Sta-Rite DDRA2P Installation Manual

1. GENERAL SAFETY GUIDELINES

2. NOMENCLATURE

2.1 Motors

2.2 Drives

2.3 Submersible Motor Controls

3. INSTALLATION AND SETUP

3.1 General Installation Guidelines

3.2 Proper Grounding

3.3 Corrosive Water and Ground

3.4 Check Valves

3.5 Start Up

4. ELECTRICAL POWER

4.1 Mixing Wire Size

4.2 Wire Splicing

4.3 Three-Phase Starters

4.4 Checking Motor Rotation

4.5 Three-Phase Current Balancing

4.6 Transformer Sizing

4.7 Using a Generator

4.8 Special Applications

5. XE-SERIES 4" SUBMERSIBLE MOTORS – 60 HZ

5.1 Motor Inspection

5.2 Testing

5.3 Storage and Transportation

5.4 4” Motor Specifications

5.5 4” Motor Dimensions

5.6 4” Motor Fuse Sizing

5.7 Cable Lengths

5.8 4” Motor Overload Protection

5.9 Motor Cooling

5.10 Starting Frequency

6. VARIABLE FREQUENCY DRIVES PID-1, PID-6 INTELLIDRIVE SERIES

6.1 General Safety

6.2 Description

6.3 Installation

6.4 Initial Startup Programming Procedure

6.5 Advanced Programming

6.6 I/O Connections

6.7 Troubleshooting

6.8 Wire Sizing, Repair Parts, Specifications

7. VARIABLE FREQUENCY DRIVES – PPC20

7.1 How Drives Work

7.2 How the PPC20 Drive Works

7.3 PPC20 Specifications

7.4 PPC20 Mounting and Installation

7.5 Wiring Connections

7.6 Start-up Operation

7.7 LED Fault Codes

7.8 PPC20 Replacement Parts

8. VARIABLE FREQUENCY DRIVES – 50/60 HZ; PPC3, PPC5 SERIES

8.1 PENTEK PPC3 and PPC5 Drives

8.2 PPC3 Specifications

8.3 PPC5 Specifications

8.4 Wiring Conections

8.5 Transducer Connection

8.6 PENTEK Assistant

8.7 Timer Function

8.8 Helpful Hints

8.9 PPC3 and PPC5 Tank Sizing

8.10 Reactors and Filters

9. SUBMERSIBLE MOTOR CONTROLS – 50/60 HZ

9.1 How It Works

9.2 Specifications

9.3 Mounting and Installation

9.4 Wiring Connections and Replacement Parts

10. MOTOR PROTECTION DEVICES – 50/60 HZ

10.1 How They Work

10.2 Specifications

10.3 Mounting and Installation

10.4 Wiring Connections

PN793 (Rev. 11/09)

Table of Contents 1

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Table of Contents 2

SECTION 1: General Safety Guidelines

11. TROUBLESHOOTING

11.1 System Troubleshooting

11.2 Motor Troubleshooting

11.3 Variable Speed Drive Troubleshooting

11.4 Motor Protection Troubleshooting

11.5 Submersible Controls Troubleshooting

12. APPENDIX

12.1 Installation Checklist

12.2 Choosing a Pump System

12.3 Sizing Submersible Pump, Motor, and Tanks

12.4 How to Select the Correct Pumping Equipment

12.5 Sizing Tanks

12.6 Record of Installation

PN793

READ AND FOLLOW SAFETY INSTRUCTIONS!

This is the safety alert symbol. When you see this

symbol on your pump or in this manual, be alert to the potential for personal injury.

warns about hazards that will cause serious

personal injury, death or major property damage if ignored.

warns about hazards that can cause serious

personal injury, death or major property damage if ignored.

warns about hazards that will or can cause

minor personal injury or property damage if ignored.

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

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.

Fatal Electrical Shock Hazard.

• Ground motor, controls, all metal pipe and accessories connected to the motor, to the power supply ground terminal. Ground wire must be at least as large as motor supply cables.

• Disconnect power before working on the system.

• Do not use the motor in a swimming area.

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

Ground pump before connecting to power supply.

All work must be done by a

trained and qualified installer

or service technician.

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SECTION 2: Nomenclature 3

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2.1 MOTORS

TABLE 2-1: Motor Nomenclature

Nomenclature

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Sample:

P43B0010A2 is a PENTEK 4" Stainless Steel Motor 1 HP, 60 Hz., 230 V, 1 PH

NAME PLATE EXAMPLE:

BRAND

P = PENTEK

MOTOR SIZE

42 = 4 Inch, 2-Wire 43 = 4 Inch, 3-Wire

MOTOR MATERIAL

B = All Stainless Steel

HORSEPOWER

0005 = 0.5 HP 0007 = 0.75 HP 0010 = 1 HP 0015 = 1.5 HP 0020 = 2 HP 0030 = 3 HP 0050 = 5 HP 0075 = 7.5 HP

P43B 001 A

0 2

FREQUENCY

A = 60 Hz. B = 50 Hz. C = 50/60 Hz.

VOLTAGE

1 = 115V, 1 PH 2 = 230V, 1 PH 3 = 230V, 3 PH 4 = 460V, 3 PH 5 = 575

V, 3 PH

8 = 200V, 3 PH

SECTION 2: Nomenclature 4

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2.2 DRIVES

2.2.1 Variable / High Speed Drive Nomenclature

The chart below shows the naming for a PPC5, 460 volt, 4 amp drive with a NEMA 1 enclosure.

Note that the output current (amps) of the control must be greater than or equal to the maximum rated motor current. Output of all drives is 3-phase power.

2.2.2 PID Variable frequency drive Nomenclature

2.3 SUBMERSIBLE MOTOR

CONTROLS

The chart below shows the naming for a Submersible Motor control, Standard box, capacitor run, 10 horse power, 230 volt single phase drive.

Series Input Voltage Output Amp Rating Enclosure

PPC5 2 (230 V, 3 ph.) 4A1 1 (NEMA 1) PPC3 4 (460 V), 3 ph.) 4 (NEMA 4) 5 (575 V), 3 ph.) 12 (NEMA 12) 1 (230 V, 1 ph.) 3 (NEMA3R)

PPC5-4-4A1-1

4A1 = 4.1 amps (Amps A tenths)

SMC

Voltage Rating:

1 = 190–265 Volt 1-Phase In, 3-Phase Out 6 = 190–265 Volt 1-Phase In, 1-Phase Out

PID – 1 – 10A1 – 1

PID-1- 10A1-1:

Product Family

PID = Pentek IntelliDrive

Max Amp Rating:

4A7 = 4.7 Amps 7A6 = 7.6 Amps 9A7 = 9.7 Amps 10A1 = 10.1 Amps 12A2 = 12.2 Amps

Enclosure Type:

1 = NEMA 1 (Indoor Rated) 3 = NEMA 3R (Outdoor Rated)

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- CR 100 2 1

Series

SMC_(Std.) SMC5 (50 Hz)

Style

CR (Cap Run) IR (Induction Run) CRP (Cap Run

with contactor)

HP x 10

05 (0.5 hp) 07 (.75 hp) 10 (1 hp) 15 (1.5 hp) 20 (2 hp) 30 (3 hp) 50 (5 hp) 75 (7.5 hp) 100 (10 hp) 150 (15 hp)

Voltage

1 (115 v) 2 (230 v)

Phase 1 (Single)

3.1 GENERAL INSTALLATION

GUIDELINES

• In order to avoid abrasion to the power and control

cables, pad the top of the well casing (a rubber pad is recommended) where the cable will pass over it; use a cable reel for cable control.

• The unit must always be easy to rotate in the hoisting

gear.

• Lay power and control cables out straight on the

ground (no loops) before installation. Guide cables during lowering so that they are not stretched or squeezed while pump is being installed. Make sure that cable insulation is not nicked or damaged before or during installation. Never use the electrical cables to move the motor/pump.

