INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
Foreward
This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Water
Technology Turbine Pumps. This manual covers a standard product. For special options, supplemental
instructions are available. This manual must be read and understood before installation and start-up.
This instruction manual covers several different pump models. Most assembly, disassembly, and inspection
procedures are the same for all the pumps. However, where there are differences, these differences will be
noted within the manual. The design, materials, and workmanship incorporated in the construction of the pumps
makes them capable of giving long, trouble-free service. The life and satisfactory service of any mechanical unit,
however, is enhanced and extended by correct application, proper installation, periodic inspection, condition
monitoring and careful maintenance. This instruction manual was prepared to assist operators in understanding
the construction and the correct methods of installing, operating, and maintaining these pumps.
The information contained in this book is intended to assist operating personnel by providing information on the
characteristics of the purchased equipment. It does not relieve the user of their responsibility of using accepted
engineering practices in the installation, operation, and maintenance of this equipment.
Goulds Water Technology shall not be liable for physical injury, damage, or delays caused by a failure to
observe the instructions for installation, operation and maintenance contained in this manual.
Warranty is valid only when genuine Goulds Water Technology parts are used.
Use of the equipment on a service other than stated in the order will nullify the warranty, unless written approval
is obtained in advance from Goulds Water Technology.
For information or questions not covered in this manual, contact Goulds Water Technology at (806) 743-5700.
THIS MANUAL EXPLAINS :
• Proper Installation • Pump Overhaul
• Start-up Procedures • Trouble Shooting
• Operation Procedures • Ordering Spare or Repair Parts
• Routine Maintenance
Pump Model Number:
Pump Serial Number:
Control Model Number:
Dealer:
Dealer Phone No.:
Date of Purchase: Installation:
Current Readings at Startup:
1 Ø 3 Ø L1-2 L2-3 L3-1
Receiving and Checking ............................................................................................................................................4
Materials and Equipment Required ...........................................................................................................................4
Preparations for Uncontrolled Long-Term Storage .....................................................................................................5
Section 3 – General Description
General Description ..................................................................................................................................................5
Well Requirements ....................................................................................................................................................6
Preparing the Foundation .......................................................................................................................................... 6
Motor and Cable Checks and Preparation .................................................................................................................6
Section 5 – Installing the Pump......................................................................................................................................7
Section 6 – Starting the Pump ........................................................................................................................................8
Inspection and Replacement ....................................................................................................................................10
Turbine Bowl and Impeller Wear Ring Installation ..................................................................................................10
Appendix A – Assembly of Pump and Motor ...............................................................................................................12
Appendix B – Splicing Power Cable to Motor Leads ....................................................................................................12
Appendix C – Electrical Tests ......................................................................................................................................13
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.
Warns of hazards that WILL cause
serious personal injury, death or major
property damage.
Warns of hazards that CAN cause
serious personal injury, death or major
property damage.
Warns of hazards that CAN cause personal injury or property damage.
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.
SECTION 1 — GENERAL INFORMATION
1–1 INTRODUCTION
The design, materials and workmanship incorporated in
the construction of Goulds Water Technology submersible turbine pumps makes them capable of giving long,
trouble-free service. The life and satisfactory service of
any mechanical unit, however, is enhanced and extended
by correct application, proper installation, periodic
inspection and careful maintenance. This instruction
manual was prepared to assist the operators in understanding the construction and correct methods of installing, operating and maintaining these pumps.
Study thoroughly Sections 1 through 8 and keep this
manual handy for reference. Further information can be
obtained by contacting Goulds Water Technology sales
office or your local branch office.
GOULDS WATER TECHNOLOGY
SHALL NOT BE LIABLE FOR ANY
DAMAGES OR DELAY CAUSED BY FAILURE TO
COMPLY WITH THE PROVISIONS OF THIS INSTRUCTION MANUAL.
1–2 RECEIVING AND CHECKING
The pump shall be carefully supported prior to unloading from the carrier. Handle all components carefully. Inspection for damage of the shipping crate shall be made
prior to unpacking the pump. After unpacking, visually
inspect the pump and check the following:
1. Contents of the pump assembly against shipping list.
2. All components for damage.
4
Any shortages or damages should be immediately called
to the attention of the local freight agent of the carrier by
which the shipment arrived and proper notation made on
the bill. This shall prevent any controversy when a claim
is made and to facilitate prompt and satisfactory adjustment.
1–3 MATERIALS AND EQUIPMENT REQUIRED
The material and equipment necessary for installation
of the pump will vary with the size of the pump and the
type of installation. The following discussion and list of
standard tools and supplies is therefore offered only as a
guide.
1. BULK MATERIAL
Anti-galling lubricant, thread compound, lubrication
oil, grease, petroleum based solvent.
2. HAND TOOLS
Pipe wrenches, two chains tongs, mechanic's hand
tools and machinist level.
3. INSTRUMENTS
One megger, or similar instrument indicating electrical
resistance, clamp-on ammeter, voltmeter and a good
grade of pipe joint compound should be available to
facilitate assembly and possible future disassembly.
4. INSTALLATION EQUIPMENT
Wooden friction blocks or steel clamps, steel column
lifting elevators of approved type and of proper size
for the column pipe, and cable sling approximately 10
feet long of adequate size for the loads involved.
Although portable derricks are sometimes used, a
properly designed pump setting rig is recommended.
It must be possible to erect the crown block to a
height so as to allow the load hook to be raised about
three feet higher than the longest piece. The lifting
device must be of sufficient strength and rigidity to
raise the total weight of the unit safely.
REMEMBER – REGARDLESS OF THE
TYPE OF LIFTING EQUIPMENT, OR
THE TYPE OF PUMPING EQUIPMENT, THE PRIMARY RULE IS: SAFETY FIRST.
