OWNERS MANUAL
Contents
1. YOLdVaV V R 553 3A VA SE NOINN FEIEN p p 319 f 31gisN3Wans LYSATE dVO STAGOW 33IAAC 193NNOOSIG 1V2I312313 lO431NOD 20 W9 f 161 14861 uojJeD SZS WO 01 1 611 SLE 16 1668 Ozc Wit L S Sr uojeD Oz L W6 1 101 97 1651 zr 3JONVISIG 715 INVL 303118 dOL OL ADNVLSIG 3ATVA 3ATVA 331134 JALVD JOIAYAS ISNOH OL paepurys SL 331214 3dld OL J18VO AdVL 3dld 3318 31971 33S 3ATVA HgOldvdv SSd1Lld HOLIMS 34155344 1O3 LNOO AWNTOA ADNVD JANSSJAd LOANNOODSIC 1VOT4 LO3 13 STHIOW FAIM 1OYLNOD dVO TIIM 3L V ILLN3A 21 TROUBLESHOOTING GUIDE PROBLEM CHECK CORRECTIVE ACTION Motor will not start but fuses do not blow No voltage No voltage at fuse box No voltage at control box No voltage at pressure switch No voltage on load side of pressure switch Cable or splices bad Control box incorrectly wired Consult power supplier check generator Check connections rewire from fuse box to control box Check connections replace control box rewire from control box to pressure switch2. Clamp or weld or both if necessary this bonding conductor to the grounding means provided with the pump which will be the equipment grounding terminal the grounding conductor on the pump housing or an equip ment grounding lead The equipment ground ing lead when provided will be the conductor having green insulation it may also have one or more yellow stripes Ground the pump motor and any metallic conduit that carries power cable conductors Ground these back to the service by connect ing a copper conductor from the pump motor and conduit to the grounding screw provided within the supply connection box wiring com partment This conductor must be at least as large as the circuit conductors supplying the pump Save these instructions 8 YM HL 3301214 Z9Z 9 09 940 Ot dWfld Pd 661 154 87 Pd 81 SvE OS 940 Ot 400 08 8EL OZ 154 u 1r ANIVA 3179 E EE oa ut eee 4 7 0 2 35 OL ADNVD 3 7553 HOLIMS 3 7553 U 107 551 LA SSIES 3dld OL AsV aS D JATVA
3. Check connections replace pressure switch Consult serviceman or licensed electrician Reconnect control box correctly see wiring diagrams Pages 12 through 15 Fuses blow or overload protector trips when motor starts Wrong size fuse or wrong size time delay fuse Wire size too small Starting capacitor defective or blown Low or high voltage Cable leads not correctly connected to control box Broken wire in control box Pump or motor stuck or binding Check fuse size against chart Page 4 Check wire size against chart Page 5 Check control box to see if starting capacitor has blown out Check that line voltage is within 10 of nameplate rated voltage while motor is running Check control box wiring diagram gainst incoming power hookup heck drop cable color coding m all connections and wiring in ontrol box heck for locked rotor in pump Install correct fuse or time delay fuse Install correct size wire Replace starting capacitor If voltage variation is greater than 10 call power company to adjust voltage Reconnect leads to match wiring diagram in control box cover Reconnect drop cable so cable color code matches motor lead color code Disconnect power and repair or replace faulty wire If necessary pull pump make all possible above ground checks first If pump is locked replace it Clean well of all sand or lime before reinstallin
4. To avoid over heating wire and excessive voltage drop at motor be sure that wire size is at least as large as size listed in Table V for your horsepow er pump and length of wire run NOTICE See Pages 11 through 15 for typical wiring hookups and control box identification NOTICE When built in overheating protection is not provided install an approved overload equipped motor control that matches motor input in full load amps Select or adjust overload element s in accordance with control instruc tions When built in overheating protection is provided use an approved motor control that matches motor input in full load amperes Rotation Phase only To make sure motor is running in the right direc tion proceed carefully as follows After electrical connections have been made as outlined and with pump hanging in well sup ported from clamp on the discharge pipe turn on then turn off the switch connecting the motor to the power supply line Note rotation of pump as motor starts If connections are properly made pump will jerk clockwise when looking into the pump discharge when started If jerk is counter clockwise the motor is running in the wrong direction Interchange any two cable leads where they connect to the lead terminals in the magnetic starter With connections proper ly made and pump lowered into water turn on the switch again and the pump should deliver water according to the perform
5. 1 1 2 1550 2480 3910 6170 9650 300 500 810 1210 2060 1 5 380 2 1130 1810 2850 4510 7060 220 370 590 880 1500 2 2 380 3 770 1230 1950 3080 4830 150 250 400 600 1030 3 7 380 5 470 750 1190 1880 2950 90 150 240 370 630 5 5 380 7 1 2 330 530 840 1330 2090 60 110 170 260 440 NOTE for 415 Volt hookup use 115 of 380 Volt table ratings Calculating Cable size when two different sizes can be used Sometimes conditions make it desirable to use more than one size cable in an installation For example Replace a pump with a 3 HP 230 volt 60 Hz single phase motor with the motor setting at 310 down the well and with 160 of 3110 cable buried between the service entrance and the well head In order to avoid replacing the buried cable the question is What size cable is required in the well Calculate as follows 1 According to Table IV a total of 300 of 10 cable is allowed to power the 3 HP motor The per cent of this total that has been used by the 160 of cable in the buried run is 160 300 533 53 3 lt 160 Ft AWG 10 gt 53 3 of Allowable Cable A 310 Ft AWG 6 41 3 of Cable gt Allowable Pump Cable Controls Service Entrance Main Fuse Box From Meter 3 HP 2 2 kw 230V 1Ph Motor With 53 3 of the allowable cable already used 46 7 of the total length is left for use in the well To
