Technical Manual for Franklin Electric models including: Franklin Electric, Submersible Motors, 50 Hz, Single-Phase Motors, Three-Phase Motors, Motor Application, Motor Installation, Motor Maintenance, Pump Control, Pumptec, Subtrol-Plus, CP Water System, SubDrive, Technical Manual, Troubleshooting Guide, Installation Guide
50 Hz AIM
Greg Emshwiller
http://www.amospumps.com/downloads/Franklin Submersible Motor Technical Manual
2004
50 Hz
Submersible Motors
Application u Installation u Maintenance
Single and Three-Phase Motors
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ATTENTION! IMPORTANT INFORMATION FOR INSTALLERS OF THIS EQUIPMENT!
THIS EQUIPMENT IS INTENDED FOR INSTALLATION BY TECHNICALLY QUALIFIED PERSONNEL. FAILURE TO INSTALL IT IN COMPLIANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES, AND WITHIN FRANKLIN ELECTRIC RECOMMENDATIONS, MAY RESULT IN ELECTRICAL SHOCK OR FIRE HAZARD, UNSATISFACTORY PERFORMANCE, AND EQUIPMENT FAILURE. FRANKLIN INSTALLATION INFORMATION IS AVAILABLE FROM PUMP MANUFACTURERS AND DISTRIBUTORS, AND DIRECTLY FROM FRANKLIN ELECTRIC. CALL FRANKLIN TOLL FREE 800-348-2420 FOR INFORMATION.
WARNING
SERIOUS OR FATAL ELECTRICAL SHOCK MAY RESULT FROM FAILURE TO CONNECT THE MOTOR, CONTROL ENCLOSURES, METAL PLUMBING, AND ALL OTHER METAL NEAR THE MOTOR OR CABLE, TO THE POWER SUPPLY GROUND TERMINAL USING WIRE NO SMALLER THAN MOTOR CABLE WIRES. TO REDUCE RISK OF ELECTRICAL SHOCK, DISCONNECT POWER BEFORE WORKING ON OR AROUND THE WATER SYSTEM. DO NOT USE MOTOR IN SWIMMING AREAS.
ATTENTION! INFORMATIONS IMPORTANTES POUR L'INSTALLATEUR DE CET EQUIPEMENT.
CET EQUIPEMENT DOIT ETRE INTALLE PAR UN TECHNICIEN QUALIFIE. SI L'INSTALLATION N'EST PAS CONFORME AUX LOIS NATIONALES OU LOCALES AINSI QU'AUX RECOMMANDATIONS DE FRANKLIN ELECTRIC, UN CHOC ELECTRIQUE, LE FEU, UNE PERFORMANCE NON ACCEPTABLE, VOIRE MEME LE NON-FONCTIONNEMENT PEUVENT SURVENIR. UN GUIDE D'INSTALLATION DE FRANKLIN ELECTRIC EST DISPONIBLE CHEZ LES MANUFACTURIERS DE POMPES, LES DISTRIBUTEURS, OU DIRECTEMENT CHEZ FRANKLIN. POUR DE PLUS AMPLES RENSEIGNEMENTS, APPELEZ SANS FRAIS LE 800-348-2420.
AVERTISSEMENT
UN CHOC ELECTRIQUE SERIEUX OU MEME MORTEL EST POSSIBLE, SI L'ON NEGLIGE DE CONNECTER LE MOTEUR, LA PLOMBERIE METALLIQUE, BOITES DE CONTROLE ET TOUT METAL PROCHE DU MOTEUR A UN CABLE ALLANT VERS UNE ALIMENTATION D'ENERGIE AVEC BORNE DE MISE A LA TERRE UTILISANT AU MOINS LE MEME CALIBRE QUE LES FILS DU MOTEUR. POUR REDUIRE LE RISQUE DE CHOC ELECTRIQUE. COUPER LE COURANT AVANT DE TRAVAILLER PRES OU SUR LE SYSTEM D'EAU. NE PAS UTILISER CE MOTEUR DANS UNE ZONE DE BAIGNADE.
ATENCION! INFORMACION PARA EL INSTALADOR DE ESTE EQUIPO.
PARA LA INSTALACION DE ESTE EQUIPO, SE REQUIERE DE PERSONAL TECNICO CALIFICADO. EL NO CUMPLIR CON LAS NORMAS ELECTRICAS NACIONALES Y LOCALES, ASI COMO CON LAS RECOMENDACIONES DE FRANKLIN ELECTRIC DURANTE SU INSTALACION, PUEDE OCASIONAR, UN CHOQUE ELECTRICO, PELIGRO DE UN INCENDIO, OPERACION DEFECTUOSA E INCLUSO LA DESCOMPOSTURA DEL EQUIPO. LOS MANUALES DE INSTALACION Y PUESTA EN MARCHA DE LOS EQUIPOS, ESTAN DISPONIBLES CON LOS DISTRIBUIDORES, FABRICANTES DE BOMBAS O DIRECTAMENTE CON FRANKLIN ELECTRIC. PUEDE LLAMAR GRATUITAMENTE PARA MAYOR INFORMACION AL TELEFONO 800-348-2420.
