7870 8610 9880

270

410 640 1020 1600 1990 2460 3040 3730 4590 5550 6750 7690 8790

300

480 750 1180 1860 2310 2850 3490 4290 5260 6340 7710 8740

380

280 450 570 690 850 1050 1290 1570 1900 2160 2470 2770 3030 3540

170

140 220

310 490 780 970 1200 1470 1800 2200 2670 3220 3660 4170 4660 5100 5910 230 370 600 750 910 1140 1390 1710 2070 2520 2860 3270 3670 4020 4680

190

150 240

430 700 1090 1360 1680 2070 2550 3120 3780 4530 5140 5880 6540 7150 8230

320

250 400

480 750 1180 1470 1810 2230 2740 3370 4060 4930 5590 6370

370

320 500

590 960 1500 1870 2310 2830 3460 4260 5130 6210 7050 8010 8980 9790

500 790

420 660

360 450 550 690 850 1050 1260 1540 1750 1990 2250 2460 2850 294 370 460 570 700 870 1050 1270 1450 1660 1870 2040 2380

180

300 480 600 750 910 1120 1380 1680 2040 2310 2640 2970 3240 3780

390 490 610 760 930 1140 1390 1690 1920 2200 2470 2700 3160

510 790 990 1230 1510 1860 2280 2760 3300 3750 4270 4750 5200 5980

630 810 990 1230 1500 1830 2220 2650 3010 3430 3820 4170 4780 540 660 840 1030 1270 1540 1870 2250 2550 2910 3220 3520 4050

340

590 960 1200 1470 1810 2220 2710 3280 3970 4510 5130 5740 6270 7270

420

400 780

550 690 855 1050 1290 1570 1900 2160 2490 2770 3040 3520

450

420 520

810 1000 1240 1530 1870 2310 2770 3360 3810 4330 4860 5310 6150 660 810 1020 1260 1540 1890 2280 2770 3150 3600 4050 4420 5160

500 610

470 590 730

1270 1590 1950 2400 2940 3600 4330 5250 5950 6780 7600 8290 9610 1030 1290 1590 1960 2400 2950 3570 4330 4930 5620 6330 6910 8050

960 1180 1450 1780 2190 2650 3220 3660 4180 4710 5140 5980

600 740

650 800 990

640 760 940 1140 1360 1540 1770 1960 2140 2470

400 490 600

420 510 620

360 440 540

760 930 1140 1410 1690 2070 2340 2680 3010 3280 3820

510 630 770

550 680 830

920 1150 1420 1740 2100 2530 2880 3270 3660 3970 4600

700 860

760 930

730 930 1110 1260 1420 1590 1740 1990

750 930 1050 1180 1320 1440 1630 660 780 970 1120 1260 1380 1600

480 580 690

880 1110 1330 1500 1830 2080 2340 2550 2940

950 1140 1380 1570 1790 2000 2180 2530

1000 1220 1390 1580 1780 1950 2270

590 730 880

1210 1480 1780 2160 2450 2790 3120 3410 3950 1060 1300 1570 1910 2170 2480 2780 3040 3540

1140 1370 1670 1890 2160 2420 2640 3070

790 940 1050 1140 1320

1070 1210 1380 1550 1690 1970

Application – Three-Phase Motors

Table 19 Three-Phase 75 °C Cable, 60 Hz (Service Entrance to Motor) Maximum Length in Feet

75 °C

MOTOR RATING 75 °C INSULATION - AWG COPPER WIRE SIZE MCM COPPER WIRE SIZE

VOLTSHPKW1412108643210000000000 250 300 350 400 500

710 1140 1800 2840 4420

510 810 1280 2030 3160

430 690 1080 1710 2670 4140 5140

310 500 790 1260 1960 3050 3780

240 390 610 970 1520 2360 2940 3610 4430 5420

180 290 470 740 1160 1810 2250 2760 3390 4130

170 280 440 690 1080 1350 1660 2040 2490 3050 3670 4440 5030

110

0 0 200 310 490 770 960 1180 1450 1770 2170 2600 3150 3560

000

0000

00000

930 1490 2350 3700 5760 8910

670 1080 1700 2580 4190 6490 8060 9860

560 910 1430 2260 3520 5460 6780 8290

420 670 1060 1670 2610 4050 5030 6160 7530 9170

320 510 810 1280 2010 3130 3890 4770 5860 7170 8780

240 390 620 990 1540 2400 2980 3660 4480 5470 6690 8020 9680

230 370 590 920 1430 1790 2190 2690 3290 4030 4850 5870 6650 7560 8460 9220

140

160

000

0000

00000

2690 4290 6730

2000 3190 5010 7860

1620 2580 4060 6390 9980

1230 1970 3100 4890 7630

870 1390 2180 3450 5400 8380

680 1090 1710 2690 4200 6500 8020 9830

400 640 1010 1590 2490 3870 4780 5870 7230 8830

270 440 690 1090 1710 2640 3260 4000 4930 6010 7290 8780

320 510 800 1250 1930 2380 2910 3570 4330 5230 6260 7390 8280 9340

200

0 0 370 590 920 1430 1770 2170 2690 3290 4000 4840 5770 6520 7430 8250 8990

000

00000

0000000

00000000

0000000000

00000000000

000000000000

0000000000000

230 370 570 720 880 1090 1330 1640 1970 2390 2720 3100 3480 3800 4420

150

250 390 490 600 740 910 1110 1340 1630 1850 2100 2350 2570 2980

160

300 380 460 570 700 860 1050 1270 1440 1650 1850 2020 2360

190

300 370 460 570 700 840 1030 1170 1330 1500 1640 1900

240

200 250

260 420 650 1020 1270 1560 1920 2340 2870 3440 4160 4710 5340 5970 6500 7510

310 490 760 950 1170 1440 1760 2160 2610 3160 3590 4100 4600 5020 5840

190

330 520 650 800 980 1200 1470 1780 2150 2440 2780 3110 3400 3940

210

160 250

440 700 1090 1350 1670 2060 2530 3090 3760 4500 5110 2840 6510 7120 8190

280

360

290

400 500 610 760 930 1140 1380 1680 1910 2180 2450 2680 3120

320 400 500 610 750 920 1120 1360 1540 1760 1980 2160 2520

200

260

570 880 1100 1350 1670 2050 2510 3040 3640 4130 4720 5250 5740 6590

470 730 910 1120 1380 1700 2080 2520 3020 3430 3920 4360 4770 5490

530

440 540

370 460 560

310 380 470 580 700 850 970 1110 1250 1360 1590

330 410 510 620 760 930 1130 1280 1470 1650 1800 2110

660 820 1010 1240 1520 1840 2200 2500 2850 3170 3470 3990

660 820 1000 1220 1480 1770 2010 2290 2550 2780 3190

690 850 1030 1250 1500 1700 1940 2150 2350 2700

460 570

700 860 1050 1270 1440 1660 1850 2030 2350

420 510 630

760 910 1030 1180 1310 1430 1650

510 620 740

520 620 700 790

840 950 1060 1160 1330

880 960 1090

560 650 750 840

550 630 700 760

920 1070

880

200 V

60 Hz ThreePhase

3 - Lead

230 V

60 Hz ThreePhase

3 - Lead

380 V

60 Hz ThreePhase

3 - Lead

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

40 30

50 37

60 45

75 55

100 75

125 90

150 110

175 130

200 150

Continued on page 20

Application – Three-Phase Motors

Table 20 Three-Phase 75 °C Cable (Continued)

MOTOR RATING 75 °C INSULATION - AWG COPPER WIRE SIZE MCM COPPER WIRE SIZE

VOLTSHPKW1412108643210000000000 250 300 350 400 500

3770 6020 9460

2730 4350 6850

2300 3670 5770 9070

1700 2710 4270 6730

1300 2070 3270 5150 8050

1000 1600 2520 3970 6200

590 950 1500 2360 3700 5750

420 680 1070 1690 2640 4100 5100 6260 7680

310 500 790 1250 1960 3050 3800 4680 5750 7050

0 0 410 650 1030 1610 2000 2470 3040 3730 4580 5530

000

0000

00000

0000000

000000000

0000000000

00000000000

5900 9410

4270 6810

3630 5800 9120

2620 4180 6580

2030 3250 5110 8060

1580 2530 3980 6270

920 1480 2330 3680 5750

660 1060 1680 2650 4150

490 780 1240 1950 3060 4770 5940

330

0 0 520 830 1300 2030 2530 3110 3840 4710

000

0000

00000

000000

0000000

00000000

000000000

0000000000

540 850 1340 2090 2600 3200 3930 4810 5900 7110

340

530 830 1300 1620 1990 2450 3010 3700 4470 5430

330

430 680 1070 1330 1640 2030 2490 3060 3700 4500 5130 5860

270

320 500

410

530 850 1340 2090 3260 4060

650 1030 1610 2520 3140 3860 4760 5830

410

680 1070 1670 2080 2560 3160 3880 4770 5780 7030 8000

430

790 1240 1540 1900 2330 2860 3510 4230 5140 5830

500

410 640

540

460 V

60 Hz ThreePhase

3 - Lead

575 V

60 Hz ThreePhase

3 - Lead

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

40 30

50 37

60 45

75 55

100 75

125 90

150 110

175 130

200 150

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

40 30

50 37

60 45

75 55

100 75

125 90

150 110

175 130

200 150

790 980 1210 1490 1830 2250 2710 3290 3730 4250

640 800 980 1210 1480 1810 2190 2650 3010 3420 3830 4180 4850

540 670

440 550 680

1000 1250 1540 1890 2310 2840 3420 4140 4700 5340 5990 6530 7580

850 1060 1300 1600 1960 2400 2890 3500 3970 4520 5070 5530 6410

690

830 1020 1250 1540 1850 2240 2540 2890 3240 3540 4100

840 1030 1260 1520 1850 2100 2400 2700 2950 3440

500 620 760

860 1060 1310 1600 1970 2380 2890 3290 3750 5220 4610 5370

640 790

970 1190 1460 1770 2150 2440 2790 3140 3430 3990

630 770 950

660 800 990

940 1130 1380 1560 1790 2010 2190 2550

600 740 890

630 760 920

1160 1400 1690 1920 2180 2440 2650 3070

700 870 1050

760 920 1110

1000 1220 1390 1560 1700 1960

1050 1190 1340 1460 1690

670 810 930

590 710 810 920

1190 1440 1630 1860 2080 2270 2640

1270 1450 1650 1860 2030 2360

1060 1190 1300 1510

1260 1440 1620 1760 2050

75 °C

1030 1130 1310

Continued on page 21

Application – Three-Phase Motors

Table 21 Three-Phase 75 °C Cable (Continued)

75 °C

MOTOR RATING 75 °C INSULATION - AWG COPPER WIRE SIZE MCM COPPER WIRE SIZE

VOLTSHPKW1412108643210000000000 250 300 350 400 500

200 V

60 Hz ThreePhase

6 - Lead

Y-D

230 V

60 Hz ThreePhase

6 - Lead

Y-D

380 V

60 Hz ThreePhase

6 - Lead

Y-D

460 V

60 Hz ThreePhase

6 - Lead

Y-D

575 V

60 Hz ThreePhase

6 - Lead

Y-D

5 3.7

7.5 5.5 10 7.5 15 11 20 15 25 18.5 30 22

5 3.7

7.5 5.5 10 7.5 15 11 20 15 25 18.5 30 22

5 3.7

7.5 5.5 10 7.5 15 11 20 15 25 18.5 30 22 40 30 50 37 60 45 75 55

100 75 125 90 150 110 175 130 200 150

5 3.7

7.5 5.5 10 7.5 15 11 20 15 25 18.5 30 22 40 30 50 37 60 45 75 55

100 75 125 90 150 110 175 130 200 150

5 3.7

7.5 5.5 10 7.5 15 11 20 15 25 18.5 30 22 40 30 50 37 60 45 75 55

100 75 125 90 150 110 175 130 200 150

160 250 420 660 1030 1620 2020 2490 3060 3730 4570 5500 6660 7540 110 180 300 460 730 1150 1440 1770 2170 2650 3250 3900 4720 5340

130 210 340 550 850 1080 1320 1630 1990 2460 2950 3580 4080 4650 5220 5700 6630 0 0 140 240 370 580 730 900 1110 1360 1660 2010 2440 2770 3150 3520 3850 4470 00 000 000

210 340 550 880 1380 2140 2680 3280 4030 4930 6040 7270 8800 9970 150 240 390 630 970 1530 1900 2340 2880 3510 4300 5160 6240 7060 8010 8950 9750

180 280 460 730 1140 1420 1750 2160 2640 3240 3910 4740 5380 6150 6900 7530 8760

110

130

00 00 000

600 960 1510 2380 3730 5800 7170 8800 400 660 1030 1630 2560 3960 4890 6000 7390 9010 300 480 760 1200 1870 2890 3570 4360 5350 6490 7840 9390 210 340 550 880 1380 2140 2650 3250 4030 4930 6000 7260 8650 9780

260 410 660 1050 1630 2020 2500 3090 3790 4630 5640 6750 7660 4260 9760

160

210

00 00 000 0000 0000 00000 000000 0000000 00000000 000000000

880 1420 2250 3540 5550 8620 630 1020 1600 2530 3960 6150 7650 9390 460 750 1180 1870 2940 4570 5700 7020 8620 310 510 810 1270 2010 3130 3900 4800 5890 7210 8850 230 380 610 970 1540 2410 3000 3700 4560 5590 6870 8290

310 490 790 1240 1950 2430 2980 3670 4510 5550 6700 8140

190

250

00 00 000 0000 0000 00000 000000 0000000 00000000

1380 2220 3490 5520 8620

990 1590 2520 3970 6220 730 1170 1860 2920 4590 7150 8910 490 790 1270 2010 3130 4890 6090 370 610 970 1540 2410 3780 4710 5790 7140 8740

490 780 1240 1950 3040 3790 4660 5760 7060

300

400 645 1020 1600 2500 3120 3840 4740 5820 7150 8670

240

300

00 00 000 0000 00000 00000 000000 000000

170 280 450 570 690 850 1050 1290 1570 1900 2160 2470 2770 3030 3540

120

190 310 490 780 970 1200 1470 1800 2200 2670 3220 3660 4170 4660 5100 5910

140

120

330 540 850 1320 1650 2020 2500 3070 3760 4560 5460 6190 7080 7870 8610 9880

270

210

410 640 1020 1600 1990 2460 3040 3730 4590 5550 6750 7690 8790

300

250

480 750 1180 1860 2310 2850 3490 4290 5260 6340 7710 8740

380

330

220 360 450 550 690 850 1050 1260 1540 1750 1990 2250 2460 2850

140

120 180

230 370 600 750 910 1140 1390 1710 2070 2520 2860 3270 3670 4020 4680 190 300 480 600 750 910 1120 1380 1680 2040 2310 2640 2970 3240 3780

150

430 700 1090 1360 1680 2070 2550 3120 3780 4530 5140 5880 6540 7150 8230 320 510 790 990 1230 1510 1860 2280 2760 3300 3750 4270 4750 5200 5980

250

480 750 1180 1470 1810 2230 2740 3370 4060 4930 5590 6370 370 590 960 1200 1470 1810 2220 2710 3280 3970 4510 5130 5740 6270 7270

320

590 960 1500 1870 2310 2830 3460 4260 5130 6210 7050 8010 8980 9790 500 790 1270 1590 1950 2400 2940 3600 4330 5250 5950 6780 7600 8290 9610

420

294 370 460 570 700 870 1050 1270 1450 1660 1870 2040 2380

240 390 490 610 760 930 1140 1390 1690 1920 2200 2470 2700 3160

400 630 810 990 1230 1500 1830 2220 2650 3010 3430 3820 4170 4780

540 660 840 1030 1270 1540 1870 2250 2550 2910 3220 3520 4050

340

450 550 690 855 1050 1290 1570 1900 2160 2490 2770 3040 3520

290

340 420

500 810 1000 1240 1530 1870 2310 2770 3360 3810 4330 4860 5310 6150

660 810 1020 1260 1540 1890 2280 2770 3150 3600 4050 4420 5160

420

310 500

390 470 590

660 1030 1290 1590 1960 2400 2950 3570 4330 4930 5620 6330 6910 8050

780 960 1180 1450 1780 2190 2650 3220 3660 4180 4710 5140 5980

400

600

520 650

520 640 760 940 1140 1360 1540 1770 1960 2140 2470

340 400 490

350 420 510

610 760 930 1140 1410 1690 2070 2340 2680 3010 3280 3820

420 510 630

450 550 680

740 920 1150 1420 1740 2100 2530 2880 3270 3660 3970 4600

800 990 1210 1480 1780 2160 2450 2790 3120 3410 3950

570 700

500 610 760

600 730 930 1110 1260 1420 1590 1740 1990

620 750 930 1050 1180 1320 1440 1630

360 440 540

410 480 580

730 880 1110 1330 1500 1830 2080 2340 2550 2940

770 950 1140 1380 1570 1790 2000 2180 2530

480 590 730

860 1060 1300 1570 1910 2170 2480 2780 3040 3540

930 1140 1370 1670 1890 2160 2420 2640 3070

660 780 970 1120 1260 1380 1600

690 790 940 1050 1140 1320

830 1000 1220 1390 1580 1780 1950 2270

880 1070 1210 1380 1550 1690 1970

Application – Three-Phase Motors

Table 22 Three-Phase Motor Speciﬁ cations (60 Hz)

TYPE

MOTOR MODEL PREFIX

234501

234511

234541

234521

234502

234512

234542

234522

234503

234513

234543

234523

234504

234514

234544

234524

234534

234305

234315

234345

234325

234335

234306

234316

234346

234326

234336

234307

234317

234347

234327

234337

234308

234318

234348

234328

234338

234549

234595

234598

HP KW VOLTS HZ S.F. AMPS WATTS AMPS WATTS S.F. F.L.