• The pump and motor are heavy. Make sure that all

connections are secure and that the hoisting gear is adequate to do the job before starting to lift pump. Don’t stand under the unit. Don’t allow extra people into the area while hoisting the unit.

• If motor or pump/motor unit are attached to a

supporting girder, do not remove girder until unit is vertical.

• Install pump at least 10’ (3m) below the lowest water

level during pumping, but at least 6’ (2m) above the bottom of the well.

• 6" motors must be installed in a vertical position only.

• 4" motors can be operated in vertical or horizontal

positions. Note that the thrust bearing will have shorter life in a non-vertical application. In such an installation, keep frequency of starts to less than 10 per day.

3.2 PROPER GROUNDING

Hazardous voltage. Can shock, burn or

cause death. Installation or service to electrical equipment should only be done by qualified electrician.

Control panels must be connected to supply ground

Proper grounding serves two main purposes:

1. It provides a path to ground in case of a ground-fault.

Otherwise the current would present a shock or electrocution hazard.

2. It protects equipment from electrical surges.

Use wire the same size as, or larger than motor’s currentcarrying wires (consult Tables in the motor section).

Installations must comply with the National Electric Code as well as state and local codes.

All systems must have lightning (surge) protection with a secure connection to ground.

The grounding should extend to the water-bearing layer to be effective.

Ground to casing if it is metal, and extends within 20’ of motor.

If a metal drop pipe is used, then ground to the drop pipe.

Do not ground only to the supply ground or driven grounding rod. These will not protect the pump.

All motors are internally grounded and requires a 3 or 4-wire drop cable.

3.3 CORROSIVE WATER AND GROUND

Some waters are corrosive, and can eventually corrode the ground wire. If the installation uses a metal well casing, any ground current will flow through it. In the case of plastic piping and casing, the water column would carry the current in a ground fault situation.

To prevent this, route the motor ground wire and the motor power leads through a GFCI with a 10 mA set point. In this way, the GFCI will trip when a ground fault has occurred AND the motor ground wire is no longer functional.

3.4 CHECK VALVES

Check valve installation is necessary for proper pump operation. The pump should have a check valve on its discharge, or within 25 feet (7.62 m) of the pump. For very deep wells, locate a check valve at least every 200 feet (61 m).

• Use only spring type or gravity-poppet check valves.

Swing type valves can cause water hammer problems.

• Do not use drain-back style check valves (drilled).

Check valves serve the following purposes:

•

Maintain Pressure:

Without a check valve, the pump has to start each cycle at zero head, and fill the drop pipe. This creates upthrust in the motor, and would eventually damage both the pump and motor.

•

Prevent Water Hammer:

If two check valves are used, and the lower one leaks, then a partial vacuum forms in the pipe. When the pump next starts, the flow fills the void area quickly, and creates a shock wave that can break piping and damage the pump. If you get water hammer on pump start, this may be the cause.

•

Prevent Back-Spin:

Without a functioning check valve, upon shutoff, the water drains back through the pump, and cause it to rotate backwards. This can create excessive wear on the thrust bearing, and if the pump restarts as water is flowing down the pipe, it will put an excessive load on the system.

SECTION 3: Installation and Setup 5

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Installation

and Setup

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SECTION 3: Installation and Setup 6

3.5 START-UP

NOTICE: To avoid sand-locking pump, follow procedure

below when starting pump for the first time. NEVER start a pump with discharge completely open unless you have done this procedure first.

1. Connect a pipe elbow, a short length of pipe and a gate valve to pump discharge at well head.

2. Make sure that controls will not be subjected to extreme heat or excess moisture.

3. Make sure power is OFF. DO NOT START PUMP YET.

4. Set gate valve on discharge 1/3 open; start pump.

5 Keep gate valve at this setting while water pumps out

on ground. Let it run until water is clear of sand or silt. (To check solids in water, fill a glass from pump and let solids settle out).

6. When water is completely clear at 1/3 setting, open gate valve to approximately two-thirds open and repeat process.

7. When water is completely clear at 2/3 setting, open gate valve completely and run pump until water is completely clear.

8. Do not stop the pump until the water is clear. Otherwise sand will accumulate in the pump stages which may bind or freeze the pump.

9. Remove gate valve and make permanent installation.

NOTICE: The motor may draw higher than normal current while the riser pipe is filling. After the riser pipe is full, the amp draw should drop back to less than the allowed current given on the motor nameplate.

When pump is in service, the amp draw must be approximately equal to or lower than the service factor amps given on the motor nameplate. If not, recheck entire installation and electrical hook-up to find out why amp draw is higher than normal.

Motor Torque

The motor exerts a strong torque force on the downpipe and any other supporting structures when it starts. This torque is usually in the direction that would unscrew righthand threads (the motor’s reaction movement is clockwise as seen from above).

All pipe and pump joints must be tightened to safely handle the starting torque. Tighten all threaded joints to a minimum of 10 ft.-lb per horsepower. i.e. 20 HP = 200 ft.-lb; 50 HP = 500 ft.-lb.

Tack welding or strap welding may be required with higher horsepower pumps.

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4.1 MIXING WIRE SIZE WITH

EXISTING INSTALLATION

Using two different cable sizes.

Sometimes conditions make it desirable to use more than one size cable, such as replacing a pump in an existing installation.

For example: Installing a pump with a 6”, 5 HP, 230 volt, single phase motor, with the motor setting at 250' (76.2 m) down the well and with 120' (36.5 m) of #8 cable buried between the service entrance and the well head. In order to avoid replacing the buried cable, the question is: What size cable is required in the well? Calculate as follows:

1. According to Table 7-7, a total of 269' (82 m) of #8 cable is the maximum length cable to power a 5 HP motor. The percent of this total that has been used by the 120' (36.5 m) of cable in the buried run is: 120'/269' = .446 = 45%.

2. With 45% of the allowable cable already used, 55% of the total length is left for use in the well. To avoid running a cable that is too small (gauge) and lowering the voltage to the motor, we have to find a cable size large enough so that 250' (76.2 m) is less than 55% of the total length allowed for that size.

3. 250 ÷ 55% = 455 feet.

4. From Table 7-7 we find that the total allowable length for #4 cable is 667'.

This is longer than needed. Therefore, #4 cable can be used for the 250' (76.2 m) of cable in the well.

Any combination of sizes can be used, provided that the total percentage of the length of the two sizes of cable is not less than 100% of the allowed lengths.

4.2 WIRE SPLICING

Splice wire to motor leads. Use only copper wire for connections to pump motor and control box.

1. Taped splice (for larger wire sizes)

A. Stagger lead and wire length so that 2nd lead is 2"

(50mm) longer than 1st lead and 3rd lead is 2" (50mm) longer than second.

B. Cut off power supply wire ends. Match colors and

lengths of wires to colors and lengths of motor leads.

C. Trim insulation back 1/2" (13mm) from supply wire

and motor lead ends.

D. Insert motor lead ends and supply wire ends into

butt connectors. Match wire colors between supply wires and motor leads.

E. Using crimping pliers, indent butt connector lugs to

attach wires.

F. Cut Scotchfil

electrical insulation putty into 3 equal parts and form tightly around butt connectors. Be sure Scotchfil overlaps insulated part of wire.

G. Using #33 Scotch tape, wrap each joint tightly;

cover wire for about 1-1/2" (38mm) on each side of joint. Make four passes with the tape. When finished you should have four layers of tape tightly wrapped around the wire. Press edges of tape firmly down against the wire.

NOTICE: Since tightly wound tape is the only means of keeping water out of splice, efficiency of splice will depend on care used in wrapping tape.

NOTICE: For wire sizes larger than No. 8 (7mm

), use

soldered joint rather than Scotchfil putty.

