GRUNDFOS INSTRUCTIONS
US Installation and operating instructions
SP4”
4-Inch Stainless Steel
Sub mers ible Pumps
Please leave these instructions with the pump for future reference.
WATER QUALITY
DRINKING WATER
SYSTEM COMPONENTS
ANSI/NSF 61
65 GM
30°C/86°F
PUMP END ONLY
SAFETY WARNING
WARNING: Reduced risk of electric shock during operation of this pump requires the
provision of acceptable grounding. If the means of connection to the supply connected
box is other than grounded metal conduit, ground the pump back to the service by
connecting a copper conductor (at least the size of the circuit supplying the pump) to the
grounding screw provided within the wiring compartment.
NOTICE: This product is designes for pumping water only. Third party agency
evalustions are based on pumping water only.
Pre-Installation Checklist
1. Well Preparation
If the pump is to be installed in a new well then the well should be fully developed and bailed
or blown free of cuttings and sand. The stainless steel construction of the GRUNDFOS
submersibles make it resistant to abrasion; however, no pump made of any material can
forever withstand the destructive wear that occurs when constantly pumping sandy water.
If this pump is used to replace an oil-filled submersible or oil-lubricated line-shaft turbine in
an existing well, the well must be blown or bailed clear of oil.
2. Make Sure You Have The Right Pump
Determine the maximum depth of the well, and the draw-down
level at the pump’s maximum capacity. Pump selection and
setting depth should be based on this data.
3. Pumped Fluid Requirements
CAUTION: Submersible well pumps are designed for pumping
clear, cold water; free of air or gases. Decreased pump
performance and life expectancy can occur if the water is not
cold, clear or contains air or gasses. Water temperature should
not exceed 102°F.
A check should be made to ensure that the installation depth of
the pump will always be at least three feet below the maximum
drawdown level of the well. The bottom of the motor should
never be installed lower than the top of the screen or within five
feet of the well bottom.
Ensure that the requirement for minimum flow past the motor is
met, as shown in the table below:
NOTES: For proper motor cooling, a flow inducer
or sleeve must be used if the water enters the
well above the motor or if there is insufficient
water flow past the motor. The minimum water
velocity past 4” motors is 0.25 feet per second.
Minimum Water Flow Requirements for
Submersible Pump Motors
MINIMUM CASING OR SLEEVE MIN. GPM FLOW
DIAMETER I.D. IN INCHES PASSING THE MOTOR
4-Inch 4 1.2
5 7
6 13
7 21
8 30
1
4. Splicing the Motor Cable
If the splice is carefully made, it will be as efficient as any other portion of the cable, and
will be completely watertight. There are a number of cable splicing kits available today –
epoxy filled, rubber-sealed and so on. Many perform well if the manufacturer’s directions
are followed carefully. If one of these kits is not used, we recommend the following
method for splicing the motor cable.
Examine the motor cable and drop cable carefully for damage. Cut the motor leads
off in a staggered manner. Cut the ends of the drop cable so that the ends match up
with the motor leads. Be sure to match the colors. Strip back and trim off one-half inch
of insulation from each lead, making sure to scrape the wire bare to obtain a good
connection. Be careful not to damage the copper conductor when stripping off the
insulation. Insert a properly sized Sta-kon-type connector on each pair of leads, again
making sure that colors are matched. Using Sta-kon crimping pliers, indent the lugs. Be
sure to squeeze down hard on the pliers, particularly when using large cable. Form a
piece of electrical insulation putty tightly around each Sta-Kon. The putty should overlap
on the insulation of the wire. Use a good quality tape such as #33 Scotch Waterproof
or Plymouth Rubber Company Slipknot Grey. Wrap each wire and joint tightly for a
distance of about 2-1/2 inches on each side of the joint. Make a minimum of four passes
over each joint and overlap each pass approximately one inch to assure a completely
watertight seal.
INSTALLATION PROCEDURES
1. Attach the Pump to the Motor
When attaching the pump to the motor we recommend the pump be bolted down in a
cross pattern around the four bolts. Starting from the back (opposite the cable opening)
and using a cross pattern, tighten the motor bolts to 13.5 ft-lbs, using progressive
tightening until torque is met. (See figure 1 for example).
