Service Manual SUBMERSIBLE PUMPS JET PUMPS GSSERVICE R5

Transcription

1 Service Manual SUBMERSIBLE PUMPS JET PUMPS GSSERVICE R5

2 TABLE OF CONTENTS Submersibles: (Pages 1 61) Page Safety Warnings Typical Systems Motor Cooling... 8 Troubleshooting Amprobe Instructions Ohmmeter Instructions Measuring Insulation Resistance Coil Checkout Relay Checkout Contactor Checkout Overload Checkout Capacitor Checkout Fuse Checkout Voltage Checkout Amperage Checkout Wire Diagrams Cable Checkout Motor Insulation & Winding Resistance Ø Motor Data and Wire Sizing Ø Motor Data and Wire Sizing Aquavar SOLO Wire Sizing Ø 6" 10" Motor Data Pressure Tank Checkout Jet Pumps: (Pages 62 99) Typical Systems Jet Pumps Troubleshooting Voltage Check Amperage Checks Ohmmeter Checks Pressure Switch Adjustment Checkout Checking Suction Lift Pressure Control Valves Rotation Three Phase Unbalance Transformer Sizes Quick Start Guides

3 Safety Warnings 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. DANGER Warns of hazards that WILL cause serious personal injury, death or major property damage. WARNING 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. CAUTION 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. SAFETY WARNINGS 3

4 SAFETY WARNINGS Important notice: Read safety instructions before proceeding with any wiring. WARNING All electrical work must be performed by a qualified technician. Always follow the National Electrical Code (NEC), or the Canadian Electrical Code, as well as all local, state and provincial codes. Code questions should be directed to your local electrical inspector. Failure to follow electrical codes and OSHA safety standards may result in personal injury or equipment damage. Failure to follow manufacturer s installation instructions may result in electrical shock, fire hazard, personal injury or death, damaged equipment, provide unsatisfactory performance, and may void manufacturer s warranty. WARNING Standard units are not designed for use in swimming pools, open bodies of water, hazardous liquids, or where flammable gases exist. Well must be vented per local codes. See specific pump catalog bulletins or pump nameplate for all agency Listings. WARNING Disconnect and lockout electrical power before installing or servicing any electrical equipment. Many pumps are equipped with automatic thermal overload protection which may allow an overheated pump to restart unexpectedly. WARNING Never over pressurize the tank, piping or system to a pressure higher than the tank's maximum pressure rating. This will damage the tank, voids the warranty and may create a serious hazard. WARNING Protect tanks from excessive moisture and spray as it will cause the tank to rust and may create a hazard. See tank warning labels and IOM for more information. WARNING Do not lift, carry or hang pump by the electrical cables. Damage to the electrical cables can cause shock, burns or death. WARNING Use only stranded copper wire to pump/ motor and ground. The ground wire must be at least as large as the power supply wires. Wires should be color coded for ease of maintenance and troubleshooting. 4

5 DANGER Install wire and ground according to the National Electrical Code (NEC), or the Canadian Electrical Code, as well as all local, state and provincial codes. WARNING WARNING Install an all leg disconnect switch where required by code. WARNING The electrical supply voltage and phase must match all equipment requirements. Incorrect voltage or phase can cause fire, motor and control damage, and voids the warranty. instructions. All splices must be waterproof. If using splice kits follow manufacturer s WARNING Select the correct type and NEMA grade junction box for the application and location. The junction box must insure dry, safe wiring connections. WARNING valve operation. All motors require a minimum 5' submergence for proper refill check WARNING Failure to permanently ground the pump, motor and controls before connecting to power can cause shock, burns or death. WARNING All three phase (3Ø) controls for submersible pumps must provide Class 10, quick-trip, overload protection. WARNING 4" motors 2 HP require a minimum flow rate of.25 ft/sec. or 7.62 cm/sec. past the motor for proper motor cooling. The following are the minimum flows in GPM per well diameter required for cooling: 1.2 GPM/4", 7 GPM/5", 13 GPM/6", 20 GPM/7", 30 GPM/8" or 50 GPM in a 10" well. Pumps 2 HP installed in large tanks WARNING should be installed in a flow inducer sleeve to create the needed cooling flow or velocity past the motor. SAFETY WARNINGS 5

6 TYPICAL SYSTEM Two-Wire System Illustrated RULE OF THUMB 1. Use same size or larger pipe as discharge on pump. 2. Always use a check valve for every 200 ft. of vertical pipe. Protected Power Supply To House Piping Disconnect Switch Pitless Adapter ➀ Check Valve ➀ Frost Level Shut-off Valve Union Pressure Switch Pressure Relief Valve Drain Tap Tank Tee Check Valve ➁ ➀ On installations with a pitless adapter the top check valve should be below the pitless, not at the tank, as the discharge line should be pressurized back to the pitless. ➁ On installations with well seals or well pits it is allowable to locate the top check valve near the tank. CAUTION All electrical equipment must be connected to supply ground. Follow applicable code requirements. 6

7 Motor Cooling, Temperature and Time Ratings All 4 inch CentriPro motors may be operated continuously in water up to 86º F. Optimum service life will be attained by maintaining a minimum flow rate past the motor of.25 feet per second. Use a Flow Sleeve if velocity is below the.25'/sec, if the well is top feeding or when the pump is used in a large body of water or large tank. Six (6) inch canned design motors from 5 40 HP will operate in water up to 95º F (35º C), without any de-rating of horsepower, with a minimum flow rate of.5 ft./sec. past the motor. 6" 50 HP and all 8" 10" motors can operate in 77º F (25º C) water with.5'/sec velocity past FLOW SLEEVE the motor. One way to make a flow sleeve is to install a well seal above the pump discharge and slip a piece of casing over the pump and affix it to the well seal. Drill three holes at 120º intervals on the lower section of the casing and insert (3) screws and nuts through the casing, just touching the motor. Tighten the nuts out against the casing. Insure that the screws do not protrude out too far as you don t want them catching on well joints. Pump Cooling and Lubrication In addition to motor cooling, another reason to maintain minimum flow rates is pump lubrication. All manufacturers, either on curves or in selection charts, show minimum flows. This insures that rotating pump parts are properly lubricated to prolong service life and reduce friction. A dead headed pump will super heat water very quickly, and hot water has no lubricity. TYPICAL SYSTEM 7

8 TECHNICAL DATA Minimum Flow Rates for Proper Motor Cooling 3.75" Dia. CP = FE = CP = Well or 4" CP or 5.5" Dia. 5.38" Dia. 7.52" Dia. Sleeve FE Motor 6" CP 6" FE 8" CP Diameter.25'/sec Motor Motor Motor (inches).5'/sec..5'/sec..5'/sec. GPM Required Multiply gpm by.2271 for m 3 /Hr. Multiply gpm by for l/min. IMPORTANT This manual is intended ONLY for use by professionals familiar with NEC (National Electric Codes) electrical codes and hydraulic and safety procedures of pump installations. 8

