Franklin Submersible Well Pump User Manual

4” and 6” SUBMERSIBLE PUMPS

OWNER'S MANUAL

All 4” models willl include either a built-in or external mounted check valve with the discharge head. 6” models do not include a check valve, and will need to be purchased separately. Example: Franklin Control Box for Franklin motors. Make certain that your available voltage corresponds to that of your motor.

READ AND FOLLOW SAFETY INSTRUCTIONS

This is the safety alert symbol. When you see

this symbol on your pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury:

BEFORE INSTALLING PUMP, BE SURE TO READ THIS OWNER’S MANUAL CAREFULLY.

CAUTION

or pump will be damaged. The motor on this pump is guaranteed by the manufacturer and in event of failure it must be returned to an authorized service station for repairs. Motor warranty is void if repairs aren’t made by an authorized repair station.

Fill pump with water before starting

INSPECT THE SHIPMENT

Examine the pump when it is received to be sure there has been no damage in shipping. Should any be evident, report it immediately to the dealer from whom the pump was purchased. Please check the pump package to see that it includes pump, motor, and motor leads (if your pump purchase includes a motor).

DANGER

serious personal injury, death or major property damage if ignored.

WARNING

serious personal injury, death or major property damage if ignored.

CAUTION

cause minor personal injury or major property damage if ignored.

The label NOTICE indicates special instructions, which are important but not related to hazards.

WARNING

Hazardous voltage. Can shock, burn, or cause death.

Ground pump before connecting to power supply. Disconnect power before working on pump, motor or tank.

Meet National Electrical Code, Canadian Electrical

Code, and local codes for all wiring.

Follow wiring instructions in this manual when

connecting motor to power lines.

warns about hazards that will cause

warns about hazards that can cause

warns about hazards that will or can

Carefully read and follow all safety instructions in this manual and on pump.

Keep safety labels in good condition.

Replace missing or damaged safety labels.

Wire motor for correct

voltage. See “Electrical” section of this manual and motor nameplate.

Ground motor before

connecting to power supply.

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 WITH 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. RETAIN THIS INFORMATION SHEET WITH THE EQUIPMENT FOR FUTURE REFERENCE.

WARNING

INSTALLATION RECORDS

It is good idea to keep an accurate record of your installation. Be sure to record the data below:

Purchased From: Date of Installation: Pump Model No.* Pump Date Code* Well Inside Dia.(in/mm): Depth of Well(ft/m): Depth of Water(ft/m): Pump Setting(ft/m): Drop Pipe Size: Wire Size(pump to control box): Wire Size(control box to power source): Horizontal Offset(between well & house):

Make of Motor*

Amps HP Volts Ph

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.

Make of Control Box

HP Volts

Power Supply

Volts HZ

Pressure Switch (PSI)

Cut-in Cut-out

* This Information is on your pump or motor tag. It will help us identify your pump in case of later inquiries.

TEST RUNNING

If test running pump before installation:

1. Insure that the power supply corresponds with that shown on the nameplate of the motor and control box. (if required).

2. Install pump and components appropriate for the test as shown in Fig. 1.

3. Make sure power supply is turned off and circuit breaker or disconnect switch is open. Make electrical connections appropriate to your motor as shown in Fig. 2, 3 or 4.

4. THREE PHASE UNIT - A three phase motor requires a magnetic starter equipped with quick-trip, ambient compensated heaters of correct size for the horsepower of the motor.

To insure correct rotation of three phase units, brace pump shell securely and apply power momentarily by snapping line switch quickly on and off. If rotation is correct, reaction of the shell will be clockwise when viewed from pump discharge (that is, pump shaft will rotate counter clockwise). Interchange any two leads at magnetic starter to reverse rotation.

5. Run pump and motor unit for a few seconds to ensure that it is in working order.

FIGURE 1 - Installation Diagram

Pressure Tank

Sanitary Well Seal or Pitless Adapter

Drop Pipe

Discharge Pipe

Submersible Cable

Spring-Loaded Check Valve (Recommended every 100’/30m)

Safety Cable

Cable (secured to drop pipe with tape or clamps every 10’/3m)

Torque Arrestor

Well Casing

Spring-Loaded Check Valve at Pump Discharge

Submersible Pump Unit

Suction Screen

Motor

Well Screen or Casing Perforations

See Wiring Diagrams

Spring-Loaded Check Valve

Pressure Relief Valve

Note: Keep pump at least 5’ from bottom of well and above well screen or casing perforations.

Pressure Gauge

Pressure Switch

Service Pipe

SUITABILITY OF WELL

Install the pump only in a well that has been properly developed. Water from an undeveloped well often contains an excessive amount of sand, dirt, and abrasives which can damage the pump. Check that the well is large enough to allow the pump to be set at the required depth. Don’t set the pump below the casing perforations or well screen unless you make arrangements to ensure an adequate ﬂ ow of water over the motor for cooling purposes. Determine the correct pump setting from the driller’s record by taking into account the static water level and the drawdown at the proposed pumping rate. Keep the pump at least ﬁ ve feet from the bottom of a drilled well.