Figure 4-1: Mixing Wire Sizes: Example

Cable

Pump

Controls

Service Entrance

(Main Fuse Box

From Meter)

5 HP (4.9 kw)

230V 1Ph Motor

120 Ft. AWG 8

250 Ft.

Figure 4-2: Insert Wires

Indent here

Figure 4-4:Wrap Splices

Completed splice

Alternate method twist and solder

Electrical Power

Figure 4-5:Twist Wires

Figure 4-3: Indent Connectors

SECTION 4: Electrical Power 7

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PN793 11/20/09 9:21 AM Page 7

1/2"

(12.7mm)

Butt Connector

PN793

2. Heat shrink splice (For wire sizes #14, 12 and 10 AWG (2, 3 and 5mm2):

A. Remove 3/8" (9.5mm) insulation from ends of motor

leads and power supply wires.

B. Put plastic heat shrink tubing over motor leads

between power supply and motor.

C. Match wire colors and lengths between power

supply and motor.

D. Insert supply wire and lead ends into butt connector

and crimp. Match wire colors between power supply and motor. Pull leads to check connections.

E. Center tubing over butt connector and apply heat

evenly with a torch (match or lighter will not supply enough heat).

NOTICE: Keep torch moving. Too much concentrated heat may damage tubing.

4.3 THREE-PHASE STARTERS

Starters are used to start the motor by engaging contacts that will energize each line simultaneously. The contacts are closed when the coil is energized.

Figures 4-7 through 4-9 show three types of starters used on the motors. The control device in the secondary circuit is typically a pressure switch. Other control could be provided by level control, timers or manual switches.

Line Voltage Control

This commonly-used control has a coil energized by line voltage. The coil voltage matches the line voltage.

Low Voltage Control

This starter arrangement uses a transformer to allow the coil to be energized by a lower voltage. Note that the secondary circuit must be fused, and the coil sized for the secondary voltage.

Separate Voltage Control

This arrangement uses power from a separate source to energize the coil.

SECTION 4: Electrical Power 8

Figure 4-6: Heat-Shrink Tubing Applied

Connector

Heat shrink tubing

Figure 4-8: Low Voltage Control

Figure 4-9: Separate Voltage Control

Figure 4-7: Line Voltage Control

PN793 11/20/09 9:21 AM Page 8

Overload Control

Coil

Control Device

Thermal Overload

Heaters

3-Phase Motor

Separate Voltage

Overload Control

Coil

Control Device

Thermal Overload

Heaters

3-Phase Motor

Overload Control

Coil

Control Device

Thermal Overload Heaters

3-Phase Motor

PN793

4.4 CHECKING MOTOR ROTATION

To check rotation before the pump is installed, follow

these steps:

During testing or checking rotation (such as “bumping” or “inching”) the number of “starts” should be limited to 3 and total run time of less than 15 seconds.

Bumping must be done while motor is in horizontal position and followed by a full 15-minute cooling-off period before any additional “starts” are attempted.

Energize the motor briefly, and observe the direction of rotation. It should be counter-clockwise when viewed from the pump (shaft) end.

To check rotation after the pump is installed:

NOTICE: NEVER continuously operate a pump with the discharge valve completely closed (dead head). This can overload the motor or destroy the pump and will void the warranty.

After energizing the motor, check the flow and pressure of the pump to make sure that the motor is rotating in the correct direction. To correct a wrong rotation, switch “any two of the three cable connections. (Three-phase motor only). The setting that gives the most flow and pressure is correct.

A cooling-off period of 15 minutes is required between starts.

Hazardous voltage. Disconnect power

before working on wiring.

Input voltage, current and insulation resistance values should be recorded throughout the installation and should be used for preventive maintenance.

4.5 3-PHASE CURRENT BALANCING

Current Unbalance Test

Before checking for current unbalance, the pump must be started, and rotation direction determined.

Determine current unbalance by measuring current in each power lead. Measure current for all three possible hookups (Figure 4-11). Use example and worksheet on the Installation Checklist and Record in Section 12 to calculate current unbalance on a three phase supply system and retain for future reference.

NOTICE: Current unbalance between leads should not exceed 5%. If unbalance cannot be corrected by rolling the leads, locate the source of the unbalance.

Here is an example of current readings at maximum pump loads on each leg of a three wire hookup. Make calculations for all three possible hookups.

A. For each hookup, add the readings for the three legs.

B. Divide each total by three to get average amps.

C. For each hookup, find current value farthest from aver-

age (Calculate the greatest current difference from the average).

D. Divide this difference by the average and multiply by

100 to obtain the percentage of unbalance.

Use smallest percentage unbalance, in this case Arrangement 2 (Table 4.1).

Use the Current-Balance worksheet located in the Installation Record

After trying all three lead hookups, if the reading furthest from average continues to show on the same power lead, most of the unbalance is coming from the power source. Call the power company.

If the reading furthest from average changes leads as the hookup changes (that is, stays with a particular motor lead), most of the unbalance is on the motor side of the starter. This could be caused by a damaged cable, leaking splice, poor connection, or faulty motor winding.

SECTION 4: Electrical Power 9

Starter

Electrical Power Supply

To Motor

Arrangement 1

Starter

Arrangement 2

Starter

Arrangement 3

Figure 4-10: Motor Rotation

Figure 4-11: 3-Phase Current Unbalance: Example

Electrical Power

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PN793

Use this worksheet to calculate current unbalance for your installation.

4.6 TRANSFORMER SIZING

The power supply to the installation must be capable of furnishing enough power to the pump and associated equipment.

Three-phase power may be furnished either through a Delta-Delta, Wye-Delta or open Delta configuration. The Delta-Delta uses three transformers to supply power to the facility. The Wye-Delta and open Delta configuration use only two transformers.

Transformers are rated by KVA capacity. This must be high enough capacity for the motor being installed. If the transformer capacity is too small, the motor will receive reduced voltage and may be damaged.

Any other loads in the system would be in addition to the motor alone.

Refer to the chart below. Note that the open delta configuration can only use 87% of the rated power of the two transformers.

SECTION 4: Electrical Power 10

Arrangement 1 Arrangement 2 Arrangement 3

Amps Amps Amps

L1–T1=17 L1–T3=16.7 L1–T2=16.7

L2–T2=15.3 L2–T1=16.3 L2–T3=16

L3–T3=17.7 L3–T2=17 L3–T1=17.3

Total Amps 50 50 50

Average Amps 50 ÷ 3 = 16.7 50 ÷ 3 = 16.7 50 ÷ 3 =16.7

From Average Amps

Deviation L1 0.3 0.0 0.0

Deviation L2 1.4 0.4 0.7

Deviation L3 1.0 0.3 0.6

% Current Unbalance

Largest Deviation 1.4 ÷ 16.7 0.3 ÷ 16.7 0.7 ÷ 16.7

% Unbalance + 8.4% 1.8% 4.2%

TABLE 4-1: Electrical Current Unbalance Example

EXAMPLE

Figure 4-12: Three Phase Power

L1 L2 L3

Wye or Open Delta 3-Phase

Full 3-Phase (Delta)

KVA Rating (smallest)

For Each Transformer

Open WYE Closed WYE

Required or D or D

HP kW KVA 2 Transformers 3 Transformers

1/2 0.37 1.5 1.0 0.5

3/4 0.55 1.5 1.0 0.5

1 0.75 2.0 1.5 0.75

1-1/2 1.1 3.0 2.0 1.0

2 1.5 4.0 2.0 1.5

3 2.2 5.0 3.0 2.0

5 3.7 7.5 5.0 3.0

7.5 5.5 10.0 7.5 5.0

10 7.5 15.0 10.0 5.0

15 11.0 20.0 15.0 7.5

20 15.0 25.0 15.0 10.0

25 18.5 30.0 20.0 10.0

30 22.0 40.0 25.0 15.0

40 30.0 50.0 30.0 20.0

50 37.0 60.0 35.0 20.0

60 45.0 75.0 40.0 25.0

TABLE 4-2: Transformer Capacity

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PN793

4.7 USING A GENERATOR

Selecting a generator

Select a generator that can supply at least 65% of rated voltage upon start-up of the motor.

The chart shows ratings of generators, both externally and internally regulated. This chart is somewhat conservative. Consult the generator manufacturer if you are uncertain.

Frequency

It is highly important that the generator maintain constant frequency (Hz), since the motor’s speed depends upon frequency.