6. 100 unless necessary to stop nuisance trip ping with measured amps in all lines below nameplate maximum NOTE 3 Adjustable overload relay amp settings apply to approved types listed below Request approval of other types from Franklin Electric Set relay adjustment at specified SET amps do not increase setting unless motor trips with mea sured amps in all lines within nameplate maxi mum amps Do not increase setting past MAX value shown Some approved types may not be available for all listed motor ratings When using relays with current transformers set relay to specified amps divided by transformer ratio Approved relays include AEG Series B175 B27S 11 17A and 15 23A B27 2 11 17A and 15 23A ASEA Type RVH40 Allen Bradley Bulletin 193 Fanal Types K7 or K7D through K400 General Electric CR4G1T CR4G1W CR4G2W CRAG3W Klockner Moeller Types ZOO Z1 Z4 PKZM3 Lovato RC 22 to RC 80 RTE Delta Types DQ LR1 D LR1 F Sprecher and Schuh Types CT CT1 CTA1 Siemens Types 3UA50 52 54 58 59 Square D Class 9065 Types TUP MR TD TE TF TR TJE Telemecanique Type LR1 D LR1 F Westinghouse Types FT13 FT23 FT33 FT43 K7D K27D K67D Westmaster OLWROO and OLWTOO suffix D through P Other relay types from these and other manufac turers should not be used without approval of Franklin Electric 50 Hz Franklin Motor Electrical Specifications TABLE VI Recommended Fus
7. Ground NN well Casing 359 0893 Follow color coding when connecting control box Yellow to Y Red to R Black to B Installation Wiring Diagrams Single Phase 3 Wire A WARNING For motors of 1 1 2 HP and above use magnetic starter to avoid damage to pressure switch Consult factory for wiring information SINGLE PHASE 1 2 HP THRU 5 HP STANDARD SINGLE PHASE 1 2 HP THRU 5 HP STANDARD CONTROL BOX WITH LIQUID LEVEL CONTROL CONTROL BOX WITH PRESSURE SWITCH amp LIQUID LEVEL CONTROL ToLine Ground Ground Switch Fused Fused Disconnect a Disconnect 9 Switch Control Switch Tox J Contro Box EMI Box BN L2 2 d BW Liquid Liquid Level Control Level T Control 6 L8 I zm o 9 Yelow Yellow Black High e Black High e Red Electrode Electrode Low Well Ground Low well Ground Electrode o Casing Electrode Casing 353 0893 1271 0994 OPEN SYSTEM SINGLE PHASE 1 2 HP THRU 5 HP STANDARD CONTROL BOX Ground To Aa Control Po
8. Wire Cable 60 Hz Copper Wire Size AWG Service to Motor Volts HP 14 12 10 8 6 4 3 2 1 0 2 150 250 390 620 970 1530 1910 2360 2390 3620 230V 3 120 190 300 470 750 1190 1490 1850 2320 2890 5 180 280 450 710 890 110 1390 1740 3 Phase 3 Wire Cable 60 Hz Volts HP 14 12 10 8 6 4 3 2 1 0 2 320 510 810 1280 2010 3130 3890 4770 5860 7170 3 240 390 620 990 1540 2400 2980 3660 4480 5470 230V 5 140 230 370 590 920 1430 1790 2190 2690 3290 7 1 2 160 260 420 650 1020 1270 1560 1920 2340 10 190 310 490 760 950 1170 1440 1760 2 1300 2070 3270 5150 8050 3 1000 1600 2520 3970 6200 460V 5 590 950 1500 2360 3700 5750 7 1 2 420 680 1070 1690 2640 4100 5100 6260 7680 10 310 500 790 1250 1960 3050 3800 4650 5750 7050 2 2030 3250 5110 8060 3 1580 2530 3980 6270 575V 5 920 1480 2330 3680 5750 7 1 2 660 1060 1680 2650 4150 10 490 780 1240 1950 3060 4770 5940 Meets NEC for individual conductor 60 C cable Only length without meet NEC for jacketed 60 C cable Local code requirements may vary TABLE IV NOTES 1 Maximum cable lengths shown maintain motor voltage at 95 of service entrance voltage running at maximum nameplate amperes If service entrance voltage will be at least motor nameplate voltage under normal load conditions 50 additional length is per mis
9. amp LIQUID LEVEL CONTROL Pressure Switch Pressure Switch MOL 3 mr rt rer M L Z Fused Disconnect Switch M ti Fused ne Disconnect Switch deu 1 8 2 Magnetic E 8 Starter pus ey ES Th Tj N amp EN x d Control TH 9 High E Electrode F Low a Electrode I wel Casing zii 361 0893 m Well Casing 362 0893 Follow color coding when connecting control box Yellow to Y Red to R Black to B Installation 6 Cut Scotchfil electrical insulation putty into 3 equal parts and form tightly CABLE SPLICING around butt connectors Be sure scotch 1 Splice cable to motor leads Use one of the fil overlaps insulated part of wire three methods outlined below Use only cop 7 Using 33 Scotch tape wrap each joint per wire for connections to pump motor and tightly cover wire for about 1 1 2 control box 38mm on each side of joint Make four A Taped splice Wire sizes No 8 8 4mm passes with the tape In other words and larger when finished you should have four lay 1 Cut off motor leads Stagger lead and ers of tape tightly wrapped around the wire length so that 2nd lead is 2 wire Press edges of tape firmly down 50mm longer than 1st lead and 3rd against the wire see Figure 8 lead is 2 50mm longer than second NOTICE Since the tightly wound tape is 2 Cut off cable ends Be
10. and above use magnetic starter to avoid damage to pressure SINGLE PHASE 2 3 amp 5 HP DELUXE CONTROL BOXES WITH LIQUID LEVEL CONTROL To Line Ground Fused l Disconnect Switch Contro Box BW Liquid a Level Control Sg 25 99 1 8 6 oO 8 8 5 o Yellow Black High P Bed Electrode Low _ m Well Ground Electrode U Casing 354 0893 SINGLE PHASE 2 3 amp 5 HP DELUXE CONTROL BOXES OPEN SYSTEM Ground ToLine Fused Y Disconnect Switch Contro Box SW lt 12 o 9 Yellow Black Well Ground Casing 1270 0994 Follow color coding when connecting control box Yellow to Y Red to R Black to B Installation Wiring Diagrams Three Phase THREE PHASE 1 1 2 HP amp LARGER THREE PHASE 1 1 2 HP amp LARGER WITH PRESSURE SWITCH WITH PRESSURE SWITCH
11. and seriously damage pump Install larger wire from meter to control box Install larger wire from control box to pump If necessary have power company raise supply voltage Clean or replace as necessary Free check valve Replace pump Air or milky water discharge from faucets Gas in well water Air volume control not working standard tanks only Check for presence of gas in well water Make sure ports and ball check valves are Clear Remove bleeder orifices plug tees Be sure plugged tees do not leak If necessary separate gas from air before it enters pressure tank Replace control if necessary 23 LIMITED WARRANTY Sta Rite Industries Inc warrants to the original consumer of the products listed below that they will be free from defects in material and workmanship for the Warranty Period from the date of original installation or manufacture as noted Product Warranty Period Water Systems Products jet pumps whichever occurs first small centrifugal pumps submersible pumps 1 year from date of original installation or and related accessories 2 years from date of manufacture Hydro Flow Filters 1 year from date of purchase Signature 2000 Fibrewound Tanks 5 years from date of original installation Pro Source Steel Pressure Tanks 5 years from date of original installation Pro Source Epoxy Lined Tanks 3 years from date of original installation Sump Sewage Effluent Produ
