Sta-Rite P43B0007A2 Installation Manual

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Page 1

OWNERS MANUAL

INSTALLATION AND

OPERATING INSTRUCTIONS

4" SUBMERSIBLE PUMPS

Two and Three Wire

Single and Three Phase

1/2 through 10 H.P.

60 Hz

Record the following information from the motor and pump nameplates for future reference:

Pump Model No.

Pump Serial No.

Motor Model No.

Motor Serial No.

H.P. Volts/Hz/Ph

Rated Amp Draw

Page 2

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

This is the safety-alert. 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.

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.

To avoid serious or fatal personal injury and possible property damage, carefully read and follow the safety instructions.

Hazardous pressure. Under certain conditions, submersible pumps can develop extremely high pressure. Install a pressure relief valve capable of passing entire pump flow at 75 PSI (517 kPa) when using an air over water pressure tank. Install a pressure relief valve capable of passing entire pump flow at 100 PSI (690 kPa) when using a pre-charged pressure tank.

Do not allow pump, pressure tank, pip-

ing, or any other system component containing water to freeze. Freezing may damage system, leading to injury or flooding. Allowing pump or system components to freeze will void warranty.

2. Hazardous voltage. Can shock, burn or cause death. To avoid dangerous or fatal electric shock hazard, use pump only in a water well.

Risk of dangerous or fatal electrical

shock. Do not install this pump in any pond,

river, or other open body of water that could be used for swimming or recreation. Do not swim, wade or play in a body of water in which a submersible pump has been installed.

Installation must meet United States

National Electrical Code, Canadian Electrical Code, and local codes (as applicable) for all wiring.

Disconnect electrical power supply before

installing or servicing pump.

Make sure line voltage and frequency of

power supply match motor nameplate voltage and frequency.

3. Install pump according to all plumbing, pump and well code requirements.

4. Test well water for purity before using well. Call

your local health department for testing procedure.

5. During installation, keep well covered as much as possible to prevent leaves and foreign matter from falling into well. Foreign objects in well can contaminate the water and cause serious mechanical damage to the pump.

6. Pipe joint compound can cause cracking in plastics. Use only teflon tape when sealing joints in plastic pipe or connecting pipe to thermoplastic pumps.

TABLE OF CONTENTS

Safety Instructions . . . . . . . . . . . . . . . . . . . . . .2

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . .2

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

PENTEK XE-Series . . . . . . . . . . . . . . . . . . . . . .4

PENTEK T-Series . . . . . . . . . . . . . . . . . . . . . .5-6

PENTEK 3-Phase . . . . . . . . . . . . . . . . . . . . . . .7

Franklin . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . .12-18

Installation . . . . . . . . . . . . . . . . . . . . . . . .19-20

Initial Startup . . . . . . . . . . . . . . . . . . . . . .20-21

Effluent Applications . . . . . . . . . . . . . . . . . .21

Connecting to Tank/Water System . . . . . .21-23

Troubleshooting Guide . . . . . . . . . . . . . .24-25

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

PRE-INSTALLATION

Inspect pump and motor for delivery damage. Report any damage immediately to the shipping carrier or to your dealer.

The well driller should thoroughly develop the well (that is, pump out all fine sand and foreign matter) before pump is installed.

Pump performance is based on pumping clear, cold, liquid water.

Warranty is void in the following conditions:

• If pump has pumped excessive sand – excessive sand can cause premature wear to pump.

• If water is corrosive.

• If entrained gas or air are present in the water being pumped – these can reduce flow and cause cavitation which can damage pump.

• If pump has been operated with discharge valve closed – severe internal damage will result.

Install pump at least 15 to 20' (4.5 to 6M) below the lowest water level reached with pump running (lowest draw-down water level), and at least 5' (1.5M) above the bottom of the well.

WIRING/GROUNDING:

Hazardous voltage. Can shock, burn, or cause death. Permanently ground pump, motor and control box before connecting power supply to motor.

Ground pump and motor in accordance with the local codes and ordinances. Use a copper ground wire at least as large as wires carrying current to motor.

Page 3

Motor is supplied with a copper ground wire. Splice this ground wire to a copper conductor that matches motor wire size specified in cable sizing charts,pages 5, 6, 10, and 11. See Pages 19 and 20 for cable splicing instructions.

Permanently ground pump, motor and control box before connecting power cable to power supply. Connect ground wire to approved ground first and then connect to equipment being installed.

Do not ground to a gas supply line.

Fire and electrical shock hazard. If using a drop cable larger than No. 10 (5.5mm2) (for example, No. 8 (8.4mm2) wire) between pump and control box, run cable to a separate junction box. Connect junction box to control box with a No. 10 (5.5mm2) or smaller wire (depending on amp rating of pump – see Table II, III, or IV).

For more information, contact your local code officials.

WIRING CONNECTIONS:

Installation must meet United States National Electrical Code, Canadian Electrical Code and local codes for all wiring (as applicable).

Use only copper wire when making connections to pump and control box.

To avoid over-heating wire and excessive voltage drop at motor, be sure that wire size is at least as large as size listed in cable sizing charts for your horsepower pump and length of wire run.

NOTICE: See Pages 14 through 18 for typical wiring hookups and control box identification.

NOTICE: When built-in overheating protection is not provided, install an approved overload

equipped motor control that matches motor input in full load amps. Select or adjust overload element(s) in accordance with control instructions. When built-in overheating protection is provided, use an approved motor control that matches motor input in full load amperes.

Rotation – (3 Phase only)

To make sure motor is running in the right direction, proceed carefully as follows:

After electrical connections have been made as outlined, and with pump hanging in well supported from clamp on the discharge pipe, turn on then turn off the switch connecting the motor to the power supply line. Note rotation of pump as motor starts. If connections are properly made, pump will “jerk” clockwise when looking into the pump discharge when started. If “jerk” is counter-clockwise, the motor is running in the

wrong direction. Interchange any two cable leads where they connect to the “lead” terminals in the magnetic starter. With connections properly made, and pump lowered into water, turn on the switch again and the pump should deliver water according to the performance charts.

OVERLOAD PROTECTION OF THREE PHASE SUBMERSIBLE MOTORS – CLASS 10 PROTECTION REQUIRED

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

If the motor is stalled, the overload must trip within 10 seconds to protect the motor windings. The installer must use SUBTROL or the quick-trip protection shown in Tables VIII and IX. All recommended overload selections are of the ambient compensated type to maintain protection at high and low air temperatures.

All heaters and amp settings shown are based on total line amps. When a six-lead motor is used with a Wye-Delta starter, divide motor amps by

1.732 to make your selection or adjustment for heaters carrying phase amps.

Table VIII lists the correct selection and settings of overloads for PENTEK T-Series motors. Table IX lists the same for Franklin motors. Approval of other types may be requested from the motor manufacturer.

NOTICE: Warranty on three phase submersible motors is void unless proper quick trip protection in all three motor lines is used.

SURGE ARRESTERS IN CONTROL BOX

Grounding: When the box has a surge arrester, the surge arrester MUST be grounded, metal to metal, all the way to the water strata for the arrester to be effective. Grounding the arrester to a driven ground rod provides little or no protection for the motor.

NOTICE: Surge arresters DO NOT protect

against direct lightning strikes. Install grounded surge arresters to protect pump

from high voltage surges. Install arrester on the incoming power line to control box or pressure switch, as close to pump motor as possible. See Figures 1 and 2 for installation wiring diagrams for arresters.

NOTICE: Ground the arrester with a No. 10 or larger bare wire. Ground according to local code requirements.

NOTICE: If surge arresters wired into the control box are against local electrical code, contact power company for correct wiring information.

Page 4

Motor Winding Service Locked Fuze Size

Volts/ Resistance Factor Rotor Standard/

HP Hz/Ph Ohms Amps Amps Dual Element

1/2 115/60/1 1.4-1.7 9.5 36.4 30/20

1/2 230/60/1 4.6-5.6 4.7 19.5 15/10

3/4 230/60/1 3.5-4.3 6.4 24.8 20/15

TABLE II:

Recommended Fusing Data PENTEK XE-Series 60 Hz., Single Phase 2 Wire Submersible Pump Motors

NOTE: 2 Wire motor leads are not color coded. Overload is

located in motor and cannot be tested from above ground.