PRE-INSTALLATION CHECKLIST
2
1
3
2
4
cable opening
Figure 1
INSTALLATION PROCEDURES
2. Attach the Pump to the Pipe
A back-up wrench should be used when riser pipe is attached to the pump. The pump
should only be gripped by the flats on the top of the discharge chamber. Under no
circumstances grip the body of the pump, cable guard or motor. When tightened down,
the threaded end of the first section of the riser pipe or the nipple must not come in
contact with the check valve retainer in the discharge chamber of the pump. After the
first section of the riser pipe has been attached to the pump, the lifting cable or elevator
should be clamped to the pipe. Do not clamp the pump. When raising the pump and
riser section, be careful not to place bending stress on the pump by picking it up by
the pump-end only. It is recommended that plastic-type riser pipe be used only with the
smaller domestic submersibles. The manufacturer or representative should be contacted
to ensure the pipe type and physical characteristics are suitable for this use. Use the
correct joint compound recommended by the specific pipe manufacturer. Besides making
sure that points are fastened, we recommend the use of a torque arrestor when using
plastic pipe.
3. Lower the Pump Into the Well
Make sure the electrical cables are not cut or damaged in any way when the pump is
being lowered in the well. Do not use the power cables to support the weight of the pump.
To protect against surface water entering the well and contaminating the water source,
the well should be finished off above grade utilizing a locally approved well seal or
pitless adaptor unit. We recommend that steel riser pipes always be used with the larger
submersibles. A pipe thread compound should be used on all joints. Make sure that the
joints are adequately tightened in order to resist the tendency of the motor to loosen the
joints when stopping and starting.
The drop cable should be secured to the riser pipe at approximately every 10 ft/3 m to
prevent sagging, looping and possible cable damage. Nylon cable clips or waterproof tape
may be used. The cable splice should be protected by securing it with clips or tape just
above each joint.
Figure 2 Figure 3
Check Valves: A check valve should always be installed at the surface of the well and one
at a maximum of 25 feet above static water level. In addition, for installations deeper than
200 feet, check valves should be installed at no more than 200 foot intervals.
IMPORTANT: Plastic pipe tends to stretch
under load. This stretching must be taken
into account when securing the cable to the
riser pipe. Leave three to four inches of slack
between clips or taped points. This tendency
for plastic pipe to stretch will also affect the
calculation of the pump setting depth. As a
general rule, you can estimate that plastic
pipe will stretch to approximately 2% of its
length. When plastic riser pipe is used, it is
recommended that a safety cable be attached
to the pump to lower and raise it. The
discharge chamber of GRUNDFOS 4-inch
submersibles is designed to accommodate
this cable. (See Figures 2 & 3.)
3
4. Electrical Connections
WARNING: Reduced risk of electric shock during operation of this pump requires
the provision of acceptable grounding. If the means of connection to the supply
connected box is other than grounded metal conduit, ground the pump back to the
service by connecting a copper conductor (at least the size of the circuit supplying
the pump) to the grounding screw provided within the wiring compartment.
Verification of the electrical supply should be made to ensure the voltage, phase and
frequency match that of the motor. Motor electrical data can be found on page 6. If
voltage variations are larger than ± 10%, do not operate the pump. Single-phase motor
control boxes should be connected as shown on the wiring diagram mounted on the
inside cover of the control box supplied with the motor. The type of wire used between
the pump control boxes should be approved for submersible pump application. The
conductor insulation should be type RW, RUW, TW or equivalent.
A high-voltage surge arrestor should be used to protect the motor against lightning and
switching surges. Lightning voltage surges in power lines are caused when lightning
strikes somewhere in the area. Switching surges are caused by the opening and closing
of switches on the main high-voltage distribution power lines.
The correct voltage-rated surge arrestor should be installed on the supply (line) side
of the control box or starter (See Figure 4a & 4b). The arrestor must be grounded in
accordance with the National Electric Code and local governing regulations.
PUMPS SHOULD NEVER BE STARTED UNLESS THE PUMP IS TOTALLY
SUBMERGED. SEVERE DAMAGE MAY BE CAUSED TO THE PUMP AND MOTOR IF
THEY ARE RUN DRY.
The control box shall be permanently grounded in accordance with the National
Electric Code and local governing codes or regulations. The ground wire should be a
bare stranded copper conductor at least the same size as the drop cable wire size.
Ground wire should be as short a distance as possible and securely fastened to a true
grounding point. True grounding points are considered to be: a grounding rod driven into
the water strata; steel well casing submerged into the water lower than the pump setting
level; and steel discharge pipes without insulating couplings. If plastic discharge pipe and
well casing are used, a properly sized bare copper wire should be connected to a stud
on the motor and run to the control panel. Do not ground to a gas supply line. Connect
the grounding wire to the ground point first, then to the terminal in the control box.