9 Pump Motor Not Running Probable Cause 1. Motor thermal protector tripped a. Incorrect control box b. Incorrect or faulty electrical connections c. Faulty thermal protector d. Low voltage e. Ambient temperature of control box/starter too high f. Pump bound by foreign matter g. Inadequate submergence 2. Open circuit breaker or blown fuse 3. Power source inadequate for load 4. Power cable insulation damage 5. Faulty power cable splice Recommended Action 1. Allow motor to cool, thermal protector will automatically reset a e. Have a qualified electrician inspect and repair, as required f. Pull pump, clean, adjust set depth as required g. Confirm adequate unit submergence in pumpage 2. Have a qualified electrician inspect and repair, as required 3. Check supply or generator capacity 4 5. Have a qualified electrician inspect and repair, as required TROUBLESHOOTING RULE OF THUMB Remember, there may be other system problems caused by auxiliary controls not covered in this booklet. 9

10 TROUBLESHOOTING Little or No Liquid Delivered by Pump Probable Cause 1. Faulty or incorrectly installed check valve 2. Pump air bound 3. Lift too high for pump 4. Pump bound by foreign matter 5. Pump not fully submerged 6. Well contains excessive amounts of air or gases 7. Excessive pump wear 8. Incorrect motor rotation 3Ø only. Recommended Action 1. Inspect check valve, repair as required 2. Successively start and stop pump until flow is delivered 3. Review unit performance, check with dealer 4. Pull pump, clean, adjust set depth as required 5. Check well recovery, lower pump if possible 6. If successive starts and stops does not remedy, well contains excessive air or gases 7. Pull pump and repair as required 8. Reverse any two motor electrical leads 10

11 Pump Will Not Start or Run... Probable Cause 1. No power 2. Incorrect voltage 3. Defective pressure switch 4. Loose wire connections 5. Cable insulation damaged 6. Damaged or poor splice 7. Pump bound by sand or abrasives Recommended Action 1. Check for tripped circuit breaker 2. Check with voltmeter 3. Inspect switch points and wires 4. Check all connections and splices 5. Perform cable check with ohmmeter 6. Perform cable check with ohmmeter 7. Pull pump and repair as required Pump Starts Too Frequently... Probable Cause 1. Waterlogged tank 2. Check valve broken or stuck open 3. Improper switch setting 4. Improper switch placement 5. Leaks in piping 6. Tank too small for pump Recommended Action 1. Check tank pressure when empty of water 2. Replace check valve 3. Adjust switch 4. Move switch closer to tank 5. Replace defective pipe 6. Install larger tank TROUBLESHOOTING 11

12 AMPROBE/OHMMETER INSTRUCTIONS The Amprobe is a multi-range, combination ammeter and voltmeter. Voltmeter Scales: 150 Volts 600 Volts Ammeter Scales: 5 Amps 40 Amps 15 Amps 100 Amps 1. When used as an ammeter, the tongs are placed around the wire being measured with the rotary scale on the 100 amp range. Then rotate the scale back to the smaller ranges until an exact reading is indicated. 2. When used as a voltmeter, the two leads are clipped into the bottom of the instrument with the rotary scale on the 600 volt range. If the reading is less than 150 volts, rotate the scale to the 150 volt range to get a more exact reading. 12

13 The Ohmmeter is used for measuring the electrical resistance of a wire circuit. The unit of measurement is called an Ohm. 1. The knob at the bottom of the Ohmmeter is adjustable through six ranges: RX 1 = R x 1 RX 10 = R x 10 RX 100 = R x 100 RX 1000 = R x 1,000 RX 10K = R x 10,000 RX 100K = R x 100,000 If your ohmmeter is digital readout type, refer to the instructions that came with it. 2. The round center knob is for the purpose of adjusting the instrument to zero (0) after clipping the two ohmmeter leads together. This must be done every time the range selection is changed. AMPROBE/OHMMETER INSTRUCTIONS CAUTION Use Ohmmeter only with power off. 13

14 MEASURING INSULATION RESISTANCE Megger This instrument is used to measure insulation resistance to ground. It consists of a crankturned magneto, on the side of the case, and will give very close readings calibrated directly in ohms. It is cranked at a moderate rate of speed, approximately 120 rpm, until the pointer reaches a steady deflection. 1. If the ohm value is normal, the motor windings are not grounded and the cable insulation is not damaged. 2. If the ohm value is below normal, either the windings are grounded or the cable insulation is damaged. Check the cable at the well seal as the insulation is sometimes damaged by being pinched. 14

15 COIL CHECKOUT! WARNING! Open master breaker and disconnect all leads from starter to avoid damage to meter or electric shock hazard. Connect the ohmmeter leads as shown above. Coil with Ohmmeter 1. Set R x Connect leads as shown. 3. Reading: Should register some value, Approx ohms. What It Means Infinity reading indicates coil is open. Zero reading indicates coil is shorted. In either case, the coil should be replaced. A reading of ohms indicates coil is ok. 15

16 RELAY CHECKOUT Voltage Relay CONTROL BOXES (CENTRIPRO OR F.E.) Checking Relay with Ohmmeter A. Voltage Relay Tests Step 1, Coil Test 1. Meter setting: R x 1, Connections: #2 & #5. 3. Correct meter readings: For 115 Volt Boxes: (700 to 1,800 ohms). For 230 Volt Boxes (4,500 to 7,000 ohms). 16

17 Voltage Relay CONTROL BOXES (CENTRIPRO OR F.E.) Step 2, Contact Test 1. Meter setting: R x Connections: #1 and #2. 3. Correct meter reading: Zero for all models. RELAY CHECKOUT B. F.E. Blue Relay - Solid State HP QD Control Boxes Used from 1994 until present time: Step 1, Triac Test 1. Meter setting: R x 1, Connections: Cap and B terminal. 3. Correct meter reading: Infinity for all models. Step 2, Coil Test 1. Meter setting: R x Connections: L1 and B. 3. Correct meter reading: Zero ohms for all models. 17

18 CONTACTOR CHECKOUT Checkout Procedure for Magnetic and Other Contactors Contactor Coil Test (Disconnect lead from one side of coil) 1. Meter setting: R X Connections: Coil terminals 3. Correct meter reading: 180 to 1,400 ohms Contactor Contact Test 1. Meter Setting: R X 1 2. Connections: L1 & T1 or L2 & T2 3. Manually close contacts 4. Correct meter reading: Zero ohms Additional information on troubleshooting and replacement parts for 1Ø Control Boxes is available in the MAID; Motor Application and Installation Manual. It is also available online at gouldswatertechnology. 18

19 1. Set Ohmmeter at R x 1 2. Connect the Ohmmeter leads to Terminal #1 and #3 on each Overload Protector. 3. Reading should be not more than 0.5 Ohms maximum on the scale. CSCR or Mag. Contactor Control Box 19 OVERLOAD CHECKOUT For 1½ HP (and Larger) Control Box

20 CAPACITOR CHECKOUT Capacitor with Ohmmeter CAUTION Discharge the capacitor before making this check. (A screwdriver can be used to make contact between capacitor s posts.) 1. Disconnect leads to capacitor post. 2. Setting: R x 1, Connect ohmmeter leads to capacitor posts. 4. Reading: Pointer should swing toward zero, then back toward infinity. 20

21 FUSE CHECKOUT 1. Set R x Connect leads as shown. 3. Reading: Should register zero. What It Means Zero reading indicates fuse OK. Infinity ( ) reading indicates bad fuse. 21