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

RATING FULL LOAD

200 60 1.6 2.8 585 3.4 860 6.6-8.4 70 64 17.5 N

230 60 1.6 2.4 585 2.9 860 9.5-10.9 70 64 15.2 N

380 60 1.6 1.4 585 2.1 860 23.2-28.6 70 64 9.2 N

460 60 1.6 1.2 585 1.5 860 38.4-44.1 70 64 7.6 N

200 60 1.5 3.6 810 4.4 1150 4.6-5.9 73 69 23.1 M

230 60 1.5 3.1 810 3.8 1150 6.8-7.8 73 69 20.1 M

380 60 1.5 1.9 810 2.5 1150 16.6-20.3 73 69 12.2 M

460 60 1.5 1.6 810 1.9 1150 27.2-30.9 73 69 10.7 M

200 60 1.4 4.5 1070 5.4 1440 3.8-4.5 72 70 30.9 M

230 60 1.4 3.9 1070 4.7 1440 4.9-5.6 72 70 26.9 M

380 60 1.4 2.3 1070 2.8 1440 12.2-14.9 72 70 16.3 M

460 60 1.4 2 1070 2.4 1440 19.9-23.0 72 70 13.5 M

200 60 1.3 5.8 1460 6.8 1890 2.5-3.0 76 76 38.2 K

230 60 1.3 5 1460 5.9 1890 3.2-4.0 76 76 33.2 K

380 60 1.3 3 1460 3.6 1890 8.5-10.4 76 76 20.1 K

460 60 1.3 2.5 1460 3.1 1890 13.0-16.0 76 76 16.6 K

575 60 1.3 2 1460 2.4 1890 20.3-25.0 76 76 13.3 K

200 60 1.25 7.7 2150 9.3 2700 1.8-2.4 69 69 53.6 L

230 60 1.25 6.7 2150 8.1 2700 2.3-3.0 69 69 46.6 L

380 60 1.25 4.1 2150 4.9 2700 6.6-8.2 69 69 28.2 L

460 60 1.25 3.4 2150 4.1 2700 9.2-12.0 69 69 23.3 L

575 60 1.25 2.7 2150 3.2 2700 14.6-18.7 69 69 18.6 L

200 60 1.15 10.9 2980 12.5 3420 1.3-1.7 75 75 71.2 K

230 60 1.15 9.5 2980 10.9 3420 1.8-2.2 75 75 61.9 K

380 60 1.15 5.8 2980 6.6 3420 4.7-6.0 75 75 37.5 K

460 60 1.15 4.8 2980 5.5 3420 7.2-8.8 75 75 31 K

575 60 1.15 3.8 2980 4.4 3420 11.4-13.9 75 75 24.8 K

200 60 1.15 18.3 5050 20.5 5810 .74-.91 74 74 122 K

230 60 1.15 15.9 5050 17.8 5810 1.0-1.2 74 74 106 K

380 60 1.15 9.6 5050 10.8 5810 2.9-3.6 74 74 64.4 K

460 60 1.15 8 5050 8.9 5810 4.0-4.9 74 74 53.2 K

575 60 1.15 6.4 5050 7.1 5810 6.4-7.8 74 74 42.6 K

200 60 1.15 26.5 7360 30.5 8450 .46-.57 76 76 188 K

230 60 1.15 23 7360 26.4 8450 .61-.75 76 76 164 K

380 60 1.15 13.9 7360 16 8450 1.6-2.0 76 76 99.1 K

460 60 1.15 11.5 7360 13.2 8450 2.5-3.1 76 76 81.9 K

575 60 1.15 9.2 7360 10.6 8450 4.0-5.0 76 76 65.5 K

380 60 1.15 19.3 10000 21 11400 1.2-1.6 75 75 140 L

460 60 1.15 15.9 10000 17.3 11400 1.8-2.3 75 75 116 L

575 60 1.15 12.5 10000 13.6 11400 2.8-3.5 75 75 92.8 L

MAXIMUM (S.F. LOAD)

LINE TO LINE RESISTANCE

OHMS

EFFICIENCY %

LOCKED

ROTOR

AMPS

KVA

CODE

Application – Three-Phase Motors

Table 23 Three-Phase Motor Fuse Sizing

1 0.75

2 1.5

3 2.2

5 3.7

RATING

200 10 5 8 10 4 15

230 8 4.5 6 8 4 15

380 5 2.5 4 5 2 15

460 4 2.25 3 4 2 15

2001571012515

230 10 5.6 8 10 5 15

380 6 3.5 5 6 3 15

460 5 2.8 4 5 3 15

2001581515615

2301571012615

380 8 4.5 8 8 4 15

460 6 3.5 5 6 3 15

200 20 12 15 20 8 15

2301591515815

380 10 5.6 8 10 4 15

460 8 4.5 8 8 4 15

575 6 3.5 5 6 3 15

200 25 15 20 25 11 20

230 25 12 20 25 10 20

3801581515615

4601561011515

575 10 5 8 10 4 15

200 35 20 30 35 15 30

230 30 17.5 25 30 12 25

380 20 12 15 20 8 15

4601591515615

5751571011515

200 60 35 50 60 25 50

230 50 30 40 45 20 40

380 30 17.5 25 30 12 25

460 25 15 20 25 10 20

575 20 12 20 20 8 20

200 90 50 70 80 35 70

230 80 45 60 70 30 60

380 45 25 40 40 20 40

460 40 25 30 35 15 30

575 30 17.5 25 30 12 25

380 70 40 60 60 25 60

460 60 30 45 50 25 45

575 45 25 35 40 20 35

380 70 35 60 60 25 60

460 60 30 45 50 25 45

575 45 25 35 40 20 35

TYPE

MOTOR MODEL PREFIX

234501

234511

234541

234521

234502

234512

234542

234522

234503

234513

234543

234523

234504

234514

234544

234524

234534

234305

234315

234345

234325

234335

234306

234316

234346

234326

234336

234307

234317

234347

234327

234337

234308

234318

234348

234328

234338

234349

234329

234339

234549

234595

234598

HP KW VOLTS

1/2 0.37

3/4 0.55

1.5 1.1

7.5 5.5

10 7.5

CIRCUIT BREAKERS OR FUSE AMPS CIRCUIT BREAKERS OR FUSE AMPS

(MAXIMUM PER NEC) (TYPICAL SUBMERSIBLE)

STANDARD

FUSE

DUAL ELEMENT TIME

DELAY FUSE

CIRCUIT

BREAKER

STANDARD

FUSE

DUAL ELEMENT TIME

DELAY FUSE

CIRCUIT

BREAKER

Application – Three-Phase Motors

Table 24 Three-Phase Motor Speciﬁ cations (60 Hz)

MAXIMUM (S.F. LOAD)

LINE TO LINE RESISTANCE

OHMS

EFFICIENCY %

LOCKED

ROTOR

AMPS

KVA

CODE

TYPE

MOTOR MODEL PREFIX

236650

236600

236660

236610

236620

236651

236601

236661

236611

236621

236652

236602

236662

236612

236622

236653

236603

236663

236613

236623

236654

236604

236664

236614

236624

236655

236605

236665

236615

236625

236656

236606

236666

236616

236626

236667

236617

236627

236668

236618

236628

236669

236619

236629

HP KW VOLTS HZ S.F. AMPS WATTS AMPS WATTS S.F. F.L.

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

40 30

50 37

60 45

RATING FULL LOAD

200 60 1.15 17.5 4700 20.0 5400 .77-.93 79 79 99 H

230 60 1.15 15 4700 17.6 5400 1.0-1.2 79 79 86 H

380 60 1.15 9.1 4700 10.7 5400 2.6-3.2 79 79 52 H

460 60 1.15 7.5 4700 8.8 5400 3.9-4.8 79 79 43 H

575 60 1.15 6 4700 7.1 5400 6.3-7.7 79 79 34 H

200 60 1.15 25.1 7000 28.3 8000 .43-.53 80 80 150 H

230 60 1.15 21.8 7000 24.6 8000 .64-.78 80 80 130 H

380 60 1.15 13.4 7000 15 8000 1.6-2.1 80 80 79 H

460 60 1.15 10.9 7000 12.3 8000 2.4-2.9 80 80 65 H

575 60 1.15 8.7 7000 9.8 8000 3.7-4.6 80 80 52 H

200 60 1.15 32.7 9400 37 10800 .37-.45 79 79 198 H

230 60 1.15 28.4 9400 32.2 10800 .47-.57 79 79 172 H

380 60 1.15 17.6 9400 19.6 10800 1.2-1.5 79 79 104 H

460 60 1.15 14.2 9400 16.1 10800 1.9-2.4 79 79 86 H

575 60 1.15 11.4 9400 12.9 10800 3.0-3.7 79 79 69 H

200 60 1.15 47.8 13700 54.4 15800 .24-.29 81 81 306 H

230 60 1.15 41.6 13700 47.4 15800 .28-.35 81 81 266 H

380 60 1.15 25.8 13700 28.9 15800 .77-.95 81 81 161 H

460 60 1.15 20.8 13700 23.7 15800 1.1-1.4 81 81 133 H

575 60 1.15 16.6 13700 19 15800 1.8-2.3 81 81 106 H

200 60 1.15 61.9 18100 69.7 20900 .16-.20 82 82 416 J

230 60 1.15 53.8 18100 60.6 20900 .22-.26 82 82 362 J

380 60 1.15 33 18100 37.3 20900 .55-.68 82 82 219 J

460 60 1.15 26.9 18100 30.3 20900 .8-1.0 82 82 181 J

575 60 1.15 21.5 18100 24.2 20900 1.3-1.6 82 82 145 J

200 60 1.15 77.1 22500 86.3 25700 .12-.15 83 83 552 J

230 60 1.15 67 22500 75 25700 .15-.19 83 83 480 J

380 60 1.15 41 22500 46 25700 .46-.56 83 83 291 J

460 60 1.15 33.5 22500 37.5 25700 .63-.77 83 83 240 J

575 60 1.15 26.8 22500 30 25700 1.0-1.3 83 83 192 J

200 60 1.15 90.9 26900 104 31100 .09-.11 83 83 653 J

230 60 1.15 79 26900 90.4 31100 .14-.17 83 83 568 J

380 60 1.15 48.8 26900 55.4 31100 .35-.43 83 83 317 J

460 60 1.15 39.5 26900 45.2 31100 .52-.64 83 83 284 J

575 60 1.15 31.6 26900 36.2 31100 .78-.95 83 83 227 J

380 60 1.15 66.5 35600 74.6 42400 .26-.33 83 83 481 J

460 60 1.15 54.9 35600 61.6 42400 .34-.42 83 83 397 J

575 60 1.15 42.8 35600 49.6 42400 .52-.64 83 83 318 H

380 60 1.15 83.5 45100 95 52200 .21-.25 82 83 501 H

460 60 1.15 67.7 45100 77 52200 .25-.32 82 83 414 H

575 60 1.15 54.2 45100 61.6 52200 .40-.49 82 83 331 H

380 60 1.15 98.7 53500 111 61700 .15-.18 84 84 627 H

460 60 1.15 80.5 53500 91 61700 .22-.27 84 84 518 H

575 60 1.15 64.4 53500 72.8 61700 .35-.39 84 84 414 H

Model numbers above are for three-lead motors. Six-lead motors with different model numbers have the same running performance, but when wye connected for starting have locked rotor amps 33% of the values shown. Six-lead individual phase resistance = table X 1.5.

Application – Three-Phase Motors

Table 25 Three-Phase Motor Fuse Sizing

RATING

200 60 35 45 50 25 45

230 45 30 40 45 20 40

380 30 17.5 25 30 12 25

460 25 15 20 25 10 20

575 20 12 15 20 8 15

200 80 45 70 80 35 70

230 70 40 60 70 30 60

380 45 25 35 40 20 35

460 35 20 30 35 15 30

575 30 17.5 25 25 11 25

200 100 60 90 100 45 90

230 90 50 80 90 40 80

380 60 35 45 50 25 45

460 45 25 40 45 20 40

575 35 20 30 35 15 30

200 150 90 125 150 60 125

230 150 80 110 125 60 110

380 80 50 70 80 35 70

460 70 40 60 60 30 60

575 60 30 45 50 25 45

200 200 110 175 175 80 175

230 175 100 150 175 70 150

380 100 60 90 100 45 90

460 90 50 70 80 35 70

575 70 40 60 70 30 60

200 250 150 200 225 100 200

230 225 125 175 200 90 175

380 125 80 110 125 50 110

460 110 60 90 100 45 90

575 90 50 70 80 35 70

200 300 175 250 300 125 250

230 250 150 225 250 100 200

380 150 90 125 150 60 125

460 125 70 110 125 50 100

575 100 60 90 100 40 80

380 200 125 175 200 90 175

460 175 100 150 175 70 150

575 150 80 110 125 60 110

380 250 150 225 250 110 225

460 225 125 175 200 90 175

575 175 100 150 175 70 150

380 300 175 250 300 125 250

460 250 150 225 250 100 225

575 200 125 175 200 80 175

TYPE

MOTOR MODEL PREFIX

236650

236600

236660

236610

236620

236651

236601

236661

236611

236621

236652

236602

236662

236612

236622

236653

236603

236663

236613

236623

236654

236604

236664

236614

236624

236655

236605

236665

236615

236625

236656

236606

236666

236616

236626

236667

236617

236627

236668

236618

236628

236669

236619

236629

HP KW VOLTS

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

40 30

50 37

60 45

CIRCUIT BREAKERS OR FUSE AMPS CIRCUIT BREAKERS OR FUSE AMPS

(MAXIMUM PER NEC) (TYPICAL SUBMERSIBLE)

STANDARD

FUSE

DUAL ELEMENT TIME

DELAY FUSE

CIRCUIT

BREAKER

STANDARD

FUSE

DUAL ELEMENT TIME

DELAY FUSE

CIRCUIT

BREAKER

Application – Three-Phase Motors

Table 26 Three-Phase Motor Speciﬁ cations (60 Hz)

MAXIMUM (S.F. LOAD)

LINE TO LINE RESISTANCE

OHMS

TYPE

MOTOR MODEL PREFIX

239660

239600

239610

239661

239601

239611

239662

239602

239612

239663

239603

239613

239664

239604

239614

239165

239105

239115

239166

239106

239116

239167

239107

239117

239168

239108

239118

RATING FULL LOAD

HP KW VOLTS HZ S.F. AMPS KILOWATTS AMPS KILOWATTS S.F. F.L.

40 30

50 37

60 45

75 55

100 75

125 90

150 110

175 130

200 150

380 60 1.15 64 35 72 40 .16-.20 86 86 479 J

460 60 1.15 53 35 60 40 .24-.30 86 86 396 J

575 60 1.15 42 35 48 40 .39-.49 86 86 317 J

380 60 1.15 79 43 88 49 .12-.16 87 87 656 K

460 60 1.15 64 43 73 49 .18-.22 87 87 542 K

575 60 1.15 51 43 59 49 .28-.34 87 87 434 K

380 60 1.15 92 52 104 60 .09-.11 88 87 797 K

460 60 1.15 76 52 86 60 .14-.17 88 87 658 K

575 60 1.15 61 52 69 60 .22-.28 88 87 526 K

380 60 1.15 114 64 130 73.5 .06-.09 88 88 1046 L

460 60 1.15 94 64 107 73.5 .10-.13 88 88 864 L

575 60 1.15 76 64 86 73.5 .16-.21 88 88 691 L

380 60 1.15 153 85 172 97.5 .05-.06 89 89 1466 L

460 60 1.15 126 85 142 97.5 .07-.09 89 89 1211 L

575 60 1.15 101 85 114 97.5 .11-.13 89 89 969 L

380 60 1.15 202 109 228 125 .03-.04 87 86 1596 K

460 60 1.15 167 109 188 125 .05-.07 87 86 1318 K

575 60 1.15 134 109 151 125 .08-.11 87 86 1054 K

380 60 1.15 235 128 266 146 .02-.03 88 87 1961 K

460 60 1.15 194 128 219 146 .04-.05 88 87 1620 K

575 60 1.15 155 128 176 146 .06-.08 88 87 1296 K

380 60 1.15 265 150 302 173 .02-.04 88 88 1991 J

460 60 1.15 219 150 249 173 .04-.05 88 88 1645 J

575 60 1.15 175 150 200 173 .06-.08 88 88 1316 J

380 60 1.15 298 169 342 194 .02-.03 88 88 2270 J

460 60 1.15 246 169 282 194 .03-.05 88 88 1875 J

575 60 1.15 197 169 226 194 .05-.07 88 88 1500 J

EFFICIENCY

LOCKED

ROTOR

AMPS

KVA

CODE

Application – Three-Phase Motors

Table 27 Three-Phase Motor Fuse Sizing

RATING

HP KW VOLTS

40 30

50 37

60 45

75 55

100 75

125 90

150 110

175 130

200 150

380 200 125 175 200 80 175

460 175 100 150 175 70 150

575 150 80 110 125 60 110

380 250 150 200 225 100 200

460 200 125 175 200 80 175

575 175 90 150 150 70 150

380 300 175 250 300 125 250

460 250 150 200 225 100 200

575 200 110 175 175 80 175

380 350 200 300 350 150 300

460 300 175 250 300 125 250

575 250 150 200 225 100 200

380 500 275 400 450 200 400

460 400 225 350 400 175 350

575 350 200 300 300 125 300

380 700 400 600 600 250 600

460 500 300 450 500 225 450

575 450 250 350 400 175 350

380 800 450 600 700 300 600

460 600 350 500 600 250 500

575 500 300 400 450 200 400

380 800 500 700 800 350 700

460 700 400 600 700 300 600

575 600 350 450 600 225 450

380 1000 600 800 1000 400 800

460 800 450 700 800 350 700

575 600 350 500 600 250 500

TYPE

MOTOR MODEL PREFIX

239660

239600

239610

239661

239601

239611

239662

239602

239612

239663

239603

239613

239664

239604

239614

239165

239105

239115

239166

239106

239116

239167

239107

239117

239168

239108

239118

CIRCUIT BREAKERS OR FUSE AMPS CIRCUIT BREAKERS OR FUSE AMPS

(MAXIMUM PER NEC) (TYPICAL SUBMERSIBLE)

STANDARD

FUSE

DUAL ELEMENT

TIME DELAY FUSE

CIRCUIT

BREAKER

STANDARD

FUSE

DUAL ELEMENT TIME

DELAY FUSE

CIRCUIT

BREAKER

Application – Three-Phase Motors

Overload Protection of Three-Phase Submersible Motors

The characteristics of submersible motors are different than standard motors and special overload protection is required.