SECTION 2 — STORAGE
2–1 STORAGE
Goulds Water Technology carefully preserves and protects its products for shipment. However, the effective
life of the preservatives applied at the factory can vary
from 3 to 18 months depending on the severity of the environment in which the equipment is stored. This section
provides procedures for preparation prior to storage and
maintenance during storage of Goulds Water Technology pumps. These procedures are necessary to protect
the precision parts of the pumps. Specific procedures
for storing motors should be obtained from the motor
manufacturer. This section is intended to be of general
assistance to users of Goulds Water Technology pumps. It
shall not modify, amend, and/or otherwise alter the scope
of the Goulds Water Technology warranty in anyway
whatsoever.
2–2 STORAGE PREPARATION
Goulds Water Technology submersible pumps require
proper preparation for storage. The pump shall be
considered in storage when it has been delivered to the
job site and is awaiting installation. If a pump has been
installed, but is not in regular operation, such as seasonal
shutdown or an extended period of time, it is suggested
that the pump be operated for at least 15 minutes every
two weeks if possible.
2–3 RECOMMENDED STORAGE PROCEDURES
1. Controlled storage facilities should be maintained at
an even temperature 10º F (5.6°C) or more above the
dew point with relative humidity less than 50% and
little or no dust. (If these requirements cannot be met
the pump is to be considered in uncontrolled storage.)
2. For uncontrolled storage periods of six months or less,
the pump is to be inspected periodically to insure that
all preservatives are intact.
3. All pipe threads and flanged pipe covers are to be
sealed with tape.
4. The pump must not be stored closer than six inches to
the ground.
2–4 PREPARATIONS FOR UNCONTROLLED
LONG TERM STORAGE
Storage periods over six months require the preceding
uncontrolled storage procedure plus the following:
1. Inspect the assembly and recoat periodically to prevent
corrosion.
2. Place ten pounds of moisture absorbing desiccant or
five pounds of vapor phase inhibitor crystals near the
center of the pump. If the pump is assembled, place an
additional one pound in the discharge nozzle securely
fastened to the discharge flange.
3. Install a moisture indicator near the perimeter of the
pump. Cover the pump with 6 mils (0.15 mm) minimum thickness black polyethylene or equal and seal
it with tape. Provide a small ventilation hole approximately ½ inch diameter.
4. Provide a roof or a shed shelter to protect from direct
exposure to the elements.
SECTION 3 — GENERAL DESCRIPTION
3–1 GENERAL DESCRIPTION
Goulds Water Technology model VS pump is a submersible turbine pump designed for maximum dependability.
See Figure 1 for typical VS pump.
3–2 DRIVERS
Goulds Water Technology furnishes only internationally
recognized motors designed for continuous operation
under any thrust which may develop throughout the
performance curve. Impeller adjustment and type of
coupling, splined or clamped, is dependent on the
specific motor being used.
3–3 DISCHARGE
The discharge bowl provides an NPT or BSP thread for
connecting to the well head or the first section of column
pipe.
Figure 1 – Typical Submersible Pump Installation
3–4 BOWL ASSEMBLY
The bowls are generally flanged construction for accurate
alignment and ease of assembly and disassembly. Impellers may be enclosed or open type. Impeller position is
set at factory. No field adjustment is required.
5
CAUTION
CAUTION
CAUTION
WARNING
CAUTION
SECTION 4 — PREPARATION FOR
INSTALLATION
4–1 WELL REQUIREMENTS
1. The well should be developed with a test pump prior
to installing the submersible pump. Test pumping the
well serves several purposes. It removes the excess
sand encountered during the initial pumping of the
well. Pumping sand or other abrasives with a submersible pump will shorten the life of the pump and can
void the warranty.
DO NOT INSTALL THE UNIT WITH
THE MOTOR IN THE MUD, SAND
OR RESTING ON THE BOTTOM OF THE WELL.
IT IS IMPORTANT TO PREVENT THE WELL FROM
SANDING UP AT ANY TIME TO THE POINT THAT
THE MOTOR BECOMES EVEN PARTIALLY BURIED.
2. The test pumping also provides a means of determin-
ing the capacity and drawdown. The well capacity
should equal or exceed the pump capacity. If the pump
removes water at a higher rate than the well produces,
the drawdown will be excessive and the pump will
cavitate or 'starve' resulting in damage of the pump
and motor.
3. The well must be deep enough so that the pump suc-
tion is at least 10 feet below the expected drawdown
level. If the well screen or water producing aquifer is
above the pumping level, the required submergence of
the pump suction would be over 20 feet.
NEVER INSTALL UNIT WITH THE
BOTTOM OF THE MOTOR CLOSER
THAN FIVE FEET FROM THE BOTTOM OF THE
WELL.
4. The motor must always be immersed in flowing water.
The flow rate must be over .5 ft./sec. If the pump is set
below the well screen openings or other conditions exist that caused the water to be supplied from above the
pump, a flow induce sleeve should be used.
5. The inside diameter of the well casing must be large
enough to allow lowering the unit into the well without damage to the power cable, the splice between the
power cable and the motor leads. Many wells have
more than one size of casings installed and frequently
the lower sections are smaller in diameter than the
upper casing.
6. The submersible pump/motor unit must be operated
in a straight portion of the well. Exerted pressures can
and will cause misalignment of bearings or coupling.
When the straightness of the well is not known, it is
recommended to lower a test blank with the same
diameter and length as the pump/motor assembly with
electrical leads into the well to the desired depth. If
there is any doubt about straightness, gagging and
plotting are recommended.
4–2 PREPARING THE FOUNDATION
The foundation must be rigid, level and of adequate
strength to support the complete weight of the pump,
motor, column, plus the weight of the liquid passing
through it. It is recommended the foundation be constructed of solid concrete, however, adequate beams or
6
timbers may be used. A common foundation consists of
the following concrete mixture:
1. One part cement
2. Two parts sand
3. Four parts gravel
4. With sufficient water to make a stiff mix
4–3 MOTOR AND CABLE CHECKS AND
PREPARATION
DO NOT USE MOTOR LEADS TO
LIFT OR HANDLE THE MOTOR. THE
MOTOR LEADS ARE EASILY DAMAGED. THEY
SHOULD BE PROTECTED AND HANDLED WITH
CARE AT ALL TIMES.