Gate Valve

DROP PIPE

Galvanized pipe is recommended for suspending submersible pumps into the well. Plastic pipe may be used only when observing the plastic pipe manufacturer’s recommendations of depth and pressure. Give special consideration to:

1. A safety cable to prevent loss of pump if pipe should break.

2. Torque arrestor just above pump to prevent chaﬁ ng the cable when pump and pipe twist during the starting and stopping cycle. (See Figure 1)

Schedule 40 galvanized pipe is suitable for settings to 600 feet(180m). For deeper settings, use schedule 40 pipe for the bottom 600 feet(180m), and schedule 80 for the remainder.

Take great care to keep pipes clean and free from pebbles, scale and thread chips. Make sound, air-tight connections at all ﬁ ttings. Pipe sealant is recommended.

CHECK VALVES

Many pumps have a built-in or externally supplied check valve. For a pump without one, install a check valve immediately above the pump. Install an additional check valve above the ground. If the pump is more than 100 feet (30m) below the wellhead, install another check valve in the drop pipe 100 feet (30m) above it. For pump settings deeper than 200 feet (60m), install additional check valves at intervals of 100 feet (30m).

REMOVABLE POPPET CHECK VALVE

4” submersible pumps with a 1-1/4” discharge are supplied with a spring-loaded REMOVABLE poppet style check valve assembly. The check valve can be removed from the pump discharge when the pump is installed in applications where drain back is desired.

WARNING

can cause the pump to rotate backwards. If pump/ motor starts during this time; damage to the pump can occur.

The check valve can be removed with the use of the T-Handle Poppet Wrench(part no. 23498207). Ordered separately. Or, with standard needle nose pliers. The poppet assembly is left hand threaded and is removed by turning CLOCKWISE.

If reinstalling a Popppet Check Valve assembly, the assembly should be tightened to 15 inch-pounds.

Fluid draining back through the pump

SPLICING THE POWER CABLE

Follow the instructions enclosed in the cable splicing kit you purchase.

Poppet Assembly

T-Handle Poppet Wrench

INSTALLATION OF PUMP, DROP PIPE, AND ASSOCIATED EQUIPMENT

Fig. 1 illustrates a typical well installation showing in ground components. Adhere to the following items when installing the pump and drop pipe:

1. Fasten the submersible cable to the drop pipe with clamps or appropriate tape every 10 ft. (3m) to prevent tangling and damage to the cable. The cable must remain slack when using plastic drop pipe to allow for stretching of pipe when installed in the well.

2. Take care not to scrape or pinch the submersible cable against the well casing.

3. Use an ohmmeter or megger to make insulation and continuity checks on the cable once the pump is installed. This locates any fault in the cable.

4. Make sure a check valve is installed immediately above the pump. Install additional check valves at 100’ (30m) intervals.

5. Install a torque arrestor just above the pump to prevent chaﬁ ng the cable when pump anad pipe twist during starting and stopping.

6. Attach a safety cable to pump to prevent loss of pump if pipe should break.

7. Place a sanitary well seal or pitless adapter with an approved cover plate over top of well per manufacturers recommendations.

8. Keep pump at least 5’ (1.5m) from bottom of well and above well screen or casing perforations.

ELECTRICAL INFORMATION

1. Employ a licensed electrician to perform the wiring.

All wiring must be done in accordance with applicable national and local electrical codes.

2. Check that the power supply corresponds with the

electrical rating of the submersible motor and the control box(if required). Make sure that the control box electrical rating matches the motor electrical rating.

3. Every installation requires a fused disconnect switch

or circuit breaker.

4. Every installation must be grounded. There must be

a reliable ground connection between the pump and the distribution panel. The motor lead incorporates a green grounding conductor.

5. Lightning arrestors are recommended for every

installation. All stainless steel, single phase motors thru 5HP have built-in lightning arrestors. Any 6” motor or 4”, 3-phase motor requires a separate lightning arrestor installed as close to the wellhead as possible. Install the arrestor in accordance with manufacturers recommendations. A lightning arrestor provides protection against induced voltage surges on

secondary power lines; it is not effective against direct hits.

6. Mount the control box in an area protected from rain, snow, direct sunlight or other high temperatures as this may cause tripping of the overload protector. Also protect the control box from extreme cold (below

F/-32oC) as this may have adverse effects on

starting capacitor.

7. A two-wire pump does not require a motor control box, since all electrical components are built inside the motor. Fig. 2 shows a typical wiring diagram for a twowire installation.