22 VOLTAGE CHECKOUT To Check Voltage with Q.D. Type Control Box 1. Remove cover to break all motor connections. CAUTION L 1 and L 2 are still connected to power. 2. To check VOLTAGE: Use voltmeter on L1 and L2 as shown. 3. When checking voltage, all other major electrical appliances (that could be in use at the same time) should be running. 4. If readings are not within the limits (see chart), call your power supplier. Voltage Limits Measured Volts Nameplate Min. Max. 115V 1Ø V 1Ø V 1Ø

23 VOLTAGE CHECKOUT 23

24 VOLTAGE CHECKOUT 3Ø STARTER Checking Voltage at Fused Disconnect and Magnetic Starter! WARNING! Power is ON during voltage checking. 1. To check voltage: Use voltmeter on L1, L2 and L3 in sequence. Check should be made at four locations. Step 1 Checking incoming power supply. Step 2 Checking fuses. Step 3 Checking contact points Step 4 Checking heaters. 2. When checking voltage, all other major electrical appliances (that could be in use at the same time) should be running. 3. If incoming power supply readings are not within the limits (see chart), call your power supplier. NOTE: Phase to phase full line voltage. Voltage Limits Name Plate Measured Volts Minimum Maximum 208V 3Ø V 3Ø V 3Ø V 3Ø Phase to neutral ½ full line voltage. (depending on transformer connection) 24

25 VOLT 6 VOLTAGE CHECKOUT VOLT

26 CURRENT (AMPERAGE) CHECKOUT! WARNING! Power is ON during current checking. Using Amprobe 1. Set scale to highest amp range. 2. Connect amprobe around lead as shown. 3. Rotate scale to proper range and read value. 4. Compare value with table. What It Means Currents above these values indicate system problems. 26

27 Service Factor Amps with QD (½ - 1 HP) or CSCR (1.5 HP & Larger) Control Boxes 1 4" CP F.E. CP F.E. 1Ø 3-Wire 3-Wire 2-Wire 2-Wire HP Volts Yel Black Red Yel Black Red Black Black ½ ½ ¾ ½ N/A Generation I CentriPro data. See pages for Generation II data. Service Factor Amps with Magnetic Contactor Control Boxes 6" 1Ø CentriPro 3-Wire Franklin Electric 3-Wire HP Volts Yel Black Red Yel Black Red N/A N/A N/A N/A N/A N/A N/A N/A CURRENT (AMPERAGE) CHECKOUT 27

28 TYPICAL WIRING DIAGRAMS Magnetic Starter and Pressure Switch To Fused Disconnect Or Circuit Breaker 3Ø 3 L1 L2 L3 1 L2 3 Phase Starter T1 T2 T3 Magnetic Starter Ground To Pump Motor Line Load Line Load 28 Requires class 10 Pressure Switch quick trip k-heaters (overloads), or adjustable class 10 overloads such as ESP100, ESP 200 NOTE: Check to be sure proper selection of pressure switch matched to system voltage has been made... refer to catalog data. Check that starter has ground.

29 To Fused Disconnect Or Circuit Breaker 3Ø To Pump Motor Magnetic Starter Line Load Ground TYPICAL WIRING DIAGRAMS Pressure Switch RULE OF THUMB Check that starter has ground. 29

30 TYPICAL WIRING DIAGRAMS Magnetic Starter, Pressure Switch and Liquid Level Control To Fused Disconnect Or Circuit Breaker 3Ø 3 L1 L2 L3 1 L2 3 Phase Starter T1 T2 T3 To Pump Motor Magnetic Starter Input Power (As Required By Level Control) Line Load Line Load Ground Level Control Pressure Switch Lower Upper Electrode Ground NOTE: Check to be sure proper selection of pressure switch matched to system voltage has been made... refer to catalog data. Check that starter has ground. 30

31 To Fused Disconnect Or Circuit Breaker 3Ø Input Power (As Required By Level Control) Magnetic Starter Ground Lower Upper Electrode TYPICAL WIRING DIAGRAMS To Pump Motor Line Load Ground Pressure Switch 31

32 TYPICAL WIRING DIAGRAMS 2-Wire Pump Wiring Diagram with PumpSaver Plus 233P 32

33 Standard 3-Wire Control Box Wiring Diagram with PumpSaver Plus 233P TYPICAL WIRING DIAGRAMS 33

34 CABLE CHECKOUT Checking Cable and Splice 1. Submerge cable and splice in steel barrel of water with both ends out of water. 2. Set ohmmeter selector on RX100K and adjust needle to zero (0) by clipping ohmmeter leads together. 3. After adjusting ohmmeter, clip one ohmmeter lead to barrel and the other to each cable lead individually, as shown. 4. If the needle deflects to zero (0) on any of the cable leads, pull the splice up out of the water. If the needle falls back to ( ) (no reading) the leak is in the splice. 5. If leak is not in the splice, pull the cable out of the water slowly until needle falls back to ( ) (no reading). When the needle falls back, the leak is at that point. 6. If the cable or splice is bad, it should be repaired or replaced. 34

35 Checking Cable and Splice Test Ohmmeter Set at RX 100K RX100 RX10 RX1 OHMS ZERO OHMS RX1000 RX10K RX 100K CABLE CHECKOUT Attach this Lead to Metal Tank 35

36 MOTOR INSULATION RESISTANCE 1. Set the scale lever to R x 100K and adjust to 0. CAUTION Open (turn off) master breaker and disconnect all leads from control box or pressure switch (Q-D type control, remove lid) to avoid damage to meter or electric shock hazard. 2. Connect an ohmmeter lead to any one of the motor leads and the other to the metal drop pipe. If the drop pipe is plastic, connect the ohmmeter lead to the metal well casing or ground wire. OHMS R x 100K R x 100 R x 10 R x 1 ZERO OHMS R x 1000 R x 10K R x 100K Drop Cable with Ground Wire 36

37 Normal Ohm and Megohm Values (Insulation Resistance) Between All Leads and Ground Insulation resistance does not vary with rating. All motors of all HP, voltage and phase rating have similar values of insulation resistance. Condition of Motor and Leads Ohms Megohm Value Value A new motor (without drop cable). 20,000, (or more) A used motor which can be 10,000, reinstalled in the well. (or more) New motor in the well 2,000, (or more) (or more) Motor in the well in good condition 500,000 2,000, Insulation damage, locate and repair Less than Less than 500, What it Means 1. If the ohm value is normal, the motor windings are not grounded and the cable insulation is not damaged. 2. If the ohm value is below normal, either the windings are grounded or the cable insulation is damaged. Check the cable at the well seal as the insulation is sometimes damaged by being pinched. MOTOR INSULATION RESISTANCE 37

38 RX100 RX10 RX1 OHMS ZERO OHMS RX1000 RX10K RX100K MOTOR WINDING RESISTANCE CHECKOUT 1. Set the scale lever to R x 1 for values under 10 ohms. For values over 10 ohms, set the scale lever to R x 10. Zero balance the ohmmeter as described earlier.! WARNING! Open master breaker and disconnect all leads from starter to avoid damage to meter or electric shock hazard. Connect the ohmmeter leads as shown below. 2. Connect the ohmmeter leads as shown below. Cable Resistance Copper Paired Wire Size Cable Resistance (ohms per foot) If aluminum cable is used the readings will be higher. Divide the ohm readings on this chart by 0.61 to determine the actual resistance of aluminum cable. Ground Wire Motor Leads RX1 or RX10 See motor data pages for motor resistance ratings. What it Means 1. If all ohm values are normal, the motor windings are neither shorted nor open, and the cable colors are correct. 2. If any one ohm value is less than normal, the motor is shorted. 3. If any one ohm value is greater than normal, the winding or the cable is open or there is a poor cable joint or connection. 4. If some ohm values are greater than normal and some less, the leads are mixed. 38