1. MOTOR SERVICING
Consult the motor manual and perform any preinstallation servicing that is required. Some motors may
require filling with oil or water.
2. ASSEMBLE OF MOTOR TO PUMP
If the pump and motor have not already been assembled, assemble per the instructions given in Appendix
A. For extra long units, it may be more practical to assemble the pump to the motor in the vertical position
at the installation site.
3. TESTING BEFORE SPLICING POWER CABLE TO
MOTOR LEADS
Perform the following tests before making the splice
between the motor leads and the drop cable. Instructions for performing resistance tests and evaluating
the results are given in Appendix C.
MOTOR TESTS
• Measure the resistance between each motor lead
and ground with the motor submerged in water.
See Appendix C.
• Measure the resistance of the motor windings. See
Appendix C. Record the values for future reference.
• Secure the pump and motor with chain tongs to
resist torque. Energize the motor momentarily (on
and immediately off) to check the rotation.
GROUND THE UNIT WHEN TEST-
ING. FAILURE TO GROUND THE
UNIT PROPERLY CAN RESULT IN SERIOUS OR
FATAL SHOCK. ALSO, THE HIGH STARTING
TORQUE OF THE MOTOR WILL CAUSE IT TO
'KICK' WHEN POWER IS APPLIED. THE UNIT
SHOULD BE RESTRAINED SUFFICIENTLY TO PREVENT DAMAGE TO THE EQUIPMENT OR PERSONAL INJURY.
NOTE: ROTATION WILL BE COUNTERCLOCK-
WISE WHEN VIEWED FROM THE DISCHARGED BOWL.
On three phase unit, if rotation is wrong, interchange
any two of the motor leads at the control panel.
CORRECT ROTATION IS OF EX-
TREME IMPORTANCE. EXCESSIVE
OVERLOADS MAY BE DEVELOPED UNDER OPERATING CONDITIONS WITH REVERSE ROTATION.
CAUTION
CAUTION
WARNING
DROP CABLE TEST
• Measure the resistance between the cable conductors and ground with the cable submerged in water.
See Appendix C.
4. SPLICING POWER CABLE TO MOTOR LEADS
A waterproof splice must be made to connect the
power cable to the motor leads. A properly made
splice will last the life of the pump. An improperly
made splice will become a service problem. Make the
splice per instructions supplied with the drop cable
or per instructions in the pump motor manual. The
splice should be located above the pump bowl. It
should be as compact as possible. A compact splice is
less likely to be damaged as the pump is being lowered
into the well. See Appendix B for instruction on splic-
ing the cable.
5. TESTING AFTER SPLICING POWER CABLE TO
MOTOR LEAD
Perform the following test after making the splice, but
before lowering the pump into the well.
• Check that the splice is waterproof by immersing it
in a container of water for approximately one hour
and then taking resistance readings between each
cable conductor and the water. See Appendix C.
• Measure the total resistance of the complete drop
cable and motor circuit to insure that a good splice
was made. Record the values for future reference.
THE MINIMUM READING FOR EACH
LEAD TO GROUND SHOULD BE 50
MEGOHMS.
SECTION 5 — INSTALLING THE PUMP
1. Check the pump and motor shaft to make sure it turns
free before installation. For some models, it may be
necessary to remove the suction screen in order to
check the shaft. Be sure to reinstall the suction screen.
2. Raise the bowl/motor assembly with the shipping skids
still in place. Remove the shipping skids and lower assembly into the well, clamping the bowl assembly near
the top.
3. Attach the elevators to the bottom column pipe imme-
diately below the column coupling. Hoist the column
section into place above the well and the top of the
bowl assembly, providing a soft board or pipe dolly
for the end of the column pipe to slide in on so that
threads will not be damaged while the section is being
raised. Clean all threads with thread lubricant. Thread
the pipe into the discharge bowl connection and make
up tight, using one set of chain tongs for backup.
THE PUMP MOTOR WILL EXERT
A TORQUE THAT WILL TEND TO
UNSCREW THREADED COLUMN PIPE CONNECTIONS. FOR THE REASON, THREADED COLUMN
JOINTS MUST BE TIGHTENED.
THE FOLLOWING TABLE GIVES THE NORMAL
AMOUNT OF THREAD ENGAGEMENT NECESSARY TO MAKE A TIGHT JOINT FOR THE NPT
THREAD JOINT:
Pipe Length of Number
Size Thread (in.) of Threads
4. Install a cable clamp on each side of the cable splice.
See Figure 1. Be careful not to damage the cable. If
an air line is to be installed, route it beside the cable,
making sure that it is not pinched by the clamps. If
there is any danger that the splice will rub against the
well casing during installation, it should be protected
by thick rubber chaffing pads or by a steel shield.
Check that the grounding system is in place.
FAILURE TO GROUND THE UNIT
PROPERLY CAN RESULT IN SERIOUS
OR FATAL SHOCK. REFER TO ELECTRICAL CODE
REQUIREMENTS.
5. Slowly lower the unit into the well (or sump) adding
joints of column pipe as the unit is lowered. Tighten
each joint securely. See note above. Remove slack from
the power cable and attach a cable clamp approximately every 20 feet. For units with large heavy power
cable, additional cable clamp may be required to give
additional support. Line up the cable on one side of
the pump and maintain as much clearance as possible
on that side when lowering the pump in the well. BE
EXTREMELY CAREFUL NOT TO SCRAPE OR
DAMAGE THE POWER CABLE, CABLE SPLICE
OR GROUNDING SYSTEM WHEN LOWERING
THE PUMP. Hold the power cable up away from the
well casing as lowering the pump into the casing.
6. If the pump does not have a built-in check valve, a line
check valve should be installed within 25 feet above
the pump bowl assembly. For a deep setting pump, a
line check valve is recommended for every 200 feet
of column pipe, However, no check valve should be installed above the pumping level.