If the motor is locked, the overload protection must trip within 10 seconds to protect the motor windings. Subtrol/ SubMonitor, a Franklin-approved adjustable overload relay, or a Franklin-approved ﬁ xed heater must be used.

Fixed heater overloads must be the ambient-compensated quick-trip type to maintain protection at high and low air temperatures.

Table 28 - 60 Hz 4" Motors

HP KW VOLTS

200 00 K31 L380A 3.2 3.4 230 00 K28 L343A 2.7 2.9

1/2 0.37

3/4 0.55

1 0.75

1.5 1.1

2 1.5

3 2.2

5 3.7

7.5 5.5

10 7.5

380 00 K22 L211A 1.7 1.8 460 00 - L174A 1.4 1.5 575 00 - - 1.2 1.3 200 00 K34 L51CA 4.1 4.4 230 00 K32 L420A 3.5 3.8 380 00 K27 L282A 2.3 2.5 460 00 K23 L211A 1.8 1.9 575 00 K21 L193A 1.5 1.6 200 00 K37 L618A 5.0 5.4 230 00 K36 L561A 4.4 4.7 380 00 K28 L310A 2.6 2.8 460 00 K26 L282A 2.2 2.4 575 00 K23 L211A 1.8 1.9 200 00 K42 L750A 6.3 6.8 230 00 K39 L680A 5.5 5.9 380 00 K32 L420A 3.3 3.6 460 00 K29 L343A 2.8 3.0 575 00 K26 L282A 2.2 2.4 200 0 K50 L111B 8.6 9.3 230 0 K49 L910A 7.5 8.1 380 0 K36 L561A 4.6 4.9 460 00 K33 L463A 3.8 4.1 575 00 K29 L380A 3.0 3.2 200 0 K55 L147B 11.6 12.5 230 0 K52 L122B 10.1 10.9 380 0 K41 L750A 6.1 6.6 460 0 K37 L618A 5.1 5.5 575 0 K34 L510A 4.1 4.4 200 1 K62 L241B 19.1 20.5 230 1 K61 L199B 16.6 17.8 380 0 K52 L122B 10.0 10.8 460 0 K49 L100B 8.3 8.9 575 0 K42 L825A 6.6 7.1 200 1 K68 L332B 28.4 30.5 230 1 K67 L293B 24.6 26.4 380 1 K58 L181B 14.9 16.0 460 1 K55 L147B 12.3 13.2 575 1 K52 L122B 9.9 10.6 380 1 K62 L241B 19.5 21.0 460 1 K60 L199B 16.1 17.3 575 1 K56 L165B 12.9 13.6

NEMA

STARTER

SIZE

HEATERS FOR

OVERLOAD RELAYS

FURNAS

(NOTE 1)

G.E.

(NOTE 2) SET MAX.

ADJUSTABLE

RELAYS

(NOTE 3)

All heaters and amp settings shown are based on total line amps. When determining amperage settings or making heater selections for a six-lead motor with a Wye-Delta starter, divide motor amps by 1.732.

pages 28, 29 and 30 list the correct selection and settings for some manufacturers. Approval for other manufacturers’ types not listed may be requested by calling Franklin’s Submersible Service Hotline at 800-348-2420.

Refer to notes on page 29.

Class 10 Protection Required

Application – Three-Phase Motors

Table 29 - 60 Hz 6" Motors

HP KW VOLTS

200 1 K61 L220B 17.6 19.1

230 1 K61 L199B 15.4 16.6

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

40 30

50 37

60 45

380 0 K52 L122B 9.4 10.1

460 0 K49 L100B 7.7 8.3

575 0 K42 L825A 6.1 6.6

200 1 K67 L322B 26.3 28.3

230 1 K64 L293B 22.9 24.6

380 1 K57 L165B 13.9 14.9

460 1 K54 L147B 11.4 12.3

575 1 K52 L111B 9.1 9.8

200 2(1) K72 L426B 34.4 37.0

230 2(1) K70 L390B 29.9 32.2

380 1 K61 L220B 18.1 19.5

460 1 K58 L181B 15.0 16.1

575 1 K55 L147B 12.0 12.9

200 3(1) K76 L650B 50.7 54.5

230 2 K75 L520B 44.1 47.4

380 2(1) K68 L322B 26.7 28.7

460 2(1) K64 L265B 22.0 23.7

575 2(1) K61 L220B 17.7 19.0

200 3 K78 L787B 64.8 69.7

230 3(1) K77 L710B 56.4 60.6

380 2 K72 L426B 34.1 36.7

460 2 K69 L352B 28.2 30.3

575 2 K64 L393B 22.7 24.4

200 3 K86 L107C 80.3 86.3

230 3 K83 L866B 69.8 75.0

380 2 K74 L520B 42.2 45.4

460 2 K72 L426B 34.9 37.5

575 2 K69 L352B 27.9 30.0

200 4(1) K88 L126C 96.7 104.0

230 3 K87 L107C 84.1 90.4

380 3(1) K76 L650B 50.9 54.7

460 3(1) K74 L520B 42.0 45.2

575 3(1) K72 L390B 33.7 36.2

380 3 K83 L866B 69.8 75.0

460 3 K77 L710B 57.7 62.0

575 3 K74 L593B 46.1 49.6

380 3 K87 L107C 86.7 93.2

460 3 K83 L950B 71.6 77.0

575 3 K77 L710B 57.3 61.6

380 4(1) K89 L126C 102.5 110.2

460 4(1) K87 L107C 84.6 91.0

575 4(1) K78 L866B 67.7 72.8

NEMA

STARTER

SIZE

HEATERS FOR

OVERLOAD RELAYS

FURNAS (NOTE 1)

(NOTE 2) SET MAX.

G.E.

ADJUSTABLE

RELAYS

(NOTE 3)

Footnotes for Tables 28, 29, and 30

NOTE 1: Furnas intermediate sizes between NEMA starter sizes apply where (1) is shown in tables, size 1.75 replacing 2, 2.5 replacing 3, 3.5 replacing 4, and 4.5 replacing 5. Heaters were selected from Catalog 294, table 332 and table 632 (starter size 00, size B). Size 4 starters are heater type 4 (JG). Starters using these heater tables include classes 14, 17 and 18 (inNOVA), classes 36 and 37 (reduced voltage), and classes 87, 88 and 89 (pump and motor control centers). Overload relay adjustments should be set no higher than 100% unless necessary to stop nuisance tripping with measured amps in all lines below nameplate maximum. Heater selections for class 16 starters (Magnetic Deﬁ nite Purpose) will be furnished upon request.

NOTE 2: General Electric heaters are type CR123 usable only on type CR124 overload relays and were selected from Catalog GEP-126OJ, page

184. Adjustment should be set no higher than 100%, unless necessary to stop nuisance tripping with measured amps in all lines below nameplate maximum.

NOTE 3: Adjustable overload relay amp settings apply to approved types listed. Relay adjustment should be set at the speciﬁ ed SET amps. Only if tripping occurs with amps in all lines measured to be within nameplate maximum amps should the setting be increased, not to exceed the MAX value shown.

NOTE 4: Heaters shown for ratings requiring NEMA size 5 or 6 starters are all used with current transformers per manufacturer standards. Adjustable relays may or may not use current transformers depending on design.

Submersible Pump Installation Check List

1. Motor Inspection

A. Verify that the model, hp or kW, voltage, phase and hertz on the motor nameplate match the

❑

installation requirements. B. Check that the motor lead assembly is not damaged.

❑

C. Measure insulation resistance using a 500 or 1000 volt DC megohmmeter from each lead wire to the

❑

motor frame. Resistance should be at least 200 megohms without drop cable. D. Keep a record of motor model number, hp or kW, voltage, and serial number (S/N).

❑

(S/N is stamped in shell above the nameplate. A typical example, S/N 07A18 01-0123)

2. Pump Inspection

A. Check that the pump rating matches the motor.

❑

B. Check for pump damage and verify that the pump shaft turns freely.

❑

3. Pump/Motor Assembly

A. If not yet assembled, check that pump and motor mounting faces are free from dirt, debris and uneven

❑

paint thickness. B. Pumps and motors over 5 hp should be assembled in the vertical position to prevent stress on pump

❑

brackets and shafts. Assemble the pump and motor together so their mounting faces are in contact and then tighten assembly bolts or nuts evenly to manufacturer speciﬁ cations. C. If accessible, check that the pump shaft turns freely.

❑

D. Assemble the pump lead guard over the motor leads. Do not cut or pinch lead wires during assembly or

❑

installation.

4. Power Supply and Controls

A. Verify that the power supply voltage, hertz, and kVA capacity match motor requirements.

❑

B. Verify control box hp and voltage matches motor (3-wire only).

❑

C. Check that the electrical installation and controls meet all safety regulations and match the motor

❑

requirements, including fuse or circuit breaker size and motor overload protection. Connect all metal plumbing and electrical enclosures to the power supply ground to prevent shock hazard. Comply with national and local codes.

5. Lightning and Surge Protection

A. Use properly rated surge (lightning) arrestors on all submersible pump installations. Motors 5 hp and

❑

smaller, which are marked “Equipped with Lightning Arrestors”, contain internal arrestors. B. Ground all above ground arrestors with copper wire directly to the motor frame, or to metal drop pipe or

❑

casing which reaches below the well pumping level. Connecting to a ground rod does not provide good surge protection.

6. Electrical Drop Cable

A. Use submersible cable sized in accordance with local regulations and the cable charts, see pages 11 and 16-21.

❑

Ground motor per national and local codes. B. Include a ground wire to the motor and surge protection, connected to the power supply ground if

❑

required by codes. Always ground any pump operated outside a drilled well.

7. Motor Cooling

A. Ensure at all times that the installation provides adequate motor cooling; see page 6 for details.

❑

8. Pump/Motor Installation

A. Splice motor leads to supply cable using electrical grade solder or compression connectors, and carefully

❑

insulate each splice with watertight tape or adhesive-lined shrink tubing, as shown in motor or pump installation data. B. Support the cable to the delivery pipe every 10 feet (3 meters) with straps or tape strong enough to

❑

prevent sagging. Use padding between cable and any metal straps. C. A check valve in the delivery pipe is recommended. More than one check valve may be required,

❑

depending on valve rating and pump setting; see page 5 for details. D. Assemble all pipe joints as tightly as practical, to prevent unscrewing from motor torque. Torque should

❑

be at least 10 pound feet per hp (2 meter-KG per kW). E. Set the pump far enough below the lowest pumping level to assure the pump inlet will always have at

❑

least the Net Positive Suction Head (NPSH) speciﬁ ed by the pump manufacturer. Pump should be at least 10 feet (3 meters) from the bottom of the well to allow for sediment build up.

Form No. 3656 02/07

Submersible Pump Installation Check List

❑

F. Check insulation resistance as pump/motor assembly is lowered into the well. Resistance may drop

gradually as more cable enters the water, but any sudden drop indicates possible cable, splice or motor lead damage; see page 44.

9. After Installation

❑

A. Check all electrical and water line connections and parts before starting the pump.

❑

B. Start the pump and check motor amps and pump delivery. If normal, continue to run the pump until delivery is clear. If three-phase pump delivery is low, it may be running backward. Rotation may be reversed (with power off) by interchanging any two motor lead connections to the power supply.

❑

C. Check three-phase motors for current balance within 5% of average, using motor manufacturer instructions. Imbalance over 5% will cause higher motor temperatures and may cause overload trip, vibration, and reduced life.

❑

D. Verify that starting, running and stopping cause no signiﬁ cant vibration or hydraulic shocks.

❑

E. After at least 15 minutes running time, verify that pump output, electrical input, pumping level, and other characteristics are stable and as speciﬁ ed.

Date _____________________ Filled In By ____________________________________________________

Notes _________________________________________________________________________________________

_______________________________________________________________________________________________

_______________________________________________________________________________________

Submersible Motor Installation Record

RMA No. _____________

INSTALLER’S NAME ___________________________ OWNER’S NAME _________________________________

ADDRESS ___________________________________ ADDRESS ______________________________________

CITY __________________ STATE_____ ZIP________ CITY ____________________ STATE_____ ZIP________

PHONE (____) _____________ FAX (____) _________ PHONE (____) _____________ FAX (____)____________

CONTACT NAME ______________________________ CONTACT NAME ________________________________

WELL NAME/ID _______________________________ DATE INSTALLED __________ DATE FAILED__________

WATER TEMPERATURE ________ °F or ________ °C

Motor:

Motor No. __________________ Date Code ___________________ hp ________ Voltage _________ Phase ______

Pump:

Manufacturer _________________ Model No. _________ Curve No. _________ Rating: ______ gpm@______ft TDH

NPSH Required ___________ ft NPSH Available_________ ft Actual Pump Delivery__________gpm@ ______ psi

Operating Cycle ______________ON (Min/h) _________________ OFF (min/h) (Circle Min or h as appropriate)

YOUR NAME ___________________________________________________________ DATE ______/______/______

WELL DATA:

Total Dynamic Head ________________ft

Casing Diameter __________________ in

Drop Pipe Diameter ________________ in

Static Water Level __________________ft

Drawdown (pumping) Water Level _____ft

Check Valves at _________ & _______ &

_________ & _______ ft

❑ Solid ❑ Drilled

TOP PLUMBING:

Please sketch the plumbing after the well head (check valves, throttling valves, pressure tank, etc.) and indicate the setting of each device.

Form No. 2207 8/00

Pump Inlet Setting _________________ft

Flow Sleeve: ___No____Yes; Dia. _____in

Casing Depth ______________________ft

❑ Well Screen ❑ Perforated Casing

From_____to_____ft & ______to______ft

Well Depth ________________________ft

Submersible Motor Installation Record

Power Supply:

Cable: Service Entrance to Control ____________ft_______ AWG/MCM ❑ Copper ❑ Aluminum ❑ Jacketed ❑ Individual Conductors Cable: Control to Motor ____________ft________ AWG/MCM ❑ Copper ❑ Aluminum ❑ Jacketed ❑ Individual Conductors

SERVICE

ENTRANCE

Transformers:

kVA __________ #1 __________ #2 __________ #3

Initial Megs (motor & lead) T1________T2_______T3________

Final Megs (motor, lead & cable) T1______T2______T3______

Incoming Voltage:

No Load L1-L2______ L2-L3_______L1-L3_______ Full Load L1-L2______ L2-L3_______L1-L3_______

Running AMPS:

HOOKUP 1: Full Load L1______L2_______L3_______ % Unbalance______ HOOKUP 2: Full Load L1______L2_______L3_______ % Unbalance______ HOOKUP 3: Full Load L1______L2_______L3_______ % Unbalance______

PUMP

PANEL

Control Panel:

Panel Manufacturer______________________________ Short Circuit Device ❑ Circuit Breaker Rating________Setting_____ ❑ Fuses Rating___________ Type__________ ❑ Standard ❑ Delay

Starter Manufacturer_____________________________ Starter Size ___________________________________ Type of Starter ❑ Full Voltage ❑ Autotransformer ❑ Other:___________Full Voltage in _____sec

Heater Manufacturer_____________________________ Number_____________Adjustable Set at _______amps. SubMonitor/Subtrol-Plus ❑ No ❑ Yes Registration No. ________ If yes, Overload Set? ❑ No ❑ Yes Set at _______amps. Underload Set? ❑ No ❑ Yes Set at _______amps.