Figure 4a Figure 4b
Single Phase Hookup Three Phase Hookup
INSTALLATION PROCEDURES
4
Single-Phase 2-Wire Wiring Diagram
for Submersible Motors
Three-Phase Wiring Diagram
for Submersible Motors
4. Starting the Pump for the First Time
A. Attach a temporary horizontal length of pipe to the riser pipe.
B. Install a gate valve and another short length of pipe to the temporary pipe.
C. Adjust the gate valve one-third of the way open.
D. Verify that the electrical connections are in accordance with the wiring diagram.
E. After proper rotation has been checked, start the pump and let it operate until the
water runs clear of sand, silt and other impurities.
F. Slowly open the valve in small increments as the water clears until the valve is all
the way open. The pump should not be stopped until the water runs clear.
G. If the water is clean and clear when the pump is first started, the valve should still
be opened until it is all the way open.
Single-Phase 3-Wire Control Box
for Submersible Motors
INSTALLATION PROCEDURES
5
MOTOR INFORMATION
6
Grundfos motors specifications
1- Phase motors
3-Phase motors
HP Ph Volt
Service
factor
Amperage Full load
Max.
thrust
(lbs)
KVA
code
Nameplate
no.
SF Start Eff. (%) Pwr fact.
4-inch, single pha se, 2- wire motors ( contro l box not required)
1/3 1 230 1.75 4.6 25.7 59 77 900 S 79952101
1/2 1 115 1.60 12.0 55 62 76 900 R 79922102
1/2 1 230 1.60 6.0 34.5 62 76 900 R 79952102
3/4 1 230 1.50 8.4 40.5 62 75 900 N 79952103
1 1 230 1.40 9.8 48.4 63 82 9 00 M 79952104
1 1/2 1 230 1.30 13.1 62 64 85 900 L 7995210 5
4-inch, sing le phase, 3-wire mot ors
1/3 1 115 1.75 9.0 2 9 59 77 900 M 79423101
1/3 1 230 1.75 4.6 1 4 59 77 900 L 79453101
1/2 1 115 1.60 12.0 42.5 61 76 900 L 79423102
1/2 1 230 1.60 6.0 21.5 62 76 900 L 79453102
3/4 1 230 1.50 8.4 31.4 62 75 900 L 79453103
1 1 230 1.40 9.8 37 63 82 900 K 79453104
1.5 1 230 1.30 11.6 45.9 69 89 900 H 79453 105
2 1 230 1.25 13.2 57 72 86 1500 G 79454506
3 1 230 1.15 17.0 77 74 93 1500 F 79454507
5 1 230 1.15 27.5 110 77 92 1500 F 794545
09
HP Ph Volt
Service
factor
Amperage Full load
Max.
thrust
(lbs)
KVA
code
Nameplate
no.
SF Sta rt. Eff. (%) Pwr fact.
4-inch, three phas e, 3-w ire motors
1 1/2 3
3
3
3
230 1.30 7.3 40.3 75 72 900 K 79302005
460 1.30 3.7 20.1 75 72 900 K 79362005
575 1.30 2.9 16.1 75 72 900 K 79392005
3
230 1.25 8.7 4 8 76 75 900 J 79302006
460 1.25 4.4 2 4 76 75 900 J 79362006
575 1.25 3.5 19.2 76 75 900 J 79392006
3
230 1.15 12.2 56 77 75 900 H 79302006
460 1.15 6.1 2 8 77 75 900 H 793 62007
575 1.15 4.8 2 2 77 75 900 H 793 95507
5
208/230 1.15 18.6/17.4 108 80 82 1500 H 79304509
440/460 1.15 8.65/8.65 54 80 82 1500 H 79354509
575 1.15 7.9 5 4 80 82 1500 H 79394509
7 1/2
208/230 1.15 27.0/25.0 130 81 82 1500 H 79305511
440/460 1.15 12.8/12.6 67 81 82 1500 J 79355511
575 1.15 10.6 53 81 82 1500 J 79395511
10 3
3
440/460 1.15 18.0/18.6 90 81 80 1500 H 79355512
575 1.15 14.4 72 81 80 1500 H 7 93955
12
Line-t o-Line
resista nce ( )
Blk-Yel Red-Yel
6.8-8.2
1.1-1.3
5.2-6.3
3.2-3.8
2.5-3.1
1.9-2.3
1.55-1.9 2.4 -3
6.8-8.3 17.3-21.1
0.9-1.1 1.9-2.35
4.7-5.7 15.8-19.6
3.2-3.9 14-17. 2
2.6-3.1 10.3-12.5
1.9-2.3 7.8-9.6
1.5-1.8 3.4-4.1
1.2-1.4 2.45 -3
0.65-0.85 2.1-
2.6
Line-t o-Line
resista nce ( )
Blk-Yel Red- Yel
3.9
15.9
25.2
3.0
12.1
18.8
2.2
9.0
13.0
1.2
5.0
7.3
0.84
3.24
5.2
1.16
1.