Motor Winding Service Locked Fuze Size

Volts/ Resistance-Ohms Factor Rotor Standard/

HP Hz/Ph R to Y B to Y Amps Amps Dual Element

1/2 115/60/1 5.7-7.0 1.1-1.4 11.5 49.6 35/20 1/2 230/60/1 16.3-19.9 4.0-4.9 6.3 22.3 20/10 3/4 230/60/1 11.1-13.6 2.7-3.3 8.3 32.0 25/15

1 230/60/1 10.6-13.0 2.5-3.1 9.7 41.2 30/20

1-1/2 230/60/1 7.4-9.1 1.9-2.4 11.0 47.8 35/20

TABLE I: Recommended Fusing Data -

PENTEK XE-Series 60 Hz., Single Phase, 3 Wire Induction Run Submersible Pump Motors

XE-Series Motor SMC Submersible Motor Control Type

Model No. (3-W) HP Volts/Hz/Ph CSIR CSCR

P43B0005A1 1/2 115/60/1 SMC-IR0511 – P43B0005A2 1/2 230/60/1 SMC-IR0521 SMC-CR0521 P43B0007A2 3/4 230/60/1 SMC-IR0721 SMC-CR0721 P43B0010A2 1 230/60/1 SMC-IR1021 SMC-CR1021 P43B0015A2 1-1/2 230/60/1 – SMC-CR1521

PENTEK XE-Series Motor, Submersible Motor Control, and Fusing/Wiring Specifications.

TABLE IV: PENTEK Motor/Control Coordination

TABLE III: Copper

Cable Length in Feet (Service to Motor)

Volts HP 14AWG 12AWG 10AWG 8AWG 6AWG 4AWG 3AWG 2AWG 1AWG

115V 1/2 99’ 157’ 250’ 398’ 633’ 1006’ 1269’ 1599’ 2016’

1/2 361 575 914 1453 2310 3673 4633 5839 7360

230V

3/4 274 436 694 1103 1753 2788 3517 4432 5587

1 235 373 593 944 1500 2385 3009 3793 4781

1-1/2 207 329 523 832 1323 2104 2653 3344 4216

PENTEK XE-Series Motors: 1 Ph, 3-Wire Cable, 60 Hz. Wire Size

Volts HP 14AWG 12AWG 10AWG 8AWG 6AWG 4AWG 3AWG 2AWG 1AWG

115V 1/2 120’ 191’ 303’ 482’ 766’ 1218’ 1536’ 1936’ 2441’

230V

1/2 485 770 1225 1947 3096 4923 6210 7827 9866 3/4 356 566 899 1430 2274 3615 4561 5748 7245

PENTEK XE-Series Motors: 1 Ph, 2-Wire Cable, 60 Hz. Wire Size

Volts HP KW 2.5 4 6 10 16 25 35 50 70

115V 1/2 .37 30m 48m 76m 121m 193m 307m 387m 488m 615m

1/2 .37 110 175 278 443 704 1119 1412 1780 2243

230V

3/4 .55 84 133 211 336 534 850 1072 1351 1703

1 .75 72 114 181 288 457 727 917 1156 1457

1-1/2 1.1 63 100 160 254 403 641 809 1019 1285

PENTEK XE-Series Motors: 1 Ph, 3-Wire Cable, 60 Hz. Wire Size in mm

TABLE III-M: Copper Cable Length in Meters (Service to Motor)

Volts HP KW 2.5 4 6 10 16 25 35 50 70

115V 1/2 .37 37m 58m 92m 147m 233m 371m 468m 590m 744m

230V

1/2 .37 148 235 373 594 944 1501 1893 2386 3007 3/4 .55 108 172 274 436 693 1102 1390 1750 2208

PENTEK XE-Series Motors: 1 Ph, 2-Wire Cable, 60 Hz. Wire Size in mm

NOTE: PENTEK XE- and T-Series Motors with model numbers beginning ‘P42’ or ‘P42T’ are 2-Wire motors and do not use a Submersible Motor Control.

Page 5

Motor Fuze Size

Winding Service Locked Standard/

Volts/ Resistance Factor Rotor Dual Element/

HP Hz/Ph Ohms Amps Amps CB

1/2 115/60/1 1 11.0 38 35/20/30

1/2 230/60/1 4 5.5 19.0 20/10/15

3/4 230/60/1 2.47 7.4 25.0 25/15/20

1 230/60/1 1.87 8.9 38 30/20/25

TABLE VI:

Recommended Fusing Data PENTEK T-Series 60 Hz., Single Phase 2 Wire Submersible Pump Motors

NOTE: 2 Wire motor leads are not color coded. Overload is

located in motor and cannot be tested from above ground.

Fuze Size

Motor Winding Service Locked Standard/

Volts/ Resistance-Ohms Factor Rotor Dual Element/

HP Hz/Ph Main Start Amps Amps CB

1/2 230/60/1 3.7 8.6 5.5 19 20/10/15

3/4 230/60/1 2.5 4.8 7.4 25 25/15/20

1 230/60/1 1.9 4.2 8.9 38 30/20/25

1-1/2 230/60/1 1.45 3.3 12.7 49 35/20/30

2 230/60/1 1.3 2.45 12.8 50 30/20/25

3 230/60/1 1.1 2.87 17.1 55 45/30/40

5 230/60/1 0.8 1.7 25.9 83 80/45/60

TABLE V: Recommended Fusing Data -

PENTEK T-Series 60 Hz., Single Phase, 3 Wire Induction Run Submersible Pump Motors

T-Series Motor SMCT Submersible Motor Control Type

Model No. (3-W) HP Volts/Hz/Ph CSCR CSCRP

P43T0005A2 1/2 230/60/1 SMCT-CR0521 – P43T0007A2 3/4 230/60/1 SMCT-CR0721 – P43T0010A2 1 230/60/1 SMCT-CR1021 _ P43T0015A2 1-1/2 230/60/1 SMCT-CR1521 _ P43T0020A2 2 230/60/1 SMCT-CR2021 SMCT-CRP2021 P43T0030A2 3 230/60/1 SMCT-CR3021 SMCT-CRP3021

P43T0050A2 5 230/60/1 SMCT-CR5021 SMCT-CRP5021

NOTE: PENTEK XE- and T-Series Motors with model numbers beginning ‘P42’ or ‘P42T’ are 2-Wire motors and do not use a Submersible Motor Control.

PENTEK T-Series Motor, Submersible Motor Control, and Fusing/Wiring Specifications.

TABLE VII: PENTEK T-Series Motor/Control Coordination

A Note on Nomenclature:

SSuubbmmeerrssiibbllee MMoottoorr CCoonnttrrooll::

The box, including the terminal strip(s), capacitor(s), relay(s), etc, which controls the basic on/off functions for a submersible motor.

VVaarriiaabbllee SSppeeeedd DDrriivvee::

A programmable motor control that varies pump speed to maintain constant pressure under varying load conditions.

Submersible Motor Control Compatability

Motor Submersible Motor Control Type Type

SMC Franklin SMCT

PENTEK XE-Series Yes Yes NO Franklin Yes Yes NO PENTEK T-Series NO NO Yes

Page 6

Volts HP KW 2.5 4 6 10 16 25 35 50 70

115V 1/2 .37 31m 50m 79m 126m 214m 320m 404m 509m 642m

1/2 .37 126 200 319 507 806 1282 1617 2038 2571 3/4 .55 93 149 237 377 599 953 1202 1515 1911

1 .75 78 124 197 313 498 792 999 1260 1589

230V 1-1/2 1.1 54 86 138 219 349 555 700 883 1115

2 1.5 54 86 137 217 346 551 694 876 1105 3 2.2 40 64 102 163 259 412 520 655 827 5 3.7 – – 67 107 171 272 343 432 546

PENTEK T-Series Motors: 1 Phase, 3- or 2- Wire Cable, 60 Hz. Wire Size in mm

Volts HP KW 2.5 4 6 10 16 25 35 50 70

230V

5 3.7 36 57 91 145 231 367 463 584 735

7-1/2 5.5 – – 67 107 170 271 342 431 544

3 2.2 231 367 584 929 1478 2350 2965 3737 4714

460V

5 3.7 144 229 365 581 924 1469 1853 2335 2946

7-1/2 5.5 106 169 270 429 682 1085 1368 1725 2176

10 7.5 83 132 211 336 534 240 1071 1350 1704

PENTEK T-Series Motors: 3 Phase, 60 Hz. Wire Size in mm

All cable lengths meet NEC for jacketed 60°C copper cable. Based on 3-Wire Induction Run requirements; Capacitor Run requirements may vary. Local code requirements may vary. For aluminum cable, go up two sizes from chart (for example, if the chart calls for No. 10 AWG for copper, go to No. 8 AWG for aluminum; the smaller the number, the larger the cable). Use oxidation inhibitors on the connections.

