INSTRUCTION MANUAL
IM103
5" and Larger
Submersible Pump
INSTALLATION AND OPERATION INSTRUCTIONS
SUBJECT |
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Safety Instructions..................................................................................................................................................................... |
3 |
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1.0 |
Preparing for Installation.................................................................................................................................................... |
4 |
2.0 |
Mechanical Installation....................................................................................................................................................... |
4 |
3.0 |
Electrical Instructions ......................................................................................................................................................... |
5 |
4.0 |
Operate Pump..................................................................................................................................................................... |
7 |
5.0 |
Literature and IOM............................................................................................................................................................ |
7 |
6.0 |
Accessories.......................................................................................................................................................................... |
7 |
Single Phase Wiring................................................................................................................................................................... |
8 |
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Three Phase Wiring................................................................................................................................................................... |
9 |
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Technical Data........................................................................................................................................................................ |
10 |
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Three Phase, 4" Motor - Electrical Data.................................................................................................................................. |
12 |
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Generation II - 3-Wire, Single Phase, 4" Motors - Electrical Data............................................................................................ |
12 |
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6" Single Phase Motors and Required Control Boxes............................................................................................................... |
13 |
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6-10" Three Phase Motors....................................................................................................................................................... |
13 |
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6" Single Phase Motors............................................................................................................................................................ |
14 |
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6-10" Three Phase Motors....................................................................................................................................................... |
14 |
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Three Phase Power Unbalance................................................................................................................................................. |
15 |
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Troubleshooting...................................................................................................................................................................... |
16 |
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Limited Warranty.................................................................................................................................................................... |
17 |
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Owner’s Information
Pump Model Number:
Pump Serial Number:
Motor Model Number:
Motor Serial Number:
Dealer:
Dealer Telephone:
Purchase Date:
Installation Date:
Dole® is a Registered Trademark of Eaton Corporation.
Cla-Val™ is a Trademark of Griswold Ind.
2
SAFETY INSTRUCTIONS
TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN MANUAL AND ON PUMP.
THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH THE PUMP.
This is a SAFETY ALERT SYMBOL. When you see this symbol on the pump or in the manual, look for one of the following signal words and be alert to the potential for personal injury or property damage.
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Warns of hazards that WILL cause serious personal injury, death or major property damage. |
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DANGER |
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Warns of hazards that CAN cause serious personal injury, death or major property damage. |
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WARNING |
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Warns of hazards that CAN cause personal injury or property damage. |
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CAUTION |
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NOTICE:INDICATES SPECIAL INSTRUCTIONS WHICH ARE VERY IMPORTANT AND MUST BE FOLLOWED. THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS PRIOR TO PERFORMING ANY WORK ON THIS PUMP. MAINTAIN ALL SAFETY DECALS.
Important notice: Read safety instructions before proceeding with any wiring
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All electrical work must be performed by a qualified technician. Always follow the National Electrical Code |
WARNING |
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(NEC), or the Canadian Electrical Code, as well as all local, state and provincial codes. Code questions should be |
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directed to your local electrical inspector. Failure to follow electrical codes and OSHA safety standards may result in personal injury or equipment damage. Failure to follow manufacturer’s installation instructions may result in electrical shock, fire hazard, personal injury or death, damaged equipment, provide unsatisfactory performance, and may void manufacturer’s warranty.
WARNING Standard units are designed to pump potable water from wells and storage tanks. They are not designed for use
in swimming pools, open bodies of water, hazardous liquids, or where flammable gases exist. Well must be vented per local codes.
Only pumps specifically Listed for Class 1, Division 1 are allowable in hazardous liquids and where flammable gases may exist.
See specific pump catalog bulletins or pump nameplate for all agency Listings.
WARNING
WARNING
WARNING
DANGER
WARNING
WARNING
CAUTION
WARNING
WARNING
WARNING
WARNING
CAUTION
DANGER
Disconnect and lockout electrical power before installing or servicing any electrical equipment. Many pumps are equipped with automatic thermal overload protection which may allow an overheated pump to restart unexpectedly.
Do not lift, carry or hang pump by the electrical cables. Damage to the Electrical Cables can cause shock, burns or death.
Use only stranded copper wire to pump/motor and ground. The ground wire must be at least as large as the power supply wires. Wires should be color coded for ease of maintenance and troubleshooting.
Install wire and ground according to the National Electrical Code (NEC), or the Canadian Electrical Code, as well as all local, state and provincial codes.
Install an all leg disconnect switch where required by code.
The electrical supply voltage and phase must match all equipment requirements. Incorrect voltage or phase can cause fire, motor and control damage, and voids the warranty.
All three phase (3Ø) controls for submersible pumps must provide Class 10, quick-trip, overload protection.
All splices must be waterproof. If using splice kits follow manufacturer’s instructions.
Select the correct type and NEMA grade junction box for the application and location. The junction box must insure dry, safe wiring connections.
Failure to permanently ground the pump, motor and controls before connecting to power can cause shock, burns or death.
Insure proper motor cooling, see Table 3, minimum flow rates chart in Technical Section.
This pump has been evaluated for use with Water Only.
Never over pressurize a storage tank to a pressure higher than the tank's maximum pressure rating. This will damage the tank, voids the warranty and may create a serious hazard.
3
1.0PREPARING FOR INSTALLATION
The well should be developed (cleaned) and disinfected before the pump is installed.
Write the pump model number, pump serial number and motor serial number in the space provided in this Installation and Operation Manual (IOM). Leave the completed IOM attached to the tank or control box in a dry area or give it to the owner. Attach your business card.
Verify that motor voltage, control voltage, coil voltage
(3 phase starters) and power supply voltage match. Electrical installation must be performed by qualified personnel.
Inspect all components for shipping damage and insure that you have all the components that are required: Pump Water End, Motor, 1Ø Motor Control Box or 3Ø Starter with Overloads, Pressure Tank, Pressure Switch, Copper Wire, Pressure Relief Valve (if required), Torque Arrestor (if required), Pipe and Fittings.