84
HP
1/3
1/3
1/2
1/2
3/4
1
1.5
2
3
5
MS402B
MS402B
MS402B
MS402B
MS402B
MS402B
MS402B
MS4000
MS4000
MS4000
SA-SPM5
SA-SPM5
SA-SPM5
SA-SPM5
SA-SPM5
SA-SPM5
SA-SPM5
SA-SPM5
SA-SPM5
SA-SPM5
GRUNDFOS
MOTOR MODEL
GRUNDFOS
CONTROL BOX
GRUNDFOS
STANDARD #’s
GRUNDFOS
RUN CAP/DELUXE #’s
RATING
GRUNDFOS Control Box SA-SPM5
VOLT
115
230
115
230
230
230
230
230
230
230
91126150
91126151
91126152
91126153
91126154
91126155
91126212
91126214
91126216
91126218
–
–
–
–
–
91126211
91126213
91126215
91126217
91126219
*All Grundfos 4” motors have a ground (green wire)
The key to long submersible motor life is good cooling. Most submersible pumps rely
on moving heat away from the motor by forced convection. The ambient/produced
fluid is typically drawn by the motor in the course of pumping to accomplish this task.
Submersible motors used in the water supply industry are typically designed to operate
at full load in water up to 30°C (86°F), provided the flow velocity can be maintained at a
minimum of 0.5 feet per second (fps).
Required Cooling Flow and Velocity
AWWA specifications state the maximum motor diameter and the minimum inside
diameter of the well shall be in such relationship that under any operating condition the
water velocity past the motor shall not exceed 12 fps (3.7 m/s) nor be less than 0.5 fps
(0.15 m/s). The AWWA specification are principally applicable to motors 6-inch and larger,
as most 4-inch motor designs are based on a minimum cooling flow velocity of 0.25 fps
(0.08 m/s) at rated ambient temperature. Table 8 relates flow, casing and motor size
requirements to accomplish minimum cooling velocity.
Table 8: Minimum Submersible Cooling Flow Requirements
Casing/Sleeve 4” Motor 6” Motor
I.D. (inches) (0.25 fps) (0.5 fps)
4 1.2 –
5 7.0 –
6 13 9
7 20 25
8 30 45
10 50 90
12 80 140
14 110 200
16 150 280
18 – 380
Notes: 1. Minor irregularities associated with motor shape and diameter variations
between manufactures are not accounted for in the table.
2. At the velocity specified in the table the temperature differential between
the motor surface and ambient water will range from 5° - 15°C (10-30°F).
MOTOR INFORMATION
(gpm)
Some submersible motor manufactures require no cooling fluid flow past the motor,
when the produced fluid temperature is 20°C (68°F) or less. Cooling by free convection
in such cases, is only permitted in the vertical position and is contingent on no adverse
operating conditions present such as; poor power, high stop/start frequency, presence
of incrustating deposits on the motor surface, etc. Detramental operating conditions are
difficult to identify or predict, and for this reason, the minimum cooling flow should be
provided whenever possible - regardless of the ambient fluid temperature.
7
MOTOR INFORMATION
Typical Motor Jacket/Shroud Configurations.
The motor shroud is generally of the next nominal diameter of standard pipe larger than
the motor or the pump, depending on the shroud configuration used. The tubular/pipe
material can be plastic or thin walled steel (corrosion resistant materials preferred). The
cap/top must accommodate power cable without damage and provide a snug fit, so that
only a very small amount of fluid can be pulled through the top of the shroud. The fit
should not be completely water tight as ventilation is often required to allow escape of the
air or gas that might accumulate. The shroud body should be stabilized to prevent rotation
and maintain the motor centered within the shroud. The shroud length should extend to a
length of 1-2 times the shroud diameter beyond the bottom of the motor when possible.
Shrouds are typically attached immediately above the pump intake or at the pump/column
correction.
A typical motor sleeve/shroud selection example is sited below and illustrated in Figure 8:
If a well feeds water from above the pump, has a casing/chamber too small to allow a
motor jacket/sleeve on the pump, and does not have adequate level and flow to allow
raising the pump above the inflow, it is difficult to properly cool the motor. When possible,
the casing depth should be increased to allow flow to come from below the motor. If this is
not practical, adequate flow past the motor can usually be attained by employing a motor
jacket with a stringer pipe or by using a jet tube.