P U

M O

T O R

Ground Wire Size ___________________AWG/MCM Motor Surge Protection ❑ Yes ❑ No

Variable Frequency Drives:

Manufacturer_________________ Model ______________ Output Frequency: _________ Hz Min _________ Hz Max Cooling Flow at Min. Freq. ___________________________ Cooling Flow at Max. Freq.________________________ Approved Overload: ❑ Built-in ________ ❑ External Model: (per above) ❑ Cables: (per above) Set Amps __________ Start Time ____________sec Stop Mode ❑ Coast __________sec ❑ Ramp __________ sec ❑ Output ﬁ lter ___________ ❑ Reactor _______________% Make __________ Model ___________ ❑ None

Maximum Load AMPS:

Drive Meter Input Amps Line 1 __________ Line 2 __________ Line 3 __________ Drive Meter Output Amps Line 1 __________ Line 2 __________ Line 3 __________ Test Ammeter Output Amps Line 1 __________ Line 2 __________ Line 3 __________ Test Ammeter Make ________________________ Model ________________________

Controls are Grounded to: ❑ Well Head ❑ Motor ❑ Rod ❑ Power Supply

Submersible Motor Booster Installation Record

Date ______ /______/_______ Filled In By _______________________________ RMA No. _______________

Installation:

Owner/User ________________________________________________ Telephone (______) ____________________ Address ____________________________________________City _______________ State ______ Zip __________ Installation Site, If Different _________________________________________________________________________ Contact ___________________________________________________ Telephone (______) ____________________ System Application________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ System Manufactured By_____________________________Model ________________ Serial No. _______________ System Supplied By_________________________________ City _________________ State ______ Zip _________ Is this a “HERO” system (10.0 - 10.5 PH)? ❑ Yes ❑ No

Motor:

Model No. _______________ Serial No. _______________ Date Code ______ Horsepower ______ Voltage ______ ❑ Single-Phase ❑ Three-Phase Diameter ______ in Slinger Removed? ❑ Yes ❑ No Check Valve Plug Removed? ❑ Yes ❑ No Motor Fill Solution ❑ Standard ❑ DI Water

Pump:

Manufacturer _______________ Model _______________ Serial No. _______________ Stages ______ Diameter ________ Flow Rate Of ________ gpm At ______TDH Booster Case Internal Diameter ________ Material _______________

Controls and Protective Devices:

SubMonitor? ❑ Yes ❑ No If Yes, Warranty Registration No._______________________________________ If Yes, Overload Set? ❑ Yes ❑ No ______ Set At _________________________ Underload Sets? ❑ Yes ❑ No ______ Set At _________________________ VFD or Reduced Voltage Starter? ❑ Yes ❑ No If Yes, Type __________________________________________ Mfr. ______________Setting ________% Full Voltage In ________sec Pump Panel? ❑ Yes ❑ No If Yes, Mfr. ______________________________Size _______________________ Magnetic Starter/Contactor Mfr. ___________________________ Model __________________Size_______________ Heaters Mfr. _____________________ No. ____________ If Adjustable Set At _______________________________ Fuses Mfr. ____________________ Size ___________ Type _____________________________________________ Lightning/Surge Arrestor Mfr. ________________________ Model __________________________________________ Controls Are Grounded to __________________ with No. ________Wire Inlet Pressure Control ❑ Yes ❑ No If Yes, Mfr.________ Model _______ Setting _____ psi Delay ____ sec Inlet Flow Control ❑ Yes ❑ No If Yes, Mfr.________ Model _______ Setting _____ gpm Delay ____ sec Outlet Pressure Control ❑ Yes ❑ No If Yes, Mfr.________ Model _______ Setting _____ psi Delay ____ sec Outlet Flow Control ❑ Yes ❑ No If Yes, Mfr.________ Model _______ Setting _____ gpm Delay ____ sec Water Temperature Control ❑ Yes ❑ No If Yes, Mfr.________ Model _________________________ Delay ____ sec Set At ________ °F Or ______ °C Located _____________________________________

Form No. 3655 8/00

Submersible Motor Booster Installation Record

Insulation Check:

Initial Megs: Motor & Lead Only Black (T1/U1)_________ Yellow (T2/V1)________ Red (T3/W1)_________

Installed Megs: Motor, Lead, & Cable Black (T1/U1)_________ Yellow (T2/V1)________ Red (T3/W1)_________

Voltage To Motor:

Non-Operating:

At Rated Flow of __________gpm B-Y (T1/U1 - T2/V1)_____ Y-R (T2/V1 - T3/W1)_____ R-B (T3/W1 - T1/U1)_____

At Open Flow ____________gpm B-Y (T1/U1 - T2/V1)_____ Y-R (T2/V1 - T3/W1)_____ R-B (T3/W1 - T1/U1)_____

Amps To Motor:

At Rated Flow of __________gpm Black (T1/U1)_________ Yellow (T2/V1)________ Red (T3/W1)_________

At Open Flow ____________gpm Black (T1/U1)_________ Yellow (T2/V1)________ Red (T3/W1)_________

At Shut Off* Black (T1/U1)_________ Yellow (T2/V1)________ Red (T3/W1)_________

*Do NOT run at Shut Off more than two (2) minutes.

Inlet Pressure __________psi Outlet Pressure __________psi Water Temperature _______

If you have any questions or problems, call the Franklin Electric Toll-Free Hot Line: 1-800-348-2420

Comments: _____________________________________________________________________________________

_______________________________________________________________________________________________

B-Y (T1/U1 - T2/V1)_____ Y-R (T2/V1 - T3/W1)_____ R-B (T3/W1 - T1/U1)_____

°F or _______ °C

_______________________________________________________________________________________________

Please sketch the system

Application – Three-Phase Motors

Recommended Adjustable Overload Relays

Advance Controls: MDR3 Overload

AEG Series: B17S, B27S, B27-2

ABB Type: RVH 40, RVH65, RVP160,

T25DU, T25CT, TA25DU

AGUT: MT03, R1K1, R1L0, R1L3, TE set Class 5

Allen Bradley: Bulletin 193, SMP-Class 10 only

Automatic Switch Types: DQ, LR1-D, LR1-F,

LR2 Class 10

Benshaw: RSD6 (Class 10) Soft Start

Bharita C-H: MC 305 ANA 3

Clipsal: 6CTR, 6MTR

Cutler-Hammer: C316F, C316P, C316S, C310-set

at 6 sec max, Advantage Class10

Fanal Types: K7 or K7D through K400

Franklin Electric: Subtrol-Plus, SubMonitor

Fuji Types: TR-OQ, TR-OQH, TR-2NQ, TR- 3NQ,

TR-4NQ, TR-6NQ, RCa 3737-ICQ & ICQH

Furnas Types: US15 48AG & 48BG, 958L, ESP100-Class 10 only, 3RB10-Class 10

General Electric: CR4G, CR7G, RT*1, RT*2, RTF3, RT*4, CR324X-Class 10 only

Kasuga: RU Set Operating Time Code = 10 & time setting 6 sec max

Klockner-Moeller Types: ZOO, Z1, Z4, PKZM1, PKZM3 & PKZ2

Lovato: RC9, RC22, RC80, RF9, RF25 & RF95

Matsushita: FKT-15N, 15GN, 15E, 15GE, FT-15N,

FHT-15N

Mitsubishi: ET, TH-K12ABKP, TH-K20KF, TH-K20KP, TH-K20TAKF, TH-K60KF, TH-K60TAKF

Omron: K2CM Set Operating Timing Code = 10 & time setting 6 sec max, SE-KP24E time setting 6 sec max

Riken: PM1, PM3

Samwha: EOCRS Set for Class 5, EOCR-ST,

EOCR-SE, EOCR-AT time setting 6 sec max

Siemens Types: 3UA50, -52, -54, -55, -58, -59, -60,

-61, -62, -66, -68, -70, 3VUI3, 3VE, 3UB (Class 5)

Sprecher and Schuh Types: CT, CT1, CTA 1, CT3K, CT3-12 thru CT3-42, KTA3, CEF1 & CET3 set at 6 sec max, CEP 7 Class 10, CT4, 6, & 7, CT3, KT7

Square D/Telemecanique: Class 9065 Types: TD, TE, TF, TG, TJ, TK, TR, TJE &TJF (Class

10), LR1-D, LR1-F, LR2 Class 10, Types 18A, 32A, SS-Class 10, SR-Class 10 and 63-A-LB Series. Integral 18,32,63, GV2-L, GV2-M, GV2-P, GV3-M (1.6-10 amp only) LR9D, SF Class 10, ST Class 10, LT6 (Class 5 or 10), LRD (Class 10), Motor Logic (Class10)

Table 30 - 60 Hz 8" Motors

HEATERS FOR

OVERLOAD RELAYS

FURNAS

(NOTE 1)

G.E.

(NOTE 2) SET MAX.

HP KW VOLTS

380 3 K78 L866B 68 73

40 30

50 37

60 45

75 55

100 75

125 90

150 110

175 130

200 150

460 3 K77 L710B 56 60

575 3 K73 L520B 45 48

380 3 K86 L107C 81 87

460 3 K78 L866B 68 73

575 3 K77 L710B 56 60

380 4(1) K89 L126C 101 108

460 4(1) K86 L107C 83 89

575 4(1) K78 L787B 64 69

380 4 K92 L142C 121 130

460 4(1) K89 L126C 100 107

575 4(1) K85 L950C 79 85

380 5(1) K28 L100B 168 181

460 4 K92 L155C 134 144

575 4 K90 L142C 108 116

380 5 K32 L135B 207 223

460 5(1) K29 L111B 176 189

575 5(1) K26 L825A 140 150

380 5 - L147B 248 267

460 5(1) K32 L122B 206 221

575 5(1) K28 L100B 165 177

380 6 K26 - 270 290

460 5 K33 L147B 233 250

575 5 K31 L111B 186 200

380 6 K27 - 316 340

460 5 K33 L165B 266 286

575 5 K32 L135B 213 229

NEMA

STARTER

SIZE

Toshiba Type: 2E RC820, set at 8 sec max.

WEG: RW2

Westinghouse Types: FT13, FT23, FT33, FT43, K7D, K27D, K67D,

Advantage (Class 10), MOR, IQ500 (Class 5)

Westmaster: OLWROO and OLWTOO sufﬁ x D thru P

ADJUSTABLE

RELAYS

(NOTE 3)

Other relay types from these and other manufacturers may or may not provide acceptable protection, and they should not be used without approval of Franklin Electric.

Some approved types may only be available for part of the listed motor ratings. When relays are used with current transformers, relay setting is the speciﬁ ed amps divided by the transformer ratio.

Application – Three-Phase Motors

SubMonitor Three-Phase Protection

Applications

SubMonitor is designed to protect 3-phase pumps/ motors with service factor amp ratings (SFA) from 5 to 350 A (approx. 3 to 200 hp). Current, voltage, and motor temperature are monitored using all three legs and allows the user to set up the SubMonitor quickly and easily.

Protects Against

• Under/Overload

• Under/Overvoltage

• Current Unbalance

• Overheated Motor (if equipped with Subtrol Heat Sensor)

• False Start (Chattering)

• Phase Reversal

Power Factor Correction

In some installations, power supply limitations make it necessary or desirable to increase the power factor of a submersible motor. The table lists the capacitive kVAR required to increase the power factor of large Franklin three-phase submersible motors to the approximate values shown at maximum input loading.

Capacitors must be connected on the line side of the overload relay, or overload protection will be lost.

Table 31 kVAR Required 60 Hz

MOTOR KVAR REQUIRED FOR PF OF:

HP KW 0.90 0.95 1.00

5 3.7

7.5 5.5

10 7.5

15 11

20 15

25 18.5

30 22

40 30

50 37

60 45

75 55

100 75

125 90

150 110

175 130

200 150

Values listed are total required (not per phase).

1.2 2.1 4.0

1.7 3.1 6.0

1.5 3.3 7.0

2.2 4.7 10.0

1.7 5.0 12.0

2.1 6.2 15.0

2.5 7.4 18.0

4.5 11.0 24.0

7.1 15.0 32.0

8.4 18.0 38.0

6.3 18.0 43.0

11.0 27.0 60.0

17.0 36.0 77.0

20.0 42.0 90.0

9.6 36.0 93.0

16.0 46.0 110.0

Application – Three-Phase Motors

Three-Phase Starter Diagrams

Three-phase combination magnetic starters have two distinct circuits: a power circuit and a control circuit.

The power circuit consists of a circuit breaker or fused line switch, contacts, and overload heaters connecting incoming power lines L1, L2, L3 and the three-phase motor.

Line Voltage Control

This is the most common type of control encountered. Since the coil is connected directly across the power lines L1 and L2, the coil must match the line voltage.

Low Voltage Transformer Control

This control is used when it is desirable to operate push buttons or other control devices at some voltage lower than the motor voltage. The transformer primary must match the line voltage and the coil voltage must match the secondary voltage of the transformer.

The control circuit consists of the magnetic coil, overload contacts and a control device such as a pressure switch. When the control device contacts are closed, current ﬂ ows through the magnetic contactor coil, the contacts close, and power is applied to the motor. Hand-Off-Auto switches, start timers, level controls and other control devices may also be in series in the control circuit.

FUSES

CONTACTS

MOTOR

PRESSURE SWITCH OR OTHER CONTROL DEVICE

OVERLOAD HEATERS AND/OR

SUBTROL PLUS

O.L. CONTACTS

COIL

FIG. 7

FUSES

CONTACTS

TRANSFORMER

OVERLOAD HEATERS AND/OR SUBTROL PLUS

PRESSURE SWITCH OR OTHER CONTROL DEVICE

FUSE

COIL

O.L. CONTACTS

External Voltage Controls

Control of a power circuit by a lower circuit voltage can also be obtained by connecting to a separate control voltage source. The coil rating must match the control voltage source, such as 115 or 24 volts.

FUSES

CONTACTS

MOTOR

OVERLOAD HEATER AND/OR

SUBTROL DEVICE

FIG. 8

PRESSURE SWITCH OR OTHER CONTROL DEVICE

O.L. CONTACTS

COIL

FIG. 9

TO SEPARATE CONTROL VOLTAGE SOURCE

Application – Three-Phase Motors

Three-Phase Power Unbalance

A full three-phase supply is recommended for all threephase motors, consisting of three individual transformers

poor performance, overload tripping or early motor failure

due to current unbalance. or one three-phase transformer. So-called “open” delta or wye connections using only two transformers can be used, but are more likely to cause problems, such as

FIG. 10 FULL THREE-PHASE

Transformer rating should be no smaller than listed in

table 4 for supply power to the motor alone.

FIG. 11 OPEN DELTA

Checking and Correcting Rotation and Current Unbalance

1. Established correct motor rotation by running in both

directions. Change rotation by exchanging any two of the three motor leads. The rotation that gives the most water ﬂ ow is always the correct rotation.

2. After correct rotation has been established, check the

current in each of the three motor leads and calculate the current unbalance as explained in 3 below.

If the current unbalance is 2% or less, leave the leads

as connected.

If the current unbalance is more than 2%, current

readings should be checked on each leg using each of three possible hook-ups. Roll the motor leads across the starter in the same direction to prevent motor reversal.

3. To calculate percent of current unbalance:

A. Add the three line amps values together.

B. Divide the sum by three, yielding average

current.

C. Pick the amp value which is furthest from the

average current (either high or low).

D. Determine the difference between this amp

value (furthest from average) and the average.

E. Divide the difference by the average. Multiply the

result by 100 to determine percent of unbalance.

4. Current unbalance should not exceed 5% at service

factor load or 10% at rated input load. If the unbalance cannot be corrected by rolling leads, the source of the unbalance must be located and corrected. If, on the three possible hookups, the leg farthest from the average stays on the same power lead, most of the unbalance is coming from the power source. However, if the reading farthest from average moves with the same motor lead, the primary source of unbalance is on the “motor side” of the starter. In this instance, consider a damaged cable, leaking splice, poor connection, or faulty motor winding.

1st Hook Up 2nd Hook Up 3rd Hook Up

EXAMPLE:

T1 = 51 amps T3 = 50 amps T2 = 50 amps

T2 = 46 amps T1 = 49 amps T3 = 48 amps T3 = 53 amps T2 = 51 amps T1 = 52 amps

Total = 150 amps Total = 150 amps Total = 150 amps

150

= 50 amps

150

= 50

50 - 46 = 4 amps 50 - 49 = 1 amp 50 - 48 = 2 amps

= 0.08 or 8%

= 0.02 or 2%

Phase designation of leads for CCW rotation viewing

shaft end.

To reverse rotation, interchange any two leads.

Phase 1 or “A” - Black, T1, or U1

Phase 2 or “B” - Yellow, T2, or V1

Phase 3 or “C” - Red, T3, or W1

NOTICE: Phase 1, 2 and 3 may not be L1, L2 and L3.

amps

150

2 50

= 50 amps

= 0.04 or 4%

supply

starter

motor

Application – Three-Phase Motors

(

Three-Phase Motor Lead Identiﬁ cation

Line Connections — Six-Lead Motors

T5-V2

(YELLOW)

WARNING: When installing 6-lead motors extra care must be used to ensure lead identiﬁ cation at the surface. Leads must be marked and connected per diagram. Motor leads are not connected red to red, yellow to yellow, etc.

T6-W2

(RED)

T4-U2

(BLACK)

T2-V1

(YELLOW)

T3-W1

(RED)

LEADS LOCATED HERE ONLY

FOR 3 LEAD

CHECK VALVE OR PIPE PLUG ON RIGHT SIDE FACING MOTOR SHAFT

T1-U1

(BLACK)

DOL) MOTORS

90° Lead Spacing

Connections for across-the-line starting, running, and any reduced voltage starting except WYE-DELTA type starters.

T1 U1

T2 V1

T4 U2

T5 V2

Each motor lead is numbered with two markers, one near each end. To reverse rotation, interchange any two line connections.

WYE-DELTA starters connect the motor as shown below during starting, then change to the running connection shown at the left.

L1 L2 L3

T2 V1

T4 U2

T5 V2

Phase Converters

There are a number of different types of phase converters available. Each generates three-phase power from a single-phase power line.

In all phase converters, the voltage balance is critical to current balance. Although some phase converters may be well balanced at one point on the system-operating curve, submersible pumping systems often operate at differing points on the curve as water levels and operating pressures ﬂ uctuate. Other converters may be well balanced at varying loads, but their output may vary widely with ﬂ uctuations in the input voltage.

The following guidelines have been established for submersible installations to be warrantable when used with a phase converter.