12. avoid running a cable that is too long and lowering the voltage to the motor we have to find a cable size large enough so that 310 is less than 46 7 of the total length allowed for that size Trying 8 cable Table IV shows that the total allowable length for a 3 HP motor is 470 470 x 46 7 470 x 467 219 5 This is not long enough Trying 6 cable Table IV shows that the total allowable length is 750 750 x 46 7 750 x 467 350 25 This is longer than needed Therefore 6 cable can be used for the 310 of cable in the well Any combination of sizes can be used pro vided that the total percentage of the length of the two sizes of cable does not exceed 10096 of the allowed lengths 218 0993 Calculating Cable size when two different sizes can be used HF 160 Ft AWG 10 gt 53 3 of Allowable Cable 310 Ft AWG 6 41 3 of Cable gt Allowable Pump Cable Controls Service Entrance Main Fuse Box From Meter 3 HP 2 2 kw 230V 1Ph Motor Example Metric When replacing pump motor in an installation already having 55M of buried 10 mm cable between service entrance and well head what size cable is required in the well from well head to motor when using a 3 HP 2 2kw 220 volt 50 Hz single phase motor set 125M below the well head Solution Metric According to Table VIII 1
13. develop extremely high pressure Install a pressure relief valve capable of passing entire pump flow at 75 PSI 517 kPa when using an air over water pressure tank Install a pres sure relief valve capable of passing entire pump flow at 100 PSI 690 kPa when using a pre charged pressure tank A Do not allow pump pressure tank piping or any other system component containing water to freeze Freezing may damage system leading to injury or flood ing Allowing pump or system components to freeze will void warranty 2 A WARNING Hazardous voltage Can shock burn or cause death To avoid dangerous or fatal electric shock hazard use pump only in a water well A Installation must meet United States National Electrical Code Canadian Electrical Code and local codes as applicable for all wiring Disconnect electrical power supply before installing or servicing pump A Make sure line voltage and frequency of power supply match motor nameplate voltage and frequency 3 Install pump according to all plumbing pump and well code requirements 4 Test well water for purity before using well Call your local health department for testing procedure 5 During installation keep well covered as much as possible to prevent leaves and foreign matter from falling into well Foreign objects in well can contaminate the water and cause serious mechanical damage to the pump 6 Pipe joint compound c
14. 50 is the maximum allowable length when using 10 mm cable with a 3 HP 2 2kw 19 motor The installation has 55 M already in place 55 M used 150 M allowed 36 Approximately 3696 of allowable cable has been used That leaves approximately 6496 of allow able cable still available for use in the well 218 0993 According to Table VIII 16 mm cable can be used to a maximum of 230 M 64 of 220M 147 M this is more than the length required therefore 16 mm wire can be used NOTICE When figuring the percent of cable length of any size that can be used remember that the total percentages of all sizes cannot add to more than 10096 INSTALLATION WIRING DIAGRAMS SINGLE PHASE 3 WIRE A WARNING For motors of 1 1 2 HP and above use magnetic starter to avoid damage to pressure switch Consult factory for wiring information A WARNING burn or kill Ground control box all metal plumbing and motor frame with copper wire in compliance with local codes Use a ground wire at least as large as the wires supplying power to motor Permanently close all unused openings in this and other equipment Disconnect power to control box before work ing on or around control box pipes cable pump or motor To be sure that starting relay will function and that overload will not nuisance trip install control box vertically with top side up Wire control box as shown on Pages 12 through 14 Pump will not op
15. ABLE Recommended Fusing Data id Singe Phase 3 Wire Capacitor Run rester Submersible Pump Motors Box Motor Winding Max Locked Fuze Size 9 8 55 Volts Resistance Ohms Load Rotor Standard HP Hz Ph RtoY Bto Y Amps Amps Dual Element E L2 230 60 52715 1623 132 510 3020 FIGURE 1 Typical 3 Wire Single Phase 230 230 60 1 30 49 09 15 17 0 820 45 30 Volt Surge Arrester 5 230 60 2 1 2 8 0 68 1 0 27 5 121 0 80 45 Red to Yellow start winding resistance Black to Yellow 2 main winding resistance Line TABLE III Recommended Fusing Data E 60 Hz 3 Phase Submersible Pump Motors dun Max Input Line to Locked Fuze Size Volts S F Load Line Rotor Standard HP Hz Ph Amps Resistance Amps Dual Element uy p L3 2 230 60 3 8 1 2 4 3 0 46 6 25 15 460 60 3 44 9 7 12 0 23 3 15 8 575 6030 3 2 151 187 18 6 10 5 3 dU ius a ded FIGURE 2 Three Phase Surge Arrester 650 575 60 3 4 3 109 1326 248 15 8 Volt Maximum 5 230 60 3 17 7 0 93 1 2 106 0 50 30 460 60 3 8 9 3 6 4 4 53 2 25 15 575 60 3 74 5 6 6 9 42 6 20 15 7 1 2 230 60 3 26 0 0 61 0 75 164 0 80 45 460 60 3 13 0 24 34 81 9 40 25 575 60 3 10 4 3 5 5 1 65 5 30 20 10 460 60 3 18 5 1 8 2 3 116 0 60 45 575 60 3 14 8 2 8 3 5 92 8 45 35 60 Hz Franklin Motor Electrical Specifications TABLE IV Cable Length in Feet 1 Phase 3