39 Motor Resistance 3-Wire CentriPro Motors Winding Resistance ¹ HP Volts Generation II (2011) 1 Generation II (2015) Winding Resistance Main (B-Y) Start (R-Y) Winding Resistance Main (B-Y) Start (R-Y) ¹ As part of Faradyne Motors' continual improvement process, two waves of improvements have been made to CentriPro motors. Generation I motors are any motor with a date code prior to April Information on Generation I motors can be found in the Motor and Installation Manual on Goulds.com. Generation II (2011) motor are motors with dates codes between April 2011 and November Generation II (2015) motors are motors with dates codes after Novmeber CentriPro motor date codes are 12 characters long, the first character represents the month and the fourth and fifth character represent the year. For example, a date code beginning with "L 15..." would be a Generation II (2015) motor. MOTOR WINDING RESISTANCE CHECKOUT RULE OF THUMB Add resistance of drop cable when checking pump in well. See Cable Resistance. 39

40 MOTOR DATA 2-Wire PSC, 1Ø, 4" Motors Electrical Data, 60 Hz, 3450 RPM GENERATION II Wire CentriPro Motors Resistance, Amps and KVA Code HP Volts FLA SF Amps LRA Resistance KVA H J F F H GENERATION II Wire CentriPro Motors Resistance, Amps and KVA Code HP Volts FLA SF Amps LRA Resistance KVA H J F F H Motor Resistance 1Ø Motors Winding Resistance Motor Only (Ohms) 6" Motors CentriPro Franklin Electric Resistance KVA Resistance KVA Type HP Volts R - Y B - Y R - B Code (B-Y) (R-Y) Code G E 6" 1Ø F F E E D E 40

41 2-Wire and 3-Wire Fuse and Circuit Breaker Amps GENERATION I & II Type 2- Wire (PSC) 3-Wire QD (CSIR) 3- Wire CSCR Order No. CentriPro HP Fuse or Circuit Breaker Amps Standard Fuse Dual Element Time Delay Circuit Breaker M M M M M M M M M M M M M M M M MOTOR DATA GENERATION II Type 2- Wire (PSC) 3-Wire QD (CSIR) 3- Wire CSCR Order No. CentriPro HP Fuse or Circuit Breaker Amps Standard Fuse Dual Element Time Delay Circuit Breaker M M M M M M M M M M M M M M M M

42 MOTOR DATA 3-Wire, 1Ø, 4" Motors - Electrical Data, 60 Hz, 3450 RPM Type Order No. CentriPro HP Volts SF M Wire with Q.D. Cap. Start Box M M M M Wire with CSCR (CR) or Magnetic Contactor (MC) Control Box M M M M M M

43 Generation II (2011) Generation II (2015) FL Amps (Y/B/R) SF Amps (Y/B/R) LRA FL Amps (Y/B/R) SF Amps (Y/B/R) LRA MOTOR DATA 8.8/8.8/0 10.9/10.9/ /9.8/0 11.6/11.6/ /5.3/0 6.1/6.1/ /5.7/0 6.3/6.3/ /6.6/0 7.8/7.8/ /6.7/0 7.9/7.9/ /8.1/0 9.4/9.4/ /8.5/0 9.5/9.5/ /4.1/ /4.3/ /4.3/ /4.5/ /4.4/ /4.9/ /4.6/ /5.1/ /5.2/ /5.8/ /6.0/ /6.3/ /8.2/ /9.4/ /8.7/ /9.9/ /9.1/ /11.7/ /12.0/ /19.1/ /13.9/ /9.1/ /11.7/ /22/ /12.0/ /19.1/ /13.9/ /22.0/

44 4" 1Ø WIRE SIZING 2-Wire 1Ø Motor Wire Sizing Chart Centripro Motor Lead Lengths - 2-Wire Motors, 1Ø, 4" Motors 60º C & 75º C Insulation - AWG Copper Wire Size Motor Lead Lengths - 2-Wire Motors Motor Rating AWG Copper Wire Size HP Volts kw FLA SFA / / / / Wire 1Ø Motor Wire Sizing Chart Centripro Motor Lead Lengths - 3-Wire Motors, 1Ø, 4" Motors 60º C & 75º C Insulation - AWG Copper Wire Size Motor Lead Lengths - 3-Wire Motors Motor Rating AWG Copper Wire Size HP Volts kw FLA SFA CSIR Control Boxes 1/ / / CSCR Control Boxes 1/ / /

45 Based on S.F. Amps, 30º C Ambient and 5% Voltage Drop /0 2/0 3/0 4/ " 1Ø WIRE SIZING Based on S.F. Amps, 30º C Ambient and 5% Voltage Drop /0 2/0 3/0 4/0 CSIR Control Boxes CSCR Control Boxes

46 3Ø, 4", MOTOR DATA CentriPro Motor Electrical Data 60 Hz, 3450 RPM GENERATION I & II Motor No. M HP Volts SF FLA Amps SFA Amps Locked Rotor Amps Line - Line Resistance M M M M M M M M M M M M M M M M M M M M M M M M DATA COMING END OF 2010 M M M M M

47 CentriPro Motor Electrical Data 60 Hz, 3450 RPM GENERATION II Motor No. M HP Volts SF FLA Amps SFA Amps Locked Rotor Amps Line - Line Resistance M M M M M M M M M M M M M M M M M M M M M M M M M M M M M Ø, 4", MOTOR DATA 47

48 CENTRIPRO 6 " 10" WIRE SIZING 75º C Cable, 60 Hz (service entrance to motor) Maximum Length in Feet 75º C Insulation - AWG Copper Wire Size Motor Rating Volts HP V 60 Hz 1Ø 230V 60 Hz 3Ø 3 Lead 460V 60 Hz 3Ø 3 Lead Lengths IN BOLD TYPE meet the National Electric Code ampacity only for individual conductor 75º C cable, in 48

49 2 1/0 2/0 3/0 4/ CENTRIPRO 6" 10" WIRE SIZING free air or water. If other cable is used, the National Electric Code as well as the local codes should be observed. 49

50 3Ø, 4", WIRE SIZING Motor Lead Lengths 3Ø Motors Based on S.F. Amps, 30º C Ambient and 5% Voltage Drop 60º C and 75º C Insulation - AWG Copper Wire Size Motor Rating Volts HP kw FLA SFA * 500* 790* * Estimated 50