Volts HP 14AWG 12AWG 10AWG 8AWG 6AWG 4AWG 3AWG 2AWG 1AWG

115V 1/2 104’ 165’ 262’ 416’ 662’ 1052’ 1327’ 1672’ 2109’

1/2 414 658 1047 1664 2646 4207 5307 6689 8438 3/4 308 489 778 1237 1967 3127 3944 4971 6271

1 256 407 647 1028 1635 2600 3280 4134 5214

230V 1-1/2 179 285 453 721 1146 1822 2298 2897 3654

2 178 283 450 715 1137 1808 2280 2874 3626 3 133 212 337 535 851 1353 1707 2151 2714 5 – – 222 353 562 893 1127 1420 1792

PENTEK T-Series Motors: 1 Phase, 3- or 2-Wire Cable, 60 Hz. Wire Size

Volts HP 14AWG 12AWG 10AWG 8AWG 6AWG 4AWG 3AWG 2AWG 1AWG

230

5 119 189 300 477 758 1205 1520 1916 2417

7-1/2 – – 221 352 560 890 1123 1415 1785

3 759 1207 1919 3051 4851 7713 9729 12263 15469

460

5 474 754 1199 1907 3032 4821 6081 7664 9668

7.5 350 557 886 1408 2239 3560 4490 5660 7140 10 274 436 694 1103 1753 2788 3517 4432 5591

PENTEK T-Series Motors: 3 Phase, 60 Hz. Wire Size

NOTE

Specifications on pages 4 to 7 are for

PENTEK motors only. For Franklin

specifications, see Pages 8 to 11.

TABLE VIII-M: Copper Cable Length in Meters (Service to Motor)

TABLE VIII: Copper Cable Length in Feet (Service to Motor)

Page 7

NEMA

Overload Heater Relays† Adjustable Relays

Motor PENTEK Starter Allen Set Max.

Type Part Number HP kW Volts Size Bradley Furnas G.E. Amps Amps

P43T0030A4 3 2.2 460 0 J21 K37 L618A 5.6 6.0

P43T0050A3 5 3.7 230 1 J33 K61 L199B 20.0 22.0

4" P43T0050A4 5 3.7 460 0 J26 K49 L100B 8.9 9.6

3-Wire P43T0075A3 7-1/2 5.5 230 1 J37 K67 L293B 24.0 26.0

P43T0075A4 7-1/2 5.5 460 1 J30 K55 L147B 12.0 13.0

P43T0100A4 10 7.5 460 1 J33 K60 L199B 15.4 16.6

TABLE IX: PENTEK T-Series Three-Phase Motor Overload Protection (60 Hz, 3450 RPM)

* Table data are generated per NEC and Heater Manufacturer Recommendations (see 2005 NEC-Chapter 3, Tables 430.52, 430.248,

430.250, Allen Bradley, Siemens (Furnas) and G.E. catalogs for more information).

† Class 10 protection required. Warranty is void if Class 10 protection is not used.

PENTEK T-Series 3-Phase 4" MOTOR OVERLOAD PROTECTION

PENTEK T-Series 3-phase submersible motors must have Class 10 overload protection that will disconnect the power within 10 seconds in the case of a locked rotor. To accomplish this, fixedheater overloads are used. Refer to the chart below for appropriate heaters. The chart is based upon total line amps.

Divide the motor amps by 1.732 when using a 6lead motor with a Y-Delta Starter.

NOTICE: General Electric overload heaters are only usable with General Electric overload relays.

Do not adjust relays to exceed nameplate amps.

For reliable 3-Phase starter operation, length of wire between starter and service entrance should be not more than 25% of total wire length.

Motor Winding Service Locked Fuze Size

Volts/ Resistance Factor Rotor Standard/

HP Hz/Ph Ohms Amps Amps Dual Element

3 460/60/3 5.72-4.68 6.0 40 15/10

5 230/60/3 0.90-0.73 22.0 132 50/30

5 460/60/3 3.70-3.02 9.6 66 25/15

7-1/2 230/60/3 0.62-0.50 26.0 180 80/45

7-1/2 460/60/3 2.60-2.10 13.0 90 40/25

10 460/60/3 2.20-1.80 16.6 110 60/30

TABLE X: Recommended Fusing Data - PENTEK

T-Series 60 Hz., 3 Phase Submersible Pump Motors

NOTE

Specifications on pages 4 to 7 are for

PENTEK motors only. For Franklin

specifications, see Pages 8 to 11.

Page 8

TABLE IX NOTES:

NOTE 1: Furnas intermediate sizes between NEMA

starter sizes apply where (1) is shown in tables, size 13/4 replacing 2, 2-1/2 replacing 3, 3-1/2 replacing 4 and 4-1/2 replacing 5. Heaters were selected from Catalog 294, Table 332 and Table 632 (starter size 00, size B). Size 4 starters are heater type 4 (JG). Starters using these heater tables include classes 14, 17 and 18 (INNOVA), classes 36 and 37 (reduced voltage), and classes 87, 88 and 89 (pump and motor control centers). Overload relay adjustments should be set no higher than 100% unless necessary to stop nuisance tripping with measured amps in all lines below nameplate maximum. Heater selections for class 16 starters (Magnetic Definite Purpose) will be furnished upon request.

NOTE 2: Allen-Bradley heaters were selected from Catalog IC-110, Table 162 (through starter size 4), Table 547 (starter size 5), and Table 196 (starter size 6). Bulletin 505, 509, 520, 540 and 570 use these heater tables. Heater selections for bulletin 1232X and 1233X starters will be furnished upon request.

NOTE 3: General Electric heaters are type CR123 usable only on type CR124 overload relays and were selected from Catalog GEP-126OJ, page 184. Adjustment should be set no higher than 100%, unless necessary to stop nuisance tripping with measured amps in all lines below nameplate maximum.

NOTE 4: Adjustable overload relay amp settings apply to approved types listed. Relay adjustment should be set at the specified SET amps. Only if tripping occurs with amps in all lines measured to be within nameplate maximum amps should the setting be increased, not to exceed the MAX value shown.

Recommended Adjustable Overload Relays

AEG Series: B17S, B27S, B27-2. Allen Bradley: Bulletin 193, SMP-Class 10 only. Fanal Types: K7 or K7D through K400. Franklin Electric: Subtrol-Plus. General Electric: CR4G, CR7G, RT*1, RT*2, RTF3, RT*4,

CR324X-Class 10 only.

Klockner-Moeller Types: Z00, Z1, Z4, PKZM1, PKZM3, PKZ2. Lovato: RC9, RC22, RC80, RF9, RF25, RF95. Siemens Types: 3UA50, -52, -54, -55, -58, -59, -60, -61, -62,

-66, -68, -70, 3VUI3, 3VE, 3UB (Class 5). Sprecher and Schuh Types: CT, CT1, CTA 1, CT3K, CT3-12

thru CT3-42, KTA3, CEF1 & CET3 set at 6 sec. max., CEP 7 Class 10, CT4, 6, & 7, CT3.

Square D/Telemecanique: Class 9065 types TD, TE, TF, TG, TJ, TK, TR, TJE, TJF (Class 10) or LR1-D, LR1-F, LR2-D13,

-D23, -D33, Types 18A, 32A, SS-Class 10, SR-Class 10 and 63-A-LB Series. Integral 18,32,63, GV2-L, GV2-M, GV2-P, GV3-M (1.6-10 amp only).

Westinghouse Types: FT13, FT23, FT33, FT43, K7D, K27D, K67D, Advantage (Class 10), MOR, IQ500 (Class 5).

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

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

Heaters for Adjustable

NEMA

Overload Relays

Relays

Starter Furnas Allen Bradley GE

(Note 4)

HP KW Volts Size (Note 1) (Note 2) (Note 3) Set Max.