7. As soon as the splice joint is submerged in the water,
take a resistance reading between the power cable
conductors and ground to assure that the insulation
and the cable or the splice was not damaged during
installation.
8. After the last piece of column pipe has been installed,
install the well head. Install a cable clamp between the
last column pipe coupling and the well head base. See Figure 1. Route the power cable and grounding system
through the large threaded hole in the head base.
Route the air line (if used) through one of the smaller
threaded holes in the head base. The remaining small
threaded hole is for connection of a well vent or other
accessories. All of these holes are threaded with standard NPT or BSP pipe threads. If a gasket is required
between the head base and its mounting surface, the
gasket should be placed on the foundation prior to
installing the well head.
7
WARNING
CAUTION
9. After the well head has been properly tightened,
carefully rotate the entire unit in the well until the
discharge flange is facing in the desired direction. Push
the unit to one side of the well, providing the maximum clearance for the drop cable when rotating the
unit.
10. Slowly lower the well head onto its mounting
surface. BE CAREFUL NOT TO DAMAGE THE
GROUNDING SYSTEM OR PINCH THE POWER
CABLE BETWEEN THE SURFACE PLATE AND
THE WELL CASING. If a gasket or other seating
device is used, be sure that it is aligned properly and
that it is not damaged. Install the mounting bolts.
11. Before connecting the power cable to the control
panel:
Take a resistance reading between the power cable
conductors and ground to assure that the insulation
on the cable or splice was not damaged during installation. See Appendix C.
Measure the resistance of the power cable and motor
circuit. See Appendix C. Compare these readings with
those taken in Section 4 to assure that the splice is still
intact. Make the electrical connection between the power
cable and the control panel. It may be desirable to use a
terminal box at the well head to simplify the electrical
work required when the pump is pulled. Be sure that the
unit is grounded properly.
FAILURE TO GROUND THE UNIT
PROPERLY CAN RESULT IN SERIOUS
OR FATAL SHOCK. REFER TO ELECTRICAL CODE
REQUIREMENTS.
Be sure to connect the leads as they were marked
previously in the procedure.
SECTION 6 — STARTING THE PUMP
INITIAL STARTUP AND TESTING
MAY REQUIRE STARTING AND
STOPPING THE PUMP SEVERAL TIMES. BE SURE
TO ALLOW ADEQUATE COOLING OFF PERIOD
BETWEEN STARTS. CONSULT THE MOTOR MANUAL. IF NO INFORMATION IS GIVEN, A GOOD
RULE-OF-THUMB IS TO ALLOW A MINIMUM OF
15 MINUTES BETWEEN STARTS.
For initial startup, allow the water to be pumped out
onto the ground. A throttle valve in the discharge line is
recommended. Position the throttle valve approximately
one-forth open for startup of the pump. This will prevent
surging the well or the pump during startup.
If the pump has been in the well for several days before
the startup, check the resistance between the cable conductor and ground to assure that water has not penetrated the splice or the cable insulation. See Section 4.
Clamp the tongs of a clamp-on type ammeter around
one power lead to the pump. Set the ammeter on the
maximum scale. After the motor starts, it can be reset to
a lower scale as desired.
Refer to the motor manual and determine the normal
operating amps for the installed motor.
Start the pump and observe and record the current
readings on each conductor of the power lead. If the
8
current exceeds the normal value determined in the motor manual, stop the pump immediately. A high current
reading indicates that something is wrong. Among the
potential problems are:
• Incorrect pump rotation (3 phase only)
• Improper voltage
• Sand locked pump
• Improper cable size or leak in cable
• Mechanical damage
In any case, the problem must be corrected before the
pump can be operated.
On three phase units, if water does not appear within
one minute (deeper settings may require approximately
one half minute per 100 feet setting) the motor may be
running backwards. Stop the pump and interchange any
two of the three cable connections. If there is any doubt
about the proper rotation, run the motor in one direction
and then the other. The rotation that gives the highest
pressure and flow is always the correct one.
Check the voltage. The voltage when the pump is running should be within 5% of the pump motor nameplate
voltage.
Open the throttle valve. If a flow meter is available, open
the throttle valve to rated flow of the pump. If sand appears in the water, throttle the pump at approximately
80% of full flow until the sand clears. If excessive noise
develops, pressure fluctuates or water appears foamy
white, the pump is probably cavitating and the flow
should be throttled until the noise diminishes, the pressure remains steady and the water is clear.
On three phase units, check for current unbalance.
Details of the current unbalance test are given in the Appendix C. THE MAXIMUM ALLOWABLE CURRENT UNBALANCE IS 5%. If the current unbalance exceeds
5% after rolling the leads and connecting them for the
lowest unbalance, the pump should be stopped and corrective action taken. Current unbalance in excess of 5%
can be expected to cause excessive heating in the motor
and premature failure. Operation with a current unbalance in excess of 5% will void the warranty.
After the unit is operating properly, a performance test
should be considered. If a performance test is conducted
when the pump is new, subsequent tests can be used to
determine the degree of wear or deterioration of the
pump without removing it from the well. After the unit
has been in operation for approximately one week, perform the routine tests.
SECTION 7 — PUMP DISASSEMBLY AND
REASSEMBLY
1. Clear a large area adjacent to the pump as storage
space for pump parts as they are disassembled. If the
pump has a long column, arrange parallel timbers on
the ground to support the pump column horizontally.
After disassembly for repair or replacement of pump
components, reassemble in all cases in the reverse
order of disassembly.
NOTE: PUMP COMPONENTS SHOULD BE
MATCH-MARKED PRIOR TO
DISASSEMBLY.
2. It is recommended that maintenance personnel be-
WARNING
WARNING
come thoroughly familiar with the VS pump before
performing any removal of the components. Consult
the manufacturer's instructions for detailed disassembly information for the motor.
A. Remove the electrical connection at the conduit box
and tag electrical leads at the motor.