Figure 8: Typical Motor Jacket Installation Scenarios
Pump
Top of Sleeve
Closed and
Clamped or
Bolted to Pump
Above Intake
Flow Inducer
Sleeve
Spacers at 3 or
4 Points Around
the Inside of
the Sleeve are
Recommended to Hold
Motor Centered and Avoid
Loosening Top During Installation
Pump Intake
Motor
All Water Flows
Past Motor
Casing
Fluid Entry
Pump
Jacket
Motor
Typical Flow Inducer Sleeve Cutaway View
8
Single-Phase 60 Hz
MOTOR RATING COPPER WIRE SIZE (AWG)
VOLTS HP 14 12 10 8 6 4 2 0 00
115 1/3 130 210 340 540 840 1300 1960 2910
1/2 100 160 250 390 620 960 1460 2160
230 1/3 550 880 1390 2190 3400 5250 7960
1/2 400 650 1020 1610 2510 3880 5880
3/4 300 480 760 1200 1870 2890 4370 6470
1 250 400 630 990 1540 2380 3610 5360 6520
1-1/2 190 310 480 770 1200 1870 2850 4280 5240
2 150 250 390 620 970 1530 2360 3620 4480
3 120 190 300 470 750 1190 1850 2890 3610
5 180 280 450 710 1110 1740 2170
Three-Phase 60 Hz
MOTOR RATIN COPPER WIRE SIZE (AWG)
VOLTS HP 14 12 10 8 6 4 2
208 1-1/2 310 500 790 1260
2 240 390 610 970 1520
3 180 290 470 740 1160 1810
5170 280 4690 1080 1660
230 1-1/2 360 580 920 1450
2 280 450 700 1110 1740
3 210 340 540 860 1340 2080
5 200 320 510 800 1240 1900
460 1-1/2 1700
2 1300 2070
3 1000 1600 2520
5 590 950 1500 2360
575 1-1/2 2620
2 2030
3 1580 2530
5 920 1480 2330
FOOTNOTES:
1. If aluminum conductor is used, multiply lengths by 0.5. Maximum allowable length of aluminum is
considerably shorter than copper wire of same size.
2. The portion of the total cable which is between the service entrance and a 3Ø motor starter should not
exceed 25% of the total maximum length to ensure reliable starter operation. Single-phase control boxes
may be connected at any point of the total cable length.
3. Cables #14 to #0000 are AWG sizes, and 250 to 300 are MCM sizes.
MOTOR INFORMATION
9
How to Measure
By means of a voltmeter, which
has been set to the proper scale,
measure the voltage at the control
box or starter. On single-phase units,
measure between line and neutral.
What it Means
When the motor is under load, the
voltage should be within ± 10% of the
nameplate voltage. Larger voltage
variation may cause winding damage.
Large variations in the voltage indicate
a poor electrical supply and the pump
should not be operated until these
variations have been corrected.
If the voltage constantly remains high or
low, the motor should be changed to the
correct supply voltage.
CURRENT
MEASUREMENT
How to Measure
By use of an ammeter, set on the
proper scale, measure the current on
each power lead at the control box.
See page 6, for motor amp draw
information.
Current should be measured when
the pump is operating at a constant
discharge pressure with the motor
fully loaded.
What it Means
If the amp draw exceeds the listed
service factor amps (SFA), check for the
following:
1. Loose terminals in control box or
possible cable defect. Check winding
and insulation resistances.
2. Too high or low supply voltage.
3. Motor windings are shorted.
4. Pump is damaged causing a motor
overload.
WINDING
RESISTANCE
How to Measure
Turn off power and disconnect the
drop cable leads in the control box.
Using an ohmmeter, set the scale
selectors to Rx1 for values under
10 ohms and Rx10 for values over
10 ohms.
Zero-adjust the meter and measure
the resistance between leads.
Record the values. Motor resistance
values can be found on page 6.
What it Means
If all the ohm values are normal, and
the cable colors correct, the windings
are not damaged. If any one ohm value
is less than normal, the motor may be
shorted. If any one ohm value is greater
than normal, there is a poor cable
connection or joint. The windings or
cable may also be open.
If some of the ohm values are greater
than normal and some less, the drop
cable leads are mixed. To verify lead
colors, see resistance values on page 6.
INSULATION
RESISTANCE
How to Measure
Turn off power and disconnect the
drop cable leads in the control box.
Using an ohm or mega ohmmeter,
set the scale selector to Rx 100K
and zero-adjust the meter. Measure
the resistance between the lead
and ground (discharge pipe or well
casing, if steel).
What it Means
For ohm values, refer to table below.
Motors of all Hp, voltage, phase and
cycle duties have the same value of
insulation resistance.