2.0MECHANICAL ASSEMBLY – Pump and Piping
2.1Typical Systems
Figure 1
Figure 2
Pump in “Can”
Figure 3
Pump with Flow Sleeve in Tank
Figure 4
Pump with Flow Sleeve in Large Diameter Well Figure 5
Horizontal Pump in “Can”
Figure 6
4
2.2 Assemble Pump End to Motor
Under no circumstance should the pump be run dry. Doing so may damage internal parts. We suggest you check the rotation on a three phase motor before assembling it to the water end (pump). All 4" and 6" single phase motors should rotate counterclockwise when viewed from the shaft end. Rotation on three phase motors should match pump specifications. Due to the high-starting torque the motor should be secured in such a way as not to damage the motor but to hold the motor from spinning.
Remove the cable guard from the pump (water end). Install the motor shaft sand slinger if included with the water end in the motor mounting hardware package. Attach the water end to the motor. Align the wires in the cable guard and reinstall it to the water end.
2.3 Install Check Valve(s)
Discharge heads are threaded with NPT pipe threads. All models, without built-in check valves, require a spring loaded check valve within 25' (7.5m) of the pump discharge and below the drawdown level of the water supply. Motor manufacturers recommend additional check valves every 200' to 250' (70m) in the vertical discharge line. Check valves are used to hold pressure in the system and to prevent backspin, water hammer and upthrust.
Backspin is allowing water to flow back through the pump to drain the system. It causes the impellers and motor rotor to rotate in a reverse direction. This can cause premature thrust bearing wear and if the motor starts during backspin the shaft can be twisted or broken.
Water Hammer occurs when the lowest check valve is more than 30' above the standing water level or the lower check valve leaks and the check valve above holds. This creates a partial vacuum (void) in the discharge piping. On the next start, water moving at a very high velocity fills the void and strikes the closed check valve and the stationary water in the pipe above it, causing a hydraulic shock. This shock (water hammer) can split pipes, break joints, and damage the pump and motor. Water hammer is an easily detected noise. When discovered the pump should be immediately shut down and the installer contacted to resolve the problem.
Upthrust is an upward movement of the impellers and motor shaft. It is caused by starting the pump at zero head due to no check valve or a leaking check valve; or very low system head due to a high static water level. Repeated upthrust can cause premature failure of either or both the pump and the motor. See 4.2
2.4 Installing Pump in Well
If you are using a torque arrestor, install it per the manufacturer’s installation instructions. On top feeding wells or large diameter wells where water velocity will not cool the motor properly install a flow sleeve over the pump. See Table 3
– Required Cooling Flow.
Connect the discharge pipe to the pump discharge head. Submersible pumps are capable of very high discharge pressures, consult with your pipe supplier to determine the best pipe material and schedule for each installation.
Lower the pump into the well. Set the pump at least 10' off the bottom but above the screens. Protect the wires from chafing on the well casing. Install a pitless adapter or similar device at the wellhead. Consult the fitting manufacturer or pitless supplier for specific installation instructions.
Using waterproof electrical tape, or wire ties, fasten the wires to the drop pipe at 10' intervals. Make sure that the tape does not loosen as it will block the pump suction if it falls down the well.
2.5 Pressure Relief Valve
Pressure relief valves are mandatory (required) on any system that is capable of producing over 100 psi or 230' TDH. In an area where a water leak or blow-off may damage property connect a drain line to the pressure relief valve. Run it to a suitable drain or an area where the water will not damage property.
2.6Pressure Tank and Pressure Switch (when used)
The pressure switch should be located at the tank cross tee on a single tank and as close to the center as possible on multiple tank installations. Multiple tank installations should have a manifold pipe 1½ to 2 times the size of the supply pipe from the pump. This is to reduce the friction head loss or pressure differential in the manifold. Excessive losses could cause switch chatter. There should be no filters, or high loss fittings between the switch and the tank(s). Wide open gate valves are allowed between the tank and switch.
2.7 Adjusting Tank Pre-Charge (when used)
Insure that the tank is empty of water. Use a high quality pressure gauge to check the tank pre-charge pressure. The pressure should be 2 psi below the pump cut-in (turn on) pressure. As an example, a 30-50 psi system would use a tank pre-charge of 28 psi.
Select an area where the temperature is above 34° F in which to install the tank, pressure switch, and pressure relief valve. The tank should be located in an area where a leak will not damage property.
3.0ELECTRICAL INSTRUCTIONS
3.1General
Note: Do not power the unit or run the pump until all electrical and plumbing connections are completed and the pump is filled with water.
Always follow the National Electric Code (N.E.C.) in the U.S., or the Canadian Electrical Code in Canada, as well as all state, provincial, or local codes.
All electrical work must be performed by qualified personnel. Some local laws require installation by only “licensed installers”.
We suggest using only copper wire. Size wire from the charts found in our ITT MAID, Motor Application & Installation Manual, or an N.E.C.( National Electric Code) manual. If discrepancies exist the N.E.C. in the U.S., and in Canada the Canadian Electrical Code prevails.
5
3.2 Splice Drop Cable to Motor Leads
When the drop cable must be spliced or connected to the motor leads it is necessary that the splice be watertight. The splice can be done with heat shrink kits, compression fittings, or waterproof tape. Match motor leads and drop cable by color codes or identify drop cable wires to insure a proper connection at the control box.
A.Heat Shrink Splice Instructions
To use a typical heat shrink kit: strip ½" from the motor wires and drop cable wires, it is best to stagger the splices. Place the heat shrink tubes on the wires. Place the crimps on the wires and crimp the ends. Slide the heat shrink tubes over the crimps and heat from the center outward. The sealant and adhesive will ooze out the ends when the tube shrinks. The tube, crimps, sealant, and adhesive create a very strong, watertight seal. Overheating may burn the heat shrink tubes.