1.5 1.1 230 00 K39 J21 L680A 5.5 5.9 460 00 K29 J15 L343A 2.8 3.0 575 00 K26 J12 L282A 2.2 2.4

2 1.5 230 0 K49 J25 L910A 7.5 8.1

460 00 K33 J18 L463A 3.8 4.1 575 00 K29 J15 L380A 3.0 3.2

3 2.2 230 0 K52 J28 L122B 10.1 10.9

460 0 K37 J21 L618A 5.1 5.5 575 0 K34 J19 L510A 4.1 4.4

5 3.7 230 1 K61 J33 L199B 16.6 17.8

460 0 K49 J26 L100B 8.3 8.9 575 0 K42 J23 L825A 6.6 7.1

7.5 5.5 230 1 K67 J37 L293B 24.6 26.4 460 1 K55 J30 L147B 12.3 13.2 575 1 K52 J28 L122B 9.9 10.6

10 7.5 460 1 K61 J33 L220B 17.5 18.8

575 1 K57 J31 L181B 14.0 15.0

TABLE XI – Overloads for 3 Phase 60 Hertz 4" Franklin Electric Motors

NOTE

Specifications on this page are for Franklin motors only. For PENTEK specifications, see Pages 4 to 7.

Page 9

FIGURE 2 - Three Phase Surge Arrester (650 Volt Maximum)

FIGURE 1 – Typical 3 Wire, Single Phase, 230 Volt Surge Arrester

Max Input Line to Locked Fuze Size

Volts/ (S.F. Load) Line Rotor Standard/

HP Hz/Ph Amps Resistance Amps

Dual Element

1-1/2 230/60/3 5.9 3.2-4.0 33.2 15/10

460/60/3 3.0 13.0-16.0 16.6 8/5 575/60/3 2.4 20.3-25.3 13.3 6/4

2 230/60/3 8.1 2.4-3.0 46.6 25/15

460/60/3 4.1 9.7-12.0 23.3 15/8 575/60/3 3.2 15.1-18.7 18.6 10/5

3 230/60/3 10.8 1.8-2.2 61.9 30/20

460/60/3 5.4 7.0-8.7 31.0 15/10 575/60/3 4.3 10.9-13.6 24.8 15/8

5 230/60/3 17.7 0.93-1.2 106.0 50/30

460/60/3 8.9 3.6-4.4 53.2 25/15 575/60/3 7.1 5.6-6.9 42.6 20/15

7-1/2 230/60/3 26.0 0.61-0.75 164.0 80/45

460/60/3 13.0 2.4-3.4 81.9 40/25 575/60/3 10.4 3.5-5.1 65.5 30/20

10 460/60/3 18.5 1.8-2.3 116.0 60/45

575/60/3 14.8 2.8-3.5 92.8 45/35

TABLE XIV: Recommended Fusing Data Franklin 60 Hz, 3 Phase Submersible Pump Motors

Motor Winding Service Locked Fuze Size

Volts/ Resistance-Ohms

Factor Rotor Standard/

HP Hz/Ph R to Y B to Y Amps Amps Dual Element

1/2 115/60/1 4.1-5.1 1.0-1.3 12.0 50.5 35/20

1/2 230/60/1 16.7-20.5 4.2-5.2 6.0 23.0 20/10

3/4 230/60/1 11.0-13.4 3.0-3.6 8.0 34.2 25/15

1 230/60/1 10.1-12.3 2.2-2.7 9.8 41.8 30/20

Motor Winding Service Locked Fuze Size

Volts/ Resistance-Ohms

Factor Rotor Standard/

HP Hz/Ph R to Y B to Y Amps Amps Dual Element

1-1/2 230/60/1 6.2-12.0 1.5-2.3 11.5 52.0 35/20

2 230/60/1 5.2-7.15 1.6-2.3 13.2 51.0 30/20

3 230/60/1 3.0-4.9 0.9-1.5 17.0 82.0 45/30

5 230/60/1 2.1-2.8 0.68-1.0 27.5 121.0 80/45

Motor Winding Service Locked Fuze Size

Volts/ Resistance-Ohms

Factor Rotor Standard/

HP Hz/Ph Amps Amps Dual Element

1/2 115/60/1 1.0-1.3 12.0 64.4 35/20 1/2 230/60/1 4.2-5.2 6.0 32.2 20/10

3/4 230/60/1 3.0-3.6 8.0 40.7 25/15

1 230/60/1 2.2-2.7 9.8 48.7 30/20

1-1/2 230/60/1 1.5-1.9 13.1 66.6 35/20

TABLE XII: Recommended Fusing Data -

Franklin 60 Hz., Single Phase, 3 Wire Standard Submersible Pump Motors

Recommended Fusing Data - Franklin 60 Hz., Single Phase, 3 Wire Capacitor Run Submersible Pump Motors

Red to Yellow = start winding resistance; Black to Yellow = main winding resistance.

TABLE XIII:

Recommended Fusing Data Franklin 60 Hz., Single Phase 2 Wire Submersible Pump Motors

NOTE: 2 Wire motor leads are not color coded. Overload is

located in motor and cannot be tested from above ground.

NOTE

Specifications on this page are for Franklin motors only. For PENTEK specifications, see Pages 4 to 7.

Surge

Arrester

Control

Box

L1 L2 R Y B

Surge Arrester

Line

T1 T2

3 Phase Surge Arrester

Page 10

Volts HP 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG 3 AWG 2 AWG 1 AWG 0 AWG

115V 1/2 100’ 160’ 250’ 390’ 620’ 960’ 1190’ 1460’ 1780’ 2160’

1/2 400 650 1020 1610 2510 3880 4810 5880 7170 8720

3/4 300 480 760 1200 1870 2890 3580 4370 5330 6470

1 250 400 630 990 1540 2380 2960 3610 4410 5360

230V 1-1/2 190 310 480 770 1200 1870 2320 2850 3500 4280

2 150 250 390 620 970 1530 1910 2360 2390 3620

3 120* 190 300 470 750 1190 1490 1850 2320 2890

5 – – 180 280 450 710 890 1110 1390 1740

TABLE XV: Cable Length in Feet (Service to Motor)

1 Phase, 3- or 2-Wire Cable, Franklin Motors 60 Hz. Copper Wire Size AWG

Volts HP 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG 3 AWG 2 AWG 1 AWG 0 AWG

1-1/2 420’ 670’ 1060’ 1670’ 2610’ 4050’ 5030’ 6160’ 7530’ 9170’

2 320 510 810 1280 2010 3130 3890 4770 5860 7170

230V

3 240 390 620 990 1540 2400 2980 3660 4480 5470

5 140* 230 370 590 920 1430 1790 2190 2690 3290

7-1/2 – 160* 260 420 650 1020 1270 1560 1920 2340

10 – – 190* 310 490 760 950 1170 1440 1760

1-1/2 1700 2710 4270 6730 ––––––

2 1300 2070 3270 5150 8050 –––––

460V

3 1000 1600 2520 3970 6200 –––––

5 590 950 1500 2360 3700 5750 – – – –

7-1/2 420 680 1070 1690 2640 4100 5100 6260 7680 –

10 310 500 790 1250 1960 3050 3800 4650 5750 7050

1-1/2 2620 4180 6580 –––––––

2 2030 3250 5110 8060 ––––––

575V

3 1580 2530 3980 6270 5750 –––––

5 920 1480 2330 3680 5750 –––––

7-1/2 660 1060 1680 2650 4150 –––––

10 490 780 1240 1950 3060 4770 5940 – – –

3 Phase, 60 Hz. - Franklin Motors, Copper Wire Size AWG

*Meets NEC for individual conductor 60°C cable. Only lengths without * meet NEC for jacketed 60°C cable. Local code requirements may vary.

Table XV NOTES:

1. Sizes given are for copper wire. For aluminum wire, go two sizes larger. For example, if table lists #12 (3mm2) copper wire, use #10 (5mm2) aluminum wire. Use oxidation inhibitors on connections.

2. For reliable 3 Phase starter operation, length of wire between starter and service entrance should be not more than 25% of total wire length.

NOTE

Specifications on this page are for Franklin motors only. For PENTEK specifications, see Pages 4 to 7.

Motor Control

HP Voltage No. Box No.