ADVERTENCIA
PUEDE OCURRIR UN CHOQUE ELECTRICO, SERIO O FATAL DEBIDO A UNA ERRONEA CONECCION DEL MOTOR, DE LOS TABLEROS ELECTRICOS, DE LA TUBERIA, DE CUALQUIER OTRA PARTE METALICA QUE ESTA CERCA DEL MOTOR O POR NO UTILIZAR UN CABLE PARA TIERRA DE CALIBRE IGUAL O MAYOR AL DE LA ALIMENTACION. PARA REDUCIR EL RIESGO DE CHOQUE ELECTRIC, DESCONECTAR LA ALIMENTACION ELECTRICA ANTES DE INICIAR A TRABAJAR EN EL SISTEMA HIDRAULICO. NO UTILIZAR ESTE MOTOR EN ALBERCAS O AREAS EN DONDE SE PRACTIQUE NATACION.
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Franklin Electric is committed to provide customers with defect free products through our program of continuous improvement. Quality shall, in every case, take precedence over quantity.
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Submersible Motors
Application · Installation · Maintenance Manual
The submersible motor is a reliable, efficient and troublefree means of powering a pump. Its needs for a long operational life are simple. They are:
1. A suitable operating environment
2. An adequate supply of electricity
3. An adequate flow of cooling water over the motor
4. An appropriate pump load
All considerations of application, installation, and maintenance of submersible motors relate to these four areas. This manual will acquaint you with these needs and assist you if service or maintenance is required.
Contents
Application - All Motors
Storage ...........................................................................3 Frequency of Starts .......................................................3 Mounting Position...........................................................3 Transformer Capacity......................................................4 Effects of Torque .............................................................4 Engine Driven Generators...............................................5 Use of Check Valves ......................................................5 Well Diameters, Casing, Top Feeding, Screens ............. 6 Water Temperature and Flow .........................................6 Flow Inducer Sleeve....................................................... 6 Head Loss Past Motor ...................................................7 Hot Water Applications .............................................. 7-8 Drawdown Seals .............................................................9 Grounding Control Boxes and Panels ...........................9 Grounding Surge Arrestors ............................................9 Control Box and Panel Environment ..............................9
Application - Single-Phase Motors
3-Wire Control Boxes ..............................................10 2-Wire Motor Solid State Controls ..........................10 Cable Selection - 2-Wire or 3-Wire .......................... 11 Two Different Cable Sizes ......................................12 Single-Phase Motor Specifications .........................13
Application - Three-Phase Motors
Cable Selection - 70°C 3 or 6 Lead .............................14 Cable Selection - 75°C 3 or 6 Lead ..........................15 Three-Phase Motor Specifications ......................... 16-17 Overload Protection .....................................................18 Subtrol-Plus .................................................................. 19 Power Factor Correction ..............................................19 Three-Phase Starter Diagrams .....................................20 Three-Phase Power Unbalance ...................................21 Rotation and Current Unbalance .................................. 21 Submersible Pump Installation Check List (No.3656) Submersible Motor Installation Record (No. 2207)
Submersible Booster Installation Record (No. 3655) Three-Phase Motor Lead Identification .......................22 Reduced Voltage Starters ............................................23 In-line Booster Pump Systems ............................... 23-25 Variable Speed Operation ....................................... 25-26
Installation - All Motors
Submersible Motors - Dimensions ...............................27 Tightening Lead Connector Jam Nut ...........................28 Pump to Motor Coupling .............................................28 Shaft Height and Free End Play ...................................28 Submersible Leads and Cables....................................28 Splicing Submersible Cables........................................29
Maintenance - All Motors
System Troubleshooting ........................................ 30-31 Preliminary Tests ..........................................................32 Insulation Resistance ...................................................33 Resistance of Drop Cable .............................................33
Maintenance - Single-Phase Motors & Controls
Identification of Cables ................................................34 Single-Phase Control Boxes.........................................34 Ohmmeter Tests............................................................35 QD Control Box Parts ...................................................36 Integral HP Control Box Parts.......................................36 Control Box Wiring Diagrams ................................. 37-38
Maintenance - Electronic Products
Pumptec-Plus Troubleshooting During Installation ......39 Pumptec-Plus Troubleshooting After Installation .........40 CP Water Troubleshooting ............................................41 Pumptec Troubleshooting.............................................42 Subtrol-Plus Troubleshooting ................................. 43-44
Application - All Motors
Storage
Franklin Electric submersible motors are a waterlubricated design. The fill solution consists of a mixture of de-ionized water and Propylene Glycol (a non-toxic antifreeze). The solution will prevent damage from freezing in temperatures to -40°C; motors should be stored in areas that do not go below this temperature. The solution will partially freeze below -3°C, but no damage occurs. Repeated freezing and thawing should be avoided to prevent possible loss of fill solution.