51 /0 2/0 3/0 4/ * 1960* 3050* 4690* 7050*

52 AQUAVAR SOLO WIRE SIZING Units with 1Ø Input and 3Ø Output (Motors) Maximum Cable Lengths in Feet to Limit Voltage Drop to 5% for 230 V Systems ➄ Copper Wire Size 75ºC Insulation Exposed to a Maximum of 50ºC (122ºF) Ambient Temperature 6 Service Entrance to Controller Controller Motor Input HP V 1Ø ½ ¾ ½ * * * * * * * * Controller to Motor Controller Motor Output HP V 3Ø ½ ¾ ½ * Reduce lengths by 13% for 200 V systems. 6 Lengths in bold require 90ºC wire. Shading indicates 40º C maximum ambient. * Wire does not meet the N.E.C. ampacity requirement. 52

53 1/0 2/0 3/0 4/ AQUAVAR SOLO WIRE SIZING 4 2 1/0 2/0 3/0 4/ To size wire, the voltage drop of each wire segment must be used and the total must not exceed 100%. Example: a 1.5 HP motor, 100' from Service Entrance to Controller (1Ø wire) and 500' from Controller to Motor (3Ø wire). Service Entrance to Controller = 100' of # 10 (100/455) = 22 % (455' from 230V 1Ø chart) Controller to Motor = 500' of # 12 (500/709) = 71 % (709' from the 3Ø chart) 71% + 22% = 93 %; See Balanced Flow Bulletin or IM182 for more info. 53

54 CENTRIPRO 6" 10" MOTOR DATA CentriPro 3Ø, 6" - 10", 1.15 S.F. Motors CentriPro Order No. HP Volts Rated Input Amps 6M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M

55 CentriPro 3Ø, 6" - 10", 1.15 S.F. Motors Continued Service Factor Amps Locked Rotor Amps L-L Resistance HP, 3Ø, 230 and 460 Motors have adjustable voltage feature, change voltage plugs to convert from 230V to 460V operation. Voltage Plug Order No's are: PLUG-230V or PLUG-460V. 55 CENTRIPRO 6" 10" MOTOR DATA

56 CENTRIPRO 6" FM-SERIES MOTOR DATA CentriPro 3Ø, 6" FM-Series Motors Motor Order No. 56 HP Volts Full Load Amps 6F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F NOTE: FM Sereis motors do not have an adjustable voltage feature. FM Series motors are designed for a specific vlotage and cannot be changed.

57 CentriPro 3Ø, 6" FM-Series Motors Continued Service Factor Amps Locked Rotor Amps Line - Line Resistance CENTRIPRO 6" FM-SERIES MOTOR DATA 57

58 PRESSURE TANK CHECKOUT PROCEDURE 1. To check: Shut off power supply and drain system to 0 pressure. 2. Air pre-charge in tank should be 2 psi less than the cut-in pressure of the pressure switch. Example: If pressure switch setting is psi, tank should be pre-charged with 28 lbs. air. 3. If water at valve, replace tank. RULE OF THUMB Improper tank sizing may cause motor damage. ½ to 1½ HP pumps Tank draw down should be equal to the pump capacity in GPM or greater. Example: ¾ HP pump; capacity 12 GPM; pressure switch setting 30/50 PSI; correct tank V HP and larger pumps tank drawdown should be double the pump capacity in GPM. Example: 3 HP pump; capacity 30 GPM; pressure switch setting 40/60 PSI; correct tank selection: 2 V350 tanks. 58

59 Tank Volumes Model No. Total Volume (Gals.) 1 Drawdown in Gals. at System Operating Pressure Range of 18/40 28/50 38/60 Maximum Drawdown Vol. (Gals.) PSIG PSIG PSIG V6P V15P V25P V45P V45B V V60B V V V80EX V V100S V140B V V200B V V V V Drawdown based on a 22 psi differential and Boyle s Law. Temperature, elevation and pressure can all affect drawdown volume. TANK SELECTION RULE OF THUMB Tank must be sized to allow a minimum run time per cycle as follows: 1 3 1½ HP = 1 minute run time 2 HP & larger = 2 minute run time 59

60 TYPICAL JET PUMP SYSTEM Shallow Well System illustrated is a Convertible jet pump with a shallow well adapter and a pressure tank. RULES OF THUMB All jet pumps should be located at the highest point in the suction side of the system. (Distance from well head to pump) If offset is greater than 20'... increase horizontal pipes by one size each. Never use pipes smaller than the pump suction tappings. 60

61 Deep Well Packer and twin pipe systems Improper Installations Trap air Hard to prime TYPICAL JET PUMP SYSTEM TRAPS AIR Proper Installations Easy to prime 61

62 JET PUMPS Jet Pump Disassembly Turn off power to motor. Disconnect service wires from pressure switch. 2. Drain system to relieve pressure. 3. Disconnect motor cord from pressure switch when used. 4. Remove casing bolts. If pump is mounted on top of tank, remove bolt holding motor adapter to mounting pad. 5. Disconnect tubing between casing or pressure control valve and pressure switch. 6. Remove motor, motor adapter casing, and rotating element. Casing remains attached to piping. 7. Remove guide vane seal ring and diaphragm gasket ring. 8. Remove guide vane from motor adapter (via 4 bolts or may be snap in type). 9. Remove motor end cover. Insert 7 16" open end wrench under switch mechanism or behind overload protector onto flats on motor shaft. While holding the shaft against rotating, turn the impeller counterclockwise. The impeller should turn completely off the shaft in this manner. 10. Using two screwdrivers, pry out holding collar of mechanical seal assembly. 11. Motor adapter can be unbolted from the motor (for motor replacement). 62

63 63 JET PUMP DISASSEMBLY

64 JET PUMPS Jet Pump Reassembly Be sure that recess for seal seat and surface where guide vane mounts on motor adapter are entirely free of all scale and dirt. 2. Clean motor shaft. 3. Apply film of light oil, such as vegetable oil, to the recess of the motor adapter and the neoprene bushing before installing the new seal seat. This is a tight fit, but it must go in all the way evenly, or a leak will result. Do not mar lapped face of this seal. The slightest scar or particle of dirt will cause a leak. 4. Bolt motor adapter to motor, making sure the motor shaft does not dislocate the stationary seal member. 5. Assemble rotating member of seal on motor shaft. Rotating seal face must fit snugly against lapped seal face of stationary member in casing cover. This is accomplished by pushing with a piece of tube against back end of neoprene washer after oiling sleeve and shaft. Be sure rotating seal face does not drop out of holding collar while sliding the rotating members of the seal on the shaft. Also, take extra care that the rotating seal face is not marred during handling. 6. While holding the shaft against rotating, screw impeller on shaft by hand until tight against shoulder of motor shaft. 7. Replace guide vane, making sure that bore of guide vane does not bind impeller hub. If screws used, tighten alternately and evenly. Check by turning the motor shaft. If binding occurs, loosen screws, readjust guide vane until impeller hub turns freely, then tighten screws as before. Some jets have snap-in guide vane. 64

65 JET PUMP REASSEMBLY 8. Replace diaphragm gasket with opening in the upper position. 9. Replace guide vane seal ring on guide vane hub. 10. Make sure all gasket surfaces are clean. Replace pump casing. 11. Tighten casing bolts alternately and evenly. 12. After reassembling pump, check to be sure impeller rotates freely. 13. Reconnect tube between pressure switch and casing cover or control valve. 14. Close all drain openings, using pipe joint compound or teflon tape on threads of plugs. 15. Prime according to Priming Instructions. RULE OF THUMB Do not start motor until pump and suction piping are filled with water. 65