16. ECTOR OR CRIMP OR SOLDER FIGURE 11 FIGURE 8 COMPLETED SPLICE CONNECTOR CAP SCREWED ON lt GASKET SLEEVE IN PLACE INSULATOR BODY CENTERED OVER SPLICE HEAT SHRINK TUBING FIGURE 12 FIGURE 9 NOTICE Keep torch moving Too much concentrated heat may damage tubing see Figure 9 C Butt Connectors with plastic insulators for 14 12 and 10 Gauge AWG Wire or 2 3 and 5 5mm wire 1 Cut off motor leads Stagger lead and wire length so that 2nd lead is 4 100mm longer than 1st lead and 3rd lead is 4 100mm longer than second 2 Cut off cable ends Be sure to match colors and lengths of wires in drop cable to colors and lengths of motor leads 3 Trim insulation back 1 2 13mm from cable ends and motor lead ends 4 Unscrew plastic caps from insulators Place a cap and a neoprene gasket sleeve on each wire end to be spliced see Figure 10 5 Slide insulator body onto one wire end Figure 10 6 Insert wire end into butt connector and crimp see Figure 11 Be sure to match cable and motor wire colors 7 Center insulator body over splice and slide neoprene sleeves into body as far as they will go Screw caps onto insula tor body Figure 12 and tighten by hand for a strong waterproof splice CABLE INSTALLATION 1 To test submersible momentarily connect it to proper power supply Power supply fre quency and voltage must match motor name plate frequency and voltage to within 10 Phase pumps se
17. EG Series B17S B27S B27 2 Allen Bradley Bulletin 193 SMP Class 10 only Fanal Types K7 or K7D through K400 Franklin Electric Subtrol Plus General Electric CR4G CR7G RT 1 RT 2 RTF3 RT 4 CR324X Class 10 only Klockner Moeller Types 700 Z1 Z4 PKZM1 PKZM3 PKZ2 Lovato RC9 RC22 RC80 RF9 RF25 RF95 Siemens Types 3UA50 52 54 55 58 59 60 61 62 66 68 70 3VUI3 3VE 3UB Class 5 Sprecher and Schuh Types CT CT1 CTA 1 CT3K CT3 12 thru CT3 42 KTA3 CEF1 amp CET3 set at 6 sec max CEP 7 Class 10 CT4 6 amp 7 CT3 Square D Telemecanique Class 9065 types TD TE TF TG TJ TK TR TJE TJF Class 10 or LR1 D LR1 F LR2 D13 D23 D33 Types 18A 32A SS Class 10 SR Class 10 and 63 A LB Series Integral 18 32 63 GV2 L GV2 M GV2 P GV3 M 1 6 10 amp only Westinghouse Types FT13 FT23 FT33 FT43 K7D K27D K67D Advantage Class 10 MOR 10500 Class 5 Other relay types from these and other manufacturers may or may not provide acceptable protection and they should not be used without approval of Franklin Electric Some approved types may only be available for part of the listed motor ratings When relays are used with cur rent transformers relay setting is the specified amps divided by the transformer ratio 60 Hz Franklin Motor Electrical Specifications T
18. STA RITE OWNERS MANUAL INSTALLATION AND OPERATING INSTRUCTIONS 4 SUBMERSIBLE PUMPS 90 GPM Single and Three Phase 2 through 10 HP 60 Hz Single and Three Phase 1 1 2 through 7 1 2 HP 50 Hz Record the following information from the motor and pump nameplates for future reference Pump Model No Pump Serial No Motor Model No Motor Serial No H P Volts Hz Ph Rated Amp Draw STA RITE INDUSTRIES INC DELAVAN WISCONSIN 53115 Printed in U S A 2003 Sta Rite Industries Inc S689 Rev 6 30 03 Carefully read and follow all safety instructions in this manual or on pump This is the safety alert When you see this symbol on your pump or in this man ual look for one of the following signal words and be alert to the potential for personal injury warns about hazards that will cause serious personal injury death or major property damage if ignored A WARNING warns about hazards that can cause serious personal injury death or major property damage if ignored CAUTION warns about hazards that will or can cause minor personal injury or property damage if ignored The word NOTICE indicates special instructions which are important but not related to hazards To avoid serious or fatal personal injury and possible property damage carefully read and follow the safety instructions 1 WARNING Hazardous pressure Under certain conditions submersible pumps can
19. an cause cracking in plastics Use only teflon tape when sealing joints in plastic pipe or connecting pipe to thermoplastic pumps TABLE OF CONTENTS Safety Instructions 2 Pre Installation 2 Electrical General 2 3 11 12 60 Hz Fuse Wire Motor Specs 4 6 50 Hz Fuse Wire Motor Specs 7 10 Wiring Diagrams 10 15 Installationi i2 ra d mme 16 17 initial Startup meme 17 18 Connecting to Tank Water System 18 21 Troubleshooting Guide 22 23 Warranty dete obcaecat 24 PRE INSTALLATION Inspect pump and motor for delivery damage Report any damage immediately to the shipping carrier or to your dealer The well driller should thoroughly develop the well that is pump out all fine sand and foreign matter before pump is installed Pump performance is based on pumping clear cold liquid water Warranty is void in the following conditions If pump has pumped excessive sand exces sive sand can cause premature wear to pump f water is corrosive If entrained gas or air are present the water being pumped these can reduce flow and cause cavitation which can damage pump f pump has been operated with discharge valve closed severe internal damage will result Install pump at least 15 to 20 4 5 to 6M below the lowest water level reached with pump run ning lowest dr
20. ance charts OVERLOAD PROTECTION OF THREE PHASE SUBMERSIBLE MOTORS CLASS 10 PROTECTION REQUIRED The characteristics of submersible motors are different from standard motors and special over load protection is required If the motor is stalled the overload must trip within 10 seconds to protect the motor wind ings The installer must use SUBTROL or the quick trip protection shown in Table All rec ommended overload selections are of the ambi ent compensated type to maintain protection at high and low air temperatures All heaters and amp settings shown are based on total line amps When a six lead motor is used with a Wye Delta starter divide motor amps by 1 732 to make your selection or adjustment for heaters carrying phase amps Tables and V list the correct selection and set tings for several manufacturers Approval of other types may be requested from the motor manufacturer NOTICE Warranty on three phase submersible motors is void unless proper quick trip protec tion in all three motor lines is used SURGE ARRESTERS IN CONTROL BOX Grounding When the box has a surge arrester the surge arrester MUST be grounded metal to metal all the way to the water strata for the arrester to be effective Grounding the arrester to a driven ground rod provides little or no pro tection for the motor NOTICE Surge arresters DO NOT protect against direct lightning strikes Install grounded surge arresters to protect pump