B.Taped Splice Instructions
1)Strip individual conductor of insulation only as far as necessary to provide room for a stake type connector. Tubular connectors of the staked type are preferred. If connector O.D. is not as large as cable insulation, build-up with rubber electrical tape.
2)Tape individual joints with rubber electrical tape, using two layers; the first extending two inches beyond each end of the conductor insulation end, the second layer two inches beyond the ends of the first layer. Wrap tightly, eliminating air spaces as much as possible.
3)Tape over the rubber electrical tape with #33 Scotch electrical tape, or equivalent, using two layers as in step “B” and making each layer overlap the end of the preceding layer by at least two inches.
C.Compression Splice Kits
Consult instructions supplied with compression splice kits or consult your local supplier.
3.3 Mounting the Motor Control Box
Single phase 3-wire control boxes are suitable for vertical mounting in indoor or outdoor locations. They will operate at temperatures between 14ºF ( -10º C) and 122º F (50º C). Select a shaded, dry place to mount the box. Insure that there is enough clearance for the cover to be removed.
3.4 Verify Voltage
Insure that motor nameplate voltage and power supply voltage are the same. Three-phase starter coils are very voltage sensitive, always verify actual supply voltage with a voltmeter. High or low voltage will damage motors and controls and is not covered under warranty.
3.5 Turn Supply Power Off
Use a disconnect switch where required by code. Turn the circuit breaker OFF and lock-out the disconnect switch in the OFF position to prevent accidentally starting the pump before you are ready.
3.6Make Connection to Single Phase (1Ø) Control Box or Three Phase (3Ø) Starter
DANGER
Do not power the unit or run the pump until all electrical and plumbing connections are completed. Exception – to verify 3 phase motor rotation, it is acceptable to power the motor before it is attached to the water end to verify correct rotation. After checking rotation lock-out disconnect or circuit breaker in OFF position!
Verify that the disconnect or breaker is OFF before making any connections to the power supply. Always follow the National Electric Code (N.E.C.) in the U.S., or the Canadian Electrical Code in Canada, as well as all state, provincial, or local codes.
A. Single Phase (1Ø) Three-Wire Control Box Wiring
CAUTION
Connect the color coded motor leads to the motor control box terminals –
Y (yellow), R (red), and B (black); and the Green or bare wire to the green ground screw.
Connect wires between the Load terminals on the pressure switch and control box terminals L1 and L2. Run a ground wire between the switch ground and the control box ground. See Fig. 7 or 8
B. Three Phase (3Ø) Starter Wiring
CAUTION
Connect the motor leads to T1, T2, and T3 on the 3 phase starter. Connect the ground wire to the ground screw in the starter box. Follow starter manufacturers instructions for connecting pressure switch (where used) to starter. See Fig. 9 or 10
3.7 Make Power Supply Connection
CAUTION
Provide a separate fused or circuit breaker protected branch circuit for the pump. Install a main disconnect switch in full view and easily accessible from the pressure switch and tank location.
Single phase:
With pressure switch – make the connection from the pressure switch Line terminals to the disconnect switch (where used) and then to the circuit breaker panel.
Without pressure switch – make the connection from the control box L1 and L2 terminals to the disconnect switch (where used) and then to the circuit breaker panel.
Three phase - make the connections between L1, L2, L3, and ground on the starter to the disconnect switch and then to the circuit breaker panel.
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Three phase submersible motors require Class 10 Quick-Trip overload protection. Use Furnas Class 14 NEMA starters with ESP100 adjustable Class 10 overloads. You can also use Furnas Class 16 starters with ambient compensated “K” heaters (overloads) which you install in the starter. “K” heaters must be purchased separately. Consult the ITT MAID or F.E. AIM manual for other acceptable overload protection devices.
Note: when replacing a line shaft turbine or other above ground pump with a submersible you must change the Class 20 overloads in the starter to Class 10 quick-trip’s for proper motor overload protection. Use of Class 20 overloads voids the submersible motor warranty.
Three phase installations must be checked for motor rotation and phase unbalance. To reverse motor rotation switch (reverse) any two power leads. See the instructions for checking three phase unbalance in the Technical Section of this manual. Failure to check and correct three phase unbalance can cause premature motor failure and nuisance overload tripping.
4.0OPERATE PUMP
4.1Throttling Discharge on Start-Up
If the pump will be started or operated with an “open” discharge you must throttle the discharge before start-up. Install a ball, globe, or Cla-valve® in the discharge line. Open the valve to approximately 1⁄3 open on system start-up. This will prevent upthrust damage to the pump and motor bearings. You can open the valve when you get a good steady stream of water. Do not exceed the maximum operating range in gpm shown on the pump curve. If you do not know the maximum gpm for the pump, call the distributor who sold you the pump. Starting or running a pump with little or no head is a major cause of premature failure.
4.2Throttling a High Static Level Well to Prevent Upthrust
A high static water level well may allow a pump to operate off the right side of the curve or outside the “Recommended Range” shown on the pump curve. We recommend using a “Dole® ” flow restrictor or throttling the discharge with a ball valve to prevent upthrust damage to the pump and motor. The maximum flow must be within the pumps recommended operating range. If you use a ball valve, set it and remove the handle, tape the handle to the pipe. Tag the valve with a note saying, “Do not open this valve or pump may be damaged”. You can set the valve by installing a pressure gauge between the well and the valve and throttling the flow/head to a value within the recommended range. You can also throttle by determining the actual flow rate, see “Determining Flow Rates” in your catalog Technical Section.
4.3 Start the Pump
Partially open a valve (boiler drain or faucet) in the system and turn the breaker to the ON position. Allow the pump to run until the water is clear. On three phase systems verify rotation, correct rotation will yield the highest flow and pressure.