BEFORE OPENING THE CONDUIT
BOX OF AN ELECTRICAL MOTOR,
BE SURE THE CURRENT TO THE MOTOR IS SHUT
OFF. SEVERE INJURY TO PERSONNEL COULD
RESULT IF CONTACT WITH LIVE MOTOR LEADS
IS MADE.
LOCK OUT SHOULD BE INSTALLED BEFORE ANY
ELECTRICAL WORK IS PERFORMED.
NOTE: MATCH-MARK PARTS IN SEQUENCE OF
DISASSEMBLY TO AID IN THE REASSEMBLY PROCEDURE.
B. Disconnect the discharge piping from the well head.
DO NOT WORK UNDER A HEAVY
SUSPENDED OBJECT UNLESS THERE
IS A POSITIVE SUPPORT UNDER IT WHICH WILL
PROTECT PERSONNEL SHOULD A HOIST OR
SLING FAIL.
3. PUMP DISASSEMBLY
In the following pump disassembly procedures, references are made to installation sections of this manual.
These sections will aid in the disassembly of the
pump.
A. Disconnect well head and begin removal of column
sections. Refer to Section 5, #7.
B. For removal of bowl/motor assembly, hoist the
bowl/motor assembly from the well, using elevator clamps. Hoist in the same manner as for the
column. For the keyed motor shaft, loosen the
setscrews on the motor end of the shaft coupling.
Remove the motor lead from the cable guard.
Disassemble the bowl assembly from the motor by
removing the connecting bolts at the flange joint.
For the short assembly, laying the bowl/motor assembly on the ground to perform these works. For
the long or large size assembly, it is recommended
to perform these works while the assembly is in the
vertical position. Refer to Section 4, #3. Proceed to
disassemble the bowl assembly as follows.
The bowl assembly shown in Figure 2 is composed of
a discharge bowl (for the model with built-in check
valve, it would be column adapter), intermediate
bowl, impellers with taper collects, motor adapter,
bearings and pump shaft.
A. Begin disassembly by removing the capscrews that
secure the top stage intermediate bowl and the second stage intermediate bowl and slide the discharge
and top intermediate bowls off the pump shaft
together. Remove the thrust washer.
B. Pull shaft out as far as possible and strike impeller
hub utilizing a taperlock driver or equivalent sliding
along the pump shaft to drive the impeller off the
taperlock. See Figure 3.
Figure 3 – Disassemble the Impeller
C. After impeller is freed, insert a screwdriver into the
taperlock to spread it. Slide taperlock and impeller
off the pump shaft.
D. Use the preceding procedures until entire turbine
bowl assembly is completely disassembled.
5. TURBINE BOWL – WEAR RINGS REMOVAL
(OPTIONAL)
A. Utilizing a diamond point chisel, cut two V-shape
grooves on the bowl wear ring, approximately 180º
apart. Use extreme care not to damage the wear
ring seat.
B. With a chisel or equal, knock the end of half of the
ring in and pry the ring out.
C. On special materials such as chrome steel, set up the
bowl in a lathe and machine the wear ring off. Use
extreme care not to machine or damage the ring
seat.
6. TURBINE BOWL – IMPELLER WEAR RING
REMOVAL (OPTIONAL)
Set up impeller in a lathe and machine wear ring out.
Use extreme care not to machine or damage ring seat
or impeller hub. Impeller wear ring may also be removed by following steps A and B, paragraph #5.
7. BOWL BEARING REMOVAL
Utilizing an arbor press and a piece of pipe or sleeve
with outside diameter slightly smaller than the bowl
bearing diameter, press the bearing out.
8. INSPECTION AND REPLACEMENT
A. Clean all parts thoroughly with a suitable cleaner.
B. Check bearing seats for deformation and wear.
C. Check pump shaft for straightness and excessive
wear on bearing surfaces. Check straightness of the
pump shaft. The straightness should within 0.0005"/
ft. TIR.
D. Visually check impellers and bowls for cracks and
pitting. Check all bowl bearings for excessive wear
and corrosion.
9. TURBINE BOWL AND IMPELLER WEAR RING
INSTALLATION (OPTIONAL)
Place chamfered face of bowl or impeller wear ring
towards the ring seat and press. Use an arbor press or
equal. Make sure ring is flush with edge of wear ring
seat.
10. BOWL BEARING INSTALLATION
Press the bearing into all the bowls by using an arbor
press or equivalent. Press the bearing in from the
bottom end of the hub until the bottom end of the
bearing is flush with the bottom end of the hub.
11. TURBINE BOWL WITH TAPERLOCK –
REASSEMBLY
A. Secure the submersible assembly jig to the motor
end of the motor adapter. See Figure 4. Be sure
to use the proper jig for the motor frame size the
bowl assembly is intended to adapt to.
B. Put some grease in the suction bearing of the
motor adapter. Slide the shaft through the bearing. Secure the shaft in place by locking the shaft
to the assembly jig with a special long bolt or all
thread and a hex nut. See Figure 4.
Figure 4 – Assembly Jig
C. Slip impeller over the shaft. Then slip taperlock
over the shaft with smaller end towards impeller.
A screwdriver can be used to spread the taperlock
for ease in slipping over the shaft.
10
D. Hold impeller firmly against the motor adapter
and drive the taperlock into place with the taperlock driver. See Figure 5. After the impeller is
secured in position, the top end of the taperlock
should be 1/8" above the impeller hub.
SHAFT
TAPERLOCK
DRIVER
ASSEMBLY
POSITION
IMPELLER
BOWL
Figure 5 – Install the Impeller
E. Put a little grease on the shaft where the inter-
mediate bearing will be. Slip intermediate bowl
over the shaft and bolt or screw it onto the motor
adapter.
F. Place the next impeller over the shaft and continue
to assemble as explained above.
G. After assembling the last impeller, slide the up-
thrust washer over the shaft before assembling the
top intermediate.
H. Slide the discharge case and top intermediate
bowl over the shaft and bolt it to the second intermediate bowl. If the pump has a built-in check
valve, install the check valve before installing the
discharge adapter.