SUPPLY
VOLTAGE
OHM VALUE MEGAOHM VALUE CONDITION OF MOTOR AND LEADS
Motor not yet installed:
2,000,000 (or more) 2.0 New Motor.
1,000,000 (or more) 1.0 Used motor which can be reinstalled in the well.
Motor in well (Ohm readings are for drop cable plus motor):
500,000 - 1,000,000 0.5 - 1.0 A motor in reasonably good condition.
20,000 - 500,000 0.02 - 0.5 A motor which may have been damaged by lightning or with damaged
leads. Do not pull the pump for this reason.
10,000 - 20,000 0.01 - 0.02 A motor which definitely has been damaged or with damaged cable.
The pump should be pulled and repairs made to the cable or the motor
replaced. The motor will still operate, but probably not for long.
less than 10,000 0 - 0.01 A motor which has failed or with completely destroyed cable insulation.
The pump must be pulled and the cable repaired or the motor replaced.
The motor will not run in this condition.
TROUBLESHOOTING
10
Pump Won’t Start
No power at the motor
If there is no voltage at the control panel,
check the feeder panel for tripped circuits and
reset those circuits.
Fuses are blown or the
circuit breakers have
tripped
Turn off the power and remove the fuses.
Check for continuity with an ohmmeter.
Replace the blown fuses or reset the circuit
breaker. If the new fuses blow or the circuit
breaker trips, the electrical installation, motor,
and wires must be check for defects.
(3-phase motors only)
Motor starter overloads
are burned or have tripped
Check for voltage on the line and load side
of the starter. Check the amp draw and
make sure the heater is sized correctly.
Replace any burned heaters or reset. Inspect
the starter for other damage. If the heater trips
again, check the supply voltage. Ensure that
heaters are sized correctly and the trip setting
is appropriately adjusted.
(3-phase motors only)
Starter does not energize
Energize the control circuit and check for
voltage at the holding coil.
Defective controls
Replace worn or defective parts or controls.
Motor or cable is defective
If an open or grounded winding is found,
remove the motor from the well and recheck
the measurements with the lead separated
from the motor. Repair or replace the motor
or cable.
(1-phase motors only)
Defective capacitor
Turn off the power and discharge the capacitor
by shorting the leads together. Check it with
an analog ohmmeter (set to R x 100k).
When the meter is connected to the capacitor,
the needle should jump toward 0 (zero) ohms
and slowly drift back to infinity (Ą). Replace
capacitor if it is defective.
Defective pressure switch
or the tubing to it is
plugged
Watch the pressure gauges as the pressure
switch operates. Remove the tubing and blow
through it.
Replace as necessary.
The pump is mechanically
bound or stuck
Turn off the power and manually rotate the
pump shaft. Also check the motor shaft rotation, the shaft height, and the motor’s amp
draw (to see if it indicates a locked rotor).
If the pump shaft doesn’t rotate, remove the
pump and examine it. If necessary, dismantle
it and check the impellers and seal for
obstruction. Check for motor corrosion.
POSSIBLE CAUSE CHECK THIS BY... CORRECT THIS BY...
Check for voltage at the control box or panel.
Turn off the power and disconnect the motor
leads from the control box. Measure the leadto-lead resistance with an ohmmeter (set to R
x 1). Measure the lead-to-ground values with
an ohmmeter (set to R x 100K).
Check all safety and pressure switches for
defects. Inspect the contacts in control devices.
If there is no voltage, check the control circuit
fuses. If there is voltage, check the holding coil
for weak connections. Ensure that the holding
coil is designed to operate with the available
control voltage. Replace the coil if defects are
found.
POSSIBLE CAUSE CHECK THIS BY... CORRECT THIS BY...
(3-phase motors only)
Shaft is turning in the
wrong direction
Correct the wiring. For single phase motors,
check the wiring diagram on the motor. For three
phase motors, simply switch any two power
leads.
Pump is operating at the
wrong speed (too slow)
Check for low voltage and phase
imbalance.
Replace defective parts or contact power
company, as applicable.
Check valve is stuck (or
installed backwards)
Remove the check valve. Re-install or replace.
Parts or fittings in the
pump are worn
– or –
Impellers or Inlet Strainer
is clogged
Install a pressure gauge near the
discharge port, start the pump, and
gradually close the discharge valve.
Read the pressure at shutoff. (Do
not allow the pump to operate for
an extended period at shutoff.)
The water level in the well
may be too low to supply
the flow desired
– or –
Collapsed well
Check the drawdown in the well
while the pump is operating.
Pull pump and inspect. Replace as necessary.