Check amps and insure they are within nameplate amp range from motor data sheet or motor nameplate. Amps should be between Rated Input and Service Factor Amps. High amps may be caused by low or high voltage. Enter the amp readings in this manual along with the pump and motor model numbers and serial numbers. On all three phase systems a three phase unbalance test must be performed to insure a balanced power supply. Leave a copy of the 3Ø unbalance worksheet with this IOM at the job site for future reference.
On pressure tank/switch systems only – close the valve when the water clears and allow the pressure to build. If properly adjusted the switch should turn the pump off at the preset pressure. Open a few outlets and allow the pump to run through a few cycles. Check switch operation and verify that pressure settings are correct. Check all fittings for leaks.
On manual systems, turn the pump off.
5.0PAPERWORK AND IOM
Please give this IOM and your business card to the owner. A sticker with your name and phone number on the tank or control box is a great sales tool for future business!
Congratulations on completing a professional installation of a submersible pump.
6.0ACCESSORIES
Pressure Tanks
Tanks should be sized to allow pumps over two (2) hp to run at least 2 minutes. If the pump averages 80 GPM it requires tanks to provide a 160 gallon “drawdown”. See your Water Products catalog for pressure tank data.
Low Water Protection
A low yield well should have low water protection added to the system. Contact your distributor for information on SymCom low water protection devices.
Electrical Panels
Customer Service will quote custom pump control panels. Please send written panel specifications to your authorized distributor. They will forward it to the Customer Service Group that supports their product line. Written specifications should include pump HP, Voltage, Phase, desired NEMA enclosure type, sequence of operation, special options needed, and a brief statement describing any special logic for alarms, timers, or duplexing features. The name and number of a contact person to answer questions is also appreciated and will speed your quote.
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Single Phase Wiring — Cableado monofásico — Montage monophasé
Incoming Supply from Fuse Box or Circuit Breaker (1)
L1 |
L2 |
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Disconnect |
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Switch (2) |
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(4) |
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(3) |
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Load Load Line |
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Line |
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(5) |
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NOTE: SymCom PumpSaver (6) |
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L1 |
L2 |
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R |
Y |
Blk |
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Three Wire |
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Yellow |
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Control Box (7) |
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Red |
Black |
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(8) |
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(9)(10)
Three Wire – Direct Connected to Pressure Switch
Trifilar – conectado directamente al interruptor por caída de presión
Moteur à trois fils – relié au prossostat
Figure (Figura) 7
Incoming Supply from Fuse Box or Circuit Breaker (1)
L1 L2
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Disconnect |
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(4) |
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Switch (2) |
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(3) |
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Load Load Line |
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Line |
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Pressure |
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Switch (5) |
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Magnetic Con- |
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tactor (11) |
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T1 |
T2 |
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L1 |
L2 |
Three Wire |
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R |
Y |
Blk |
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Control Box (7) |
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Red |
Yellow |
Black |
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(8) |
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(9)(10)
Three Wire – Connected through Magnetic Contactor
Trifilar – conectado a través del contactador magnético
Moteur à trois fils – relié par contacteur magnétique
Figure (Figura) 8
1.Suministro de entrada de la caja de fusibles o del cortacircuitos
2.Interruptor de desconexión
3.Línea
4.Carga
5.Interruptor por caída de presión
6.NOTA: PumpSaver
7.Caja de control trifilar
8.Rojo
9.Amarillo
10.Negro
11.Contactador magnético
1.Courant d’entrée provenant de la boîte à fusibles ou du disjoncteur
2.Sectionneur
3.Ligne
4.Charge
5.Pressostat
6.Protection PumpSaver
7.Boîte de commande à trois fils
8.Rouge
9.Jaune
10.Noir
11.Contacteur magnétique
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Three Phase Wiring — Cableado trifásico — Montage triphasé
Incoming Supply from Fuse Box or Circuit Breaker (1)
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(3) |
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Disconnect |
Line |
Load Load Line |
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Switch (2) |
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3 |
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Pressure Switch (5) |
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L1 |
L2 |
L3 |
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T1 |
T2 |
T3 |
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Heaters (6) |
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Ambient Compensated |
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Magnetic Starter with |
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Quick-Trip Heaters (7) |
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Three Phase Starter and Pressure Switch
Tres conexiones de fase
Pressostat et démarreur triphasé
Figure (Figura) 9
Incoming Supply from Fuse Box or Circuit Breaker (1)
Disconnect
Switch (2)
Field Connected (11)
L1 L2 L3
T1 T2 T3
2
Ambient
Compensated
Magnetic Starter
with Quick-Trip
Heaters (7)
Optional Motor
Grounding (10)
L1 L2
3
Control Transformer (Shunts must be matched to the Supply Voltage) (12)
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(4) |
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(3) |
(9) GND |
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Pressure |
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Line Load Load Line |
Switch |
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or other Pilot Switches (8)
Three Phase Starter with Control Voltage Transformer Arrancador trifásico con transformador de tensión de control Démarreur triphasé avec transformateur de tension de commande
1.Suministro de entrada de la caja de fusibles o del cortacircuitos
2.Interruptor de desconexión
3.Línea
4.Carga
5.Interruptor por caída de presión
6.Calentadores
7.Arrancador magnético con compensación ambiental con calentadores de disparo rápido
8.Interruptor por caída de presión u otros interruptores pilotos
9.Tierra
10.Puesta a tierra opcional del motor
11.Conexión de campo
12.Transformador de control (Las derivaciones deben coincidir con la tensión de suministro)
1.Courant d‘entrée provenant de la boîte à fusibles ou du disjoncteur
2.Sectionneur
3.Ligne
4.Charge
5.Pressostat
6.Dispositifs de protection contre la surcharge (DPS)
7.Démarreur magnétique compensé (température ambiante) avec DPS à déclenchement rapide
8.Pressostat ou autre contacteur de commande
9.Terre
10.Mise à la terre optionnelle pour le moteur
11.Connexion sur place
12.Transformateur de commande (les circuits dérivés [shunts] doivent convenir à la tension d’alimentation)
Figure (Figura) 10 |
9 |
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Technical Data
MOTOR INSULATION RESISTANCE READINGS
Normal Ohm/Megohm readings, ALL motors, between all leads and ground
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To perform insulation resistance test, open breaker and disconnect all leads from QD control box or |
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CAUTION |
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pressure switch. Connect one ohmmeter lead to any motor lead and one to metal drop pipe or |
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a good ground. R x 100K Scale |
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Condition of Motor and Leads |
OHM Value |
Megohm Value |
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New motor, without power cable |
20,000,000 (or more) |
20.0 |
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Used motor, which can be reinstalled in well |
10,000,000 (or more) |
10.0 |
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Motor in well – Readings are power cable plus motor |
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New motor |
2,000,000 (or more) |
2.0 |
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Motor in reasonably good condition |
500,000 to 2,000,000 |
0.5 – 2.0 |
Motor which may be damaged or have damaged power cable |
20,000 to 500,000 |
0.02 – 0.5 |
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Do not pull motor for these reasons |
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Motor definitely damaged or with damaged power cable |
10,000 to 20,000 |
0.01 – 0.02 |
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Pull motor and repair |
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Failed motor or power cable |
Less than 10,000 |
0 – 0.01 |
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Pull motor and repair |
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Generator Sizing |
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Note: Always consult the generator manufacturer when questions arise.