I. When the bowl is completely assembled, unlock
the shaft and remove the assembly jig. Rotate the
shaft by hand to see whether it rotates freely. Push
the shaft all the way in and then pull it all the
way out to check the lateral clearance. The lateral
should be between 0.187" to 0.250".
J. Install the square key in the keyway at the motor
end of the pump shaft. Slide the shaft coupling
over the shaft and secure it to the key with two
setscrews.
SECTION 8 — TROUBLESHOOTING CHART
In case of difficulties, refer to the chart to locate basic problems with the system. Once the problem is located, refer to
specific sections in this manual for details.
CONDITION PROBABLE CAUSE REMEDY
PUMP WILL1. Motor overload protector trip 1. Allow motor to cool, overload will
NOT RUN a. Incorrect control box. automatically reset. Investigate cause
b. Incorrect connections. of overload.
c. Faulty overload protector. a-e. Have a qualified electrician inspect
d. Low voltage. and repair, as required.
e. Ambient temperature of control box
or starter too low. f. Pull the pump, examine and clean.
f. Pump bound by foreign matter. Adjust set depth as required.
2. Blown fuse, broken or loose electric 2. Check fuses, relays or heater elements
connections. for correct size capacitor and all electrical
connections.
3. Motor control box or starter not in 3. Make sure box is in upright position.
proper position.
4. Cable insulation damaged. 4. Locate and repair as per instructions.
5. Splice may be open or grounded. 5. Check resistance between cable leads
with ohmmeter. If open or grounded,
pull pump and resplice.
BUT NO WATER 2. Pump is air-bound. 2. Successively start and stop pump until water flows normally.
3. Lift too high for the pump. 3. Review performance requirement.
4. Suction screen or impeller plugged, 4. Pull the pump and clean, check well
or pump in mud or sand. depth. Raise setting if necessary.
5. Pump not submerged. 5. Check water level. Lower pump if
permissible.
6. Well may contain excessive amounts 6. Start and stop pump several times. If this
of air or gas. does not remedy conditions, pump may
not be able to cooperate because of too
much gas in the well.
7. Three-phase unit running backwards. 7. Reverse rotation.
11
SECTION 8 — TROUBLESHOOTING CHART (continued)
CONDITION PROBABLE CAUSE REMEDY
REDUCED 1. Lift too high for the pump. 1. Check rating.
CAPACITY OR 2. Screen or impellers partly plugged. 2. Pull pump and clean. INSUFFICIENT 3. Scaled or corroded discharge pipe or 3. Replace pipe and repair leaks.
TANK PRESSURE leaks anywhere in system.
4. Well may contain excessive amounts of 4. Start and stop pump several times. If this
air or gas. does not remedy conditions, pump may
not be able to cooperate because of too
much gas in the well.
5. Excess wear due to abrasives. 5. Replace worn parts.
SWITCH2. Switch opening plugged. 2. Pull pump and clean.
DOES NOT 3. Leaks anywhere in system. 3. Repair leaks.
CUT OUT4. Three-phase pump running backward. 4. Reverse rotation.
PUMP STARTS 1. Water-logged tank. 1. a. Check tank for leaks (plug at top of TOO FREQUENTLY tank may be leaking air). b. Be sure drain and 'Y' fittings are
functioning properly. Check operation
of snifter valve.
2. Check valve leaking. 2. Replace check valve.
3. Pressure switch out of adjustment. 3. Readjust to correct setting or replace.
4. Leaks in service line. 4. Locate and correct.
APPENDIX A — ASSEMBLY OF PUMP AND
MOTOR
Most of the time, the pump and the motor are shipped
separately in two different boxes. They need to be assembled together in the field prior to being installed in
the well. For the short pump (less than 5 stages), the motor and pump may be assembled together on the ground
horizontally. If the pump is over 6 stages long, it is recommended to assemble them in the vertical position.
1. Check that the pump shaft and the motor shaft turn
freely.
2. Clean the flange faces and the registers on the pump
and the motor. Remove all burrs from these areas.
Clean the exposed portion of the pump shaft and
motor shaft. If the pump is supplied with the coupling
assembled on the shaft, clean the inside of the motorend of the coupling.
3. Install the key on the motor shaft, if it is not the
splined shaft.
4. If the shaft coupling has setscrews in the motor half of
the coupling, loosen or remove these setscrews.
5. Align the motor with the pump and slide the motor shaft into the shaft coupling on the pump until
the shaft butts. Make sure the motor shaft lifts the pump shaft by 1/8" to ¼" (for enclosed impeller only).
Be careful not to damage the shaft, the coupling or
the key. Orient the motor so that the motor leads
are aligned with the notch provided in the pump's
mounting flange. If the shaft coupling has setscrews
in the motor half the coupling, install and tighten the
setscrews.
6. Install and tighten the mounting bolts (or capscrews)
on the flange.
12
7. Unite the cableguard on the pump and reassemble it
with the motor leads under the cableguard to prevent
damaging the leads, when lowering the pump into the
well.
APPENDIX B — SPLICING POWER CABLE
TO MOTOR LEADS
A waterproof splice must be made to connect the power
cable to the motor leads. A properly made splice will
last the life of the pump. An improperly made splice will
become a service problem. In the market, there are different materials and methods to make waterproof cable
splices. For example: by waterproof tapes, by resin castings, by heat shrink tubes.
TAPED CABLE SPLICE:
1. Strip the insulation of each conductor of the power cable back enough to allow the conductor to extend half
way through a sleeve type connector. Crimp connector to the conductor. Strip the insulation of the motor
lead same as the power cable. Fit it into the connector
and butt against cable end. Crimp connector as before.
Pull on wire to make sure connector is firmly crimped
to both the motor lead and the power cable. Scrape
the insulation to move any loose bits of tape or thread
and roughen surface. Thoroughly clean surface with
solvent. This will insure a watertight splice.