1/2 115

214304

28010449

214504

1/2 230

214305

28010549

214505

3/4 230

214307

28010749

214507

1 230

214308

28010849

214508

1-1/2 230 224300 28230081

2 230 224301

28230181 28230183

3 230 224302

28230281 28230283

5 230 224303

28211381 28211383

TABLE XVI: Franklin Control Box Selection

Submersible Motor Control Compatability

Motor Submersible Motor Control Type Type

SMC Franklin SMCT

PENTEK XE-Series Yes Yes NO

Franklin Yes Yes NO PENTEK T-Series NO NO Yes

Page 11

NOTE

Specifications on this page are for Franklin motors only. For PENTEK specifications, see Pages 4 to 7.

Table XV-M NOTES:

1. Sizes given are for copper wire. For aluminum wire, go two sizes larger. For example, if table lists 4mm2 (#12) copper wire, use 6mm2(#10) aluminum wire. Use oxidation inhibitors on connections.

2. For reliable 3 Phase starter operation, length of wire between starter and service entrance should be not more than 25% of total wire length.

Volts HP KW 2.5 4 6 10 16 25 35 50 70

115V 1/2 .37 30m 49m 76m 119m 189m 293m 445m 543m 658m

1/2 .37 122 650 1020 1610 2510 3880 5880 7170 8720

3/4 .55 91 198 232 366 570 881 1332 1625 1970

1 .75 76 122 192 302 469 725 1100 1344 1634

230V 1-1/2 1.1 58 94 146 235 366 570 869 1067 1305

2 1.5 46 76 390 119 296 466 719 893 1103

3 2.2 37 58 300 91 229 363 564 707 881

5 3.7 – – 55 85 137 216 338 424 530

TABLE XV-M: Cable Length in Meters (Service to Motor)

1 Phase, 3- or 2-Wire Cable, Franklin Motors 60 Hz. Copper Wire Size in mm

Volts HP KW 2.5 4 6 10 16 25 35 50 70

1-1/2 1.1 120m 204m 323m 509m 796m 1234m 1878m 2295m 2795m

2 1.5 98 155 247 390 613 954 1454 1786 2185

230V

3 2.2 73 119 189 189 143 222 340 416 508

5 3.7 43 70 113 180 280 436 668 820 1003

7-1/2 5.5 – 49 79 128 198 311 475 585 713

10 7.5 – – 58 94 149 232 357 439 536

1-1/2 1.1 518 826 1301 2051 –––––

2 1.5 396 631 997 1570 2454 – – – –

460V

3 2.2 305 488 768 1210 1890 – – – –

5 3.7 180 290 457 719 1128 1753 – – –

7-1/2 5.5 128 207 326 515 805 1250 1908 2341 –

10 7.5 95 152 241 381 597 930 1417 1753 2149

1-1/2 1.1 799 1274 2006 ––––––

2 1.5 619 990 1558 2457 –––––

575V

3 2.2 482 771 1213 1911 –––––

5 3.7 280 451 710 1122 1753 – – – –

7-1/2 5.5 201 323 512 808 1265 – – – –

10 7.5 149 238 378 594 933 1454 – – –

3 Phase, 60 Hz. - Franklin Motors, Copper Wire Size in mm

Based on 3-Wire Induction Run requirements; Capacitor Run requirements may vary. Local code requirements may vary. For aluminum cable, go up two sizes from chart (for example, if the chart calls for No. 10 AWG for copper, go to No. 8 AWG for aluminum; the smaller the number, the larger the cable).

Page 12

Calculating Cable size when two different sizes can be used.

Sometimes conditions make it desirable to use more than one size cable in an installation.

For example: Replace a pump with a 3 HP, 230 volt, 60 Hz, single phase motor, with the motor setting at 210' down the well and with 160' of #10 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 VIII, a total of 280' of #10 cable is allowed to power the 3 HP motor. The per cent of this total that has been used by the 160' of cable in the buried run is: 160'/280' = .571 = 57.1%.

2. With 57.1% of the allowable cable already used,

42.9% of the total length is left for use in the well. To avoid running a cable that is too long and lowering the voltage to the motor, we have to find a cable size large enough so that 210' is less than 42.9% of the total length allowed for that size.

3. Trying #8 cable, Table VIII shows that the total allowable length for a 3 HP motor is 443'.

443' x 42.9% = 443' x .429 = 190.0' This is not long enough.

4. Trying #6 cable, Table VIII shows that the total allowable length is 689'.

689' x 42.9% = 689' x .429 = 295.6' This is longer than needed. Therefore, #6 cable

can be used for the 210' 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 does not exceed 100% of the allowed lengths.

Calculating Cable size when two different sizes can be used.

Example (Metric): When replacing pump motor in an installation already having 45M of buried 10 mm

cable between service entrance and well head, what size cable is required in the well (from well head to motor) when using a 3 HP (2.2kw), 230 volt, single phase motor set 125M below the well head?

Solution (Metric): According to Table VIII-M, 135M is the maximum allowable length when using 10 mm

cable with a 3 HP (2.2kw) 1ø motor. The installation has 45M already in place.

45M (used) ÷ 135M (allowed) = 33%. Approximately 33% of allowable cable has been used. That leaves approximately 67% of allowable cable still available for use in the well.

According to Table VIII-M, 16 mm

cable can be used to a maximum of 210M. 67% of 210M = 140M; this is more than the length required, therefore 16 mm

wire can be used.

NOTICE: When figuring the percent of cable length of any size that can be used, remember that the total percentages of all sizes cannot add to more than 100%.

45 M of 10 mm

(33% of Allowable Cable)

Service Entrance

(Main Fuse Box

From Meter)

(57.1% of Allowable Cable)

160 Ft. AWG 10

210 Ft. AWG 6

(42.9% of Allowable

Cable)

5411 0506

Pump

Controls

230V 1Ph Motor

Cable

3 HP (2.2 kw)

Service Entrance

(Main Fuse Box

From Meter)

Pump

Controls

Cable

3 HP (2.2 KW)

230V 1PH Motor

125 M of

16 mm

(67% of

Allowable

Cable)

Page 13

INSTALLATION WIRING DIAGRAMS SINGLE PHASE, 3 WIRE

For motors of 1-1/2 HP and above, use magnetic starter to avoid damage to pressure switch. Consult factory for wiring information.

Hazardous voltage. Can shock, burn, or kill.

Ground control box, all metal plumbing, and motor frame with copper wire in compliance with local codes. Use a ground wire at least as large as the wires supplying power to motor.

Permanently close all unused openings in this and other equipment.

Disconnect power to control box before working on or around control box, pipes, cable, pump, or motor.

To be sure that starting relay will function and that overload will not “nuisance trip”, install control box vertically with top side up.

Wire control box as shown on Pages 14 through

18. Pump will not operate without control box, and some boxes require a switch or a jumper lead between ‘SW’ and ‘L2’ terminals. Operation without control box will burn out motor.

Installation must meet United States National Electrical Code, Canadian Electrical Code, and local codes for all wiring (as applicable).

If main overload trips, look for:

1. Shorted Capacitor

2. Voltage Problems

3. Overloaded or locked pump. NOTICE: Match motor to control box or sub-

mersible motor control as shown on pages 4, 5 and

10. Franklin motor and control box model numbers may include additional suffix numbers to the right of the numbers shown here. These additional numbers are not important for control box selection.

LIQUID LEVEL (PUMP DOWN) CONTROLS:

Use pump down controls on wells with low flow to prevent pumping well dry. See Wiring diagrams, Pages 14 through 18, for proper installation.

NOTICE: Ground controls according to local code requirements.

If start overload trips, replace start relay. Reset and analyze for tripping cause. To avoid motor burnout, do not remove or short circuit overload protection.

Page 14

Installation Wiring Diagrams – Single Phase, 3 Wire

For motors of 1-1/2 HP and above, use magnetic starter to avoid damage to pressure

switch. Consult factory for wiring information.

SINGLE PHASE - 1/2 HP THRU 5 HP STANDARD

CONTROL BOX WITH ADEQUATE RATED

PRESSURE SWITCH

SINGLE PHASE - 1/2 HP THRU 5 HP STANDARD

CONTROL BOX WITH PRESSURE SWITCH (One pump

for 2 houses) With adequate rated pressure switch

Follow color coding when connecting control box (Yellow to Y, Red to R, Black to B).