66 TROUBLESHOOTING An amprobe, ohmmeter and vacuum pressure gauge are essential for properly checking a system. Use of the amprobe and ohmmeter are explained in Amprobe/ Ohmmeter Instructions. Use of the compound vacuum pressure gauge is explained in Checking Suction Lift. Find the basic problem for which numerous symptoms and possible solutions are given for each. RULE OF THUMB Remember there may be other system problems caused by auxiliary controls not covered in this booklet. 66 Pump Will Not Run... Probable Cause Recommended Action 1. Blown fuse or power Replace fuse close all turned off switches. 2. Broken or loose Examine all wiring and wiring connections. repair any bad connections. 3. Motor overload Overload contacts will protection contacts close automatically in a open. short time. a. Improper voltage. See Volt Ammeter b. Pump bound mechanically Remove motor end cap, will not turn freely. turn motor shaft by hand. Unit should rotate freely. 4. Pressure switch faulty or Adjust or replace switch. out of adjustment. 5. Tubing or fittings on Remove switch tubing pressure switch plugged. and/or all fittings and clean. 6. Faulty motor. See Jet pump ohmmter checks.

67 Pump Runs But... Little or no water delivered Problem Recommended Action 1. Pump or pipes not Fill pump completely with completely primed. water through priming opening (reprime pump). a. Deep Well system Control valve must be set properly or system will not pump. See Pressure Control Valves. 2. Foot valve or end of suction a. Shallow Well system pipe either not submerged Install vacuum gauge or buried. See Checking Suction Lift. b. Deep Well system Physically check well conditions. Foot valve in well or line Replace foot valve if check valve stuck closed. necessary. (Very high vacuum, 22 inches or more. see Checking Suction Lift. 3. Leaks on suction side of pump Pressurize system and (Very common problem.) inspect. TROUBLESHOOTING 67

68 TROUBLESHOOTING Pump Runs But... Problem Recommended Action 4. Jet assembly plugged. A. Shallow Well system Clean if necessary (Insert wire through ½" plug in shallow well adapter.) b. Deep Well system Pull jet assembly and clean. 5. Punctured diaphragm Disconnect the tubing and in air control. plug the connection Galvanized tanks. in pump. If this corrects the trouble, the air control must be replaced. 6. Original installation, Check rating in product incorrect nozzle or diffuser catalog. combination. 68

69 Pump Runs But... Pump starts and stops too often... Problem Recommended Action 1. Leaks in piping system. Pressurize piping system and inspect. Repair or replace. 2. Faulty pressure switch. Check contact points. Adjust or replace switch. 3. Waterlogged galvanized tank, Pumps using Brady control: faulty air control. Test by holding your ear on air control. If control is operating, air can be heard passing from control into tank when pump stops. If no air movement is heard, air control should be replaced. 4. Leaking tank or air valve. Use soapy water to find leaks. Repair or replace. 5. Not enough suction lift on Throttle suction line with shallow well system water partially closed valve. flows into pump (flooded suction). 6. Insufficient vacuum or vacuum Pump requires minimum 3" does not exist for long enough vacuum for 15 seconds. time to operate air control. 7. Improper air change in See tank checkout. captive air tank. 8. Tank too small for pump. Replace with proper size for pump. storage tank. TROUBLESHOOTING 69

70 TROUBLESHOOTING Pump Runs But... Pumps water, but does not develop 40 lbs. tank pressure... Problem Recommended Action 1. Leaks in well piping or Pressurize piping system discharge pipe. and inspect. 2. Jet or screen on foot valve Clean if necessary. partially plugged. 3. Improper pressure control valve See Pump IOM setting (deep well only). 4. Suction lift too high for shallow Use vacuum gauge on well system. shallow well systems Vacuum should not exceed 22 inches at sea level. a. Jet set too deep for On deep well system deep well system. check ratings tables in catalog for maximum jet depth. 5. Faulty air charger. Disconnect the tubing and plug the hole. If this corrects the trouble, the air control must be replaced. 6. Worn impeller hub and/or Replace if necessary. guide vane bore. Clearance should not exceed.012 on a side or.025 diametrically. 7. Overpumping the well. Throttle a valve on the pump suction do not exceed 22" Hg. 70

71 Pump Runs But... Pump develops 40 lbs. pressure, but switch does not cut out... Problem Recommended Action 1. Pressure switch incorrectly See Switch Adjustment. set. 2. Tubing or fittings between Remove switch tubing and/or switch and pump plugged. all fittings and clean. 3. Faulty switch or corroded Replace if necessary. contact points. TROUBLESHOOTING Switch Chatter... Problem Recommended Action 1. Caused by pressure differential Move pressure switch to between switch and tank. tank cross tee or mount in Equivalent feet of pipe should be a discharge tee near pump. less than 4' to prevent chatter. Friction loss of fittings can add many feet of equivalent pipe, ex. a ¾" - 90º elbow = 2' of pipe; 1" 90 = 2.7'. See TTECHWP Tech Manual for pipe fitting equivalents. 2. High volume flows can cause Contact switch supplier switch chatter (not pump mfg) for a pressure pulsation plug - they have very small holes which can easily plug with dirt and sand - use only if absolutely nothing else works and water is clean. 71

72 VOLTAGE CHECK How to Use Volt-Ammeter CAUTION Power is ON during voltage checking. 1. Attach leads to volt-ammeter and select proper voltage scale for voltage to be tested. 2. Place leads in A position to test for presence of incoming voltage. Voltage should be within + 10% of the design voltage specified on the motor nameplate in A, B and C test positions. 3. With disconnect switch in ON position, move leads to B position and test voltage flow through fuse(s). 4. The C position tests voltage at pressure switch terminals. The voltage should be within limits with the motor operating. Voltage Limits Nameplate Measured Volts Min. Max. 115V 1Ø V 1Ø V 1Ø

73 CURRENT (AMPERAGE) CHECKOUT! WARNING! Power is ON during voltage checking. Using Amprobe 1. Set scale to highest amp range. 2. Connect amprobe around lead as shown. 3. Rotate scale to proper range and read value. 4. Compare value with table. What It Means Currents above these values indicate system problems. 73

74 CURRENT (AMPERAGE) CHECKOUT CAUTION Power is ON during amperage testing. 74

75 CAUTION Use ohmmeter only with POWER OFF. Power supply OFF. Disconnect motor leads (L1 and L2). On dual-voltage motors, motor must be wired 230V for the checks listed below and illustrated on the page indicated for each check. Rewire for 230V if necessary. OHMMETER CHECKS CHECK: Page a. Ground...76 b. Winding Continuity c. Contact Points (Switch)...80 d. Overload Protector e. Capacitor

76 OHMMETER CHECKS Ground Check CAUTION Disconnect Power Source before checking. a. Set ohmmeter to R x 1,000. b. Attach one probe to ground screw and touch other probe to all terminals on terminal board, switch, capacitor and protector any ohmmeter reading indicates ground. If digital meter is used, the reading should be at least one megohm. c. If grounded, check all external leads for cuts, breaks, frayed wires, etc. Replace damaged leads and recheck for grounds and proper lead routings. Make sure replaced leads are not pinched between canopy and end bell. If ground is in stator, replacement of motor is recommended. 76