1. Limit pump loading to rated horsepower. Do not load into motor service factor.

2. Maintain at least 3 ft/s ﬂ ow past the motor. Use a ﬂ ow sleeve when necessary.

3. Use time delay fuses or circuit breakers in pump panel. Standard fuses or circuit breakers do not provide secondary motor protection.

4. SubMonitor may be used with electro mechanical type phase converters, however special connections are required. Consult SubMonitor Manual for connections of receiver and lightning arrestor.

5. SubMonitor will not work with electronic solid state phase converters.

6. Current unbalance must not exceed 10%.

Application – Three-Phase Motors

Reduced Voltage Starters

All Franklin three-phase submersible motors are suitable for full-voltage starting. Under this condition the motor speed goes from zero to full speed within a half second or less. The motor current goes from zero to locked rotor amps, then drops to running amps at full speed. This may dim lights, cause momentary voltage dips to other electrical equipment, and shock power distribution transformers.

In some cases the power companies may require reduced-voltage starters to limit this voltage dip. There are also times when reduced-voltage starters may be desirable to reduce motor starting torque thus reducing the stress on shafts, couplings, and discharge piping. Reduced-voltage starters also slow the rapid acceleration of the water on start-up to help control upthrust and water hammer.

Reduced-voltage starters may not be required if the maximum recommended cable length is used. With maximum recommended cable length there is a 5% voltage drop in the cable at running amps, resulting in about 20% reduction in starting current and about 36% reduction in starting torque compared to having rated voltage at the motor. This may be enough reduction in starting current so that reduced-voltage starters are not required.

Three-Lead Motors: Autotransformer or solid-state reduced-voltage starters may be used for soft-starting standard three-phase motors.

When autotransformer starters are used, the motor should be supplied with at least 55% of rated voltage to ensure adequate starting torque. Most autotransformer starters have 65% and 80% taps. Setting the taps on these starters depends on the percentage of the

maximum allowable cable length used in the system. If the cable length is less than 50% of the maximum allowable, either the 65% or the 80% taps may be used. When the cable length is more than 50% of allowable, the 80% tap should be used.

Six-Lead Motors: Wye-Delta starters are used with six-lead Wye-Delta motors. All Franklin 6" and 8" three-phase motors are available in six-lead Wye-Delta construction. Consult the factory for details and availability. Part winding starters are not compatible with Franklin Electric submersible motors and should not be used.

Wye-Delta starters of the open-transition type, which momentarily interrupt power during the starting cycle, are not recommended. Closed-transition starters have no interruption of power during the start cycle and can be used with satisfactory results.

Reduced-voltage starters have adjustable settings for acceleration ramp time, typically preset at 30 seconds. They must be adjusted so the motor is at full voltage within THREE SECONDS MAXIMUM to prevent excessive radial and thrust bearing wear.

If Subtrol-Plus or SubMonitor is used the acceleration time must be set to TWO SECONDS MAXIMUM due to the 3 second reaction time of the Subtrol-Plus or SubMonitor.

Solid-state starters AKA soft starts may not be compatible with Subtrol-Plus/SubMonitor. However, in some cases a bypass contactor has been used. Consult the factory for details.

During shutdown, Franklin Electric’s recommendation is for the power to be removed, allowing the pump/motor to coast down. Stopping the motor by ramping down the voltage is possible, but should be limited to three (3) seconds maximum.

Inline Booster Pump Systems

Franklin Electric offers three different types of motors for non-vertical applications.

1. The Booster motors are speciﬁ cally designed for booster applications. They are the “Best Choice”

for sealed Reverse Osmosis applications.

These motors are the result of two years of focused development and bring additional value and durability to booster module systems. These motors are only available to OEMs or Distributors who have demonstrated capability in Booster Module systems design and operation and adhere to Franklin’s Application Manual requirements.

2. The Hi-Temp motors have many of the internal design features of the Booster motor. It’s additional length allows for higher temperature handling and the Sand Fighter sealing system provides greater abrasion resistance. One or both of these conditions

are often experienced in open atmosphere applications such as lakes, ponds, etc.

3. The Standard Vertical Water Well (40-125 hp) motors can be adapted to non-vertical applications when applied per the below guidelines. However, they will be more sensitive to application variances than the other two designs.

All of the above motors must be applied per the guidelines listed below. In addition, for all applications where the motor is applied in a sealed system, a Submersible Motor Booster Installation Record (Form

3655) or its equivalent must be completed at startup and

received by Franklin Electric within 60 days. A sealed system is one where the motor and pump intake are mounted in a sleeve and the water feeding the pump intake is not open to the atmosphere.

Application – Three-Phase Motors

Inline Booster Pump Systems (continued)

Design And Operational Requirements

1. Non-Vertical Operation: Vertical Shaft-up (0°) to Horizontal (90°) operation is acceptable as long as the pump transmits “down-thrust” to the motor within 3 seconds after start-up and continuously during operation. However, it is best practice to provide a positive slope whenever it is possible, even if it is only a few degrees.

2. Motor, Sleeve, and Pump Support System: The booster sleeve ID must be sized according to the motor cooling and pump NPSHR requirements. The support system must support the motor’s weight, prevent motor rotation and keep the motor and pump aligned. The support system must also allow for thermal axial expansion of the motor without creating binding forces.

3. Motor Support Points: A minimum of two support points are required on the motor. One in the motor/ pump ﬂ ange connection area and one in the bottom end of the motor area. The motor castings, not the shell area, are recommended as support points. If the support is a full length support and/or has bands in the shell area, they must not restrict heat transfer or deform the shell.

water must be done by an approved Franklin service shop or representative using a vacuum ﬁ ll system per Franklin’s Motor Service Manual instruction. The motor shell then must be permanently stamped with a D closely behind the Serial Number.

The maximum pressure that can be applied to the motor internal components during the removal of the factory ﬁ ll solution is 7 psi (0.5 bar.)

Derating Factor for Motors That Must Have Their Factory Fill

Replaced With Deionized Water 8" Encapsulated Motor

1.8

1.75

1.7

1.65

1.6

1.55

1.5

1.45

1.4

1.35

1.3

1.25

Pump Load Multiplier

1.2

1.15

1.1

1.15 Service Factor (60Hz)

1.05 1

1.00 Service Factor (50Hz)

30 25 20 15 10

Feed WaterTemperature (°C)

FIG. 12

4. Motor Support Material and Design: The support system shall not create any areas of cavitation or other areas of reduced ﬂ ow less than the minimum rate required by this manual. They should also be designed to minimize turbulence and vibration and provide stable alignment. The support materials and locations must not inhibit the heat transfer away from the motor.

5. Motor and Pump Alignment: The maximum allowable misalignment between the motor, pump, and pump discharge is 0.025 inch per 12 inches of length (2 mm per 1000 mm of length). This must be measured in both directions along the assembly using the motor/pump ﬂ ange connection as the starting point. The booster sleeve and support system must be rigid enough to maintain this alignment during assembly, shipping, operation and maintenance.

6. The best motor lubrication and heat resistance is obtained with the factory based propylene glycol ﬁ ll solution. Only when an application MUST HAVE deionized (DI) water should the factory ﬁ ll solution be replaced. When a deionized water ﬁ ll is required, the motor must be derated as indicated on the below chart. The exchange of the motor ﬁ ll solution to DI

First: Determine maximum Feed Water Temperature

that will be experienced in this application. If the feed water exceeds the maximum ambient of the motor, both the DI water derating and a hot water application derating must be applied.

Second: Determine the Pump Load Multiplier from the

appropriate Service Factor curve. (Typical 1.15 Service Factor is for 60 Hz ratings &1.00 Service Factor for 50 Hz ratings).

Third: Multiply the Pump Load Requirement times the pump

load multiplier number indicated on the vertical axis to determine the Minimum Motor Nameplate Rating.

Fourth: Select a motor with a nameplate equal or higher than

the above calculated value.

7. Motor Alterations - Sand Slinger & Check Valve Plug: On 6" and 8" motors, the rubber sand slinger located on the shaft must be removed. The pipe plug covering the check valve must be removed from Niresist and 316 SS motors. The special Booster motor already has these alterations made.

8. Frequency of Starts: Fewer than 10 starts per 24-hour period are recommended. Allow at least 20 minutes between shutdown and start-up of the motor.

Application – Three-Phase Motors

Inline Booster Pump Systems (continued)

9. Controls-Soft Starters and VFDs: Reduced voltage starters and variable speed drives (inverter drives) may be used with Franklin three-phase submersible motors to reduce starting current, upthrust, and mechanical stress during start-up. The guidelines for their use with submersible motors are different than with normal air cooled motor applications. Refer to the Franklin Electric Application, Installation and Maintenance (AIM) Manual Reduced Voltage Starters section or Variable Speed Submersible Pump Operation, Inverter Drives sections for speciﬁ c details including required ﬁ ltering.

10. Motor Overload Protection: Submersible motors require properly sized ambient compensated Class 10 quick-trip overloads per Franklin’s AIM Manual guidelines to protect the motor. Class 20 or higher overloads are NOT acceptable. Franklin’s SubMonitor is strongly recommended for all large submersibles since it is capable of sensing motor heat without any additional wiring to the motor. Applications using Soft Starters with a SubMonitor require a start-up bypass - consult the factory for details. SubMonitor can not be used in applications using a VFD control.

11. Motor Surge Protection: Properly sized, grounded and dedicated motor surge arrestors must be installed in the supply line of the booster module as close to the motor as possible. This is required on all systems including those using soft-starters and variable speed drives (inverter drives).

12. Wiring: Franklin’s lead assemblies are only sized for submerged operation in water to the motor nameplate maximum ambient temperature and may overheat and cause failure or serious injury if operated in air. Any wiring not submerged must meet applicable national and local wiring codes and

Franklin Cable Chart tables 16-21. (Notice: wire size, wire rating and insulation temperature rating must be known when determining its suitability to operate in air or conduit. Typically, for a given size and rating, as the insulation temperature rating increases its ability to operate in air or conduit also increases.)

13. Check Valves: Spring-loaded check valves must be used on start-up to minimize motor upthrusting, water hammer, or in multiple booster (parallel) applications to prevent reverse ﬂ ow.

14. Pressure Relief Valves: A pressure relief valve is required and must be selected to ensure that, as the pump approaches shut-off, it never reaches the point that the motor will not have adequate cooling ﬂ ow past it.

15. System Purge (Can Flooding): An air bleeder valve must be installed on the booster sleeve so that ﬂ ooding may be accomplished prior to booster startup. Once ﬂ ooding is complete, the booster should be started and brought up to operating pressure as quickly as possible to minimize the duration of an upthrust condition. At no time should air be allowed to gather in the booster sleeve because this will prevent proper cooling of the motor and permanently damage it.

16. System Flush – Must Not Spin Pump: Applications may utilize a low ﬂ ow ﬂ ushing operation. Flow through the booster sleeve must not spin the pump impellers and the motor shaft. If spinning takes place, the bearing system will be permanently damaged and the motor life shortened. Consult the booster pump manufacturer for maximum ﬂ ow rate through the pump when the motor is not energized.

Table 37 Franklin Cable chart (See 12. Wiring)

CABLE

TEMP.

RATING

(°C)

135

MOTOR NAME-

PLATE RATED

AMPS FULL

LOAD

3-LEAD (DOL)

6-LEAD (Y-∆)

3-LEAD (DOL)

6-LEAD (Y-∆)

3-LEAD (DOL)

6-LEAD (Y-∆)

#10 AWG #8 AWG #6 AWG #4 AWG #2 AWG

IN AIR

40A 28A 56A 40A 76A 52A 100A 68A 136A 92A

69A 48A 97A 69A 132A 90A 173A 118A 236A 19A

44A 32A 64A 44A 84A 60A 112A 76A 152A 104A

76A 55A 111A 76A 145A 104A 194A 132A 263A 180A

63A 46A 74A 51A 104A 74A 145A 98A 185A 126A

109A 80A 127A 88A 180A 129A 251A 320A 320A 219A

CONDUIT

IN AIR

CONDUIT

IN AIR

CONDUIT

Based on 30 °C maximum ambient with cable length of 100 feet or less.

IN AIR

CONDUIT

IN AIR

CONDUIT

SOURCE OF CABLE

AMPACITY

US N.E.C., 2002 edition, tables 310.16 & 310.17

Standard AAR (American Association of Railroads)

RP-585

Application – Three-Phase Motors

Inline Booster Pump Systems (continued)

17. Open Atmosphere Booster Pump Systems: When an open booster is placed in a lake, tank, etc. that is open to atmospheric pressure, the water level must provide sufﬁ cient head pressure to allow the pump to operate above its NPSHR requirement at all times and all seasons. Adequate inlet pressure must be provided prior to booster start-up.

Four Continuous Monitoring System Requirements for Sealed Booster Systems.

1. Water Temperature: Feed water on each booster must be continuously monitored and not allowed to exceed the motor nameplate maximum ambient temperature at any time. IF THE INLET TEMPERATURE EXCEEDS THE MOTOR NAMEPLATE MAXIMUM AMBIENT TEMPERATURE, THE SYSTEM MUST SHUTDOWN IMMEDIATELY TO PREVENT PERMANENT MOTOR DAMAGE. If feed water temperatures are expected to be above the allowable temperature, the motor must be derated. See Franklin’s AIM Manual Hot Water Applications section for derating guidelines. (The high temperature feed water derating is in addition to the exchange to DI water derating if the motor factory ﬁ ll solution was exchanged to DI water.)

2. Inlet Pressure: The inlet pressure on each booster module must be continuously monitored. It must always be positive and higher than the NPSHR (Net Positive Suction Head Requirement) of the pump. A minimum of 20 PSIG (1.38 Bar) is required at all times, except for 10 seconds or less when the motor is starting and the system is coming up to pressure.

Even during these 10 seconds the pressure must remain positive and be higher than the NPSHR (Net Positive Suction Head Requirement) of the pump.

PSIG is the actual value displayed on a pressure gauge in the system piping. PSIG is the pressure above the atmospheric conditions. If at any time these pressure requirements are not being met, the motor must be de-energized immediately to prevent permanent damage to the motor. Once the motor is damaged, it is usually not immediately noticeable, but progresses and results in a premature motor failure weeks or months after the damage occurred.

Motors that will be exposed to pressure in excess of 500 psi (34.47 Bar) must undergo special high pressure testing. Consult factory for details and availability.

3. Discharge Flow: The ﬂ ow rate for each pump must not be allowed to drop below the motor minimum cooling ﬂ ow requirement. IF THE MOTOR MINIMUM COOLING FLOW REQUIREMENT IS NOT BEING MET FOR MORE THAN 10 SECONDS, THE SYSTEM MUST BE SHUT DOWN IMMEDIATELY TO PREVENT PERMANENT MOTOR DAMAGE.

4. Discharge Pressure: The discharge pressure must be monitored to ensure that a downthrust load toward the motor is present within 3 seconds after start-up and continuously during operation. IF THE MOTOR DISCHARGE PRESSURE IS NOT ADEQUATE TO MEET THIS REQUIREMENT, THE SYSTEM MUST BE SHUT DOWN IMMEDIATELY TO PREVENT PERMANENT MOTOR DAMAGE.

Application – Three-Phase Motors

Variable Speed Submersible Pump Operation, Inverter Drives

Franklin three-phase submersible motors are operable from variable frequency inverter drives when applied within guidelines below. These guidelines are based on present Franklin information for inverter drives, lab tests and actual installations, and must be followed for warranty to apply. Franklin two-wire and three-wire single-phase submersible motors are not recommended for variable speed operation.

WARNING: There is a potential shock hazard from contact with insulated cables from a PWM drive to the motor. This hazard is due to high frequency voltage content of a PWM drive output.

Load Capability: Pump load should not exceed motor nameplate service factor amps at rated voltage and frequency.

Frequency Range: Continuous between 30 Hz and rated frequency (50 or 60 Hz). Operations above rated frequency require special considerations, consult factory for details.

Volts/Hz: Use motor nameplate volts and frequency for the drive base settings. Many drives have means to increase efﬁ ciency at reduced pump speeds by lowering motor voltage. This is the preferred operating mode.

Voltage Rise-time or dV/dt: Limit the peak voltage to the motor to 1000 V and keep the rise-time greater than 2 µsec. Alternately stated: keep dV/dt < 500 V/µsec. See Filters or Reactors below.

Motor Current Limits: Load no higher than motor nameplate service factor amps. For 50 Hz ratings, nameplate maximum amps are rated amps. See Overload Protection below.

Motor Overload Protection: Protection in the drive (or separately furnished) must be set to trip within 10 seconds at 5 times motor maximum nameplate amps in any line, and ultimately trip within 115% of nameplate maximum amps in any line.

Start and Stop: One second maximum ramp-up and ramp-down times between stopped and 30 Hz Stopping by coast-down is preferable.

Successive Starts: Allow 60 seconds before restarting.

Filters or Reactors: Required if all three of the following

conditions are met: (1) Voltage is 380 or greater and (2) Drive uses IGBT or BJT switches (rise-times < 2 µsec) and (3) Cable from drive to motor is more than 50 ft (15.2 m) A low-pass ﬁ lter is preferable. Filters or reactors should be selected in conjunction with the drive manufacturer and must be speciﬁ cally designed for VFD operation.

Cable Lengths: Per Franklin’s cable tables unless a reactor is used. If a long cable is used with a reactor, additional voltage drop will occur between the VFD and the motor. To compensate, set the VFD output voltage higher than the motor rating in proportion to the reactor impedance (102% voltage for 2% impedance, etc.).