A drop of just 1 to 2 Hz can noticeably lower pump performance. An increase of 1 to 2 Hz can cause overload conditions.

Voltage Regulation

There is a significant difference in the performance of internally and externally regulated generators.

An external regulator senses output voltage dips and triggers an increase in the voltage output of the generator.

An internal regulator, senses current and responds to increased current by supplying more voltage.

Generator Operation

Start the generator before starting the pump motor.

The motor must be stopped before turning off the generator.

If the generator runs out of fuel, and the pump is still connected, it will put excess strain on the thrust bearings as the generator slows.

Electrocution Hazard. Use transfer switches

when the generator is used as a backup to the power grid. contact your power company for proper use of standby or backup generators.

4.8 SPECIAL APPLICATIONS

4.8.1 Using Phase Converters

Phase converters allow three-phase motors to operate from one-phase supply. Various styles of phase converters are available. Many converters do not supply a properly balanced voltage, and using these will void the motor’s warranty unless approval is obtained first.

GUIDELINES FOR PHASE CONVERTERS:

• Current unbalance must be less than 5%.

• Converter to be sized to service factor capacity

• Maintain motor cooling with a cooling flow of at least 3’ per second.

• Fuses and circuit breakers must be time-delay type.

MOTOR STARTING WITH REDUCED VOLTAGE

Starting a motor with full voltage will bring it to full speed in less than 1/2 second. This can:

• Spike the load current, causing brief voltage dips in other equipment.

• Over-stress pump and piping components because of high torque.

• Cause water hammer.

4.8.2 Motor Starters (3-Phase Only)

Various types of motor starters are available. Autotransformers are recommended because of reduced current draw.

When motor starters are used, they should supply a minimum of 55% of rated voltage for adequate starting torque.

SECTION 4: Electrical Power 11

Motor

Externally Regulated Internally Regulated

HP kW KVA kW KVA

1/2 2.0 2.5 1.5 1.9

3/4 3.0 3.8 2.0 2.5

1 4.0 5.0 2.5 3.1

1-1/2 5.0 6.3 3.0 3.8

2 7.5 9.4 4.0 5.0

3 10.0 12.5 5.0 6.25

5 15.0 18.8 7.5 9.4

7-1/2 20.0 25.0 10.0 12.5

10 30.0 37.5 15.0 18.8

15 40.0 50.0 20.0 25.0

20 60.0 75.0 25.0 31.0

25 75.0 94.0 30.0 37.5

30 100.0 125.0 40.0 50.0

40 100.0 125.0 50.0 62.5

50 150.0 188.0 60.0 75.0

60 175.0 220.0 75.0 94.0

TABLE 4-3: Ratings of Generators

Electrical Power

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5.1 MOTOR INSPECTION

Check the motor for damage in shipping.

Before installation, check the following.

• Check over all tools, especially the hoisting gear, for wear or damage before hoisting unit.

• Inspect the motor cable for any nicks or cuts.

• Verify that motor nameplate data matches registration card information exactly.

• Verify that motor nameplate voltage is correct for available power supply voltage. Voltage must not vary more than +/-10% from nameplate rated voltage.

• Verify that the well diameter is large enough to accommodate the motor/pump unit all the way to the pump setting depth.

• For installations with tight well casings, make sure that riser pipe flanges are recessed to protect the power and control cables from abrasion and squeezing during installation.

Heavy object. Lifting equipment must be

capable of lifting motor and attached equipment.

• If the total length of the pump motor unit (without any riser pipe) exceeds 10’ (3m), the unit must be supported with a girder while hoisting. Do not remove supporting girder until unit is standing vertically in the hoist. Check for damage.

5.2 TESTING

Insulation Resistance

To check for insulation resistance:

Disconnect power to the motor for this test.

Connect an Ohm meter (resistance in Ω) between the power leads and the motor ground or well casing.

20KΩ Damaged motor, possible result of

lightning strike.

500KΩ Typical of older installed motor in well.

2 MΩ Newly installed motor

10 MΩ Used motor, measured outside of well

20 MΩ New motor without cable

5.3 STORAGE AND TRANSPORTATION

Storage site should be clean, well vented, and cool.

Keep humidity at the storage site as low as possible.

Protect motor and cables from direct sunlight.

Protect power supply cables and control cables from moisture by taping the cable ends with electrician’s tape.

Do not kink power supply or control cables.

Take care when moving unit (packed or unpacked) with crane or hoisting gear not to knock it against walls, steel structure, floors, etc. Do not drop motor.

Do not lift motor or motor/pump unit by power supply or control cables.

SECTION 5: XE-Series 4" Submersible Motors - 60 Hz 12

PN793

PN793 11/20/09 9:21 AM Page 12

5.4 4" MOTOR SPECIFICATIONS

SECTION 5: XE-Series 4" Submersible Motors - 60 Hz 13

XE-Series Motors

PN793

Motor

PENTEK

Rating Full Load Maximum (S.F. Load)

Type Part Number HP kW Volts Hz. Service Factor Amps Watts Amps Watts

P42B0005A1 1/2 0.37 115 60 1.6 7.4 845 9.5 1088

4" P42B0005A2 1/2 0.37 230 60 1.6 3.7 834 4.7 1073

2-Wire P42B0007A2 3/4 0.55 230 60 1.5 5.0 1130 6.4 1459

P42B0010A2 1 0.75 230 60 1.4 7.9 1679 9.1 1990 P42B0015A2 1-1/2 1.1 230 60 1.3 9.2 2108 11.0 2520

Y - 11.0 Y - 12.6

P43B0005A1 1/2 0.37 115 60 1.6 B - 11.0 733 B - 12.6 1021

R - 0.0 R - 0 Y - 5.5 Y - 6.3

P43B0005A2 1/2 0.37 230 60 1.6 B - 5.5 745 B - 6.3 1033

CSIR R - 0 R - 0

3-Wire Y - 7.2 Y - 8.3

P43B0007A2 3/4 .55 230 60 1.5 B - 7.2 1014 B - 8.3 1381

R - 0 R - 0 Y - 8.4 Y - 9.7

P43B0010A2 1 0.75 230 60 1.4 B - 8.4 1267 B - 9.7 1672

R - 0 R - 0 Y - 4.1 Y - 4.9

P43B0005A2 1/2 0.37 230 60 1.6 B - 4.1 720 B - 4.4 955

R - 2.2 R - 2.1 Y - 5.1 Y - 6.3

P43B0007A2 3/4 0.55 230 60 1.5 B - 5.0 1000 B - 5.6 1300

R - 3.2 R - 3.1 Y - 6.1 Y - 7.2

P43B0010A2 1 0.75 230 60 1.4 B - 5.7 1205 B - 6.3 1530

R - 3.3 R - 3.3

CSCR

Y - 9.7 Y - 11.1

P43B0015A2 1-1/2 1.1 230 60 1.3 B - 9.5 1693 B - 11.0 2187

3-Wire

R - 1.4 R - 1.3 Y - 9.9 Y - 12.2

P43B0020A2 2 1.5 230 60 1.25 B - 9.1 2170 B - 11.7 2660

R - 2.6 R - 2.6 Y - 14.3 Y - 16.5

P43B0030A2 3 2.2 230 60 1.15 B - 12.0 3170 B - 13.9 3620

R - 5.7 R - 5.6 Y - 24.0 Y - 27.0

P43B0050A2 5 3.7 230 60 1.15 B - 19.1 5300 B - 22.0 6030

R - 10.2 R - 10.0

TABLE 5-1: SINGLE PHASE Motor Specifications (115 and 230 Volt, 60 Hz, 3450 RPM)

PN793 11/20/09 9:21 AM Page 13

SECTION 5: XE-Series 4" Submersible Motors - 60 Hz 14

PN793

Maximum Load

Motor PENTEK Rating Full Load (SF Load)