21. aw down water level and at least 5 1 5M above the bottom of the well WIRING GROUNDING A WARNING Hazardous voltage Can shock burn or cause death Permanently ground pump motor and control box before connect ing power supply to motor Ground pump and motor in accordance with the local codes and ordinances Use a copper ground wire at least as large as wires carrying current to motor Motor is supplied with a copper ground wire Splice this ground wire to a copper conductor that matches motor wire size specified in Table V See Pages 16 and 17 for cable splicing instructions Permanently ground pump motor and control box before connecting power cable to power supply Connect ground wire to approved ground first and then connect to equipment being installed Do not ground to a gas supply line AWARNING Fire and electrical shock hazard If using a drop cable larger than No 10 5 5mm for example No 8 8 4mm wire between pump and control box run cable to a separate junction box Connect junction box to control box with a No 10 5 5mm or smaller wire depending on amp rating of pump see Table II or IV For more information contact your local code officials WIRING CONNECTIONS Installation must meet United States National Electrical Code Canadian Electrical Code and local codes for all wiring as applicable Use only copper wire when making connections to pump and control box
22. cts 1 year from date of original installation or 2 years from date of manufacture Our warranty will not apply to any product that has been subject to negligence misapplication improper installation or maintenance In the event a three phase submersible motor is operated with single phase power through a phase converter or if three leg ambient compensated extra quick trip overload relays of recommended size are not used our warranty is void Buyer s only remedy and Sta Rite Industries Inc s only duty is to repair or replace defective prod ucts at Sta Rite Industries Inc s choice Buyer agrees to pay all labor and shipping charges asso ciated with this warranty and to request warranty service through the installing dealer as soon as a problem is discovered If warranty service is requested more than 30 days after the Warranty Period has ended it will not be honored STA RITE INDUSTRIES INC SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL INCIDEN TAL OR CONTINGENT DAMAGES WHATSOEVER THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WAR RANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE SHALL NOT EXTEND BEYOND THE WARRANTY PERIOD PROVIDED HEREIN Certain states do not permit the exclusion or limitation of incidental or consequential damages or the placing of limitations on the duration of an implied warranty therefore th
23. e Rotation Page 3 Fasten cable leads securely to pump dis charge section leave 4 5 100 127mm of slack in leads at this point Securely fasten leads to plastic pipe within 6 150mm of the pump discharge section Use torque arresters to protect pump and pipe from twisting dam age as pump starts and stops Connect copper ground wire to motor brack et Ground wire must be at least as large as wires supplying current to motor Consult cur rent National Electrical Code Canadian Electrical Code and local codes as applica ble for grounding information Use only submersible cable supplied by pump manufacturer When lowering pump into well secure cable to discharge pipe at 10 3 5M intervals with Scotch 33 electrical tape Take care not to damage pump cable NOTICE To avoid dropping the pump down the well or damaging cable or cable splices NEVER allow pump cable to support weight of pump PUMP INSTALLATION 1 If a standard air over water pressure tank is being used install two bleeder orifices about 2 6M apart as shown in Figure 15 Page 21 These orifices will automatically charge the tank with air See Figure 15 to determine orifice location NOTICE If Pre charged tank is used DO NOT install bleeder orifices If pump and pre charged tank are replacing a standard tank system remove bleeder orifices before installing pump in well To prevent losing pump down the well con nect a
24. e limitations or exclusions herein may not apply This warranty sets forth specific legal rights and obligations however addi tional rights may exist which may vary from state to state Supersedes all previous publications This warranty is valid only in the United States and Canada Sta Rite Industries Inc 293 Wright St Delavan WI 53115 24
25. erate without control box and deluxe boxes require a switch or a jumper lead between SW and L2 terminals Operation without control box will burn out motor Hazardous voltage Can shock Installation must meet United States National Electrical Code Canadian Electrical Code and local codes for all wiring as applicable If main overload trips look for 1 Shorted Capacitor 2 Voltage Problems 3 Overloaded or locked pump NOTICE Match motor to control box as shown below Franklin motor and control box model numbers may include additional suffix numbers to the right of the numbers shown here These additional numbers are not important for control box selection LIQUID LEVEL PUMP DOWN CONTROLS Use pump down controls on wells with low flow to prevent pumping well dry See Wiring diagrams Pages 12 through 15 for proper installation NOTICE Ground controls according to local code requirements TABLE IX Control Box Selection Motor Control HP Voltage No Box No 2 230 224301 po ns 3 230 224302 pecu 5 230 224303 em 1 If start overload trips replace start relay Reset and analyze for tripping cause To avoid motor burnout do not remove or short circuit overload protection CHECKING PROCEDURE ALL BOXES Hazardous voltage Can shock burn or cause death Disconnect power to con trol box before doing these check procedures A General Procedures Power to contr