FIGURE 2 - 2 WIRE, 1 Phase, 1/3 thru 1-1/2 HP Pump Wiring Diagram

Circuit Breaker or Fuse Disconnect Switch

Pressure Switch

Incoming 1 Phase Power

1 Phase Submersible Motor

Submersible Cable

8. A three-wire, single-phase pump requires a motor control box incorporating overload relays. Fig. 3 shows a typical wiring diagram for a three-wire, singlephase installation. Note that a magnetic contactor must be used if the pressure switch electrical rating is not sufﬁ cient to handle the submersible motor electrical rating. The pressure switch would then be incorporated into a pilot circuit to control the magnetic contactor. Make the connections at the control box in accordance with the wiring diagram in the control box to avoid damage to the motor.

FIGURE 3 - 3-WIRE, 1 Phase, 1/3 thru 15 HP Pump Wiring Diagram

Note: Order of red, yellow and black may

Pressure Switch (for pilot circuit) If Magnetic Contactor is used for starting.

Circuit Breaker or Fused Disconnect Switch

Incoming 1 Phase Power

Pressure Switch (for direct switching) OR Magnetic Contactor (w/ pilot circuit)

vary from control box to control box. Always connect like colors.

1 Phase Sumbersible Motor

L2 R

Red

Yellow

Black

Single Phase Control Box

9. A three-phase pump does not require a motor control box . Fig. 4 shows a typical wiring diagram for a 3wire, three-phase installation. A magnetic contractor with 3-leg protection having quick-trip ambient compensated overload relays must be used.

FIGURE 4 - 3-Wire, 3 Phase, 1-1/2 thru 50 HP Pump Wiring Diagram

Circuit Breaker OR Fused Disconnect Switch

Incoming 3 Phase Power

Pressure Switch

Magnetic Contactor w/ 3-leg protection having quick-trip ambient conpensated overload relays

3 Phase Submersible Motor

10. Use an ohmeter to make continuity and insulation

checks after the installation is completed.

11. Place the additional pump nameplate onto the

submersible label and place both onto disconnect switch or circuit breaker box for future reference.

WELL TEST

Check the pump and well performance before making

the ﬁ nal connection to the discharge system.

1. Install a gate valve on the end of the pipe. Partially open the valve.

2. Start the pump.

3. Open valve gradually to give full ﬂ ow.

4. If the discharge is not clear, let the pump run until water clears. If water does not clear in 30 minutes, stop the pump and take the necessary steps to correct the condition. After the water has appeared clear, check for sand by discharging into a clean bucket or suitable container.

5. Close valve until maximum required system ﬂ ow rate is obtained (this should correspond to the cutin pressure of the pressure switch). Ensure that the output of the pump at this setting is not greater than the yield of the well. This can be checked by monitoring the well drawdown level and ensuring tht the level is stable at the maximum required system ﬂ ow rate.

CAUTION

submerged in water. If run without water, the pump and motor could be damaged. Note also that air drawn into the pump can cause an airlock under certain conditions.

Never run pump unless it’s completely

LOW-YIELDING WELL

A low-yielding well exists when the output from the pump is greater than the yield of the well. It can reduce the water level to the suction screen so that a mixture of air and water enters the pump. Pumping may stop since the pump cannot generate pressure with insufﬁ cient water. In this case, the column of water already in the drop pipe holds the check valve closed and an airlock may develop inside the pump. Because the conditions ensure neither adequate lubrication of the pump nor proper cooling for the motor, damage can result if power is not cut off quickly. use one or more of the following methods to correct and/or protect this installation.

1. Install additional length of drop pipe to place pump lower in well if possible.

2. Install a Franklin Pumptec or similar electronic drawdown sensor.

3. Install a ﬂ oatless liquid level control. This device consists of an electrical relay activated by currents ﬂ owing through the ground-return circuits of electrodes hung in the well. The lower(STOP) electrode, just above the pump, ensures that the water level can never be pumped down to the suction screen. The upper(START) electrode, just below the lowest static water level, ensures that the pump can start again as soon as the well has recovered. A ﬂ oatless liquid level control works in series with the pressure switch. Refer to the manufacturers instructions provided with control.

4. Install a ﬂ ow control valve in the discharge line upstream from the pressure switch. This restricts the output from the pump without affecting the rate that water can be drawn from the pressure tank. Nevertheless, a heavy demand for water could empty the pressure tank, so a tank with a bonded diaphragm, air cell, or water bag is recommended.

5. Install a smaller pump to avoid over pumping the well. Have dealer size pump to the well yield.

6. Install a low-pressure cut-off switch. A low pressure cut off switch, or a pressure switch with such an arrangement built in, protects a shallow-well pump from losing its prime, but it does not always provide satisfactory protection to a submersible pump from the effects of over pumping the well. This is because it responds to a loss of pressure at the surface, which may occur after an air lock has formed inside the pump. We recommend either a ﬂ oatless liquid level control or a ﬂ ow control valve, in that order, in preference to a low-pressure cutoff switch as protection against over pumping.

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