Type Part Number HP kW Volts Hz Service Factor Amps Watts Amps Watts

P43B0007A8 3/4 0.55 200 60 1.5 3.8 812 4.5 1140 P43B0010A8 1 0.75 200 60 1.4 4.6 1150 5.5 1500 P43B0010A3 1 0.75 230 60 1.4 4.0 1090 4.7 1450 P43B0010A4 1 0.75 460 60 1.4 2.2 1145 2.5 1505 P43B0015A8 1 1/2 1.1 200 60 1.3 6.3 1560 7.2 1950 P43B0015A3 1 1/2 1.1 230 60 1.3 5.2 1490 6.1 1930 P43B0015A4 1 1/2 1.1 460 60 1.3 2.8 1560 3.2 1980 P43B0015A5 1 1/2 1.1 575 60 1.3 2 1520 2.4 1950

3-Phase P43B0020A8 2 1.5 200 60 1.25 7.5 2015 8.8 2490

P43B0020A3 2 1.5 230 60 1.25 6.5 1990 7.6 2450 P43B0020A4 2 1.5 460 60 1.25 3.3 2018 3.8 2470 P43B0020A5 2 1.5 575 60 1.25 2.7 1610 3.3 2400 P43B0030A8 3 2.2 200 60 1.15 10.9 2890 12.0 3290 P43B0030A3 3 2.2 230 60 1.15 9.2 2880 10.1 3280 P43B0030A4 3 2.2 460 60 1.15 4.8 2920 5.3 3320 P43B0030A5 3 2.2 575 60 1.15 3.7 2850 4.1 3240 P43B0050A8 5 3.7 200 60 1.15 18.3 4850 20.2 5515 P43B0050A3 5 3.7 230 60 1.15 15.7 4925 17.5 5650 P43B0050A4 5 3.7 460 60 1.15 7.6 4810 8.5 5530 P43B0050A5 5 3.7 575 60 1.15 7.0 5080 7.6 5750 P43B0075A8 7 1/2 5.6 200 60 1.15 27.0 7600 30.0 8800 P43B0075A3 7 1/2 5.6 230 60 1.15 24.0 7480 26.4 8570 P43B0075A4 7 1/2 5.6 460 60 1.15 12.2 7400 13.5 8560 P43B0075A5 7 1/2 5.6 575 60 1.15 9.1 7260 10.0 8310

TABLE 5-2: THREE PHASE Motor Specifications (230, 460, 200 and 575 Volt, 60 Hz, 3450 RPM,

60° and 75° C.)

TABLE 5-3: SINGLE PHASE 4” Motor Electrical Parameters (115 and 230 Volt, 60 Hz, 3450 RPM,

2 and 3 wire)

Winding Efficiency % Power Factor %

Locked

Motor PENTEK M = Main S = Start Rotor KVA

Type Part Number Resistance* Resistance F.L. S.F. F.L. S.F. Amps Code

P42B0005A1 M 1.3-1.8 49 61 99 99 36.4 K

P42B0005A2 M 4.5-5.2 50 62 97 99 19.5 K

PSC P42B0007A2 M 3.0-4.8 55 65 97 99 24.8 J

2-W

P42B0010A2 M 4.2-5.2 58 65 94 96 21.7 F

P42B0015A2 M 1.9-2.3 59 64 99 99 42.0 H

P43B0005A1 M 0.9-1.6 S 5.7-7.0 51 59 54 69 49.6 N

CSIR P43B0005A2 M 4.2-4.9 S 17.4-18.7 50 58 58 71 22.3 M 3-W

P43B0007A2 M 2.6-3.6 S 11.8-13.0 55 61 61 72 32.0 L

P43B0010A2 M 2.2-3.2 S 11.3-12.3 59 62 66 75 41.2 L

P43B0005A2 M 4.2-4.9 S 17.4-18.7 52 62 76 85 22.3 M

P43B0007A2 M 2.6-3.6 S 11.8-13.0 56 65 85 90 32.0 L

P43B0010A2 M 2.2-3.2 S 11.3-12.3 62 68 86 92 41.2 L

CSCR P43B0015A2 M 1.6-2.3 S 7.9-8.7 66 67 80 85 47.8 J

3-W

P43B0020A2 M 1.6-2.2 S 10.8-12.0 68 69 96 95 49.4 G

P43B0030A2 M 1.1-1.4 S 2.0-2.5 72 72 96 97 76.4 G

P43B0050A2 M0.62-0.76 S 1.36-1.66 71 71 97 98 101.0 E

* Main winding is between the yellow and black leads. Start winding is between the yellow and red leads.

PN793 11/20/09 9:21 AM Page 14

SECTION 5: XE-Series 4" Submersible Motors - 60 Hz 15

TABLE 5-4: THREE PHASE Motor Electrical Parameters (230, 460, 200 and 575 Volt, 60 Hz, 3450

RPM, 60° and 75° C.)

PN793

Locked

Motor Pentek Line to Line Efficiency % Rotor KVA

Type Part Number Resistance (Ohms) FL SF Amps Code

P43B0007A8 2.6-3.0 69 74 32.0 R P43B0010A8 3.4-3.9 66 70 29.0 M P43B0010A3 4.1-5.1 69 72 26.1 M P43B0010A4 17.8-18.8 65 69 13.0 M P43B0015A8 1.9-2.5 72 74 40.0 L P43B0015A3 2.8-3.4 75 76 32.4 L P43B0015A4 12.3-13.1 72 73 16.3 L P43B0015A5 19.8-20.6 73 74 11.5 J P43B0020A8 1.4-2.0 74 75 51.0 K

3-Phase P43B0020A3 1.8-2.4 75 75 44.0 K

P43B0020A4 8.0-8.7 74 75 23.0 K P43B0020A5 9.4-9.7 78 78 21.4 M P43B0030A8 0.9-1.3 77 77 71.0 K P43B0030A3 1.3-1.7 77 77 58.9 J P43B0030A4 5.9-6.5 76 77 30.0 J P43B0030A5 9.4-9.7 78 78 21.4 J P43B0050A8 0.4-0.8 76 76 113.0 J P43B0050A3 .85-1.25 76 76 93.0 J P43B0050A4 3.6-4.0 77 77 48.0 J P43B0050A5 3.6-4.2 75 75 55.0 M P43B0075A8 0.5-0.6 74 74 165.0 J P43B0075A3 0.55-0.85 75 75 140.0 J P43B0075A4 1.9-2.3 76 76 87.0 L P43B0075A5 3.6-4.2 77 77 55.0 J

PN793 11/20/09 9:21 AM Page 15

PN793

5.5 4" MOTOR DIMENSIONS

Motor PENTEK Length Length Weight Weight

Type Part Number HP kW (in) (mm) (lbs) (kg)

P42B0005A1 1/2 0.37 11.0 279 19.2 8.7

4-Inch P42B0005A2 1/2 0.37 11.0 279 19.2 8.7

2-Wire P42B0007A2 3/4 0.56 12.4 314 22.7 10.3

P42B0010A2 1 0.75 13.3 337 24.5 11.1

P42B0015A2 1-1/2 1.10 14.9 378 28.9 13.1

P43B0005A1 1/2 0.37 10.0 253 18.9 8.6

P43B0005A2 1/2 0.37 9.7 246 18.1 8.2

P43B0007A2 3/4 0.56 10.8 275 21.4 9.7

4-Inch

P43B0010A2 1 0.75 11.7 297 23.1 10.5

3-Wire

P43B0015A2 1-1/2 1.10 13.6 345 27.4 12.4

P43B0020A2 2 1.50 15.1 383 31.0 14.1

P43B0030A2 3 2.20 18.3 466 40.0 18.1

P43B0050A2 5 3.70 27.7 703 70.0 31.8

TABLE 5-5: SINGLE PHASE Motor Dimensions (115 and 230 Volt, 60 Hz, 3450 RPM)