2. Tape individual joints with rubber electrical tape. Start
at the center of the connector and tape 2" past the end
of conductor insulation end. Stretching tape about
10% while taping, overlap tapes about one half of
tape width. Make two layers. The end of second layer
should be 2" beyond the end of the first layer.
3. Tape over the rubber electrical tape with #33 Scotch
electrical tape or equivalent, using two layers as in
step #2 and making each layer overlap the end of the
preceding layer by 2".
CAST CABLE SPLICE:
DANGER
DANGER
1. To prepare the 3-conductor power cable for splicing,
insert a sharp knife blade between the cable jacket and
lead insulation and strip the jacket back 21/2" from the
end. Taking care not to cut the lead insulation. Strip
the cambric wrapping (if any) off the conductors and
strip back rubber insulation 5/8" from the end. Assemble the cable connectors and crimp them in place using
a crimping tool.
2. Cut off the motor leads to equal length. Clean off the
ends of the leads for about a foot, using a cloth wet
with gasoline or solvent. Clean the end of the power
cable also. Insert the three motor leads into the corresponding holes in the bottom of the rubber casing
and push them several inches out the top. Crimp the
motor leads into the corresponding connectors, crimping the center one first. Bend the cables into line with
the holes in the casing and slip the casing up until the
connectors are inside the holes and about 1/4" from the
top.
3. Mix the resin as directed. Cut off a corner of the bag
and squeeze all of the resin into casing. With the roll
of tape on hand, fold the bag and tape the top of the
bag snuggly to the power cable until the resin runs
out over the top. This will assure maximum coverage
of the resin and minimum size of the finished splice.
When the resin is firm to touch, the splice may be immersed for testing.
APPENDIX C — ELECTRICAL TESTS
1. MEASURING INSULATION RESISTANCE
(GROUND TEST)
The condition of the insulation around a conductor
can be determined by measuring the electrical resistance between the conductor and ground. This measurement can be made with a megger or an ohmmeter.
The value is stated in ohms or megohms (ohms x
1,000,000). High ohm values indicate good insulation.
The basic procedure for measuring insulation resistance is given below:
A. Turn off all power and disconnect the leads to be
tested from the electrical panel. Lock out the panel.
FAILURE TO TURN OFF THE POWER
WILL DAMAGE THE METER AND
CAN CAUSE SERIOUS OR FATAL SHOCK.
Failure to disconnect the leads can result in false
readings.
B. Set the meter selector knob to RX 100K or RX
100,000 (some meters may not have RX 100K
in which case EX 10K or EX 10,000 scale can be
used). Clip the meter leads together and adjust the
meter to zero.
C. Unclip the leads and attach one of the meter leads
to one of the power cable leads or motor leads. The
other meter to the ground.
D. Do not touch any bare wires or allow bare wires
to come in contact with the ground or metal. False
readings will result.
E. If the meter needle is at either extreme end of the
scale, a more accurate reading can be obtained
by switching the selector switch to another scale.
Rezero the meter each time the selector switch is
moved.
The readings obtained from power cables and motor leads should be within the range specified in Table
C.1. Low readings indicate that the motor windings are
grounded or that the cable or splice insulation is damaged. If low or marginal readings are obtained on a new
installation the problem should be corrected before
proceeding with the installation.
2. MEASURING RESISTANCE BETWEEN LEADS
(MOTOR WINDING RESISTANCE)
The general conditions of motor windings can be
determined by measuring the resistance of the motor
windings (i.e. the resistance between the motor leads)
and comparing the measured resistance with values
given in the motor manual. The resistance is measured
with an ohmmeter and the value is stated in ohms.
The basic procedure for measuring motor winding
resistance is given below:
A. Turn off the power and disconnect the leads to be
tested from the panel. Lock out the panel.
FAILURE TO TURN OFF THE POWER
WILL DAMAGE THE METER AND
CAN CAUSE SERIOUS OR FATAL ELECTRICAL
SHOCK.
Failure to disconnect the leads can result in false
readings.
B. Set the meter selector knob to 'RX 1'. Clip the me-
ter leads together and adjust the meter to zero.
C. Unclip the meter leads and attach them to the
motor leads.
Resistance measured between the motor leads prior to
splicing the power cable to the motor leads should be
within the motor winding resistance limits specified in
the motor manual.
13
TABLE C.1 — NORMAL INSULATION RESISTANCE VALUES BETWEEN ALL LEGS AND
GROUND
Insulation resistance does not vary with rating. Motors of all HP, voltage and phase rating have the same insulation
resistance ranges.
METER READING
R x 100,000 R x 10,000
Scale Scale
BENCH TESTS
• A new motor (without drop cable). 20,000,000+ 20+ 200+ 2000+ or 2K+
• A used motor which can be reinstalled 10,000,000+ 10+ 100+ 1000+ or 1K+
• Cable splice after immersion for one 2,000,000+ 2+ 20+ 200+
WELL TESTS Ohm readings are for drop
cable plus motor.
• A new motor or used motor in good 2,000,000+ 2+ 20+ 200+
condition.
• A motor in reasonably good condition. 500,000– 0.5–2.0 5–20 50–200
2,000,000
• A motor which may have been damaged 20,000– 0.02–0.5 0.2–5 2–50
by lightning or with damaged leads. 500,000
Do not pull the pump for this reason.
• A motor which denitely has been 10,000– 0.01–0.02 0.1–0.2 1–2
damaged or with damaged cable. The 20,000
pump should be pulled and repairs
made to the cable or the motor replaced.
The motor will not fail for this reason
alone, but will probably not operate for
long.
• A motor which has failed or with Less than 0–0.01 0–0.1 0–1
completely destroyed cable insulation. 10,000
The pump must be pulled and the
cable repaired or the motor replaced.
+ Indicates that the reading should be the value shown or greater. Higher readings indicate better insulation.
CONDITION OF MOTORS
AND LEADS
in the well.
hour in water.