These sizing charts are recommendations based on motor service factor loading for typical continuous duty generators. If you need to call the generator manufacturer, be prepared to tell them the motor KVA code, the service factor amperage, locked rotor amperage, phase, hertz, motor type, etc.
You must know which type generator you have before using the charts as the required generator size varies by type. Internally regulated generators are also called self-excited. Externally regulated generators are the most common. In addition to the Kw/KVA rating, the generator frequency (Hertz, typically
60 HZ in USA) is very important when operating pumping equipment because frequency variations affect pump output in direct relation to the pump Affinity Laws. Operating under 60 hertz will reduce flow and head while operating over 60 hertz will increase flow, head, HP and amp draw and could overload the motor.
The generator should always be started before the pump/ motor is started and always stop the pump/motor before shutting down the generator. Operating generators at higher elevations or using natural gas as fuel can affect performance, consult the generator manufacturer for their recommendations in these instances.
Generator Recommendations
|
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Externally Regulated |
Internally Regulated |
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Motor |
HP |
KW |
KVA |
KW |
KVA |
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Minimum Generator Rating |
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|
.5 |
2 |
2.5 |
1.5 |
1.9 |
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.75 |
3 |
3.8 |
2 |
2.5 |
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1 |
4 |
5 |
2.5 |
3.2 |
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1.5 |
5 |
6.3 |
3 |
3.8 |
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2 |
7.5 |
9.4 |
4 |
5 |
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3 |
10 |
12.5 |
5 |
6.3 |
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5 |
15 |
18.8 |
7.5 |
9.4 |
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7.5 |
20 |
25 |
10 |
12.5 |
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3-Wire |
10 |
30 |
37.5 |
15 |
18.8 |
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15 |
40 |
50 |
20 |
25 |
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1Ø |
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20 |
60 |
75 |
25 |
31 |
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and |
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25 |
75 |
94 |
30 |
37.5 |
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3Ø |
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30 |
100 |
125 |
40 |
50 |
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Motors |
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40 |
100 |
125 |
50 |
62.5 |
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||||||
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50 |
150 |
188 |
60 |
75 |
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60 |
175 |
220 |
75 |
94 |
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75 |
250 |
313 |
100 |
125 |
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100 |
300 |
375 |
150 |
188 |
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125 |
375 |
469 |
175 |
219 |
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150 |
450 |
563 |
200 |
250 |
|
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175 |
525 |
656 |
250 |
313 |
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200 |
600 |
750 |
275 |
344 |
|
10
Technical Data (Continued)
Transformer Capacity Required for Submersible |
Frequency of Starts |
|
Motors – Single or Three Phase |
The average number of starts per day over a period of |
|
Distribution transformers must be adequately sized to satisfy |
months or years influences the life of a submersible pumping |
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system. Excessive cycling affects the life of control compo- |
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the KVA requirements of the submersible motor. When |
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nents such as pressure switches, starters, relays and capaci- |
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transformers are too small to supply the load, there is a |
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tors, plus splines and bearings. Rapid cycling can also cause |
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reduction in voltage to the motor. |
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motor overheating and winding failures. |
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Table 1 references the motor horsepower rating, single |
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The pump size, tank size and other controls should be select- |
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phase and three phase, total effective KVA required, and the |
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ed to keep the starts per day as low as practical for longest |
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smallest transformer required for open or closed three phase |
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life, based upon the maximum number of starts per 24 hour |
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systems. Open systems require larger transformers since only |
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day, as shown in Table 2. |
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two transformers are used. |
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Motors over 2 HP should be allowed to run a minimum of |
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Other loads would add directly to the KVA sizing require- |
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2 minutes to dissipate heat build up from starting current. |
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ments of the transformer bank. |
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|
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Table 1 – Transformer Capacity |
Table 2 – Number of Starts |
|
|
Smallest KVA Rating – |
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|
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Each Transformers |
|
Motor HP |
|
Open WYE |
Closed |
|
Total Effective |
or DELTA |
WYE or DELTA |
|
KVA Required |
2 Transformers |
3 Transformers |
1½ |
3 |
2 |
1 |
2 |
4 |
2 |
1.5 |
3 |
5 |
3 |
2 |
5 |
7.5 |
5 |
3 |
7½ |
10 |
7.5 |
5 |
10 |
15 |
10 |
5 |
15 |
20 |
15 |
7.5 |
20 |
25 |
15 |
10 |
25 |
30 |
20 |
10 |
30 |
40 |
25 |
15 |
40 |
50 |
30 |
20 |
50 |
60 |
35 |
20 |
60 |
75 |
40 |
25 |
75 |
90 |
50 |
30 |
100 |
120 |
65 |
40 |
125 |
150 |
85 |
50 |
150 |
175 |
100 |
60 |
175 |
200 |
115 |
70 |
200 |
230 |
130 |
75 |
Motor Rating |
Maximum Starts per 24 hour day |
||
Single Phase |
Three Phase |
||
|
|||
½ HP through 5 HP |
100 |
300 |
|
7½ HP through 30 HP |
50 |
100 |
|
40 HP and over |
— |
100 |
|
Motor Cooling, Temperature and Time Ratings
All 4 inch CentriPro motors may be operated continuously in water up to 86º F. Optimum service life will be attained by maintaining a minimum flow rate past the motor of .25 feet per second. Use a Flow Sleeve if velocity is below the
.25'/sec, if the well is top feeding or when the pump is used in a large body of water or large tank.