CHECKING PROCEDURE (ALL BOXES):

Hazardous voltage. Can shock, burn, or cause death. Disconnect power to con-

trol box before doing these check procedures.

A. General Procedures. (Power to control box

disconnected)

1. Disconnect line.

2. Inspect for damaged or burned parts, loose connections, etc.

3. Check for misconnections against diagram in control box.

4. If box is too hot, circuit breakers may trip or fuses blow. Ventilate or shade box. Move away from heat source.

5. If problem has not been found, check motor and control box. Use test procedures that follow.

B. Ground (Insulation Resistance) Test. (Power

to control box disconnected)

1. Ohmmeter Setting: Highest scale (usually Rx100K or Rx10,000).

2. Terminal Connections: One ohmmeter lead to “Ground” screw on control box and touch other lead to each of the terminals on terminal board.

3. Ohmmeter Reading: Pointer should remain at infinity (∞) and not deflect.

C. Capacitor Tests. (Power to control box dis-

connected)

Risk of electric shock. Short

capacitor across terminals before testing.

1. Ohmmeter Setting: Rx1000.

2. Terminal Connections: Connect ohmmeter leads to black and orange wires out of capacitor case.

3. Ohmmeter Reading: Pointer should swing toward “zero” and “float” back to (∞). Capacitor is shorted if pointer does not move back to (∞), open if it does not move from (∞).

4. To reset capacitor, reverse ohmmeter connection to capacitor terminals.

D.Triac Test. (Solid state switch only)

1. Ohmmeter Setting: Rx1000.

2. Connect the leads to “R” (start) terminal and to orange lead terminal on start switch.

3. Ohmmeter reading: Infinity (∞).

E. Coil Test. (Solid state switch only)

1. Ohmmeter Setting: Rx1.

2. Connect leads to “Y” (common) and L2 terminal and to orange lead terminal on start switch.

3. Ohmmeter reading: Infinity (∞).

To Line

Fused

Disconnect

Switch

Ground

CONTROL

BOX

L1 M1

M2L2

L1 L2 R Y B

Pressure

Switch

Red

Yellow

Black

Well

Casing

Ground

355 0893

Pressure

Switch

Fused

Disconnect

Switch

L1 M1

M2L2

Aux. Relay

or Equivalent

To LineTo Line

Red Yellow

Black

Well

Casing

Ground

Pressure

L1 M1

M2L2

CONTROL

L1 L2 R Y B

Switch

BOX

Ground

359 0893

Page 15

Installation Wiring Diagrams – Single Phase, 3 Wire

For motors of 1-1/2 HP and above, use magnetic starter to avoid damage to pressure

switch. Consult factory for wiring information.

SINGLE PHASE - 1/2 HP THRU 5 HP STANDARD

CONTROL BOX WITH LIQUID LEVEL CONTROL

SINGLE PHASE - 1/2 HP THRU 5 HP STANDARD

CONTROL BOX WITH PRESSURE SWITCH &

LIQUID LEVEL CONTROL

To Line

Follow color coding when connecting control box (Yellow to Y, Red to R, Black to B).

OPEN SYSTEM-SINGLE PHASE - 1/2 HP THRU 5 HP

STANDARD CONTROL BOX

SINGLE PHASE - 2, 3 & 5 HP DELUXE CONTROL

BOXES WITH PRESSURE SWITCH

Fused

Disconnect

Switch

Liquid

Level

Control

Ground

Fused

Disconnect

Control

Box

L1 L2 R

Switch

BW Liquid

Level Control

To Line

Ground

Pressure

Switch

Control

Box

L1 L2 Y

High

Electrode

Low

Electrode

To Line

Fused

Disconnect

Switch

Red

Yellow

Black

Ground

Well

Casing

353 0893

Ground

Control

Box

L1 L2 R

Red Yellow Black

Well

Casing

Ground

357 0893

High

Electrode

Low

Electrode

Fused

Disconnect

Switch

To Line

Pressure

Switch

Yellow Black

Red

Ground

Yellow Black

Red

Well

Casing

Well

Casing

Ground

Control

Box

L1 L2 Y

3108 1197

1271 0994

Ground

Page 16

Installation Wiring Diagrams – Single Phase, 3 Wire

For motors of 1-1/2 HP and above, use magnetic starter to avoid damage to pressure

switch. Consult factory for wiring information.

SINGLE PHASE - 1/2 HP THRU 5 HP STANDARD

CONTROL BOX WITH LIQUID LEVEL CONTROL

SINGLE PHASE - 1/2 HP THRU 5 HP STANDARD

CONTROL BOX WITH PRESSURE SWITCH &

LIQUID LEVEL CONTROL

Follow color coding when connecting control box (Yellow to Y, Red to R, Black to B).

To Line

OPEN SYSTEM-SINGLE PHASE - 1/2 HP THRU 5 HP

STANDARD CONTROL BOX

Fused

Disconnect

Switch

Ground

Fused

Disconnect

Control

BW Liquid

Level Control

Box

L1 L2 Y

Switch

Level Control

BW Liquid

To Line

Ground

Pressure

Switch

Control

Box

L1 L2 Y

Yellow

Black

High

Electrode

Low

Electrode

Red

Well

Casing

Ground

354 0893

To Line

Fused

Disconnect

Switch

Ground

Yellow

Black

Red

High

Electrode

Low

Electrode

Control

Box

L1 L2 Y

Yellow

Black

Red

Well

Casing

Ground

358 0893

1270 0994

Well

Casing

Ground

Page 17

Installation Wiring Diagrams – Three Phase

THREE PHASE - 1-1/2 HP & LARGER

WITH PRESSURE SWITCH

THREE PHASE - 1-1/2 HP & LARGER

WITH PRESSURE SWITCH &

LIQUID LEVEL CONTROL

Follow color coding when connecting control box (Yellow to Y, Red to R, Black to B).

Fused Disconnect Switch

Magnetic

Starter

Pressure

Switch

L 2

L 3

L 1

T 3

T 2

T 1

Well

Casing

362 0893

Fused

Disconnect

Switch

Liquid Level Control

High Electrode

Lo Electrode

Pressure

Switch

Magnetic

Starter

L 2

L 1

T 1

Well

Casing

L 3

T 3

T 2

361 0893

Page 18

Installation Wiring Diagrams – 2 Wire

For motors of 1-1/2 HP and above, use magnetic starter to avoid damage to pressure

switch. Consult factory for wiring information.

WITH PRESSURE SWITCH

AND LIQUID LEVEL CONTROL

ONE PUMP FOR TWO HOUSES

WITH PRESSURE SWITCH

Follow color coding when connecting control box (Yellow to Y, Red to R, Black to B).

ONE PUMP FOR ONE HOUSE

WITH PRESSURE SWITCH

Fused

Disconnect

High

Electrode

Switch

To Line

Ground

Pressure

Switch

BW Liquid

Level Control

House No. 1

Line

Aux. Relay

or Equivalent

Fused

Disconnect

Switch

Pressure

Switch

House No. 2

Line

Low

Electrode

To Line

Disconnect

Fused

Switch

Ground

L1 M1

Black

Red

M2L2

Pressure

Well

Casing

Switch

Well

Casing

360 0893

Ground

363 0994

Ground

(Green)

Ground

Well

Casing

3109 1197

Page 19

FIGURE 10

FIGURE 11

FIGURE 12

Installation

CABLE SPLICING:

1. Splice cable to motor leads. Use one of the three methods outlined below. Use only copper wire for connections to pump motor and control box.

A. Taped splice (Wire sizes No. 8 (8.4mm2)

and larger):

1. Cut off motor leads. 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.

2. Cut off cable ends. Be sure to match colors and lengths of wires in drop cable to colors and lengths of motor leads.

3. Trim insulation back 1/2" (13mm) from cable ends and motor lead ends.

4. Insert motor lead ends and cable ends into butt connectors (see Figure 4). Be sure to match wire colors between drop cable and motor leads.

5. Using crimping pliers (Figure 7), indent butt connector lugs (see Figure 5) to attach wires.

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

7. 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. In other words, when finished you should have four layers of tape tightly wrapped around the wire. Press edges of tape firmly down against the wire (see Figure 8). NOTICE: Since the tightly wound tape is the only means of keeping water out of the splice, the efficiency of the splice will depend on the care used in wrapping the tape. NOTICE: For wire sizes larger than #8, (8.4mm

) use a soldered joint rather than

Scotchfil putty (see Figure 6).