OHMS MEGOHMS or or
R x 100K R x 10K
Resistance measured between the power cable leads after
splicing the power cable to the motor leads will indicate
the resistance of the power cable plus the motor windings. The motor winding resistance is obtained by the
formula below. The calculated value should be within the
limits specified in the motor manual.
Motor Winding = Reading taken – Cable Resistance
Resistance at Power Cable from Table 2.
14
A higher winding resistance than shown in the motor
manual indicates a possible burned (open) winding, an
open cable, a loose connection or the wrong motor (different HP or voltage than readings being referenced).
A considerably lower winding resistance than shown in
the motor manual indicates a possible shorted (burned
together) winding or the wrong motor.
Unequal resistance between the windings on a three
phase motor indicates a burned winding or a faulty connection.
TABLE C.2 — POWER CABLE RESISTANCE
Pump Setting (feet)
1ST HOOK UP
2ND HOOK UP
3RD HOOK UP
The values below are for copper conductors. If aluminum conductor drop cable is used, the resistance will be higher
for each foot of cable of the same size. To determine the actual resistance of aluminum drop cable, divide the ohm
readings from this chart by 0.61. This chart shows total resistance of cable from control box to motor and back.
1750
1500
1250
1000
750
500
250
#0
#2
#4
#6
#8 Cable
#10 Cable
#12 Cable
#14 Cable
0
00.5
1
1.522.533.544.5
Power Cable Ohms
3. CURRENT UNBALANCE TEST:
A. For three phase units, after correct rotation has
been established, 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 over 2%, current readings should
be checked on each leg using one of three possible
hook-ups indicated in the table below. Roll the
motor leads across the starter in the same direction
to prevent motor rotation reversal. This procedure
is commonly known as "rolling the leads". THE
HOOKUP THAT RESULTS IN THE LOWEST
PERCENT CURRENT UNBALANCE SHOULD
BE USED FOR THE FINAL CONNECTION OF
THE POWER LEADS.
B. Current unbalance is determined by measuring
the amperage of each of the three legs and then
calculating the percent current unbalance using the
formula below. This calculation must be performed
using each of the three hookups shown.
Maximum Current difference in
Percent Current Unbalance = any leg from average current x 100
Average Current
L1L2L3
T2
T1T3
L1L2L3
T1
T3T2
L1L2L3
T3
T2T1
SUPPLY
STARTER
MOTOR
Sample Calculation
• Measure current in T1 L1 51 amps T1 L1
each leg. T2 L2 46 amps T2 L2
T3 L3 53 amps T3 L3
• Add leg currents to 150 amps
determine total
current.
• Calculate average
leg current. 50 amps
• Determine maximum 51 – 50 = 1
difference of any one 50 – 46 = 4 max
leg from the average. 53 – 50 = 3
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 correct.
D. By observing where the furthest current reading from
the average is for each leg of each of the hookups, the
cause of the unbalance can be determined. If the leg
furthest from average is always on the same motor
lead, the primary source of unbalance is on the "motor
side" of the starter. In this instance, consider a damaged cable, leaking splices, poor connection or faulty
motor winding.
LIMITED WARRANTY
Company warrants title to the product(s) and, except as noted with respect to items not of Company’s manufacturer, also warrants
the product(s) on date of shipment to Purchaser, to be of the kind and quality described herein, and free of defects in workmanship
and material. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, INCLUDING BUT NOT LIMITED TO
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS, AND CONSTITUTES THE ONLY WARRANTY OF COMPANY
WITH RESPECT TO THE PRODUCT(S).
If within one year from date of initial operation, but not more than 18 months from date of shipment by Company of any item of
product(s), Purchaser discovers that such item was not as warranted above and promptly notifies Company in writing thereof, Company
shall remedy such nonconformance by, at Company’s option, adjustment or repair or replacement of the item and any affected part
of the product(s). Purchaser shall assume all responsibility and expense for removal, reinstallation, and freight in connection with the
foregoing remedies. The same obligations and conditions shall extend to replacement parts furnished by Company hereunder. Company
shall have the right of disposal of parts replaced by it. Purchaser agrees to notify Company, in writing, of any apparent defects in design,
material or workmanship, prior to performing any corrective action back-chargeable to the Company. Purchaser shall provide a detailed
estimate for approval by the Company.
ANY SEPARATE LISTED ITEM OF THE PRODUCT(S) WHICH IS NOT MANUFACTURED BY THE COMPANY IS NOT
WARRANTED BY COMPANY and shall be covered only by the express warranty, if any, of the manufacturer thereof.
THIS STATES THE PURCHASER’S EXCLUSIVE REMEDY AGAINST THE COMPANY AND ITS SUPPLIERS RELATING TO THE
PRODUCT(S), WHETHER IN CONTRACT OR IN TORT OR UNDER ANY OTHER LEGAL THEORY, AND WHETHER ARISING
OUT OF WARRANTIES, REPRESENTATIONS, INSTRUCTIONS, INSTALLATIONS OR DEFECTS FROM ANY CAUSE. Company
and its suppliers shall have no obligation as to any products which have been improperly stored or handled, or which have not been
operated or maintained according to instructions in Company or supplier furnished manuals.
LIMITATION OF LIABILITY – Neither Company nor its suppliers shall be liable, whether in contract or in tort or under any other
legal theory, for loss of use, revenue or profit, or cost of capital or of consequential damages, or for any other loss or cost of similar type
or for claims by Purchaser for damages of Purchaser’s customers. Likewise, Company shall not under any circumstances be liable for the
fault, negligence, wrongful acts of Purchaser or Purchaser’s employees, or Purchaser other contractors or suppliers.
IN NO EVENT SHALL COMPANY BE LIABLE IN EXCESS OF THE SALES PRICE OF THE PART OR PRODUCT FOUND
DEFECTIVE.
Xylem Inc.
PO Box 5487
Lubbock, TX 79408
Phone: 1-806-763-7867
Fax: 1-800-453-4749
www.gouldswatertechnology.com
Goulds is a registered trademark of Goulds Pumps, Inc. and is used under license.