Six (6) inch canned design motors from 5 – 40 HP will operate in water up to 95º F (35º C), without any de-rating of horsepower, with a minimum flow rate of .5 ft./sec. past the motor. 6" – 50 HP and all 8" – 10" motors can operate in 77º F (25º C) water with .5'/sec velocity past the motor.
NOTE: Transformers shown are standard nominal KVA ratings. If power company experience and practice allows transformer loading higher than nominal rating under the specific operating conditions and maintains correct voltage and balance, such higher loading values may be used for transformer(s) to meet total effective KVA required.
Mounting Position
Motors are suitable for operation in mounting positions from vertical shaft up to horizontal. If 4 inch motors through 2 HP are started more than 10 times per day, it is recommended the shaft be tilted up at 15° from horizontal to minimize coast-down wear of the upthrust washer.
Table 3 – Minimum Flow Rates For Proper Motor Cooling
Well or |
3.75" Diameter |
CP = 5.5" Dia. |
CP = 7.52" Dia. |
Sleeve |
4" CP or FE Motor |
6" CP Motor |
8" CP Motor |
Diameter |
.25'/sec |
.5'/sec. |
.5'/sec. |
(inches) |
|
GPM Required |
|
4 |
1.2 |
– |
– |
5 |
7 |
– |
– |
6 |
13 |
7 |
– |
7 |
20 |
23 |
– |
8 |
30 |
41 |
9 |
10 |
50 |
85 |
53 |
12 |
80 |
139 |
107 |
14 |
110 |
198 |
170 |
16 |
150 |
276 |
313 |
Multiply gpm by .2271 for m3/Hr.
Multiply gpm by 3.785 for l/min.
11
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Full Load |
Service Factor |
Locked Rotor |
Line - Line |
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CentriPro # |
HP |
kW |
Volts |
SF |
Amps |
Watts |
Amps |
Watts |
Amps |
Resistance |
||
M30430 |
3 |
2.2 |
|
1.15 |
10.9 |
2890 |
12.0 |
3290 |
71 |
0.9-1.3 |
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M50430 |
5 |
3.7 |
200 |
1.15 |
18.3 |
4850 |
20.2 |
5515 |
113 |
0.4-0.8 |
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M75430 |
7.5 |
5.5 |
|
1.15 |
27.0 |
7600 |
30.0 |
8800 |
165 |
0.5-0.6 |
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M30432 |
3 |
2.2 |
|
1.15 |
9.2 |
2880 |
10.1 |
3280 |
58.9 |
1.3-1.7 |
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M50432 |
5 |
3.7 |
230 |
1.15 |
15.7 |
4925 |
17.5 |
5650 |
93 |
.85-1.25 |
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M75432 |
7.5 |
5.5 |
|
1.15 |
24 |
7480 |
26.4 |
8570 |
140 |
.55-.85 |
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M30434 |
3 |
2.2 |
|
1.15 |
4.8 |
2920 |
5.3 |
3320 |
30 |
5.9-6.5 |
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M50434 |
5 |
3.7 |
460 |
1.15 |
7.6 |
4810 |
8.5 |
5530 |
48 |
3.58-4.00 |
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M75434 |
7.5 |
5.5 |
1.15 |
12.2 |
7400 |
13.5 |
8560 |
87 |
1.9-2.3 |
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M100434 |
10 |
7.5 |
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1.15 |
15.6 |
9600 |
17.2 |
11000 |
110 |
1.8-2.2 |
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M30437 |
3 |
2.2 |
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1.15 |
3.7 |
2850 |
4.1 |
3240 |
21.1 |
9.4-9.7 |
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M50437 |
5 |
3.7 |
575 |
1.15 |
7.0 |
5080 |
7.6 |
5750 |
55 |
3.6-4.2 |
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M75437 |
7.5 |
5.5 |
|
1.15 |
9.1 |
7260 |
10.0 |
8310 |
55 |
3.6-4.2 |
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Full Load |
Service Factor |
Locked |
Winding |
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Resistance |
Required |
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Rotor |
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Type |
Order |
HP |
kW |
Volts |
SF |
Amps |
Watts |
Amps |
Watts |
Main |
Start |
Control Box1 |
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No. |
Amps |
(B-Y) |
(R-Y) |
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3-Wire |
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Y – 14.3 |
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Y – 16.5 |
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with CSCR |
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1.1 - |
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2.0 - |
CB30412CR or |
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M30412 |
3 |
2.2 |
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B – 12.0 |
3170 |
B – 13.9 |
3620 |
76 |
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(CR) or |
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R – 5.7 |
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R – 5.6 |
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1.4 |
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2.5 |
CB30412MC |
Magnetic |
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230 |
1.15 |
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Contactor |
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Y – 24.0 |
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Y – 27.0 |
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(MC) |
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.62 - |
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1.36 - |
CB50412CR or |
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M50412 |
5 |
3.7 |
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B – 19.1 |
5300 |
B – 22.0 |
6030 |
101 |
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Control |
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.76 |
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1.66 |
CB50412MC |
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R – 10.2 |
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R – 10.0 |
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Box |
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¹ A CSCR control box with a CR suffix can be replaced by a Magnetic Contactor model ending in MC.