B. Heat-shrink splice (For wire sizes #14, 12

and 10 AWG, or 2, 3, and 5.5mm2):

1. Remove 3/8" (10mm) insulation from ends of motor leads and drop cable wires.

2. Put plastic heat shrink tubing over motor leads.

3. Match wire colors and lengths in drop cable to wire colors and lengths of motor leads.

4. Insert cable and motor wire ends into butt connectors and crimp (See Figures 4 and 5). BE SURE to match wire colors between drop cable and motor leads. Pull leads to check connections.

5. Center tubing over butt connector and apply heat evenly with a torch (a match or lighter will not supply enough heat).

FIGURE 4

FIGURE 5

FIGURE 6

FIGURE 7

FIGURE 8

FIGURE 9

1/2"

(12.7mm)

BUTT CONNECTOR

INDENT HERE

ALTERNATE METHOD TWIST AND SOLDER

NOTCH

END CAP

12.7mm 12.7mm

GASKET

INSULATOR BODY

CONNECTOR

HEAT SHRINK TUBING

COMPLETED SPLICE

GASKET SLEEVE IN PLACE

BUTT CONNECTOR OR

CRIMP OR SOLDER

CAP SCREWED ON

INSULATOR BODY

CENTERED OVER SPLICE

Page 20

NOTICE: Keep torch moving. Too much concentrated heat may damage tubing (see Figure 9).

C. Butt Connectors with plastic insulators (for

14, 12 and 10 Gauge AWG Wire, or 2, 3 and 5.5mm2wire):

1. Cut off motor leads. Stagger lead and wire length so that 2nd lead is 4" (100mm) longer than 1st lead and 3rd lead is 4" (100mm) longer than second.

2. Cut off cable ends. Be sure to match colors and lengths of wires in drop cable to colors and lengths of motor leads.

3. Trim insulation back 1/2" (13mm) from cable ends and motor lead ends.

4. Unscrew plastic caps from insulators. Place a cap and a neoprene gasket sleeve on each wire end to be spliced (see Figure 10).

5. Slide insulator body onto one wire end (Figure 10).

6. Insert wire end into butt connector and crimp (see Figure 11). Be sure to match cable and motor wire colors.

7. Center insulator body over splice and slide neoprene sleeves into body as far as they will go. Screw caps onto insulator body (Figure 12) and tighten by hand for a strong, waterproof splice.

CABLE INSTALLATION

1. To test submersible, momentarily connect it to proper power supply. Power supply frequency and voltage must match motor nameplate frequency and voltage to within ±10%. (3 Phase pumps – see “Rotation,” Page 3).

2. Fasten cable leads securely to pump discharge section; leave 4-5" (100-127mm) of slack in leads at this point. Securely fasten leads to plastic pipe within 6" (150mm) of the pump discharge section. Use torque arresters to protect pump and pipe from twisting damage as pump starts and stops.

3. Connect copper ground wire to motor bracket. Ground wire must be at least as large as wires supplying current to motor. Consult current National Electrical Code, Canadian Electrical Code and local codes (as applicable) for grounding information.

4. Use only submersible cable supplied by pump manufacturer. When lowering pump into well, secure cable to discharge pipe at 10' (3.5M) intervals with Scotch #33 electrical tape. Take care not to damage pump cable. NOTICE: To avoid dropping the pump down the well or damaging cable or cable splices, NEVER allow pump cable to support weight of pump.

PUMP INSTALLATION

1. If a standard air over water pressure tank is being used, install two bleeder orifices about 2' (.6M) apart as shown in Figure 15, Page

21. These orifices will automatically charge the tank with air. See Figure 15 to determine orifice location. NOTICE: If Pre-charged tank is used, DO NOT install bleeder orifices. If pump and precharged tank are replacing a standard tank system, remove bleeder orifices before installing pump in well.

2. To prevent losing pump down the well, connect a safety rope strong enough to support pump and drop pipe (minimum 5/16" (8mm) twisted polypropylene or pronila rope) to eyelet on pump discharge. Tie off other end of safety rope securely to well seal, well cap or pitless adapter.

3. Discharge outlet is threaded 2” NPT (60 Hz) or 2” BSP (50 Hz). Use 100 PSI rated polyethylene plastic pipe for installations up to 100’ depth. Use 160 PSI rated polyethylene plastic pipe for installation up to 220’ depth. For depths beyond 220’, use galvanized steel pipe for the entire drop pipe.

INITIAL START-UP

NOTICE: NEVER operate pump with discharge

valve completely closed. Pump can destroy itself if run with discharge shut off (“deadheaded”) and warranty will be void.

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 (see Figure 13).

2. Mount motor control box (3-wire pump), fused disconnect switch (2-wire pump), or magnetic starter (3-phase pump) in a permanently weather proofed place. Make sure that controls will not be subjected to extreme heat or excess moisture.

3. Make sure controls are in OFF position.

4. Connect motor leads and power supply to motor control box, fused disconnect switch, or magnetic starter (see Wiring Diagrams, Pages 14 through 18). DO NOT START PUMP YET.

5. Set gate valve on discharge 1/3 open; start pump (see Figure 13).

6. 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).

Page 21

7. When water is completely clear at 1/3 setting, open gate valve to approximately twothirds open and repeat process.

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

9. Remove gate valve for permanent installation near tank (see Figures 14 and 15, Pages 22 and 23).

10. Install sanitary well seal or pitless adapter unit, well unit, electrical conduit and surface piping according to local code requirements.

EFFLUENT APPLICATIONS

Pumps designed and tested for effluent applications must meet the following:

Risk of electric shock. Do not

remove cord and strain relief. Do not connect conduit to pump.

1. Only qualified personnel should install the

pump and associated control equipment.

2. Vent sewage or septic tank according to local

codes.

3. Do not install pump in any location classified

as hazardous by National Electrical Code, ANSI/NFPA 70-1984.

4. These pumps are intended for permanent

connection only. Provide strain relief at control box for power supply cord connection to box. All control components must be UL listed and suitable for end use application.

CONNECTING TO TANK/WATER SYSTEM

Hazardous pressure. Submersible pumps can develop very high pressure in some situations. To prevent tank blowup, install a pressure relief valve able to pass full pump flow at 75 PSI (517 kPa) when using an air over water pressure tank. Install a pressure relief valve capable of passing entire pump flow at 100 PSI (690 kPa) when using a pre-charged pressure tank. Install this relief valve between pump and tank.

NOTICE: Allowing pump or piping system to

freeze may severely damage pump and will void warranty. Protect pump and entire piping system (including pressure tank) from freezing.

Standard Tank Hookup:

See Figure 15, Page 23 for piping connections to standard pressure tank and for correct distance of bleeder orifices from pressure tank.

Pre-charged Pressure Tank Hookup:

See Figure 14, Page 22 for piping connections to pre-charged pressure tank.

NOTICE: Check air pre-charge in tank before starting pump. Adjust pre-charge to 2 PSI (13.8 kPa) below pump cut-in setting. (For example, a

pre-charge tank used with a 30-50 switch should be pre-charged with air to 28 PSI (193 kPa) . Adjust pre-charge by either adding or bleeding air through tire valve located on top of tank. Check pre-charge annually and adjust as needed.

Important Electrical

Grounding Information

Hazardous voltage. Can shock, burn, or kill.To reduce the risk of electrical shock during pump operation, ground and bond the pump and motor as follows:

A. To reduce risk of electrical shock from metal

parts of the assembly other than the pump,

bond together all metal parts accessible at the well head (including metal discharge pipe, metal well casing, and the like). Use a metal bonding conductor at least as large as the

power cable conductors running down the well to the pump's motor.

B. Clamp or weld (or both if necessary) this

bonding conductor to the grounding means provided with the pump, which will be the equipment-grounding terminal, the grounding conductor on the pump housing, or an equipment-grounding lead. The equipment-grounding lead, when provided, will be the conductor having green insulation; it may also have one or more yellow stripes.

C. Ground the pump, motor, and any metallic

conduit that carries power cable conductors. Ground these back to the service by connecting a copper conductor from the pump, motor, and conduit to the grounding screw provided within the supply-connection box wiring compartment. This conductor must be at least as large as the circuit conductors supplying the pump

Save these instructions.