SECTION 5: XE-Series 4" Submersible Motors - 60 Hz 16

Motor Pentek Length Length Weight Weight

Type Part Number HP kW Inches mm Lb Kg

P43B0007A8 3/4 0.55 10.8 275 21.4 9.7 P43B0010A8 1 0.75 11.7 297 23.1 10.5 P43B0010A3 1 0.75 11.7 297 23.1 10.5 P43B0010A4 1 0.75 11.7 297 23.1 10.5 P43B0015A8 1 1/2 1.1 11.7 297 23.1 10.5 P43B0015A3 1 1/2 1.1 11.7 297 23.1 10.5 P43B0015A4 1 1/2 1.1 11.7 297 23.1 10.5 P43B0015A5 1 1/2 1.1 11.7 297 23.1 10.5 P43B0020A8 2 1.5 13.8 351 27.4 12.4 P43B0020A3 2 1.5 13.8 351 27.4 12.4 P43B0020A4 2 1.5 13.8 351 27.4 12.4

3-Phase P43B0020A5 2 1.5 15.3 389 32.0 14.5

P43B0030A8 3 2.2 15.3 389 32.0 14.5 P43B0030A3 3 2.2 15.3 389 32.0 14.5 P43B0030A4 3 2.2 15.3 389 32.0 14.5 P43B0030A5 3 2.2 15.3 389 32.0 14.5 P43B0050A8 5 3.7 21.7 550 55.0 24.9 P43B0050A3 5 3.7 21.7 550 55.0 24.9 P43B0050A4 5 3.7 21.7 550 55.0 24.9 P43B0050A5 5 3.7 27.7 703 70.0 31.8 P43B0075A8 7 1/2 5.6 27.7 703 70.0 31.8 P43B0075A3 7 1/2 5.6 27.7 703 70.0 31.8 P43B0075A4 7 1/2 5.6 27.7 703 70.0 31.8 P43B0075A5 7 1/2 5.6 27.7 703 70.0 31.8

TABLE 5-6: THREE PHASE Motor Dimensions (230, 460, 200 and 575 Volt, 60 Hz, 3450 RPM)

PN793 11/20/09 9:21 AM Page 16

PN793

Figure 5-1:“XE” Series 4" Motor Dimensions – Single and Three Phase

SECTION 5: XE-Series 4" Submersible Motors - 60 Hz 17

XE-Series Motors

PN793 11/20/09 9:21 AM Page 17

1.508 (38.30)

1.498 (38.05)

All dimensions in inches (mm)

3.00 (7.62)

3.750 (95.2)

4” Motor

Shaft free end-play .005 -.040 (.127 - 1.02)

Length

14 Teeth 24/48 Pitch 30 Degee Pressure Angle Min 0.50 (23.1) Full Spline ANSI B92.1 Compliant

0.97 (24.6) max

0.79 (20.1) min

1.5 (38.1)max.

0.6255 (15.89)

0.6245 (15.86)

Sand Boot

(4) 5/16 - 24 UNF-2A Threaded Studs on 3” (76.2) Dia. Circle

PN793

SECTION 5: XE-Series 4" Submersible Motors - 60 Hz 18

5.6 4" MOTOR FUSE SIZING

TABLE 5-7: SINGLE PHASE Motor Fuse Sizing (115 and 230 Volt, 60 Hz, 3450 RPM)

Volts and Circuit Breaker Amps

(Maximum Rating per NEC)

Dual Element

Motor PENTEK Standard Time Delay Circuit

Type Part Number HP kW Volts Fuse Fuse Breaker

P42B0005A1 0.5 0.37 115 25 15 20

4" P42B0005A2 0.5 0.37 230 15 10 10

2-Wire P42B0007A2 0.75 0.55 230 20 10 15

P42B0010A2 1 0.75 230 25 15 20 P42B0015A2 1.5 1.1 230 30 15 25 P43B0005A1 0.5 0.37 115 30 20 30

P43B0005A2 0.5 0.37 230 15 10 15

3-Wire

P43B0007A2 0.75 0.55 230 20 10 20

CSIR

P43B0010A2 1 0.75 230 25 15 25 P43P0005A2 0.5 0.37 230 15 10 10 P43B0007A2 0.75 0.55 230 20 10 15

4" P43B0010A2 1.0 0.75 230 20 10 15

3-Wire P43B0015A2 1.5 1.1 230 30 15 25

CSCR P43B0020A2 2.0 1.5 230 30 20 25

P43B0030A2 3.0 2.2 230 45 25 40 P43B0050A2 5.0 3.7 230 70 40 60

Fuse Sizing Based on NEC

Dual Element

Motor PENTEK Standard Time Delay Circuit

Type Part Number HP kW Volts Fuse Fuse Breaker

P43B0007A8 3/4 0.55 200 15 10 10 P43B0010A8 1 0.75 200 15 10 10 P43B0010A3 1 0.75 230 15 6 10 P43B0010A4 1 0.75 460 6 3 6 P43B0015A8 1 1/2 1.1 200 20 10 15 P43B0015A3 1 1/2 1.1 230 20 10 15 P43B0015A4 1 1/2 1.1 460 8 6 6 P43B0015A5 1 1/2 1.1 575 6 3 6 P43B0020A8 2 1.5 200 25 15 20 P43B0020A3 2 1.5 230 20 15 20 P43B0020A4 2 1.5 460 15 6 10

3-Phase P43B0020A5 2 1.5 575 10 6 10

P43B0030A8 3 2.2 200 35 20 30 P43B0030A3 3 2.2 230 30 15 25 P43B0030A4 3 2.2 460 15 10 15 P43B0030A5 3 2.2 575 15 10 10 P43B0050A8 5 3.7 200 60 35 50 P43B0050A3 5 3.7 230 45 30 40 P43B0050A4 5 3.7 460 25 15 20 P43B0050A5 5 3.7 575 25 15 20 P43B0075A8 7 1/2 5.6 200 80 50 70 P43B0075A3 7 1/2 5.6 230 70 45 60 P43B0075A4 7 1/2 5.6 460 40 25 35 P43B0075A5 7 1/2 5.6 575 30 20 25

TABLE 5-8: THREE PHASE Motor Fuse Sizing (230, 460, 200 and 575 Volt, 60 Hz, 3450 RPM,

60° and 75° C.)

PN793 11/20/09 9:21 AM Page 18

PN793

SECTION 5: XE-Series 4" Submersible Motors - 60 Hz 19

TABLE 5-9: Cable Lengths, SINGLE PHASE 115 and 230 Volt, 60 Hz, 3450 RPM, 2- and 3-wire

Motors, 60° and 75° C. Service Entrance to Motor: Maximum Length in F

eet

5.7 CABLE LENGTHS

XE-Series Motors

Wire Size, AWG

HP Volt 14 12 10 8 6 4 3 2 1 0 00

CSIR Control Boxes

1/2 115 87 138 221 349 544 867 1090 1376 1734 2188 2761

1/2 230 348 553 883 1398 2175 3467 4359 5505 6935 8753 –

3/4 230 264 420 670 1061 1651 2632 3309 4178 5264 6644 8383

1 230 226 359 573 908 1413 2252 2831 3575 4504 5685 7173

CSCR Control Boxes

1/2 230 447 711 1135 1797 2796 4458 5604 7078 8916 11254 –

3/4 230 348 553 883 1398 2175 3467 4359 5505 6935 8753 11044

1 230 304 484 772 1223 1903 3034 3814 4817 6068 7659 9663

1 1/2 230 197 314 501 793 1234 1968 2474 3124 3936 4968 6268

2 230 180 286 456 722 1123 1790 2251 2843 3581 4520 5703

3 230 133 211 337 534 830 1324 1664 2102 2648 3342 4217

5 230 – – 206 326 507 809 1017 1284 1618 2042 2577

* Table data are generated per NEC standards.