12
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Motor |
HP |
kW |
Volts |
Phase |
Motor Dia. |
S.F. |
Rated Input |
Service Factor |
L.R. |
Control Box |
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Order No. |
vs Flange Dia. |
Amps |
Watts |
Amps |
Watts |
Amps |
Order No. |
|||||||
6M051 |
5 |
3.7 |
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|
24 |
4987 |
27.5 |
5735 |
124 |
CB05MC (3R) |
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6M071 |
7.5 |
5.5 |
230 |
1 |
6” x 6” |
1.15 |
36 |
7675 |
41 |
8950 |
167 |
CB07MC (3R) |
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6M101 |
10 |
7.5 |
50 |
10135 |
58 |
11830 |
202 |
CB10MC (3R) |
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6M151 |
15 |
11 |
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72 |
15180 |
85 |
18050 |
275 |
CB15MC (3R) |
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NEMA 3R control boxes will be replacing the current models.
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Motor |
HP |
kW |
Volts |
Phase |
Motor Dia. |
S.F. |
Rated Input |
Service Factor |
L.R. |
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Order No. |
vs Flange Dia. |
Amps |
Watts |
Amps |
Watts |
Amps |
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6M058 |
5 |
3.7 |
200 |
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17.5 |
4910 |
19.5 |
5610 |
124 |
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6M052 |
5 |
3.7 |
230 |
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15.0 |
4857 |
17.0 |
5520 |
110 |
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6M054 |
5 |
3.7 |
460 |
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7.5 |
4857 |
8.5 |
5520 |
55 |
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6M078 |
7.5 |
5.5 |
200 |
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25.4 |
7180 |
28.5 |
8230 |
158 |
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6M072 |
7.5 |
5.5 |
230 |
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22.0 |
7127 |
26.0 |
8140 |
144 |
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6M074 |
7.5 |
5.5 |
460 |
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11.0 |
7127 |
13.0 |
8140 |
72 |
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6M108 |
10 |
7.5 |
200 |
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33.3 |
9360 |
37.2 |
10700 |
236 |
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6M102 |
10 |
7.5 |
230 |
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29.0 |
9407 |
33.0 |
10730 |
208 |
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6M104 |
10 |
7.5 |
460 |
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14.5 |
9407 |
16.5 |
10730 |
104 |
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6M158 |
15 |
11 |
200 |
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47.4 |
13700 |
53.5 |
15710 |
347 |
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3 |
6" x 6" |
1.15 |
42.0 |
13700 |
46.0 |
15800 |
320 |
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6M152 |
15 |
11 |
230 |
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21.0 |
13700 |
23.0 |
15800 |
160 |
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6M154 |
15 |
11 |
460 |
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6M208 |
20 |
15 |
200 |
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61.2 |
18040 |
69.5 |
20820 |
431 |
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6M202 |
20 |
15 |
230 |
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54.0 |
17930 |
60.0 |
20650 |
392 |
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6M204 |
20 |
15 |
460 |
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27.0 |
17930 |
30.0 |
20650 |
196 |
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6M258 |
25 |
18.5 |
200 |
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77.3 |
22740 |
87.5 |
26190 |
578 |
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6M252 |
25 |
18.5 |
230 |
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68.0 |
22470 |
76.0 |
25800 |
530 |
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6M254 |
25 |
18.5 |
460 |
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34.0 |
22470 |
37.0 |
25800 |
265 |
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6M308 |
30 |
22 |
200 |
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91.8 |
27000 |
104.0 |
31120 |
674 |
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6M302 |
30 |
22 |
230 |
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82.0 |
27130 |
94.0 |
31160 |
610 |
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6M304 |
30 |
22 |
460 |
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41.0 |
27130 |
47.0 |
31160 |
305 |
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6M404 |
40 |
30 |
460 |
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6" x 6" |
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53.0 |
35530 |
60.0 |
41100 |
340 |
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66M504 |
50 |
37 |
460 |
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70.0 |
45210 |
79.0 |
52380 |
465 |
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86M504 |
50 |
37 |
460 |
|
8" x 6" |
|
65.0 |
44360 |
73.0 |
51000 |
435 |
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86M604 |
60 |
45 |
460 |
|
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80.0 |
52850 |
90.0 |
60900 |
510 |
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8M754 |
75 |
55 |
460 |
3 |
|
1.15 |
96.0 |
65900 |
109.0 |
76100 |
650 |
||
8M1004 |
100 |
75 |
460 |
|
8" x 8" |
|
127.0 |
87600 |
145.0 |
101300 |
795 |
||
8M1254 |
125 |
90 |
460 |
|
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160.0 |
110800 |
180.0 |
126000 |
980 |
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8M1504 |
150 |
110 |
460 |
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195.0 |
130700 |
220.0 |
152000 |
1060 |
||
10M2004 |
200 |
150 |
460 |
|
10 "x 10" |
|
235.0 |
171100 |
270.0 |
198600 |
1260 |
||
5-30 HP, 3 Phase 230 and 460 Motors have adjustable voltage feature, change voltage plugs to convert from 230V to 460V operation. Spare Change Plug Order No's are: PLUG-230V or PLUG-460V.