FIGURE 13

Control

center

electrical

disconnect

box

Pump installation

for developing a well

Temporary wiring

to control center or

electrical disconnect box

Temporary piping

Gate valve

Pump in well

689 0993

Page 22

PRESSURE SWITCH

FIGURE 14 – Typical Submersible Installation with Pre-charged Tank

Cut-In PSI Cut-Off PSI Pre-charge Pressure

20 (138 kPa) 40 (276 kPa) 18 PSI (124 kPa)

30 (207 kPa) 50 (345 kPa) 28 PSI (193 kPa)

40 (276 kPa) 60 (414 kPa) 38 PSI (262 kPa)

PRE-CHARGED TANK

ELECTRICAL DISCONNECT

CONTROL BOX

(3WIRE MODELS)

TO HOUSE SERVICE

PRESSURE GAUGE

RELIEF

VALVE

UNION

GATE VALVE

VENTILATED

WELL CAP

SUBMERSIBLE

CABLE

PITLESS

ADAPTOR

CHECK

VALVE

TAPE CABLE

TO PIPE

PUMP

Page 23

PRESSURE SWITCH

FIGURE 15 – Standard Pressure Tank Installation

CHECK VALVE DISTANCE TO TOP BLEEDER ORIFICE

TANK SIZE DISTANCE

42 Gallon (159L) 2' (.6M)

82 Gallon (310L) 3' (.9M)

120 Gallon (454L) 5' (1.4M)

220 Gallon (833L) 5' (1.4M)

315 Gallon (1192L) 10' (3.0M)

525 Gallon (1987L) 15' (4.6M)

AIR VOLUME CONTROL

PRESSURE GAUGE

TO HOUSE SERVICE

GATE VALVE

ELECTRICAL DISCONNECT

CONTROL BOX

(3 WIRE MODELS)

SUBMERSIBLE

VENTILATED

WELL CAP

CABLE

UNION

PITLESS

ADAPTOR

RELIEF VALVE

SEE TABLE

BLEEDER

CHECK VALVE

2 ft.

(.6m)

ORIFICE

& TEE

PIPE

COUPLING

PUMP

TAPE CABLE

TO PIPE

Page 24

PROBLEM CHECK CORRECTIVE ACTION

Motor will not start but fuses do not blow

No voltage No voltage at fuse box. Consult power supplier, check generator.

No voltage at control box. Check connections, rewire from fuse box to

control box.

No voltage at pressure switch Check connections, replace control box, rewire

from control box to pressure switch. No voltage on load side of Check connections, replace pressure switch. pressure switch. Cable or splices bad. Consult serviceman or licensed electrician. Control box incorrectly wired. Reconnect control box correctly (see wiring

diagrams, Pages 14 through 18).

Fuses blow or overload protector trips when motor starts

Wrong size fuse or wrong Check fuse size against chart, Page 4. Install correct fuse or time delay fuse. size time delay fuse.

Wire size too small Check wire size against chart, Page 5. Install correct size wire. Starting capacitor Check control box to see if starting Replace starting capacitor.

defective or blown. capacitor has blown out. Low or high voltage Check that line voltage is within ±10% of If voltage variation is greater than ±10%, call

nameplate rated voltage while motor is power company to adjust voltage. running.

Cable leads not correctly Check control box wiring diagram Reconnect leads to match wiring diagram in connected to control box. against incoming power hookup. control box cover.

Check drop cable color coding. Reconnect drop cable so cable color code

matches motor lead color code.

Broken wire in control Examine all connections and wiring in Disconnect power and repair or replace faulty box. control box. wire.

Pump or motor stuck or Check for locked rotor in pump. If necessary, pull pump (make all possible binding. above ground checks first). If pump is locked,

replace it. Clean well of all sand or lime before

reinstalling pump.

Fuses blow or overload protector trips when motor is running

Low or high voltage. Check that line voltage is within ±10% of If voltage variation is more than ±10%, call

rated nameplate voltage while motor is power company to adjust voltage. running.

High ambient Check temperature of control box. Do not mount control box in direct sunlight. (atmospheric temperature)

Control box with wrong Compare voltage and horsepower on Replace control box if numbers do not match. voltage or horsepower motor nameplate with those given on rating. control box nameplate or on circuit

diagram inside control box cover.

Wire size too small Check wire size against chart, Page 5. Install correct wire size. Cable splices or motor Consult licensed electrician or qualified Do not attempt to disassemble pump or motor.

leads grounded, shorted, serviceman. or open.

TROUBLESHOOTING GUIDE

Page 25

PROBLEM CHECK CORRECTIVE ACTION

Pump starts too frequently

Leaks in system. Check all tank connections with System must be air and water tight.

soapsuds for air leaks. Check plumbing for leaks.

Pressure switch. Check for defective switch or switch out Re-adjust or replace pressure switch.

of adjustment.

Tank waterlogged. Pre-charged tanks; check tank pre- Pre-charge tanks: adjust air pressure to 2 PSI

charge air pressure, check for leak in (13.8 kPa) less than pump cut-in pressure (when bladder. there is no water pressure on system).

Replace bladder if necessary. Air over water tanks: check for air leaks. Air over water tanks: repair or replace tanks;

Check Air Volume Control (AVC). replace snifter valves if necessary. Check snifter valve operation.

Leak in drop pipe. Raise drop pipe one length at a time Replace pipe above that point.

until water stands in pipe.

Pressure switch too far Measure distance from pressure switch Move switch to within one foot (.3M) of tank. from tank. to tank.

Little or no water delivered

Bleeder orifice check valve Examine valve. If stuck, free valve; if installed backwards, stuck or installed back- reverse it. wards (standard tank only).

Low water level. Determine lowest water level in well Lower pump further into well (but at least 5' (1.6M)

while pump is running and compare to above bottom of well). Throttle pump pump depth setting. discharge until discharge equals recovery rate

of well. NOTICE: Running pump while airlocked can cause loss of prime and seriously damage pump.

Low voltage. Check voltage at control box with pump Install larger wire from meter to control box.

running. Check incoming wire size and Install larger wire from control box to pump. drop cable size against chart, Page 5. If necessary, have power company raise supply

voltage.

Plugged intake screen. Pull pump and check condition of screen. Clean or replace as necessary.

Check valve at pump Pull pump and examine check valve. Free check valve. discharge stuck.

Worn impellers and Make sure system is clear of obstructions Replace pump. diffusers. and pump is in solid water and operation

normally.

Air or milky water discharge from faucets

Gas in well water. Check for presence of gas in well water. Remove bleeder orifices; plug tees. Be sure

plugged tees do not leak. If necessary, separate gas from air before it enters pressure tank.

Air volume control not Make sure ports and ball check valves Replace control if necessary. working (standard tanks are clear. only).

TROUBLESHOOTING GUIDE (cont.)

Page 26

LIMITED WARRANTY

PENTAIR WATER warrants to the original consumer of the products listed below, that they will be free from defects in material and workmanship for the Warranty Period from the date of original installation or manufacture as noted.

Product Warranty Period

Water Systems Products – jet pumps,

whichever occurs first:

small centrifugal pumps, submersible pumps 1 year from date of original installation, or and related accessories 2 years from date of manufacture

Our warranty will not apply to any product that has been subject to negligence, misapplication,

improper installation or maintenance. In the event a three phase submersible motor is operated

with single phase power through a phase converter, or if three-leg ambient compensated, extra- quick trip overload relays of recommended size are not used, our warranty is void.

Buyer’s only remedy and PENTAIR WATER’s only duty is to repair or replace defective products (at PENTAIR WATER’s choice). Buyer agrees to pay all labor and shipping charges associated with this warranty and to request warranty service through the installing dealer as soon as a problem is discovered. If warranty service is requested more than 30 days after the Warranty Period has ended, it will not be honored.

PENTAIR WATER SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT DAMAGES WHATSOEVER.

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE WARRANTY PERIOD PROVIDED HEREIN.

Certain states do not permit the exclusion or limitation of incidental or consequential damages or the placing of limitations on the duration of an implied warranty, therefore, the limitations or exclusions herein may not apply.This warranty sets forth specific legal rights and obligations, however, additional rights may exist, which may vary from state to state.

Supersedes all previous publications.

PENTAIR WATER, 293 Wright St., Delavan, WI 53115