77 Winding Continuity - A.O. Smith / Century Motor CAUTION Disconnect Power Source before checking. 1. Terminal board connected for 230 V. 2. Set ohmmeter to R x 1, adjust to Slip a heavy piece of paper between motor switch points, discharge the capacitor and take the following ohm readings: a. Resistance between L1 and A must be the same as between A and yellow. b. Yellow to red (winding side of switch) must be the same as L1 to same red terminal. OHMMETER CHECKS OVERLOAD PROTECTOR GOVERNOR 115/230 VOLT VOLTAGE SELECTOR SWITCH START CAPACITOR WIRING TERMINAL BOARD START SWITCH PRESSURE SWITCH L1 = Blue wire L2 = White wire A = Purple wire 77

78 OHMMETER CHECKS Ohmmeter tests on the new style terminal board with the quick-change voltage selector switch, see picture on pg. 76 (Black plastic part with 2 wires in it) is simplified if your ohmmeter is equipped with the sharp, pointed probes rather than alligator clips. With the voltage change plug on the 230 volt terminal the Black wire in the plug is positioned on Terminal A. Simply touch one ohmmeter probe on the Black wire in the voltage change plug to get the A terminal reading. Another method is to remove the terminal board screws and place the alligator clip on the wire on the bottom side of Terminal A. Old Style (Brown) Terminal Board Wiring A.O. SMITH MOTOR WIRING 115 Volt 230 Volt Black (from motor) Black (from motor) on L1 on A Black/White (Black tracer from overload) on A Black/White (Black tracer from overload) on B 78

79 Winding Continuity - US Motor CAUTION Disconnect Power Source before checking. 1. Terminal board connected for 230 V. 2. Set ohmmeter to R x 1, adjust to 0 (NOTE: Digital meters are typically used, the reading on this equipment should be showing OL or infinity). 3. Discharge the capacitor and take the following ohm readings: a. Measure resistance between L1 and L2 on switch, this measures Main and Aux. winding continuity. b. Measure resistance between L1 and L2 on switch, depress the actuator sleeve and this removes Aux. from circuit giving continuity of Main winding only. OHMMETER CHECKS OVERLOAD PROTECTOR 115/230 VOLTAGE CHANGE SWITCH TERMINAL BOARD L1 L2 START CAPACITOR ACTUATOR SLEEVE START SWITCH 79

80 OHMMETER CHECKS Contact Points (Start Switch) CAUTION Disconnect Power Source before checking. 1. Set ohmmeter to R x 1, adjust to Remove leads from start switch. 3. Attach ohmmeter leads to each side of switch reading should be Flip governor weight to run position. Reading should be infinity. A.O. Smith / Century Motor Overload Protector CAUTION Disconnect Power Source before checking. 1. Set ohmmeter to R x 1, adjust to Disconnect the overload leads. 3. Check resistance between terminals 1 and 2, then 2 and 3. If either reading is higher than 1, replace the overload. 1 = Blue wire 2 = Black/ white wire 3 = Yellow wire BLACK/WHITE LEAD YELLOW LEAD BLUE LEAD 80

81 Motor Overload Protector - US Motor CAUTION Disconnect Power Source before checking. 1. Set ohmmeter to R x 1, adjust to 0 (NOTE: Digital meters are typically used, the reading on this equipment should be showing OL or infinity) 2. Dissconnect the Overload protector leads 3. Check Resistance between terminals 1 and 2, then 2 and 3. If readings is higher that 1, replace the overload. OHMMETER CHECKS BLACK/WHITE LEAD PURPLE LEAD BLACK LEAD L1 L2 Terminal 1 = Purple wire Terminal 2 = Black/White wire Terminal 3 = Black Wire 81

82 OHMMETER CHECKS AO SMITH MOTORS 82

83 83 OHMMETER CHECKS

84 OHMMETER CHECKS Capacitor CAUTION Disconnect Power Source before checking. IMPORTANT Discharge capacitor by touching the two terminals with the blade of an insulated handle screwdriver. ALL MOTORS 1. Set ohmmeter to R x 1,000, adjust to Disconnect leads on capacitor. 3. Attach ohmmeter leads to each terminal. Needle should swing to right and drift slowly to left. To double check, switch ohmmeter leads and repeat procedure. If the needle will not move or moves toward 0 and stays there, the capacitor is bad. 4. If a digital meter is used, readings should start low and rapidly increase to maximum value. 84

85 Adjust in proper Sequence: 1. CUT-IN: Turn range nut down for higher cut-in pressure, or up for lower cut-in. 2. CUT-OUT: Turn differential nut down for higher cut-out pressure, or up for lower cut-out. Note: Adjustment to range (cut-in) nut will also change cut-out pressure.! CAUTION To avoid damage, do not exceed maximum allowable system pressure. Check switch operation after re-setting. CentriPro or Square "D" Switches Adjust in proper sequence: 1. CUT-IN: Turn nut down for higher cut-in pressure, or up for lower cut-in. 2. CUT-OUT: Turn nut down for higher cut-out pressure, or up for lower cut-out. PRESSURE SWITCH ADJUSTMENT CHECKOUT ADJUSTMENT Differential: adjust for cut-out point Line L1 Grounding Provisions #8-32 screws Load Load Line L2 Range: adjust for cut-in point 85

86 CHECKING SUCTION LIFT A vacuum gauge indicates total suction lift (vertical lift + friction loss = total lift) in inches of mercury. 1" on the gauge = 1.13 ft. of total suction lift (based on pump located at sea level). RULE OF THUMB Practical suction lift at sea level is 25 ft. Deduct 1 ft. of suction lift for each 1,000 ft. of elevation above sea level. Shallow Well System Install vacuum gauge in shallow well adapter. See opposite page. When pump is running, the gauge will show no vacuum if the end of suction pipe is not submerged or there is a suction leak. If the gauge shows a very high vacuum (22 inches or more), this indicates that the end of suction pipe is buried in mud, the foot valve or check valve is stuck closed or the suction lift exceeds capability of pump. High Vacuum (22 inches or more) Suction pipe end buried in mud Foot valve or check valve stuck closed Suction lift exceeds capability of the pump Low Vacuum (or 0 vacuum) Suction pipe not submerged Suction leak 86

87 Compound Vacuum Pressure Gauge This gauge will show the pressure or vacuum at any position in a pump or system where it is installed. CHECKING SUCTION LIFT A reading of 20" on a vacuum gauge placed on the suction side of the pump would tell you that you have a vacuum or suction lift of 22.6 ft. 20" x 1.13' = 22.6 ft. Vacuum Gauge 22.6' Vertical Lift Plus Friction 87

88 PRESSURE CONTROL VALVES When pump is first started or under maximum flow condition, pressure control should be immediately adjusted to the pressure corresponding to H.P. and jet assembly used. See rating tables in catalog for proper pressure setting. 1. Turn left to reduce pressure. 2. Turn right to increase pressure. RULE OF THUMB If pressure control valve is set too high, the air volume control will not function. If pressure control valve is set too low, the pump may not shut off. To Adjust Pressure Control Valve: 1. Close pressure control valve. 2. Open faucet in house. 3. Turn pump on. 4. As pump picks up its prime, the pressure will begin to rise on the gauge. 5. Turn adjusting screw to set pressure control valve to pressure recommended in catalog. 88