13
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Motor |
HP |
kW |
Volts |
Phase |
F.L. |
KVA |
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Resistance - Ohms |
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Order No. |
Efficiency % |
Code |
R - Y |
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B - Y |
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R - B |
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6M051 |
5 |
3.7 |
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74.8 |
G |
2.172 |
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0.512 |
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2.627 |
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6M071 |
7.5 |
5.5 |
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230 |
1 |
72.9 |
F |
1.401 |
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0.400 |
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1.774 |
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6M101 |
10 |
7.5 |
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73.6 |
E |
1.052 |
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0.316 |
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1.310 |
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6M151 |
15 |
11 |
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73.7 |
D |
0.678 |
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0.230 |
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0.850 |
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Motor |
HP |
kW |
Volts |
Phase |
F.L. |
KVA |
Line - Line |
Time Delay Fuse |
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Order No. |
Efficiency % |
Code |
Resistance |
Standard |
Dual Element |
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6M058 |
5 |
3.7 |
200 |
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75.9 |
K |
0.618 |
50 |
25 |
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6M052 |
5 |
3.7 |
230 |
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76.8 |
K |
0.806 |
45 |
20 |
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6M054 |
5 |
3.7 |
460 |
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76.8 |
K |
3.050 |
25 |
10 |
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6M078 |
7.5 |
5.5 |
200 |
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77.9 |
J |
0.504 |
80 |
40 |
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6M072 |
7.5 |
5.5 |
230 |
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78.5 |
J |
0.651 |
70 |
30 |
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6M074 |
7.5 |
5.5 |
460 |
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78.5 |
J |
2.430 |
35 |
15 |
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6M108 |
10 |
7.5 |
200 |
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79.7 |
K |
0.315 |
100 |
50 |
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6M102 |
10 |
7.5 |
230 |
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79.3 |
K |
0.448 |
90 |
40 |
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6M104 |
10 |
7.5 |
460 |
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79.3 |
K |
1.619 |
45 |
20 |
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6M158 |
15 |
11 |
200 |
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81.7 |
K |
0.213 |
175 |
70 |
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81.7 |
K |
0.312 |
150 |
60 |
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6M152 |
15 |
11 |
230 |
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81.7 |
K |
1.074 |
70 |
30 |
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6M154 |
15 |
11 |
460 |
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6M208 |
20 |
15 |
200 |
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82.7 |
J |
0.189 |
200 |
90 |
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6M202 |
20 |
15 |
230 |
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83.2 |
J |
0.258 |
175 |
70 |
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6M204 |
20 |
15 |
460 |
3 |
83.2 |
J |
0.861 |
90 |
35 |
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6M258 |
25 |
18.5 |
200 |
82.0 |
K |
0.146 |
250 |
110 |
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6M252 |
25 |
18.5 |
230 |
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83.0 |
K |
0.210 |
225 |
90 |
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6M254 |
25 |
18.5 |
460 |
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83.0 |
K |
0.666 |
110 |
45 |
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6M308 |
30 |
22 |
200 |
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82.9 |
J |
0.119 |
300 |
125 |
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6M302 |
30 |
22 |
230 |
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82.5 |
K |
0.166 |
250 |
100 |
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6M304 |
30 |
22 |
460 |
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82.5 |
K |
0.554 |
125 |
50 |
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6M404 |
40 |
30 |
460 |
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84.0 |
H |
0.446 |
175 |
70 |
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66M504 |
50 |
37 |
460 |
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82.5 |
J |
0.388 |
225 |
90 |
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86M504 |
50 |
37 |
460 |
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84.1 |
H |
0.331 |
200 |
90 |
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86M604 |
60 |
45 |
460 |
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84.7 |
H |
0.278 |
250 |
110 |
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8M754 |
75 |
55 |
460 |
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84.9 |
H |
0.218 |
300 |
125 |
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8M1004 |
100 |
75 |
460 |
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85.2 |
H |
0.164 |
400 |
175 |
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8M1254 |
125 |
90 |
460 |
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84.2 |
G |
0.132 |
500 |
225 |
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8M1504 |
150 |
110 |
460 |
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85.6 |
G |
0.115 |
600 |
250 |
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10M2004 |
200 |
150 |
460 |
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87.2 |
F |
0.0929 |
800 |
350 |
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14
THREE PHASE POWER UNBALANCE
A full three phase supply consisting of three individual transformers or one three phase transformer is recommended. “Open” delta or wye connections using only two transformers can be used, but are more likely to cause poor performance, overload tripping or early motor failure due to current unbalance.
Check the current in each of the three motor leads and calculate the current unbalance as explained below.
If the current unbalance is 2% or less, leave the leads as connected.
If the current unbalance is more than 2%, current readings should be checked on each leg using each of the three possible hook-ups. Roll the motor leads across the starter in the same direction to prevent motor reversal.
To calculate percent of current unbalance:
A.Add the three line amp values together.
B.Divide the sum by three, yielding average current.
C.Pick the amp value which is furthest from the average current (either high or low).
D.Determine the difference between this amp value (furthest from average) and the average.
E.Divide the difference by the average.
Multiply the result by 100 to determine percent of unbalance.
Current unbalance should not exceed 5% at service factor load or 10% at rated input load. If the unbalance cannot be corrected by rolling leads, the source of the unbalance must be located and corrected. If, on the three possible hookups, the leg farthest from the average stays on the same power lead, most of the unbalance is coming from the power source.
Contact your local power company to resolve the imbalance.
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Hookup 2 |
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Hookup 3 |
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Starter Terminals |
L1 |
L2 |
L3 |
L1 |
L2 |
L3 |
L1 |
L2 |
L3 |
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Motor Leads |
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R |
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B |
Y |
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Y |
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R |
B |
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B |
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Y |
R |
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T3 |
T1 |
T2 |
T2 |
T3 |
T1 |
T1 |
T2 |
T3 |
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Example: |
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T3-R = 51 amps |
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T2-Y = 50 amps |
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T1-B = 50 amps |
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T1-B = 46 amps |
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T3-R = 48 amps |
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T2-Y = 49 amps |
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T2-Y = 53 amps |
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T1-B = 52 amps |
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T3-R = 51 amps |
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Total = 150 amps |
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Total = 150 amps |
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Total = 150 amps |
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÷ 3 = 50 amps |
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÷ 3 = 50 amps |
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÷ 3 = 50 amps |
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— 46 = 4 amps |
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— 48 = 2 amps |
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— 49 = 1 amps |
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4 ÷ 50 = .08 or 8% |
2 ÷ 50 = .04 or 4% |
1 ÷ 50 = .02 or 2% |
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15
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