Wire Size, AWG

HP Volt 14 12 10 8 6 4 3 2 1 0 00

1/2 115 115 183 293 463 721 1150 1445 1825 2299 2902 3662

1/2 230 466 742 1183 1874 2915 4648 5843 7379 9295 11733 –

3/4 230 342 545 869 1376 2141 3413 4291 5419 6826 8617 10871

1 230 241 383 611 968 1506 2400 3018 3811 4801 6060 7646

1 1/2 230 199 317 505 801 1246 1986 2496 3153 3972 5013 6325

3-Wire in Feet

2-Wire in Feet

PN793 11/20/09 9:21 AM Page 19

PN793

SECTION 5: XE-Series 4" Submersible Motors - 60 Hz 20

TABLE 5-10: Cable Lengths, THREE PHASE 230, 460, 200 and 575 Volt, 60 Hz, 3450 RPM

Motors, 60° and 75° C. Service Entrance to Motor: Maximum Length in F

eet

Wire Size, AWG

HP Volt 14 12 10 8 6 4 3 2 1 0 00

1 230 466 742 1183 1874 2915 4648 5843 7379

1 1/2 230 359 571 912 1444 2246 3581 4502 5685 7162 9040

2 230 288 459 732 1159 1803 2874 3613 4563 5748 7256 9155

3 230 217 345 551 872 1357 2163 2719 3434 4326 5460 6889

5 230 — — 318 503 783 1248 1569 1982 2496 3151 3976

7 1/2 230 — — — 334 519 827 1040 1314 1655 2089 2635

1 460 1753 2789 4448 7045

1 1/2 460 1370 2179 3475 5504

2 460 1153 1835 2926 4635 7212

3 460 827 1315 2098 3323 5171

5 460 516 820 1308 2072 3224 5140

7 1/2 460 325 516 824 1305 2030 3236 4068 5138 6472

* Table data are generated per NEC standards.

Wire Size, AWG

HP Volt 14 12 10 8 6 4 3 2 1 0 00

3/4 200 423 674 1074 1702 2648

1 200 346 551 879 1392 2166 3454 4342

1 1/2 200 265 421 672 1064 1655 2638 3317

2 200 217 344 549 870 1354 2158 2714 3427 4317 5449

3 200 159 253 403 638 993 1583 1990 2513 3166 3996

5 200 94 150 239 379 590 940 1182 1493 1881 2374 2995

7 1/2 200 64 101 161 255 397 633 796 1005 1266 1598 2017

1 1/2 575 2283 3631 5792

2 575 1660 2641 4212 6671

3 575 1336 2126 3390 5370

5 575 721 1147 1829 2897 4507

7 1/2 575 548 871 1390 2202 3426

Three Phase

PN793 11/20/09 9:21 AM Page 20

5.8 4" MOTOR OVERLOAD

PROTECTION

Single Phase Motors

Single phase motors have overload protection either in the motor or in the control box. Motors less than or equal to 1 HP have built-in protection. This automatic protection will continue to cycle under a locked or stalled rotor condition.

Single phase motors larger than 1 HP use overload protection located in the SMC (Submersible Motor Controls). These are manual overloads and must be manually reset if an overload condition occurs.

5.9 MOTOR COOLING

PENTEK 4" XE-Series motors are designed to operate to a maximum SF (Service Factor) horsepower in water up to 86° F (30° C).

4" MOTORS: MINIMUM COOLING WATER FLOW OVER 3 HP

I.D of casing Flow GPM (LPM) required

4 1.2 (4.5 5 7 (26.5) 6 13 (49) 7 20 (76)

8 30 (114) 10 50 (189) 12 80 (303) 14 110 (416) 16 150 (568)

If the flow is less than specified, a flow-inducer sleeve can be installed. This will act like a smaller casing size, and force flow around the motor to aid cooling.

5.10 STARTING FREQUENCY

To extend the life of the pump motor and control, limit the number of starts to 300 per day.

If higher starting frequencies are necessary, consult your factory.

To prevent overheating, run motor for a minimum of one minute.

Figure 5-2: Flow Inducer Sleeve

Motor Rating Maximum Starts in 24 Hours

HP KW Single Phase Three Phase 1/5 to 3/4 HP Up to .55 300 300 1 to 1-1/2 .75 thru 4 100 300

TABLE 5-11: Maximum starts in 24 hours

SECTION 5: XE-Series 4" Submersible Motors - 60 Hz 21

XE-Series Motors

PN793 11/20/09 9:21 AM Page 21

SECTION 6:Variable Frequency Drives 22 PID-1, PID-6 INTELLIDRIVE Series

PN793

6.1 GENERAL SAFETY

Risk of high-voltage electrical shock from the EMI/RFI Filter if the front cover of the VFD is open or removed while power is connected to the VFD or the VFD is running. The front cover of the VFD must be closed during operation.

• After allowing at least 5 minutes for the EMI/RFI Filter

to discharge and before starting any wiring or inspection procedures, check for residual voltage with a voltage tester.

Risk of electrical shock if VFD is connected to the power wiring before hanging the box. Always hang

the VFD box before connecting the wires to it.

Risk of electrical shock if the VFD is handled or serviced with wet or damp hands. Always

make sure your hands are dry before working on the VFD. Perform all operations on the HMI with dry hands.

Risk of electrical shock and hand injury. Do not reach into or change the cooling fan while power is on to the VFD.

Risk of electrical shock. Do not touch the printed circuit board when power is on to the VFD.

Fire hazard if installed with incorrect or inadequate circuit breaker protection. To make sure of

protection in the event of an internal fault in the VFD, install the VFD on an independent branch circuit protected by a circuit breaker (see Table 6-2, Page 23 for circuit breaker sizing), with no other appliances on the circuit.

Risk of burns. The drive can become hot during normal operation. Allow it to cool for 10 minutes after shut-down before handling it to avoid burns.

NOTE: To avoid damage to the drive or problems with the drive:

• Connect the output cables to 3-wire and 3-phase motors as follows: Red to R, Yellow to Y, Black to B. Any other order will reverse the motor rotation and may damage the motor.

• Do not modify the equipment.

• Do not use power factor correction capacitors with this VFD; they will damage both the motor and the VFD.

• Do not remove any parts unless instructed to do so in the owner’s manual.

• Do not use a magnetic contactor on the VFD for frequent starting/stopping of the VFD.

• Do not install or operate the VFD if it is damaged or parts are missing.

• Before starting a VFD that has been stored for a long time, always inspect it and test operation.

• Do not carry out a megger (insulation resistance) test on the control circuit of the VFD.

• Do not allow loose foreign objects which can conduct electricity (such as screws and metal fragments) inside the VFD box at any time. Do not allow flammable substances (such as oil) inside the VFD box at any time.

• Ground the VFD according to the requirements of the National Electrical Code Section 250, IEC 536 Class 1, or the Canadian Electrical Code (as applicable), and any other codes and ordinances that apply.

• All installation, service work, and inspections must be done by a qualified electrician.

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

Risk of high-voltage electrical shock from EMI/RFI Filter inside Drive. Make all wiring connections, then close and fasten the cover before turning on power to Drive.

DO NOT open the box when power is connected to the Drive .

Before doing any service or maintenance inside the Drive:

1. DISCONNECT power.

2. WAIT 5 minutes for retained voltage to discharge.

3. Open box.

Before connecting or disconnecting any wires inside the Drive:

1. DISCONNECT power.

2. WAIT 5 minutes for retained voltage to discharge.

3. Open box.

EMI/RFI Filter

Hazardous voltage. Drive internal components retain

high voltage for up to 5 minutes after input power is disconnected.

EMI/RFI Filter carries high voltage when pump is running.

Disconnect power and wait 5 minutes before opening and removing VFD cover.

PN793 11/20/09 9:21 AM Page 22

SECTION 6:Variable Frequency Drives 23 PID-1, PID-6 INTELLIDRIVE Series

PN793

6.2 DESCPRIPTION

The PENTEK INTELLIDRIVE is specifically designed to operate 4” submersible pumps in water well applications. Each drive is rated for horsepower and amp draw. Any use of the drive outside of its intended use and design parameters will void the warranty.

Transducer

The drive uses a 4-20mA, 0-100PSI pressure transducer to control the speed of the motor.