26. ers were selected from Catalog 294 Table 332 and Table 632 starter size 00 size B Size 4 starters are heater type 4 JO Starters using these heater tables include classes 14 17 and 18 INNOVA classes 36 and 37 reduced voltage and classes 87 88 and 89 pump and motor control cen ters Overload relay adjustments should be set no higher than 100 unless necessary to stop nuisance tripping with measured amps in all lines below name plate maximum Heater selections for class 16 starters Magnetic Definite Purpose will be furnished upon request NOTE 2 Allen Bradley heaters were selected from Catalog IC 110 Table 162 through starter size 4 Table 547 starter size 5 and Table 196 starter size 6 Bulletin 505 509 520 540 and 570 use these heater tables Heater selections for bulletin 1232X and 1233X starters will be furnished upon request NOTE 3 General Electric heaters are type CR123 usable only on type CR124 overload relays and were selected from Catalog 1260 page 184 Adjustment should be set no higher than 100 unless necessary to stop nuisance tripping with measured amps in all lines below nameplate maximum NOTE 4 Adjustable overload relay amp settings apply to approved types listed Relay adjustment should be set at the specified SET amps Only if tripping occurs with amps in all lines measured to be within nameplate maximum amps should the setting be increased not to exceed the MAX value shown A
27. es 8 through 12 DO NOT START PUMP YET Set gate valve on discharge 1 3 open start pump see Figure 13 Keep gate valve at this setting while water pumps out on ground Let it run until water is clear of sand or silt To check solids in water fill a glass from pump and let solids settle out 7 When water is completely clear at 1 3 set ting open gate valve to approximately two thirds open and repeat process 8 When water is completely clear at 2 3 set ting open gate valve completely and run pump until water is completely clear 9 Remove gate valve for permanent installation near tank see Figures 14 and 15 Pages 20 and 21 10 Install sanitary well seal or pitless adapter unit well unit electrical conduit and surface piping according to local code requirements CONNECTING TO TANK WATER SYSTEM AWARNING Hazardous pressure Submersible pumps can develop very high pressure in some situations To prevent tank blowup install a pressure relief valve able to pass full pump flow at 75 PSI 517 kPa when using an air over water pressure tank Install a pressure relief valve capable of passing entire pump flow at 100 PSI 690 kPa when using a pre charged pressure tank Install this relief valve between pump and tank NOTICE Allowing pump or piping system to freeze may severely damage pump and will void warranty Protect pump and entire piping system including pressure tank from freezing Contr
28. from high voltage surges Install arrester on the incoming power line to control box or pressure switch as close to pump motor as possible See Figures 1 and 2 for installation wiring diagrams for arresters NOTICE Ground the arrester with a No 10 or larger bare wire Ground according to local code requirements NOTICE If surge arresters wired into the control box are against local electrical code contact power company for correct wiring information 60 Hz Franklin Motor Electrical Specifications TABLE I Overloads for 3 Phase 60 Hertz 4 Franklin Motors Heaters for Adjustable NEMA Overload Relays Relays Starter Furnas Allen Bradley GE Note 4 HP KW Volts Size Note 1 Note 2 Note 3 Set Max 2 1 5 230 0 K49 J25 L910A 75 8 1 460 00 K33 J18 L463A 3 8 4 575 00 K29 J15 L380A 3 0 32 3 22 230 0 K52 J28 L122B 10 1 10 9 460 0 K37 J21 L618A 54 5 5 575 0 K34 J19 L510A 44 44 5 3 7 230 1 K61 J33 L199B 16 6 17 8 460 0 K49 J26 L100B 8 3 8 9 575 0 K42 J23 L825A 6 6 74 75 5 5 230 1 K67 J37 L293B 24 6 26 4 460 1 K55 J30 L147B 12 3 13 2 575 1 K52 J28 L122B 9 9 10 6 10 7 5 460 1 K61 J33 L220B 17 5 18 8 575 1 K57 J31 L181B 14 0 15 0 TABLE I NOTES Recommended Adjustable NOTE 1 Furnas intermediate sizes between NEMA Overload Relays starter sizes apply where 1 is shown in tables size 1 3 4 replacing 2 2 1 2 replacing 3 3 1 2 replacing 4 and 4 1 2 replacing 5 Heat
29. g pump Fuses blow or overload protector trips when motor is running Low or high voltage High ambient atmospheric temperature Control box with wrong voltage or horsepower rating Wire size too small Cable splices or motor leads grounded shorted or open Check that line voltage is within 10 of rated nameplate voltage while motor is running Check temperature of control box Compare voltage and horsepower on motor nameplate with those given on control box nameplate or on circuit diagram inside control box cover Check wire size against chart Page 5 Consult licensed electrician or qualified serviceman If voltage variation is more than 10 call power company to adjust voltage Do not mount control box in direct sunlight Replace control box if numbers do not match Install correct wire size Do not attempt to disassemble pump or motor 22 TROUBLESHOOTING GUIDE cont PROBLEM CHECK CORRECTIVE ACTION Pump starts too frequently Leaks in system Pressure switch Tank waterlogged Leak in drop pipe Pressure switch too far from tank Check all tank connections with soapsuds for air leaks Check plumbing for leaks Check for defective switch or switch out of adjustment Pre charged tanks check tank pre charge air pressure check for leak in bladder Air over water tanks check for air leaks Check Air Volume Control AVC Check snifter valve opera