Motor Cooling Flow: For installations that are variable-ﬂ ow, variable-pressure, minimum ﬂ ow rates must be maintained at nameplate frequency. In variableﬂ ow, constant pressure installations, minimum ﬂ ow rates must be maintained at the lowest ﬂ ow condition. Franklin’s minimum ﬂ ow requirements for 4" motors :

0.25 ft/s (7.26 cm/sec) and for 6" and 8" motors: 0.5 ft/s

(15.24 cm/sec)

Carrier Frequency: Applicable to PWM drives only. These drives often allow selection of the carrier frequency. Use a carrier frequency at the low end of the available range.

Miscellaneous: Franklin Electric three-phase motors are not declared “Inverter Duty” motors per NEMA MG1 standards. The reason is Part 31 of NEMA standard MG1 does not include a section covering encapsulated winding designs. However, Franklin submersible motors can be used with VFDs without problems and/or warranty concerns provided these guidelines are followed.

Subtrol-Plus and SubMonitor: Franklin’s Subtrol-Plus and SubMonitor protection systems ARE NOT USABLE on VFD installations.

Installation – All Motors

4” Super Stainless — Dimensions

(Standard Water Well)

1.48"

5/16 - 24 UNF-2A MOUNTING STUDS

0.161" MAX LEAD BOSS HEIGHT

0.030" R MAX

MAX

3.75" DIA.

0.50" MIN. FULL SPLINE

1.508"

1.498"

0.97"

0.79"

4” High Thrust — Dimensions

(Standard Water Well)

1.48" MAX

0.50" MIN. FULL SPLINE

1.508"

1.498"

1.09"

0.91"

5/16 - 24 UNF-2A MOUNTING STUDS

0.161" MAX LEAD

BOSS HEIGHT

0.030" R MAX

3.75" DIA.

6” — Dimensions

(Standard Water Well)

3.000"

15 TOOTH 16/32" DIAMETRAL PITCH

.94" MIN. FULL SPLINE

0.75"

1/2 - 20 UNF-2B

MOUNTING HOLES

2.997"

5.44" DIA.

1.0000"

0.9995"

0.250"

0.240"

CHECK VALVE

6.25"

DIA.

2.875"

2.869"

23 TOOTH 16/32" DIAMETRAL PITCH

SHAFT DIA

1.5000"

1.4990"

5.130"

1.06"

5.120"

0.94"

M8 x 1.25 6G GROUND SCREW

8” — Dimensions

(Standard Water Well)

1.69"

5.000"

4.997"

7.70" DIA MAX

MIN FULL SPLINE

0.240"

CHECK VALVE WATER WELL MODELS PIPE PLUG STAINLESS STEEL MODELS

7.00"

FINNED

23 TOOTH 16/32" DIAMETRAL PITCH

4.000"

3.990"

MOUNTING HOLES

CLEARANCE FOR

5/8" BOLTS

SHAFT DIA

1.5000"

1.4990"

1.06"

0.94"

M8 x 1.25 6G GROUND SCREW

5.130"

5.120"

5.000"

4.997"

7.70" DIA MAX

1.69" MIN FULL SPLINE

0.240"

CHECK VALVE

2.75"

FINNED

4.000"

3.990"

40 to 100 hp

125 to 200 hp

* Motor lengths and shipping weights are available on Franklin Electric’s web site (www.franklin-electric.com) or by calling Franklin’s submersible hotline (800-348-2420).

Installation – All Motors

Tightening Motor Lead Connector Jam Nut

4" Motors:

15 to 20 ft-lb (20 to 27 Nm)

6" Motors:

50 to 60 ft-lb (68 to 81 Nm)

8" Motors with 1-3/16” to 1-5/8” Jam Nut:

50 to 60 ft-lb (68 to 81 Nm)

8" Motors with 4 Screw Clamp Plate:

Apply increasing torque to the screws equally in a

criss-cross pattern until 80 to 90 in-lb (9.0 to 10.2 Nm) is reached.

Jam nut tightening torques recommended for ﬁ eld assembly are shown. Rubber compression set within the

Pump to Motor Coupling

Assemble coupling with non-toxic FDA approved waterproof grease such as Mobile FM102, Texaco CYGNUS2661, or approved equivalent. This prevents abrasives from entering the spline area and prolongs spline life.

Shaft Height and Free End Play

Table 41

MOTOR

8" TYPE 1

8" TYPE 2.1

NORMAL

SHAFT HEIGHT

1 1/2" 38.1 mm

2 7/8" 73.0 mm

4" 101.6 mm

DIMENSION

SHAFT HEIGHT

1.508"

1.498"

2.875"

2.869"

4.000"

3.990"

4.000"

3.990"

38.30

38.05

73.02

72.88

101.60

101.35

101.60

101.35

ﬁ rst few hours after assembly may reduce the jam nut torque. This is a normal condition which does not indicate reduced seal effectiveness. Retightening is not required, but is permissible and recommended if original torque was questionable.

A motor lead assembly should not be reused. A new lead assembly should be used whenever one is removed from the motor, because rubber set and possible damage from removal may prevent proper resealing of the old lead.

All motors returned for warranty consideration must have the lead returned with the motor.

FREE END PLAY

MIN MAX.

0.010"

0.25 mm

0.030"

0.76 mm

0.008"

0.20 mm

0.030"

0.76 mm

0.045"

1.14 mm

0.050"

1.27 mm

0.032"

0.81 mm

0.080"

2.03 mm

If the height, measured from the pump-mounting surface of the motor, is low and/or end play exceeds the limit, the motor thrust bearing is possibly damaged, and should be replaced.

Submersible Leads and Cables

A common question is why motor leads are smaller than speciﬁ ed in Franklin’s cable charts.

The leads are considered a part of the motor and actually are a connection between the large supply wire and the motor winding. The motor leads are short and there is virtually no voltage drop across the lead.

In addition, the lead assemblies operate under water, while at least part of the supply cable must operate in air. Lead assemblies running under water operate cooler.

CAUTION: Lead assemblies on submersible motors are suitable only for use in water and may overheat and cause failure if operated in air.

Maintenance – All Motors

System Troubleshooting

Motor Does Not Start

POSSIBLE CAUSE CHECKING PROCEDURES CORRECTIVE ACTION

A. No power or incorrect voltage.

B. Fuses blown or circuit breakers tripped.

C. Defective pressure switch.

D. Control box malfunction. For detailed procedure, see pages 46-54. Repair or replace.

E. Defective wiring.

F. Bound pump.

G. Defective cable or motor. For detailed procedure, see pages 44 & 45. Repair or replace.

Check voltage at line terminals. The voltage must be ± 10% of rated voltage.

Check fuses for recommended size and check for loose, dirty or corroded connections in fuse receptacle. Check for tripped circuit breakers.

Check voltage at contact points. Improper contact of switch points can cause voltage less than line voltage.

Check for loose or corroded connections or defective wiring

Check for misalignment between pump and motor or a sand bound pump. Amp readings will be 3 to 6 times higher than normal until the overload trips

Contact power company if voltage is incorrect.

Replace with proper fuse or reset circuit breakers.

Replace pressure switch or clean points.

Correct faulty wiring or connections.

Pull pump and correct problem. Run new installation until the water clears

Motor Starts Too Often

A. Pressure switch.

B. Check valve - stuck open.

C. Waterlogged tank. Check air charge Clean or replace.

D. Leak in system. Check system for leaks. Replace damaged pipes or repair leaks.

Check setting on pressure switch and examine for defects.

Damaged or defective check valve will not hold pressure.

Reset limit or replace switch.

Replace if defective.

Maintenance – All Motors

System Troubleshooting

Motor Runs Continuously

POSSIBLE CAUSE CHECKING PROCEDURES CORRECTIVE ACTION

A. Pressure switch.

B. Low water level in well.

C. Leak in system. Check system for leaks. Replace damaged pipes or repair leaks.

D. Worn pump.

E. Loose coupling or broken motor shaft. Check for loose coupling or damaged shaft. Replace worn or damaged parts.

F. Pump screen blocked. Check for clogged intake screen. Clean screen and reset pump depth.

G. Check valve stuck closed. Check operation of check valve. Replace if defective.

H. Control box malfunction. See pages 46-54 for single-phase. Repair or replace.

Check switch for welded contacts. Check switch adjustments.

Pump may exceed well capacity. Shut off pump, wait for well to recover. Check static and drawdown level from well head.

Symptoms of worn pump are similar to those of drop pipe leak or low water level in well. Reduce pressure switch setting, if pump shuts off worn parts may be the fault.

Clean contacts, replace switch, or adjust setting.

Throttle pump output or reset pump to lower level. Do not lower if sand may clog pump.

Pull pump and replace worn parts.

Motor Runs But Overload Protector Trips

A. Incorrect voltage.

B. Overheated protectors.

C. Defective control box. For detailed procedures, see pages 46-54. Repair or replace.

D. Defective motor or cable. For detailed procedures, see pages 44 & 45. Repair or replace.

E. Worn pump or motor. Check running current, see tables 13, 22, 24 & 26. Replace pump and/or motor.

Using voltmeter, check the line terminals. Voltage must be within ± 10% of rated voltage.

Direct sunlight or other heat source can raise control box temperature causing protectors to trip. The box must not be hot to touch.

Contact power company if voltage is incorrect.

Shade box, provide ventilation or move box away from source.

Maintenance – All Motors

Table 44 Preliminary Tests - All Sizes Single- and Three-Phase

“TEST” PROCEDURE WHAT IT MEANS

Insulation

Resistance

Winding

Resistance

1. Open master breaker and disconnect all leads from control box or pressure switch (QD type control, remove lid) to avoid electric shock hazard and damage to the meter.

2. Use a megohmmeter or set the scale lever to R X 100K on an Ohmmeter. Zero the meter.

3. Connect one meter lead to any one of the motor leads and the other lead to the metal drop pipe. If the drop pipe is plastic, connect the meter lead to ground.

1. Open master breaker and disconnect all leads from control box or pressure switch (QD type control, remove lid) to avoid electric shock hazard and damage to the meter.

2. Set the scale lever to R X 1 for values under 10 ohms. For values over 10 ohms, set the scale lever to R X 10. “Zero” the Ohmmeter.

3. On 3-wire motors measure the resistance of yellow to black (Main winding) and yellow to red (Start winding).

On 2-wire motors: measure the resistance from line-to-line.

Three-phase motors: measure the resistance line-to-line for all three combinations.

1. If the ohms value is normal (table 45), the motor is not grounded and the cable insulation is not damaged.

2. If the ohms value is below normal, either the windings are grounded or the cable insulation is damaged. Check the cable at the well seal as the insulation is sometimes damaged by being pinched.

1. If all ohms values are normal (tables 13, 22, 24 & 26), the motor windings are neither shorted nor open, and the cable colors are correct

2. If any one value is less than normal, the motor is shorted.

3. If any one ohm value is greater than normal, the winding or the cable is open, or there is a poor cable joint or connection.

4. If some ohms values are greater than normal and some less on single-phase motors, the leads are mixed. See page 46 to verify cable colors.

POWER

{

SUPPLY

POWER MUST BE SHUT OFF

ATTACH THIS LEAD

TO WELL CASING OR

DISCHARGE PIPE

RED

MEGGER

CONNECT THIS LEAD

TO GROUND

PUMP

{

POWER

{

SUPPLY

POWER MUST BE SHUT OFF

GROUND

L1 L2

GROUND

L1 L2

L2 R Y B

YELLOW

BLACK

YELLOW

RED

GROUND

OR OHMMETER

SET AT R X 100K

FIG. 13 FIG. 14

L2 R Y B

RED

YELLOW

BLACK

YELLOW

RED

GROUND

OHMMETER

SET AT R X 1

PUMP

{

Maintenance – All Motors

Insulation Resistance Readings

Table 45 Normal ohm and Megohm Values Between All Leads and Ground

CONDITION OF MOTOR AND LEADS OHMS VALUE MEGOHM VALUE

A new motor (without drop cable).

A used motor which can be reinstalled in well.

MOTOR IN WELL. READINGS ARE FOR DROP CABLE PLUS MOTOR.

New motor.

Motor in good condition.

Insulation damage, locate and repair.

Insulation resistance varies very little with rating. Motors of all hp, voltage, and phase rating have similar values of insulation resistance.

The table above is based on readings taken with a megohm meter with a 500 VDC output. Readings may vary using a lower voltage Ohmmeter, consult Franklin Electric if readings are in question.

Resistance of Drop Cable (ohms)

200,000,000 (or more)

10,000,000 (or more)

2,000,000 (or more)

500,000 - 2,000,000

Less than 500,000

200.0 (or more)

10.0 (or more)

2.0 (or more)

0.50 - 2.0

Less than .50

The values below are for copper conductors. If aluminum conductor drop cable is used, the resistance will be higher. To determine the actual resistance of the aluminum drop cable, divide the ohm readings from this chart by 0.61. This chart shows total resistance of cable from control to motor and back.

Winding Resistance Measuring

The winding resistance measured at the motor should fall within the values in tables 13, 22, 24 & 26. When measured through the drop cable, the resistance of the drop cable must be subtracted from the Ohmmeter readings to get the winding resistance of the motor. See table below.

Table 45A DC Resistance in ohms per 100 ft of Wire (Two conductors) @ 50 °F

AWG OR MCM WIRE SIZE (COPPER) 14 12 10 86432

OHMS

1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700

0.026 0.021 0.017 0.013 0.010 0.0088 0.0073 0.0063 0.0056 0.0044 0.0037 0.0032

0.544 0.338 0.214 0.135 0.082 0.052 0.041 0.032

Maintenance – Single-Phase Motors & Controls

Identiﬁ cation Of Cables When Color Code Is Unknown (Single-Phase 3-Wire Units)

If the colors on the individual drop cables cannot be found with an Ohmmeter, measure:

Cable 1 to Cable 2 Cable 2 to Cable 3 Cable 3 to Cable 1

Find the highest resistance reading.

The lead not used in the highest reading is the yellow lead.

Use the yellow lead and each of the other two leads to get two readings:

Highest is the red lead. Lowest is the black lead.

Single-Phase Control Boxes

Checking and Repairing Procedures (Power On)

WARNING: Power must be on for these tests. Do not touch any live parts.

A. VOLTAGE MEASUREMENTS

Step 1. Motor Off

1. Measure voltage at L1 and L2 of pressure switch or line contactor.

2. Voltage Reading: Should be ± 10% of motor rating.

Step 2. Motor Running

1. Measure voltage at load side of pressure switch or line contactor with pump running.

2. Voltage Reading: Should remain the same except for slight dip on starting. Excessive voltage drop can be caused by loose connections, bad contacts, ground faults, or inadequate power supply.

3. Relay chatter is caused by low voltage or ground faults.

EXAMPLE: The Ohmmeter readings were:

Cable 1 to Cable 2—6 ohms Cable 2 to Cable 3—2 ohms Cable 3 to Cable 1— 4 ohms

The lead not used in the highest reading (6 ohms) was Cable 3—Yellow

From the yellow lead, the highest reading (4 ohms) was To Cable 1—Red

From the yellow lead, the lowest reading (2 ohms) was To Cable 2—Black

B. CURRENT (AMP) MEASUREMENTS

1. Measure current on all motor leads.

2. Amp Reading: Current in red lead should momentarily be high, then drop within one second to values in table 13. This veriﬁ es relay or solid state relay operation. Current in black and yellow leads should not exceed values in table 13.

3. Relay or switch failures will cause red lead current to remain high and overload tripping.

4. Open run capacitor(s) will cause amps to be higher than normal in the black and yellow motor leads and lower than normal in the red motor lead.

5. A bound pump will cause locked rotor amps and overloading tripping.

6. Low amps may be caused by pump running at shutoff, worn pump, or stripped splines.

7. Failed start capacitor or open switch/relay are indicated if the red lead current is not momentarily high at starting.

CAUTION: The tests in this manual for components such as capacitors, relays, and QD switches should be regarded as indicative and not as conclusive. For example, a capacitor may test good (not open, not shorted) but may have lost some of its capacitance and may no longer be able to perform its function.

To verify proper operation of QD switches or relays, refer to operational test procedure described above in Section B-2.

Maintenance – Single-Phase Motors & Controls

Ohmmeter Tests

QD, Solid State Control Box (Power Off)

A. START CAPACITOR AND RUN CAPACITOR IF APPLICABLE (CRC)

1. Meter Setting: R x 1,000.

2. Connections: Capacitor terminals.

3. Correct meter reading: Pointer should swing toward zero, then back to inﬁ nity.

B. Q.D. (BLUE) RELAY

Step 1. Triac Test

1. Meter setting: R x 1,000.

2. Connections: Cap and B terminal.

3. Correct meter reading: Inﬁ nity for all models.

Step 2. Coil Test

1. Meter Setting: R x 1.

2. Connections: L1 and B.

3. Correct meter reading: Zero ohms for all models.

Ohmmeter Tests

Integral Horsepower Control Box (Power Off)

A. OVERLOADS (Push Reset Buttons to make sure contacts are closed.)

1. Meter Setting: R x 1.

2. Connections: Overload terminals.

3. Correct meter reading: Less than 0.5 ohms.

B. CAPACITOR (Disconnect leads from one side of each capacitor before checking.)

1. Meter Setting: R x 1,000.

2. Connections: Capacitor terminals.

3. Correct meter reading: Pointer should swing toward zero, then drift back to inﬁ nity, except for capacitors with resistors which will drift back to 15,000 ohms.

C. POTENTIAL (VOLTAGE) RELAY

Step 1. Coil Test

1. Meter setting: R x 1,000.

2. Connections: #2 & #5.

3. Correct meter readings: 4.5-7.0 (4,500 to 7,000 ohms) for all models.

C. POTENTIAL (VOLTAGE) RELAY

Step 1. Coil Test

1. Meter setting: R x 1,000.

2. Connections: #2 & #5.

3. Correct meter readings:

For 115 Volt Boxes:

0.7-1.8 (700 to 1,800 ohms).