The transducer senses pressure in the pipe and converts it to an electrical signal which it sends to the drive. The drive processes the signal in the PID (Proportional, Integration, Derivative) control. When operating in PID mode the drive increases and decreases the speed of the pump motor as needed to maintain constant pressure in the system.

Fan

The PENTEK INTELLIDRIVE has a thermostatically controlled internal fan. The fan may not operate under normal operating conditions. It will automatically start when necessary to cool the drive.

Keypad

The Keypad programs the drive, monitors the status of the pump, and views faults if they occur. Each button has a unique function (see Page 22). The LCD display shows a text display of the status of the drive’s operation. Other LEDs light up to indicate when certain buttons are pressed or certain events occur.

VFD

PID-1, PID-6

Table 6-1: Model Number Structure

Voltage Rating:

1 = 190–265 Volt 1-Phase In, 3-Phase Out 6 = 190–265 Volt 1-Phase In, 1-Phase Out

PID – 1 – 10A1 – 1

PID-1- 10A1-1:

Product Family

PID = Pentek IntelliDrive

Max Amp Rating:

4A7 = 4.7 Amps 7A6 = 7.6 Amps 9A7 = 9.7 Amps 10A1 = 10.1 Amps 12A2 = 12.2 Amps

Enclosure T ype:

1 = NEMA 1 (Indoor Rated) 3 = NEMA 3R (Outdoor Rated)

Figure 6-1: Overall Layout – Typical installation

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Transducer; install at least one foot away from pipe fittings on each side.

Grnd

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6.3 INSTALLATION

Mounting (See Figure 6-3)

Mount the drive in an easily accessible area with temperature maintained between –4°F and 104°F (–20°C to 40°C). NEMA 1 enclosures must be mounted indoors; NEMA 3R enclosures may be mounted outdoors with the same ambient temperature limits.

To mount the drive, mark the location of the top keyhole on the wall or stud. Drive a screw into the structure and hang the drive on it. Back out the screw on the bottom of the front cover and lift the cover off. Mark the locations of the bottom two mounting holes. Mount the drive with screws in all three holes.

Be sure that the ventilation holes are not blocked and that there is enough space around the drive to allow free air flow (minimum 3” clearance, top, bottom, and sides). Once the drive is mounted, you are ready to connect the wires.

Figure 6-2: Keypad functions

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Figure 6-3

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Toggles the pressure setpoint

Hazardous pressure.

Do not connect to system or restrict discharge flow when running in “Pump Out” mode.

confirms numeric value changes

between 40, 60, and 70 PSI

(default is 60)

Runs the Drive at 45 Hz

(with no pressure control)

to allow the installer

to pump out the well

Changes the display to

the previous screen

Selects menu items and

Power is on to the Drive

Views and changes parameters

Shows the last 15 faults

With code, locks and unlocks the password protected keys (default password is 7777)

Toggles between English, Spanish, and French (Default is English )

The Drive is in Temporary Performance

Mode (TPM) or Jam condition

A fault has occurred

Displays the Drive’s

urrent oper

changes the display parameters

ating conditions and

Stops the motor

Checks for line fill, then starts the pump in constant pressure mode

The left and right arrows move the cursor.

The up and down arrows scroll through the menus and change numeric values.

Resets the fault that stopped the pump

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Wiring

To allow for ease of wiring, the wiring area is free of electronics other than the terminals. Conduit holes and knockouts are located so that the wire can be fed straight through to the connectors, with minimal bending. The terminals accept 6-14 AWG wire.

NOTE: For convenience in wiring, the input and motor terminals unplug from the box. Pull them down to remove them for ease of access. See Figure 6-4.

BE SURE that when you replace them, they are completely pushed in and seated.

Note: The best practice is to connect all output wires first and all input wires last.

Output Connections (See Figure 6-5, Page 24):

See Tables 6-5 and 6-6, Page 32, for correct wires sizes, VFD to motor.

The output of PID-1 Series drives is 230V three phase power.

The output of PID-6 Series drives is 230V single phase power.

NOTE: PID-1 series drives will not operate single phase motors. PID-6 series drives will not operate three phase motors.

The output power terminals (motor wire connections) are located on the lower right side of the drive and are labeled R (Red), Y (Yellow), and B (Black). Feed the motor cable through the 3/4” conduit hole on the bottom right side and into the appropriate terminals. If the wire is large enough to require a larger conduit hole, remove the 1-1/4” knockout and use the appropriate conduit connections. Attach the motor ground wire to the grounding lug, located to the upper right of the terminal block. Attach the motor power wires to the terminals as shown in Figure 6-5, Page 24.

VFD

PID-1, PID-6

Wire Size Minimum 240VAC Controller Motor CB to VFD C.B. Size Generator Model No. Volts/Hz/Ph H.P. Amps (AWG) (Amps) Cap’y (kVA)

PID-1-4A7-X 230/60/3 1 4.7 12 20 4.2 kVA

PID-1-7A6-X

230/60/3 1.5 6.1

10 30 6.9

230/60/3 2 7.6

PID-1-10A1-X 230/60/3 3 10.1 8 40 9.1

230/60/1 0.5 4.9

PID-6-9A7-X 230/60/1 0.75 6.3 12 20 4.4

230/60/1 1 7.2

PID6-12A2-X

230/60/1 1.5 11.1

10 30 7.4

230/60/1 2 12.2

Table 6-2: Circuit Breaker and Wire Sizes

Figure 6-4: Pull the input and motor terminals down to unplug them for ease of wiring.

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SECTION 6:Variable Frequency Drives 26 PID-1, PID-6 INTELLIDRIVE Series

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Pressure Tank Recommendations:

Minimum tank size is 5 gallons. Use a pre-charged pressure tank with the Drive. The tank size must equal at least 20% of the pump’s rated flow in gallons per minute (GPM), but cannot be less than 5 gallons capacity. For example, a pump rated at 10 GPM would require a tank of 5 gallons capacity or larger. A pump rated at 50 GPM would require a 10 gallon tank or larger. A larger tank will reduce cycling of the pump.

NOTE: Set the pressure tank’s pre-charge to 70% of the system operating pressure. When using an external set point as well as an internal set point, pre-charge the tank to 70% of the lower set point of the two. Some applications may require a different percentage when figuring the set point.

Transducer Connections (See Figure 6-5):

Use the transducer provided with the drive. Install the transducer downstream of the tank. Install the transducer in a tee in a straight section of pipe with at least 1 foot of straight pipe on each side of the tee (that is, all fittings must be at least one foot away from the transducer).

Feed the transducer cable through the open 1/2” conduit hole on the bottom of the drive enclosure.

The transducer terminals, marked AI+ and AI-, are located to the left of the output terminals. Connect the red wire of the transducer cable to AI+, connect the black wire to AI–, and connect the cable shield to the metal lug to the right. NOTE: Do not use the clear wire on the transducer cable for any connections; tape the end and tie it back to the cable with electrical tape so that it does not touch any other components or connections.

Note: To connect the wires;

1. If the wire ends are not pre-stripped, strip them back about 1/2”.

2. Push the spring terminals up (back).

3. Insert the wires.

4. Release the spring terminals.

Table 6-3: Control Pressure Set Point and Tank Pre-Charge Pressure Values (PSI)

Pressure Point Precharge

Setting (PSI) Pressure (PSI)

25 18 30 21 35 25 40 28 45 32

50 35 55 39

60 (Default) 42

65 46 70 49

75 53 80 56 85 60 90 63 95 67

Cable Shield

Clear Wire; tape end to cable.

Red to AI+

Black to AI–

Transducer Cable Connections

Connections for Both 3-Phase and 3-Wire Motors.

Cable Shield Lug

Output Ground Screw

Input Power Connections

Input Ground Screw

See Figures 5–9, Page 11, for information

about I/O Connections O1, I1,V+, and V–.

Red Yellow

Black

Green/Yellow (Ground)

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Figure 6-5: Basic Wiring Connections for Startup.

NOTE: Do not connect the clear wire on the transducer cable to any terminal; instead, tie it back with electrician’s tape so that it cannot touch any other components or connections.

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