30. ing Data 50 Hz Single Phase 3 Wire Capacitor Run Submersible Pump Motors Line to Line Max Input Resistance Locked Volts S F Load M Main Rotor Fuze Size KW HP Hz Ph Amps Watts S Start Amps Standard Dual Element 14 1 5 220 50 1 Y 97 1690 2 4 2 9 M 40 6 20 9 B 9 6 6 4 7 8 S R1 0 1 5 2 220 50 1 Y 112 2160 2 0 2 5 M 54 3 30 15 B 10 6 8 0 9 7 5 820 22 3 220 50 1 Y 17 3 3270 1 1 1 4M 87 5 50 25 B 16 7 3 7 4 5 S R35 3 7 5 220 50 1 Y 25 5 5150 79 97 M 118 0 70 30 B 22 4 2 4 2 9 S R77 TABLE VII Recommended Fusing Data 50 Hz 3 Phase Submersible Pump Motors Max Input Locked Volts S F Load Line to Line Rotor Fuze Size KW HP Hz Ph Amps Watts Resistance Amps Standard Dual Element 14 15 220 50 3 5 1 1600 5 9 7 2 20 8 15 6 0 380 50 3 3 1 1510 12 1 14 7 15 5 15 3 5 415 50 3 2 9 1540 12 1 14 7 16 9 15 3 5 1 5 2 220 50 3 6 6 2120 3 0 3 7 35 8 20 8 0 380 50 3 3 8 2120 91 111 20 7 15 45 415 50 3 3 8 2080 91 111 226 15 4 5 2 2 3 220 50 3 9 5 3100 24 29 46 7 25 12 380 50 3 5 5 3100 7 2 8 8 27 0 15 7 415 50 3 5 6 3080 7 2 8 8 29 5 15 7 3 7 5 220 50 3 15 4 5030 1 3 1 6 79 6 40 20 380 50 3 8 9 5030 4 0 4 9 46 1 25 10 415 50 3 9 0 5100 4 0 4 9 50 4 25 10 5 5 75 220 50 3 22 8 7430 0 84 1 0 120 0 60 30 380 50 3 13 2 7430 2 5 3 1 69 5 35 15 415 50 3 13 4 7450 2 5 3 1 75 9 35 15 NOTE 1 Maximum cable lengths shown maintain motor vol
31. ol center or X electrical disconnect box Temporary wiring to control center or electrical disconnect box Temporary piping 4 Gate valve Pump installation Pump in well for developing a well 689 0993 FIGURE 13 Standard Tank Hookup See Figure 15 Page 21 for piping connections to standard pressure tank and for correct dis tance of bleeder orifices from pressure tank Pre charged Pressure Tank Hookup See Figure 14 Page 20 for piping connections to pre charged pressure tank NOTICE Check air pre charge in tank before starting pump Adjust pre charge to 2 PSI 13 8 kPa below pump cut in setting For example a pre charge tank used with a 30 50 switch should be pre charged with air to 28 PSI 193 kPa Adjust pre charge by either adding or bleeding air through tire valve located on top of tank Check pre charge annually and adjust as needed Important Electrical Grounding Information A WARNING Hazardous voltage Can shock burn or kill To reduce the risk of electrical shock during pump operation ground and bond the pump and motor as follows A To reduce risk of electrical shock from metal parts of the assembly other than the pump bond together all metal parts accessible at the well head including metal discharge pipe metal well casing and the like Use a metal bonding conductor at least as large as the power cable conductors running down the well to the pump s motor
32. ol box disconnected 1 Disconnect line 2 Inspect for damaged or burned parts loose connections etc 3 Check for misconnections against diagram in control box 4 If box is too hot circuit breakers may trip or fuses blow Ventilate or shade box Move away from heat source 5 If problem has not been found check motor and control box Use test proce dures that follow B Ground Insulation Resistance Test Power to control box disconnected 1 Ohmmeter Setting Highest scale usually Rx100K or Rx10 000 2 Terminal Connections One ohmmeter lead to Ground screw on control box and touch other lead to each of the terminals on terminal board 3 Ohmmeter Reading Pointer should remain at infinity and not deflect C Capacitor Tests Power to control box dis connected AWARNING Risk of electric shock Short capacitor across terminals before testing 1 Ohmmeter Setting Rx1000 2 Terminal Connections Connect ohmmeter leads to black and orange wires out of capacitor case 3 Ohmmeter Reading Pointer should swing toward zero and float back to oo Capacitor is shorted if pointer does not move back to open if it does not move from 4 To reset capacitor reverse ohmmeter con nection to capacitor terminals D Triac Test Solid state switch only 1 Ohmmeter Setting Rx1000 2 Connect the leads to R start terminal and to orange lead terminal on sta
33. rt switch 3 Ohmmeter reading Infinity E Coil Test Solid state switch only 1 Ohmmeter Setting Rx1 2 Connect leads to Y common and L2 ter minal and to orange lead terminal on start switch 3 Ohmmeter reading Infinity Installation Wiring Diagrams Single Phase 3 Wire WARNING switch Consult factory for wiring information SINGLE PHASE 1 2 HP THRU 5 HP STANDARD CONTROL BOX WITH ADEQUATE RATED PRESSURE SWITCH Ground To Line md CONTROL BOR L1 99000 o 12 2 o o Fused AU Disconnect Switch Pressure Switch Red Yellow Black E Ground well Casing 355 0893 For motors of 1 1 2 HP and above use magnetic starter to avoid damage to pressure SINGLE PHASE 1 2 HP THRU 5 HP STANDARD CONTROL BOX WITH PRESSURE SWITCH One pump for 2 houses With adequate rated pressure switch To Line To Line Ground Fused 3 8 5 5 Pressure Switch Switch Li 12 2 19 L2 o 20 Pressure 1 i Switch L Ll CONTROL Aux Relay OUD or Equivalent Red Yellow Black 8
34. sable for all sizes 2 Sizes given are for copper wire For alu minum wire go two sizes larger For exam ple if table lists 12 copper wire use 10 5mm aluminum wire 3 For reliable 3 Phase starter operation length of wire between starter and service entrance should be not more than 25 of total wire length 50 Hz Franklin Motor Electrical Specifications TABLE Overloads for 3 Phase 50 Hertz 4 Franklin Electric Motors Heaters for Adjustable NEMA Overload Relays Relays Starter Furnas Allen GE Note 3 HP KW Volts Size Note 1 Bradley Note 2 Set Max 15 1 1 220 00 K37 J20 L561A 4 09 5 1 380 415 00 K28 J14 L343A 2 67 2 9 2 1 5 220 0 K41 J23 L750A 6 07 6 6 380 415 00 K32 J17 L420A 3 50 3 8 3 22 220 0 K52 J26 L111B 8 74 9 5 380 415 0 K37 J22 L618A 5 06 5 5 5 3 7 220 1 K57 J31 L181B 142 15 4 380 415 0 K49 J26 L100B 8 19 8 9 75 5 5 220 1 K63 J35 L265B 21 0 22 8 380 415 1 K55 J30 L147B 12 1 13 2 TABLE V NOTES NOTE 1 Heaters listed apply to Innova 45 designs and Definite Purpose Class 16 starters through their available range and to standard starters in larger sizes Set overload relay adjust ments no higher than 100 unless necessary to stop nuisance tripping with measured amps in all lines below nameplate maximum NOTE 2 General Electric heaters are type CR123 usable only on type CR124 overload relays Adjustment should be set no higher than