For 230 Volt Boxes:

4.5-7.0 (4,500 to 7,000 ohms).

Step 2. Contact Test

1. Meter setting: R x 1.

2. Connections: #1 & #2.

3. Correct meter reading: Zero for all models.

Step 2. Contact Test

1. Meter Setting: R x 1.

2. Connections: #1 & #2.

3. Correct meter reading: Zero ohms for all models.

D. CONTACTOR

Step 1. Coil

1. Meter setting: R x 100

2. Connections: Coil terminals

3. Correct meter reading:

1.8-14.0 (180 to 1,400 ohms)

Step 2. Contacts

1. Meter Setting: R X 1

2. Connections: L1 & T1 or L2 & T2

3. Manually close contacts

4. Correct meter reading: Zero ohms

To verify proper operation of QD switches or relays, refer to operational test procedure described on page 46, Section B-2.

Maintenance – Single-Phase Motors & Controls

Table 48 QD Control Box Parts 60 Hz

HP VOLTS

115 280 102 4915 223 415 905 275 464 125 159-191 110

1/3

230 280 103 4915 223 415 901 275 464 126 43-53 220

115 280 104 4915 223 415 906 275 464 201 250-300 125

230 280 105 4915 223 415 902 275 464 105 59-71 220

1/2

230 282 405 5015 (CRC) 223 415 912 275 464 126 43-53 220 156 362 101 15 370

230 280 107 4915 223 415 903 275 464 118 86-103 220

3/4

230 282 407 5015 (CRC) 223 415 913 275 464 105 59-71 220 156 362 102 23 370

230 280 108 4915 223 415 904 275 464 113 105-126 220

230 282 408 5015 (CRC) 223 415 914 275 464 118 86-103 220 156 362 102 23 370

CONTROL BOX

MODEL NUMBER

QD (BLUE) RELAY

START

CAPACITOR

MFD VOLTS

RUN

CAPACITOR

MFD VOLTS

NOTE 1: Control boxes supplied with QD Relays are designed to operate on 230 volt systems. For 208 volt systems or where line voltage is between 200 volts and 210 volts use the next larger cable size, or use a boost transformer to raise the voltage.

NOTE 2: Voltage relays kits for 115 volts (305102901) and 230 volts (305102902) will replace current, voltage or QD Relays, and solid state switches.

Table 48B Overload Kits 60 Hz

HP VOLTS KIT (1)

1/3 115 305 100 901

1/3 230 305 100 902

1/2 115 305 100 903

1/2 230 305 100 904

3/4 230 305 100 905

1 230 305 100 906

(1) For Control Boxes with model numbers that end with 4915.

Table 48A QD Capacitor Replacement Kits

CAPACITOR NUMBER KIT

275 464 105 305 207 905

275 464 113 305 207 913

275 464 118 305 207 918

275 464 125 305 207 925

275 464 126 305 207 926

275 464 201 305 207 951

156 362 101 305 203 907

156 362 102 305 203 908

Table 48C QD Relay Replacement Kits

QD RELAY NUMBER KIT

223 415 901 305 101 901

223 415 902 305 101 902

223 415 903 305 101 903

223 415 904 305 101 904

223 415 905 305 101 905

223 415 906 305 101 906

223 415 912 (CRC) 305 105 901

223 415 913 (CRC) 305 105 902

223 415 914 (CRC) 305 105 903

Maintenance – Single-Phase Motors & Controls

Table 49 Integral Horsepower Control Box Parts 60 Hz

MOTOR

SIZE

4" & 6"

MOTOR

RATING HP

1 - 1.5

STANDARD

DELUXE

STANDARD

DELUXE

STANDARD

DELUXE

7.5

STANDARD

7.5

DELUXE

STANDARD

DELUXE

X-LARGE

CONTROL BOX (1)

MODEL NO.

282 300 8110

282 300 8610

282 301 8110

282 301 8310

282 302 8110

282 302 8310

282 113 8110

282 113 9310

282 201 9210

282 201 9310

282 202 9210

282 202 9230

282 202 9310

282 202 9330

282 203 9310

282 203 9330

282 203 9621

PART NO. (2) MFD. VOLTS QTY.

275 464 113 S 155 328 102 R

275 464 113 S 155 328 101 R

275 464 113 S 155 328 103 R

275 463 111 S 155 327 109 R

275 468 119 S 155 327 114 R

275 468 119 S 275 468 118 S 155 327 109 R

275 468 119 S

275468 120 S

155 327 102 R

275 463 120 S 275 468 118 S 275 468 119 S 155 327 102 R

275 468 119 S

275468 120 S

155 327 102 R

275 463 120 S 275 468 118 S 275 468 119 S 155 327 102 R

275 468 120 S 155 327 109 R

275 463 122 S 275 468 119 S 155 327 109 R

275 468 120 S 155 327 109 R

CAPACITORS

105-12610220

105-12615220

105-12620220

208-25045220

270-32440330

270-324 216-259

270-324 350-420

130-154 216-259 270-324

270-324 350-420

130-154 216-259 270-324

350-42045330

161-193 270-324

350-42045330

37011

37012

330 330 370

330 330 330 370

330 330 370

330 330 330 370

37023

330 330 370

37023

OVERLOAD (2)

PART NO.

275 411 107 155 031 102

None

(See Note 4)

275 411 117 S 275 411 113 M

275 411 118 S 275 411 115 M

275 411 119 S 275 406 102 M

275 411 102 S

275 406 122 M

275 411 102 S

275 406 121 M

275 406 103 S

155 409 101 M

275 406 103 S 1 1 2

155 409 101 M

275 406 103 S 1

155 409 101 M 2

275 406 103 S 1 1 2

155 409 101 M

275 406 103 S

155 409 102 M

275 406 103 S 2 3

155 409 102 M

275 406 103 S

155 409 102 M

RELAY (3)

PART NO.

155 031 102

155 031 102 155 325 102 L

155 031 102

155 031 102 155 325 102 L

155 031 601

155 031 601 155 326 101 L

155 031 601

155 031 601 155 326 102 L

155 031 601

155 031 601 155 326 102 L

155 031 601 155 429 101 L

155 031 601

2 required

CONTACTOR (2)

PART NO.

155 429 101 L

FOOTNOTES:

(1) Lightning arrestors 150 814 902 are suitable for all control boxes.

(2) S = Start, M = Main, L = Line, R = Run Deluxe = Control box with line contactor.

(3) For 208-volt systems or where line voltage is between 200 V and 210 V, a low voltage relay is required. On 3 hp

and smaller control boxes use relay part 155 031 103 in place of 155 031 102 and use the next larger cable size than speciﬁ ed in the 230 V table. On 5 hp and larger use relay 155 031 602 in place of 155 031 601 and next larger wire. Boost transformers per page 15 are an alternative to special relays and cable.

(4) Control box model 282 300 8610 is designed for use with motors having internal overload protectors. If used with a

1.5 hp motor manufactured prior to date code 06H18, Overload/Capacitor Kit 305 388 901 is required.

Maintenance – Single-Phase Motors & Controls

Table 50 Integral hp Capacitor Replacement Kits

CAPACITOR NUMBER KIT

275 463 122 305 206 912

275 463 111 305 206 911

275 463 120 305 206 920

275 464 113 305 207 913

275 468 117 305 208 917

275 468 118 305 208 918

275 468 119 305 208 919

275 468 120 305 208 920

155 327 101 305 203 901

155 327 102 305 203 902

155 327 109 305 203 909

155 327 114 305 203 914

155 328 101 305 204 901

155 328 102 305 204 902

155 328 103 305 204 903

Table 50A Integral hp Overload Replacement Kits

OVERLOAD NUMBER KIT

275 406 102 305 214 902

275 406 103 305 214 903

275 406 121 305 214 921

275 406 122 305 214 922

275 411 102 305 215 902

275 411 107 305 215 907

275 411 108 305 215 908

275 411 113 305 215 913

275 411 115 305 215 915

275 411 117 305 215 917

275 411 118 305 215 918

275 411 119 305 215 919

Table 50B Integral hp Voltage Relay Replacement Kits

RELAY NUMBER KIT

155 031 102 305 213 902

155 031 103 305 213 903

155 031 601 305 213 961

155 031 602 305 213 904

Table 50C Integral hp Contactor Replacement Kits

CONTACTOR KIT

155 325 102 305 226 901

155 326 101 305 347 903

155 326 102 305 347 902

155 429 101 305 347 901

Maintenance – Single-Phase Motors & Controls

Control Box Wiring Diagrams

GND

GREEN

B (MAIN) Y R (START) L2 L1

GND

GREEN

CAP

BL1

BLACK

(MOTOR LEADS) (LINE LEADS)

ORANGE

START

CAPACITOR

RED

B (MAIN) Y R (START) L2 L1

BLACK

(MOTOR LEADS) (LINE LEADS)

ORANGE

QD RELAY

YELLOW

CAP

BL1

RED

QD RELAY

BLUE

RED

YELLOW

CAPACITOR

BLUE

RUN

GREEN

CAPACITOR

BLUE

GND

1/3 - 1 hp QD RELAY

280 10_ 4915

Sixth digit depends on hp

GND

1/2 - 1 hp CRC QD RELAY

282 40_ 5015

Sixth digit depends on hp

RUN CAPACITOR

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER, AND OTHER CONTROL IF USED.

ORG

RELAY

GROUND LEAD

1 - 1.5 hp

282 300 8110

BLK

BLU

OVERLOAD

START CAPACITOR

BLK

RED

YEL

RED

YEL

BLK

RED

YEL

RED

BLK

YEL

BLK

GROUND LEAD

TO MOTOR

RUN CAPACITOR START CAPACITOR

BLK

ORG

YEL

RED

YEL

BLK

YEL

BLK

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER, AND OTHER CONTROL IF USED.

GROUND LEAD

RELAY

BLK

RED

BLK

RED

BLK

GROUND

MOTOR

LEAD

1 - 1.5 hp

282 300 8610

Maintenance – Single-Phase Motors & Controls

RUN CAPACITOR

GROUND LEAD

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER, AND OTHER CONTROL IF USED.

START CAPACITOR

BLK

RED

ORG

YEL

BLK

YEL

RED

BLK

YEL

BLK

START OVERLOAD

RELAY

BLU

MAIN OVERLOAD

2 hp STANDARD

282 301 8110

RED

BLK

GROUND LEAD

TO MOTOR

GROUND LEAD

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER

LINE

CONTACTOR

BLK

COIL

TO PRESSURE OR OTHER CONTRO L SWITCH

RUN CAPACITOR

BLK

YEL

BLK

MAIN OVERLOAD

2 hp DELUXE

282 301 8310

START CAPACITOR

BLK

RED

ORG

RELAY

YEL

BLU

YEL

RED

BLK

RED

BLK

START OVERLOAD

BLK

GROUND LEAD

TO MOTOR

RUN CAPACITOR

GROUND LEAD

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER, AND OTHER CONTROL IF USED.

3 hp STANDARD

BLK

ORG

RELAY

YEL

BLU

MAIN OVERLOAD

BLK

START OVERLOAD

282 302 8110

START CAPACITOR

RED

YEL

RED

BLK

YEL

RED

BLK

RED

BLK

GROUND LEAD

TO MOTOR

GROUND LEAD

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER

LINE

BLK

CONTACTOR

COIL

BLK

PRESSURE

OR OTHER

CONTRO L

SWITCH

RUN CAPACITOR

BLK

YEL

MAIN OVERLOAD

3 hp DELUXE

282 302 8310

ORG

RELAY

RED

START CAPACITOR

BLK

YEL

BLU

YEL

RED

BLK

RED

BLK

START OVERLOAD

BLK

GROUND LEAD

TO MOTOR

Maintenance – Single-Phase Motors & Controls

START CAPACITOR

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER, AND OTHER CONTROL IF USED.

BLK

GROUND LEAD

ORG

BLU

RELAY

BLK

MAIN OVERLOAD

5 hp STANDARD

282 113 8110

BLK

RED

YEL

START OVERLOAD

YEL

RED

BLK

RUN CAPACITOR

RED

BLK

GROUND LEAD

START CAPACITOR

RED

YEL

TO MOTOR

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER

GROUND LEAD

TO PRESSURE OR OTHER CONTRO L SWITCH

BLK

ORG

YEL

BLK

MAIN OVERLOAD

BLK

RELAY

COIL

BLK

LINE

CONTACTOR

BLU

RED

YEL

BLK

YEL

BLK

START OVERLOAD

RED

RUN CAPACITOR

RED

YEL

BLK

GROUND LEAD

TO MOTOR

5 hp DELUXE

282 113 8310 or 282 113 9310

START CAPACITOR

GROUND LEAD

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER, AND OTHER CONTROL IF USED.

ORG

BLK

ORG

RELAY

BLU

MAIN OVERLOAD

ARRESTOR

SURGE

YEL

BLK

RUN CAPACITOR

BLK

YEL

BLK

START OVERLOAD

7.5 hp STANDARD

282 201 9210

BLK

RED

START CAPACITOR

BLK

RED

YEL

RED

BLK

GROUND LEAD

TO MOTOR

START CAPACITOR

GROUND

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER

LEAD

START CAPACITOR

BLK

PRESSURE

OR OTHER

CONTROL

SWITCH

ORG

YEL

MAIN OVERLOAD

LINE

COIL

CONTACTOR

COIL

RELAY

SURGE

ARRESTOR

BLU

BLK

START OVERLOAD

7.5 hp DELUXE

282 201 9310

RUN CAPACITOR

BLK

RED

YEL

BLK

RED

YEL

BLK

RED

YEL

RED

BLK

GROUND

LEAD

MOTOR

Maintenance – Single-Phase Motors & Controls

START CAPACITOR

GROUND

LEAD

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER, AND OTHER CONTROL IF USED.

RED

YEL

RED

BLK

RED

START CAPACITOR

RUN CAPACITOR

RED

BLK

GROUND LEAD

BLK

YEL

BLK

TO MOTOR

START CAPACITOR

ORG

BLK

ORG

BLK

RED

RUN CAPACITOR

ORG

BLK

RELAY

ARRESTOR

BLK

MAIN

OVERLOAD

SURGE

YEL

BLK

RED

BLK

START

OVERLOAD

RED

BLK

GROUND LEAD

TO MOTOR

YEL

START CAPACITOR

GROUND LEAD

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER

BLK

TO PRESSURE OR OTHER CONTRO L SWITCH

ORG

BLK

ORG

YEL

BLK

RELAY

MAIN

OVERLOAD

COIL

LINE

CONTACTOR

YEL

BLK

SURGE

ARRESTOR

START

OVERLOAD

BLK

START CAPACITOR

GROUND

LEAD

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER

10 hp STANDARD

282 202 9210 or 282 202 9230

RUN CAPACITOR

TO PRESSURE OR OTHER CONTRO L SWITCH

ORG

BLK

YEL

MAIN

RED

COIL

BLK

L1 L2

RELAY

BLK

ORG

OVERLOAD

YEL

BLK

OVERLOAD

YEL

SURGE

ARRESTOR

START

BLK

RED

BLK

GROUND LEAD

BLK

YEL

BLK

TO MOTOR

282 202 9230 or 282 202 9330

RUN CAPACITOR

START CAPACITOR

SURGE

ARRESTOR

LEAD

GROUND

LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER

10 hp DELUXE

COIL

LINE CONTACTOR

COIL

TO PRESSURE OR OTHER CONTRO L SWITCH

OVERLOAD

MAIN

RELAY

TO MOTOR

GROUND LEAD

RELAY

START

OVERLOAD

15 hp DELUXE

282 203 9330 or 282 203 9330

15 hp X-LARGE

282 203 9621

Maintenance – Electronic Products

Pumptec-Plus

Pumptec-Plus is a pump/motor protection device designed to work on any 230 V single-phase induction motor (PSC, CSCR, CSIR, and split phase) ranging in size from 1/2 to 5 horsepower. Pumptec-Plus uses a micro-computer to continuously monitor motor power and line voltage to provide protection against dry well, water logged tank, high and low voltage and mud or sand clogging.

Pumptec-Plus – Troubleshooting During Installation

SYMPTOM POSSIBLE CAUSE SOLUTION

Unit Appears Dead

(No Lights)

Flashing Yellow Light

During Calibration

Flashing Red and

Yellow Lights

Flashing Red Light

No Power to Unit

Unit Needs to Be Calibrated

Miscalibrated

2-Wire Motor

Power Interruption

Float Switch

High Line Voltage

Unloaded Generator

Check wiring. Power supply voltage should be applied to L1 and L2 terminals of the Pumptec-Plus. In some installations the pressure switch or other control devices is wired to the input of the Pumptec-Plus. Make sure this switch is closed.

Pumptec-Plus is calibrated at the factory so that it will overload on most pump systems when the unit is ﬁ rst installed. This overload condition is a reminder that the PumptecPlus unit requires calibration before use. See step 7 of the installation instructions.

Pumptec-Plus should be calibrated on a full recovery well with the maximum water ﬂ ow. Flow restrictors are not recommended.

Step C of the calibration instructions indicate that a ﬂ ashing green light condition will occur 2 to 3 seconds after taking the SNAPSHOT of the motor load. On some two wire motors the yellow light will ﬂ ash instead of the green light. Press and release the reset button. The green should start ﬂ ashing.

During the installation of Pumptec-Plus power may be switched on and off several times. If power is cycled more than four times within a minute Pumptec-Plus will trip on rapid cycle. Press and release the reset button to restart the unit.