89 Correct rotation is a must on all 3Ø installations. Rotation can be checked by one of these three ways: Visual 1 1. Connect 3 motor leads to starter, run unit at open discharge. 2. Switch any 2 leads and again run unit at open discharge. 3. Largest quantity of water indicates correct rotation. Visual 2 1. Remove water end from meter. Run motor and observe rotation ROTATION Pressure 1. Connect 3 motor leads to starter. Run unit against closed discharge, take maximum pressure reading. 2. Switch any 2 leads and again run unit against closed discharge. Take maximum pressure reading. 3. Highest pressure reading indicates correct rotation.! WARNING! Prolonged reverse rotation operation can cause pump/motor damage. 89

90 THREE PHASE UNBALANCE L1 L2 L3 T1 T2 T3 1st Hookup L1 L2 L3 Starter T1 T2 T3 Supply 2nd Hookup L1 L2 L3 Starter T3 T1 T2 Motor Supply Starter Motor 3rd Hookup L1 L2 L3 Starter T2 T3 T1 L 1 L 2 L 3 T 1 T 2 T 3 For the best protection, we recommend no more than a 5% current deviation from average current. Current readings in amps should be checked on each leg using the three possible hookups.! CAUTION To prevent changing motor rotation, the motor leads should be reordered in the same direction, see example on page 53. RULE OF THUMB If the unbalance moves with the motor leads the unbalance is caused by the motor, wet splice, or damaged cable. If the unbalance remains with the terminals the unbalance is in the power supply. 90

91 Calculate percentage of current unbalance for all three hookups. Example: Hook Up 1 Hook Up 2 Hook Up 3 T1= 51 Amps T3 = 50 Amps T2 = 50 Amps T2 = 46 Amps T1= 48 Amps T3 = 49 Amps T3 = 53 Amps T2 = 52 Amps T1= 51 Amps Add up all three readings for hook up number 1. T1 = 51 Amps T2 = 46 Amps +T3 = 53 Amps Total 150 Amps Divide the total by three to obtain the average. 50 Amps = Average Amps Calculate the greatest amp difference from the average. Could be greater than average. 50 Amps -46 Amps 4 Amps Divide this difference by the average to obtain the percentage of unbalance..08 or 8% Amps Hook Up #1 = 8% Hook Up #2 = 4% Hook Up #3 = 2% Always use hook up with lowest % current unbalance. Loads on a transformer bank vary. Readings should be taken at peak load period. What It Means 1. Hook ups below 5% = system balanced. 2. Hook ups not below 5% if the unbalance moves with the motor leads the unbalance is caused by the motor, wet splice, or damaged cable. Check the motor on pages If the unbalance remains with the terminals the unbalance is in the power supply contact power company. 91 THREE PHASE UNBALANCE

92 TRANSFORMER SIZES A full 3Ø supply is recommended for all 3Ø motors, consisting of three individual transformers or one 3Ø transformer. Open delta or wye connections using only two transformers can be used, but are more likely to cause problems from current unbalance. Transformer ratings should be no smaller than listed in the table for supply power to the motor alone. Transformer Capacity Required for Submersible Motors Smallest KVA Rating - Submersible Total Each Transformer 3Ø Motor 3Ø Motor Open WYE WYE HP Rating HP Rating or Delta 2 Delta 3 Transformers Transformers

93 TRANSFORMER SIZES Open Delta or Wye Full Three Phase 93

94 QUICK START GUIDE Aquavar SOLO 2 Quick Installation Guide 1. Mount Drive (in a vertical position); Must have 6 minimum clearance on all sides for proper cooling. 2. Connect Input Power Wire (Single Phase, 230V, Size Wire Ampacity for 75 C Copper Wire) Review Circuit Breaker Sizing see IMS-SOLO2Q-2 or IM Wire Motor Drop Cable (Size Wire Ampacity for 75 C Copper Wire) 3AS Models - Use with Three Phase, 230V, ¾ to 5 HP Motors 1AS15 Model - Compatible with Single Phase, 230V Motors 3-Wire HP CentriPro / Pentek XE; HP Franklin Electric and Grundfos 2-Wire CentriPro, Pentek XE, Franklin Electric and Grundfos 2-Wire Review Wire Sizing (Table 4 of IM260) 4. Mount Transducer and Connect Transducer Cable Wiring Transducer cable maximum length = 200 feet Connect Pressure Transducer to piping manifold and to ground 5. User Interface Board Adjustments Select proper Current Limit Setting (equal to motor SFA) 1AS15 Only - Set Pump Stop Sensitivity - High 40 Hz is Default 3AS Only - Select maximum frequency setting (60 Hz or 80 Hz); 60 Hz = matching Liquid End HP and Motor HP 80 Hz = over-speed application; motor HP is greater than Liquid End HP (typically 2x larger) Dry Well Sensitivity - Set on High position; If nuisance tripping occurs, switch to Low position Low Pressure Cut-Off and Pressure Drop setting adjusted to application / system requirements. Optional use of Run/Stop Input, Setpoint Select Input and Relay Output, refer to IM Adjust Tank Pressure Set approximately 20 PSI below pressure Setpoint Adjust as needed to optimize - see IMS-SOLO2Q-2 or IM Turn Drive Power On - Adjust Pressure - Purge Air Purge air from system and check for leaks Factory default is 60 psi for Setpoint 1 and 70 psi for Setpoint 2- push and hold Increase Pressure button if higher pressure is desired and also adjust tank pre-charge. Setpoint Select Input Terminal is used to switch from 2 different pressure Setpoints, refer to IM Check Motor Rotation and Confirm Performance Refer to Aquavar SOLO 2 Installation Manual, IM260, for complete details. Check Motor Insulation Resistance on retrofit jobs before replacing drive. 94

95 Aquavar SOLO 2 User Interface Board 1AS Controllers 3AS Controllers QUICK START GUIDE 1) Basic Drive Settings 2) Controller Status Indicator 3) Setpoint and Parameter Adjust 4) Run/Stop Indicator 5) Relay Output 6) Transducer Input 7) Transducer Jumper 8) Run/Stop Input 9) Setpoint Select Input 10) Display Mode Adjust 11) Status and Parameter Display Service Factor Amps All Motors HP 230 Volt 200 Volt 1Ø 2-Wire 1Ø 3-Wire 3Ø 3Ø CentriPro 1 Franklin Grundfos CentriPro Franklin Grundfos CentriPro Franklin Grundfos CentriPro Franklin ½ 4.7/ N/A N/A N/A N/A N/A ¾ 6.4/ N/A / N/A ½ 11.0/ N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A CentriPro 2-Wire motors have Generation 1 and Generation 2 amp ratings, see motor nameplate or motor data sticker that was supplied with motor. 2. Amps are higher than controller overload range - use of these motors will current limit and provide reduced performance. Pressure Ranges for All Available Transducers Transducer 1AS15 / 3AS20 3AS30 3AS50 (Min. PSI) (Max. PSI) (Min. PSI) (Max. PSI) (Min. PSI) (Max. PSI) 100 PSI (1) PSI (2) PSI (1) Standard on 1AS15, 3AS20 and 3AS30 (2) Standard on 3AS50 95