35. safety rope strong enough to support pump and drop pipe minimum 5 16 8mm twisted polypropylene or pronila rope to eye let on pump discharge Tie off other end of safety rope securely to well seal well cap or pitless adapter Discharge outlet is threaded 2 NPT 60 Hz or 2 BSP 50 Hz Use 100 PSI rated polyethylene plastic pipe for installations up to 100 depth Use 160 PSI rated polyethylene plastic pipe for installation up to 220 depth For depths beyond 220 use galvanized steel pipe for the entire drop pipe INITIAL START UP NOTICE NEVER operate pump with discharge valve completely closed Pump can destroy itself if run with discharge shut off deadheaded and warranty will be void NOTICE To avoid sand locking pump follow procedure below when starting pump for the first time NEVER start a pump with discharge completely open unless you have done this pro cedure first 1 Connect a pipe elbow a short length of pipe and a gate valve to pump discharge at well head see Figure 13 Mount motor control box 3 wire pump fused disconnect switch 2 wire pump or magnetic starter 3 phase pump in a perma nently weather proofed place Make sure that controls will not be subjected to extreme heat or excess moisture Make sure controls are in OFF position Connect motor leads and power supply to motor control box fused disconnect switch or magnetic starter see Wiring Diagrams Pag
36. sure to match the only means of keeping water out of colors and lengths of wires in drop cable the splice the efficiency of the splice to colors and lengths of motor leads will depend on the care used in wrap 3 Trim insulation back 1 2 13mm from ping the tape cable ends and motor lead ends NOTICE For wire sizes larger than 8 4 Insert motor lead ends and cable ends 8 4mm use a soldered joint rather than into butt connectors see Figure 4 Be Scotchfil putty see Figure 6 sure to match wire colors between drop B Heat shrink splice For wire sizes 14 12 cable and motor leads and 10 AWG or 2 3 and 5 5mm 5 Using crimping pliers Figure 7 indent 1 Remove 3 8 10mm insulation from butt connector lugs see Figure 5 to ends of motor leads and drop cable attach wires Wires 2 Put plastic heat shrink tubing over motor leads J BUTT CONNECTOR 3 Match wire colors and lengths in drop LT cable to wire colors and lengths of FIGURE 4 motor leads 4 Insert cable and motor wire ends into butt connectors and crimp See Figures a ae au 4 and 5 BE SURE to match wire colors between drop cable and motor leads FIGURE 3 Pull leads to check connections 5 Center tubing over butt connector and ATERIA TE METOD apply heat evenly with a torch a match C or lighter will not supply enough heat FIGURE 6 END CAP INSULATOR BODY en tay Bu 12 7mm Ur GASKET FIGURE 10 BUTT CONN
37. tage at 95 of service entrance voltage running at maximum nameplate amperes If service entrance voltage will be at least motor nameplate voltage under nor mal load conditions 50 additional length is permissable for all sizes Sizes given are for copper wire For alu minum wire go two sizes larger For exam ple if table lists 12 copper wire use 10 5mm aluminum wire For reliable 3 Phase starter operation length of wire between starter and service entrance should be not more than 25 of total wire length 50 Hz Franklin Motor Electrical Specifications TABLE VIII Maximum Cable Length in Feet AWG Wire or Meters mm Wire 1 Phase 3 Wire Cable 50 Hz Copper Wire Size Service to Motor Motor Rating AWG Feet mm Meters KW Volts HP 14 12 10 8 6 1 5 2 5 4 6 10 1 1 220 1 1 2 220 360 570 900 1410 40 70 120 180 300 1 5 220 2 170 280 440 690 1090 30 60 90 130 230 2 2 220 3 110 180 280 440 700 20 40 60 90 150 3 7 220 5 0 0 190 300 480 0 20 40 60 100 3 Phase 3 Wire Cable 60 Hz Motor Rating AWG Feet mm Meters KW Volts HP 14 12 10 8 6 1 5 2 5 4 6 10 1 1 220 1 1 2 480 770 1220 1940 3040 90 160 250 380 650 1 5 220 2 370 600 940 1500 2350 70 120 190 290 500 2 2 220 3 250 410 650 1030 1610 50 80 130 200 340 3 7 220 5 150 250 390 620 980 30 50 80 120 210 5 5 220 7 1 2 0 170 280 440 700 0 30 60 90 150 1 1 380
38. tion Raise drop pipe one length at a time until water stands in pipe Measure distance from pressure switch to tank System must be air and water tight Re adjust or replace pressure switch Pre charge tanks adjust air pressure to 2 PSI 13 8 kPa less than pump cut in pressure when there is no water pressure on system Replace bladder if necessary Air over water tanks repair or replace tanks replace snifter valves if necessary Replace pipe above that point Move switch to within one foot 3M of tank Little or no water delivered Bleeder orifice check valve stuck or installed back wards standard tank only Low water level Low voltage Plugged intake screen Check valve at pump discharge stuck Worn impellers and diffusers Examine valve Determine lowest water level in well while pump is running and compare to pump depth setting Check voltage at control box with pump running Check incoming wire size and drop cable size against chart Page 5 Pull pump and check condition of screen Pull pump and examine check valve Make sure system is clear of obstructions and pump is in solid water and operation normally If stuck free valve if installed backwards reverse it Lower pump further into well but at least 5 1 6M above bottom of well Throttle pump discharge until discharge equals recovery rate of well NOTICE Running pump while airlocked can cause loss of prime
39. x j sN Fused Disconnect Switch Red Yellow Pl Black Well Ground Casing 357 0893 Follow color coding when connecting control box Yellow to Y Red to R Black to B 13 AWARNING switch Consult factory for wiring information SINGLE PHASE 2 3 amp 5 HP DELUXE CONTROL BOXES WITH PRESSURE SWITCH Ground To iai a Fused m Disconnect Switch Control Box SW L1 12 Y BRR 4 9999 M1 Pressure L2 M2 Switch 10 Yellow Black Red Well Ground Casing Ss 3108 1197 SINGLE PHASE 2 3 amp 5 HP DELUXE CONTROL BOXES WITH PRESSURE SWITCH amp LIQUID LEVEL CONTROL Ground ine m re Switch To Fused m n Disconnect mus Switch s Y m Mi Box Bs EYBSNO BW Liquid Level 1 2 9 5 7 Yellow Black High 1 Red Electrode Electrode Low 7 well Ground 358 0893 Installation Wiring Diagrams Single Phase and Three Phase For motors of 1 1 2 HP
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