A bobbing ﬂ oat switch may cause the unit to detect a rapid cycle condition on any motor or an overload condition on two wire motors. Try to reduce water splashing or use a different switch.

The line voltage is over 253 volts. Check line voltage. Report high line voltage to the power company.

If you are using a generator the line voltage may become too high when the generator unloads. Pumptec-Plus will not allow the motor to turn on again until the line voltage returns to normal. Over voltage trips will also occur if line frequency drops too far below 60 Hz.

Solid Red Light

Low Line Voltage The line voltage is below 207 volts. Check line voltage.

Loose Connections Check for loose connections which may cause voltage drops.

If you are using a generator the line voltage may become too low when the generator

Loaded Generator

loads. Pumptec-Plus will trip on undervoltage if the generator voltage drops below 207 volts for more than 2.5 seconds. Undervoltage trips will also occur if the line frequency rises too far above 60 Hz.

Maintenance – Electronic Products

Pumptec-Plus

Pumptec-Plus - Troubleshooting After Installation

SYMPTOM POSSIBLE CAUSE SOLUTION

Solid Yellow Light

Yellow Flashing Light

Solid Red Light

Dry Well

Blocked Intake Clear or replace pump intake screen.

Blocked Discharge Remove blockage in plumbing.

Check Valve Stuck Replace check valve.

Broken Shaft Replace broken parts.

Severe Rapid Cycling

Worn Pump Replace worn pump parts and recalibrate.

Stalled Motor Repair or replace motor. Pump may be sand or mud locked.

Float Switch

Ground Fault Check insulation resistance on motor and control box cable.

Low Line Voltage

Loose Connections

Wait for the automatic restart timer to time out. During the time out period the well should recover and ﬁ ll with water. If the automatic reset timer is set to the manual position, then the reset button must be pressed to reactivate the unit.

Machine gun rapid cycling can cause an underload condition. See ﬂ ashing red and yellow lights section below.

A bobbing ﬂ oat switch can cause two-wire motors to stall. Arrange plumbing to avoid splashing water. Replace ﬂ oat switch.

The line voltage is below 207 volts. Pumptec-Plus will try to restart the motor every two minutes until line voltage is normal.

Check for excessive voltage drops in the system electrical connections (i.e. circuit breakers, fuse clips, pressure switch, and Pumptec-Plus L1 and L2 terminals). Repair connections.

Flashing Red Light

Flashing Red and

Yellow Lights

High Line Voltage

Rapid Cycle

Leaky Well System Replace damaged pipes or repair leaks.

Stuck Check Valve Failed valve will not hold pressure. Replace valve.

Float Switch

The line voltage is over 253 volts. Check line voltage. Report high line voltage to the power company.

The most common cause for the rapid cycle condition is a waterlogged tank. Check for a ruptured bladder in the water tank. Check the air volume control or snifter valve for proper operation. Check setting on the pressure switch and examine for defects.

Press and release the reset button to restart the unit. A bobbing ﬂ oat switch may cause the unit to detect a rapid cycle condition on any motor or an overload condition on 2-wire motors. Try to reduce water splashing or use a different switch.

Maintenance – Electronic Products

QD Pumptec and Pumptec

QD Pumptec and Pumptec are load sensing devices that monitor the load on submersible pumps/motors. If the load drops below a preset level for a minimum of 4 seconds the QD Pumptec or the Pumptec will shut off the motor.

The QD Pumptec is designed and calibrated expressly for use on Franklin Electric 230 V 3-wire motors (1/3 to 1 hp.) The QD Pumptec must be installed in QD relay boxes.

The Pumptec is designed for use on Franklin Electric 2- and 3-wire motors (1/3 to 1.5 hp) 115 and 230 V. The Pumptec is not designed for jet pumps.

QD Pumptec & Pumptec – Troubleshooting

SYMPTOM CHECKS OR SOLUTION

A. Is the voltage less than 90% of nameplate rating?

B. Are the pump and motor correctly matched?

If the QD Pumptec or Pumptec trips in about 4 seconds with some water delivery.

If the QD Pumptec or Pumptec trips in about 4 seconds with no water delivery.

C. Is the QD Pumptec or Pumptec wired correctly? For the Pumptec check the wiring

diagram and pay special attention to the positioning of the power lead (230 V or 115 V).

D. For QD Pumptec is your system 230 V 60 Hz or 220 V 50 Hz?

A. The pump may be airlocked. If there ia a check valve on top of the pump, put another

section of pipe between the pump and the check valve.

B. The pump may be out of water.

C. Check the valve settings. The pump may be dead-heading.

D. Pump or motor shaft may be broken.

E. Motor overload may be tripped. Check the motor current (amperage).

If the QD Pumptec or Pumptec will not timeout and reset.

If your pump/motor will not run at all.

If your QD Pumptec or Pumptec will not trip when the pump breaks suction.

If your QD Pumptec or Pumptec chatters when running.

A. Check switch position on side of circuit board on Pumptec. QD Pumptec check timer

position on top/front of unit. Make sure the switch is not between settings.

B. If the reset time switch is set to manual reset (position 0), QD Pumptec and Pumptec

will not reset (turn power off for 5 sec then back on to reset).

A. Check voltage.

B. Check wiring.

C. Remove the QD Pumptec from the control box. Reconnect wires in box to original

state. If motor does not run the problem is not QD Pumptec. Bypass Pumptec by connecting L2 and motor lead with jumper. Motor should run. If not, the problem is not Pumptec.

D. On Pumptec only check that Pumptec is installed between the control switch and

the motor.

A. Be sure you have a Franklin motor.

B. Check wiring connections. On Pumptec is lead power (230 V or 115 V) connected to

correct terminal? Is motor lead connected to correct terminal?

C. Check for ground fault in the motor and excessive friction in the pump.

D. The well may be “gulping” enough water to keep QD Pumptec or Pumptec from

tripping. It may be necessary to adjust the QD Pumptec or the Pumptec for these extreme applications. Call the Franklin Electric Service Hotline at 800-348-2420 for information.

E. On Pumptec applications does the control box have a run capacitor? If so, Pumptec

will not trip. (Except for Franklin 1.5 hp motors).

A. Check for low voltage.

B. Check for waterlogged tank. Rapid cycling for any reason can cause the QD Pumptec

or the Pumptec relay to chatter.

C. On Pumptec make sure the L2 and motor wires are installed correctly. If they are

reversed, the unit can chatter.

Maintenance – Electronic Products

SubDrive75, 150, 300, MonoDrive, & MonoDrive XT

The Franklin Electric SubDrive/MonoDrive Constant Pressure controller is a variable-speed drive that delivers water at a constant pressure.

WARNING: Serious or fatal electrical shock may result from failure to connect the motor, SubDrive/MonoDrive Controller, metal plumbing and all other metal near the motor or cable to the power supply ground terminal using wire no smaller than motor cable wires. To reduce the risk of electrical shock, disconnect power before working on or around the water system. Capacitors inside the SubDrive/MonoDrive Controller can still hold a lethal voltage even after power has been removed. Allow 10 minutes for dangerous internal voltage to discharge. Do not use motor in swimming areas.

SubDrive/MonoDrive Troubleshooting

Should an application or system problem occur, a built-in diagnostics will protect the system. The “FAULT” light on the front of the SubDrive/MonoDrive Controller will ﬂ ash a given number of times indicating the nature of the fault. In some cases, the system will shut itself off until corrective action is taken. Fault codes and their corrective actions are listed below. See SubDrive Installation Manual for installation data.

# OF

FLASHES

(MonoDrive Only)

FAULT

Air-locked pump.

Motor Underload

Undervoltage

Locked Pump

Incorrectly Wired Start winding resistance too low.

Open Circuit

Short Circuit

Over Current

Overpumped or dry well. Worn pump. Damaged shaft or coupling. Blocked pump or screen.

Low line voltage. Misconnected input leads.

Motor/pump misaligned. Abrasive/sand bound pump. Dragging pump or motor.

Loose connections. Defective motor or cable.

When fault is indicated immediately after power-up, short circuit due to loose connection, defective cable, splice or motor.

When fault is indicated while motor is running, over current due to loose debris trapped in pump.

POSSIBLE

CAUSE

CORRECTIVE ACTION

Wait for well to recover and automatic restart timer to time out. If the problem does not correct, check motor and pump. See description on “smart reset” at the end of the installation manual.

Check for loose connections. Check line voltage. Report low voltage to the power company. Unit will start automatically when proper power is supplied.

Unit will attempt to free a locked pump. If unsuccessful, check the motor and pump.

Check if main and start wires are swapped. Make certain proper motor is installed.

Check motor wiring. Make certain all connections are tight. Make certain proper motor is installed. *Cycle input power to reset.

Check motor wiring. *Cycle input power to reset.

Check pump.

Overheated

Controller

High ambient temperature. Direct sunlight. Obstruction of air ﬂ ow.

This fault automatically resets when temperature returns to a safe level.

* “Cycle input power” means turn the power off until both lights fade off and apply power again

Maintenance – Electronic Products

SubMonitor

SubMonitor Troubleshooting

FAULT MESSAGE PROBLEM/CONDITION POSSIBLE CAUSE

SF Amps Set Too High

Phase Reversal

Underload

Overload

Overheat

Unbalance

SF Amps setting above 359 Amps. Motor SF Amps not entered.

Reversed incoming voltage phase sequence. Incoming power problem.

Normal line current. Wrong SF Max Amps setting.

Over pumping well. Clogged pump intake.

Low line current.

Normal line current. Wrong SF Max Amps setting.

High line current.

Motor temperature sensor has detected excess motor temperature.

Current difference between any two legs exceeds programmed setting.

Closed valve. Loose pump impeller. Broken shaft or coupling. Phase loss.

High or low line voltage. Ground fault. Pump or motor dragging. Motor stalled or bound pump.

High or low line voltage. Motor is overloaded. Excessive current unbalance. Poor motor cooling. High water temperature. Excessive electrical noise (VFD in close proximity).

Phase loss. Unbalanced power supply. Open delta transformer.

Overvoltage

Undervoltage

False Starts

Line voltage exceeds programmed setting. Unstable power supply.

Line voltage below programmed setting.

Power has been interrupted too many times in a 10 second period.

Poor connection in motor power circuit. Unstable or weak power supply.

Chattering contacts. Loose connections in motor power circuit. Arcing contacts.

Maintenance – Electronic Products

Subtrol-Plus (Obsolete - See SubMonitor)

Subtrol-Plus - Troubleshooting After Installation

SYMPTOM POSSIBLE CAUSE OR SOLUTION

Subtrol-Plus Dead

Green Off Time

Light Flashes

Green Off Time

Light On

Overheat Light On

Overload Light On

Underload Light On

When the Subtrol-Plus reset button is depressed and released, all indicator lights should ﬂ ash. If line voltage is correct at the Subtrol-Plus L1, L2, L3 terminals and the reset button does not cause lights to ﬂ ash, Subtrol-Plus receiver is malfunctioning.

The green light will ﬂ ash and not allow operation unless both sensor coils are plugged into the receiver. If both are properly connected and it still ﬂ ashes, the sensor coil or the receiver is faulty. An Ohmmeter check between the two center terminals of each sensor coil connected should read less than 1 ohm, or coil is faulty. If both coils check good, receiver is faulty.

The green light is on and the Subtrol-Plus requires the speciﬁ ed off time before the pump can be restarted after having been turned off. If the green light is on except as described, the receiver is faulty. Note that a power interruption when the motor is running will initiate the delay function.

This is a normal protective function which turns off the pump when the motor reaches maximum safe temperatures. Check that amps are within the nameplate maximum on all three lines, and that the motor has proper water ﬂ ow past it. If overheat trip occurs without apparent motor overheating, it may be the result of an arcing connection somewhere in the circuit or extreme noise interference on the power lines. Check with the power company or Franklin Electric. A true motor overheat trip will require at least ﬁ ve minutes for a motor started cold. If trips do not conform to this characteristic, suspect arcing connections, power line noise, ground fault, or SCR variable speed control equipment.

This is a normal protective function, protecting against an overload or locked pump. Check the amps in all lines through a complete pumping cycle, and monitor whether low or unbalanced voltage may be causing high amps at particular times. If overload trip occurs without high amps, it may be caused by a faulty rating insert, receiver, or sensor coil. Recheck that the insert rating matches the motor. If it is correct, carefully remove it from the receiver by alternately lifting sides with a knife blade or thin screwdriver, and make sure it has no pins bent over. If the insert is correct and its pins are okay, replace receiver and/or sensor coils.

This is a normal protective function.

A. Make sure the rating insert is correct for the motor.

B. Adjusting the underload setting as described to allow the desired range of operating conditions. Note that a

DECREASE in underload setting is required to allow loading without trip.

C. Check for drop in amps and delivery just before trip, indicating pump breaking suction, and for unbalanced

line current.

D. With the power turned off, recheck motor lead resistance to ground. A grounded lead can cause underload trip.

Maintenance – Electronic Products

Subtrol-Plus (Obsolete - See SubMonitor)

Subtrol-Plus - Troubleshooting After Installation (Continued)

SYMPTOM POSSIBLE CAUSE OR SOLUTION

Whenever the pump is off as a result of Subtrol-Plus protective function, the red tripped light is on.

Tripped Light On

A steady light indicates the Subtrol-Plus will automatically allow the pump to restart as described, and a ﬂ ashing light indicates repeated trips, requiring manual reset before the pump can be restarted. Any other red light operation indicates a faulty receiver. One-half voltage on 460 V will cause tripped light on.

Control Circuit

Fuse Blows

Contactor Will

Not Close

Contactor Hums or Chatters

Contactor Opens When Start

Switch is Released

Contactor Closes But

Motor Doesn’t Run

Signal Circuit Terminals

Do Not Energize

With power turned off, check for a shorted contactor coil or a grounded control circuit lead. The coil resistance should be at least 10 ohms and the circuit resistance to panel frame over 1 megohm. A standard or delay-type 2 amp fuse should be used.

If proper voltage is at the control coil terminals when controls are operated to turn the pump on, but the contactor does not close, turn off power and replace the coil. If there is no voltage at the coil, trace the control circuit to determine if the fault is in the Subtrol-Plus receiver, fuse, wiring, or panel operating switches. This tracing can be done by ﬁ rst connecting a voltmeter at the coil terminals, and then moving the meter connections step by step along each circuit to the power source, to determine at which component the voltage is lost.

With the Subtrol-Plus receiver powered up, with all leads disconnected from the control terminals and with an Ohmmeter set at RX10, measure the resistance between the control terminals. It should measure 100 to 400 ohms. Depress and hold in the reset button. The resistance between the control terminals should measure close to inﬁ nity.

Check that coil voltage is within 10% of rated voltage. If voltage is correct and matches line voltage, turn off power and remove the contactor magnetic assembly and check for wear, corrosion, and dirt. If voltage is erratic or lower than line voltage, trace the control circuit for faults similar to the previous item, but looking for a major drop in voltage rather than its complete loss.

Check that the small interlocks switch on the side of the contactor closes when the contactor closes. If the switch or circuit is open, the contactor will not stay closed when the selector switch is in HAND position.

Turn off power. Check the contactor contacts for dirt, corrosion, and proper closing when the contactor is closed by hand.

With the Subtrol-Plus receiver powered up and all leads disconnected from the Signal terminals, with an Ohmmeter set at RX10, measure the resistance between the Signal terminals. Resistance should measure close to inﬁ nite. Depress and hold in the reset button. The resistance between the Signal terminals should measure 100 to 400 ohms.

Abbreviations

A Amp or amperage

AWG American Wire Gauge

BJT Bipolar Junction Transistor

°C Degree Celsius

CB Control Box

CRC Capacitor Run Control

DI Deionized

Dv/dt Rise Time of the Voltage

EFF Efﬁ ciency

°F Degree Fahrenheit

FDA Federal Drug Administration

FL Full Load

ft Foot

ft-lb Foot Pound

ft/s Feet per Second

GFCI Ground Fault Circuit Interrupter

gpm Gallon per Minute

HERO High Efﬁ ciency Reverse Osmosis

hp Horsepower

Hz Hertz

ID Inside Diameter

IGBT Insulated Gate Bipolar Transistor

in Inch

kVA Kilovolt Amp

kVAR Kilovolt Amp Rating

kW Kilowatt (1000 watts)

L1, L2, L3 Line One, Line Two, Line Three

lb-ft Pound Feet

L/min Liter per Minute

mA Milliamp

max Maximum

MCM Thousand Circular Mils

mm Millimeter

MOV Metal Oxide Varister

NEC National Electrical Code

NEMA National Electrical Manufacturer

Association

Nm Newton Meter

NPSH Net Positive Suction Head

OD Outside Diameter

OL Overload

PF Power Factor

psi Pounds per Square Inch

PWM Pulse Width Modulation

QD Quick Disconnect

R Resistance

RMA Return Material Authorization

RMS Root Mean Squared

rpm Revolutions per Minute

SF Service Factor

SFhp Service Factor Horsepower

S/N Serial Number

TDH Total Dynamic Head

UNF Fine Thread

V Voltage

VAC Voltage Alternating Current

VDC Voltage Direct Current

VFD Variable Frequency Drive

W Watts

XFMR Transformer

Y-D Wye-Delta

Ω ohms

Notes

M1311 03/07

TOLL FREE HELP FROM A FRIEND

800-348-2420 • 260-827-5102 (fax)

Phone Franklin’s toll free SERVICE HOTLINE for answers to your pump and motor installation questions. When you call, a Franklin expert will offer assistance in troubleshooting and provide immediate answers to your system application questions. Technical support is also available online. Visit our website at:

www.franklin-electric.com

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