There are leaks in the
fittings or piping
Pull the pump out of the well. The suction pipe, valves, and fittings must be
made tight. Repair any leaks and retighten all
loose fittings.
Pump Does Not Produce Enough Flow (GPM)
Broken shaft or coupling
Check to make sure the electrical
connections in the control panel are
correct.
If the pumping water level (including drawdown)
is not AT LEAST 3 FEET above the pump’s inlet
strainer, either:
1. Lower the pump further down the well.
2. Throttle back the discharge valve to decrease
the flow, thereby reuding drawdown.
Convert the PSI you read on the gauge to Feet
of Head by:
PSI x 2.31 ft/PSI = ______ ft.
Specific Gravity
Add to this number the number of feet
(vertically) from the gauge down to the water’s
pumping level.
Refer to the pump curve for the model you are
working with to determine the shutoff head you
should expect for that model. If that head is
close to the figure you came up with (above),
the pump is probably OK. If not, remove the
pump and inspect impellers, chambers, etc.
11
TROUBLESHOOTING
POSSIBLE CAUSE CHECK THIS BY... CORRECT THIS BY...
Improper voltage
Check the voltage at the control box or
panel.
If the voltage varies by more than 10% (+ or
-), contact the power company.
If the incoming voltage is OK, check the
wire size and the distance between the
pump motor and the pump control panel.
Rewire with correct gauge. Undersized
wire and a great distance between the
control panel and the pump motor increases
resistance and decreases the voltage by the
time it reaches the pump motor.
The starter overloads are
set too low
Cycle the pump and measure the
amperage.
Increase the heater size or adjust the
trip setting. Do not, however, exceed the
recommended rating.
Fuses Blow or Heaters Trip
(3-phase motors only)
The three-phase current is
imbalanced
Check the current draw on each lead to
the motor.
The current draw on each lead must be
within 5% of each other (+ or -). If they are
not, check the wiring.
The wiring or connections
are faulty
Check to make sure the wiring is correct
and there are no loose terminals.
Tighten any loose terminals and replace any
damaged wire.
(1-phase motors only)
Capacitor is defective
Turn off the power and discharge the
capacitor. Check the capacitor with an
ohmmeter (set at R x 100k). See page 15
for instructions.
When the meter is connected to the
capacitor, the needle should jump toward
0 (zero) ohms and then slowly drift back to
infinity (¥). Replace capacitor if it is defective.
Fuse, heater, or starter are
the wrong size
Check the fuses and heaters against the
motor manufacturer’s specification charts.
Replace as necessary.
The control box location
is too hot
Touch the box with your bare hand during
the hottest part of the day – you should be
able to keep your hand on it without burning.
Shade, ventilate, or move the control box so
its environment does not exceed 120°F.
(1-phase motors only)
Wrong control box
Check requirements for the motor against
the control box specifications.
Replace as necessary.
The motor is shorted or
grounded.
Turn off the power and disconnect the
wiring. Measure the lead-to-lead resistance
with an ohmmeter (set to R x 1). Measure
the lead-to-ground values with an ohmmeter
(set to R x 100K) or a megaohmmeter.
Compare these measurements to the rated
values for your motor.
If you find an open or grounded winding,
remove the motor and recheck the leads. If
OK, check the leads for continuity and for
bad splice.
Defective pressure switch
Watch gauges as pressure switch
operates.
Replace as necessary.
Poor motor cooling
Find the internal diameter of the well
casing (or sleeve, if used).
For proper cooling, the flow of water
must not be less than the GPM shown
across the bottom scale on page __.
Throttle up the pump flow (GPM) so proper
cooling is possible.
– or –
Pull the pump out of the well and add a
sleeve with a smaller internal diameter.
Pump Cycles Too Often
The pressure switch is
defective or is not properly
adjusted
Check the pressure setting on the switch.
Check the voltage across closed contacts.
Readjust the pressure switch or
replace it if defective.
The tank is too small
Check the tank size and amount of air
in the tank. The tank volume should be
approximately 10 gallons for each GallonPer-Minute of pump capacity. At the pump
cut-in pressure, the tank should be about
2/3 filled with air.
Replace the tank with one that is the
correct size.
There is insufficient air
charging of the tank or
piping is leaking
Pump air into the tank or diaphragm chamber.
Check the diaphragm for leaks. Check the
tank and piping for leaks with soapy water.
Check the air-to-water ratio in the tank.
Repair as necessary.
Plugged snifter valve or bleed
orifice (causing pressure tank
to be waterlogged)
Examine them for dirt or erosion. Repair or replace as necessary.
Leak in the pressure tank
or piping
Apply soapy water to pipes and tank, then
watch for bubbles, indicating leaks.
Repair or replace as necessary.
The level control is defective
or is not properly set
Check the setting and operation of the
level control.
Readjust the level control setting
(according to the manufacturer’s
instructions) or replace it if defective.
Pump is oversized for the
application. It is outpumping
the yield of the well and
pumping itself dry.
Check the yield of the well (determined
by the well-test) against the pump’s
performance curve.
Reduce the flow by throttling back
the valve.
– or –
Change the pump.
POSSIBLE CAUSE CHECK THIS BY... CORRECT THIS BY...
TROUBLESHOOTING
12
13
LIMITED WARRANTY
Products manufactured by GRUNDFOS are war rant ed to the original user only to be free of
defects in material and workmanship for a period of 24 months from date of installation, but
not more than 30 months from date of manufacture. GRUNDFOS’ liability under this warranty
shall be limited to repairing or replacing at GRUNDFOS’ option, without charge, F.O.B.
GRUNDFOS’ factory or authorized service sta tion, any prod uct of GRUNDFOS’ man u fac ture.
GRUNDFOS will not be liable for any costs of removal, in stal la tion, transportation, or any
other charges which may arise in connection with a war ran ty claim. Products which are
sold but not man u fac tured by GRUNDFOS are subject to the warranty provided by the
manufacturer of said products and not by GRUNDFOS’ war ran ty. GRUNDFOS will not be
liable for damage or wear to products caused by abnormal operating con di tions, accident,
abuse, misuse, unauthorized alteration or repair, or if the product was not installed in
accordance with GRUNDFOS printed installation and operating in struc tions.
To obtain service under this warranty, the defective product must be re turned to the
distributor or dealer of GRUNDFOS products from which it was pur chased together with
proof of purchase and installation date, failure date, and supporting installation data. Unless
otherwise provided, the distributor or deal er will contact GRUNDFOS or an au tho rized
service station for in struc tions. Any defective product to be returned to GRUNDFOS or a
service station must be sent freight prepaid; documentation supporting the warranty claim
and/or a Return Material Authorization must be included if so instructed.
MANUFACTURER WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CON SE QUEN TIAL
DAMAGES, LOSS ES, OR EXPENSES ARISING FROM IN STAL LA TION, USE, OR ANY
OTHER CAUSES. THERE ARE NO EXPRESS OR IMPLIED WARRANTIES, IN CLUD ING
MERCHANTABILITY OR FIT NESS FOR A PAR TIC U LAR PURPOSE, WHICH EXTEND
BEYOND THOSE WAR RAN TIES DESCRIBED OR REFERRED TO ABOVE. EXCEPT AS
EXPRESSLY HEREIN PROVIDED THE GOODS ARE SOLD “AS IS”, THE ENTIRE RISK
AS TO QUALITY AND FITNESS FOR A PARTICULAR PURPOSE, AND PERFORMANCE
OF THE GOODS IS WITH THE BUYER, AND SHOULD THE GOODS PROVE DEFECTIVE
FOLLOWING THEIR PURCHASE, THE BUYER AND NOT THE MANUFACTURER,
DISTRIBUTOR, OR RETAILER ASSUMES THE ENTIRE RISK OF ALL NECESSARY
SERVICING OR REPAIR.
Some jurisdictions do not allow the exclusion or limitation of implied warranties of
merchantability and fitness for a particular purpose, of incidental or con se quen tial damages
and some jurisdictions do not allow limitations on how long implied warranties may last or
require you to pay certain expenses as set forth above. Therefore, the above limitations or
exclusions may not apply to you. This warranty gives you specific legal rights and you may
also have other rights which vary from jurisdiction to jurisdiction.
L-SP-TL-048 Rev. 3/09(US)
U.S.A.
Grundfos Pumps Corporation
17100 W. 118th Terrace
Olathe, KS 66061
Telephone (913) 227-3400
Fax: (913) 227-3500
Canada
Grundfos Canada, Inc.
2941 Brighton Road
Oakville, Ontario L6H 6C9, Canada
Telephone: (905) 829-9533
Fax: (905) 829-9512
Mexico
Bombas Grundfos de Mexico, S.A. de C.V.
Boulevard TLC No. 15
Parque Industrial Stiva Aeropuerto
Apodaca, N.L. Mexico
C.P. 66600 Apodaca, N.L. Mexico
Telephone: 011-52-81-8144-4000
Fax: 011-52-81-8144-4010
Being responsible is our foundation
Thinking ahead makes it possible
Innovation is the essence
www.grundfos.com
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