There may be an interchange of fill solution with well water during operation. Care must be taken with motors removed from wells during freezing conditions to prevent damage.
When the storage temperature does not exceed 37°C, storage time should be limited to two years. Where temperatures reach 37° to 54°C, storage time should be limited to one year.
Loss of a few drops of liquid will not damage the motor as an excess amount is provided, and the filter check valve will allow lost liquid to be replaced by filtered well water upon installation. If there is reason to believe there has been a considerable amount of leakage, consult the factory for checking procedures.
Frequency of Starts
The average number of starts per day over a period of months or years influences the life of a submersible pumping system. Excessive cycling affects the life of control components such as pressure switches, starters, relays and capacitors. Rapid cycling can also cause motor spline damage, bearing damage, and motor overheating. All these conditions can lead to reduced motor life.
The pump size, tank size and other controls should be selected to keep the starts per day as low as practical for longest life. The maximum number of starts per 24-hour period is shown in Table 3.
Motors should run a minimum of one minute to dissipate heat build up from starting current.
TABLE 3 Number of Starts
Motor Rating
HP
KW
Up to .75 HP Up to .55
1 thru 5.5
.75 thru 4
7.5 thru 30 5.5 thru 22
40 and over 30 and over
Max Starts Per 24 Hr. Period
Single-Phase
Three-Phase
300
300
100
300
50
100
100
Mounting Position
Franklin submersible motors are designed primarily for operation in the vertical, shaft-up position.
During acceleration, the pump thrust increases as its output head increases. In cases where the pump head stays below its normal operating range during startup and full speed condition, the pump may create upward thrust. This creates upward thrust on the motor upthrust bearing. This is an acceptable operation for short periods at each start, but running continuously with upthrust may cause excessive wear on the upthrust bearing.
With certain restrictions, motors are also suitable for operations in positions from shaft-up to shaft-horizontal.
As the mounting position becomes further from vertical and closer to horizontal, the probability of shortened thrust bearing life increases. For normal thrust bearing life expectancy with motor positions other than shaft-up, follow these recommendations:
1. Minimize the frequency of starts, preferably to fewer than 10 per 24-hour period.
2. Do not use in systems which can run even for short periods at full speed without thrust toward the motor.
3
Application - All Motors
Transformer Capacity - Single-Phase or Three-Phase
Distribution transformers must be adequately sized to satisfy the KVA requirements of the submersible motor. When transformers are too small to supply the load, there is a reduction in voltage to the motor.
Table 4 references the motor horsepower rating, singlephase and three-phase, total effective KVA required,
and the smallest transformer required for open or closed three-phase systems. Open systems require larger transformers since only two transformers are used.
Other loads would add directly to the KVA sizing requirements of the transformer bank.
TABLE 4 Transformer Capacity
Motor Rating
HP KW
1.5 1.1
2
1.5
3
2.2
5
3.7
7.5 5.5
10
7.5
15
11
20
15
25 18.5
30
22
40
30
50
37
60
45
75
55
100
75
125
90
150 110 175 130
200 150
Total Effective KVA Required
3 4 5 7.5 10 15 20 25 30 40 50 60 75 90 120 150 175 200 230
Smallest KVA Rating-Each Transformer
Open WYE or DELTA 2-Transformers
2 2 3 5 7.5 10 15 15 20 25 30 35 40 50 65 85 100 115 130
Closed WYE or DELTA 3-Transformers
1 1.5 2 3 5 5 7.5 10 10 15 20 20 25 30 40 50 60 70 75
NOTE: Standard KVA ratings are shown. If power company experience and practice allows transformer loading higher than standard, higher loading values may be used for transformer(s) to meet total effective KVA required provided correct voltage and balance is maintained.
Effects of Torque
During starting of a submersible pump, the torque developed by the motor must be supported through the pump, delivery pipe or other supports. Most pumps rotate in the direction which causes unscrewing torque on right-handed threaded pipe or pump stages. All threaded joints, pumps and other parts of the pump support system must be capable of withstanding the maximum torque repeatedly without loosening or breaking. Unscrewing joints will break electrical cable and may cause loss of the pump-motor unit.
To safely withstand maximum unscrewing torques with a minimum safety factor of 1.5, tightening all threaded joints to at least 13.57 N-m per motor horsepower is recommended (Table 4A). It may be necessary to tack or strap weld pipe joints on high horsepower pumps, especially at shallower settings.
TABLE 4A Torque Required (Examples)
Motor Rating
HP
KW
HP x 13.57 N-m
1 HP & Less
.75 KW & Less
1 X 13.57
20 HP
15 KW
20 X 13.57
75 HP
55 KW
75 x 13.57
200 HP
150 KW
200 x 13.57
Minimum Safe Torque-Load
13.57 N-m 271.4 N-m 1017.8 N-m 2714 N-m
4
Application - All Motors
Engine Driven Generators
Refer to generator manufacturer's recommendations and locked rotor amps listed on page 13 (single-phase) and pages 16-17 (three-phase).
Use of Check Valves
It is recommended that one or more check valves always be used in submersible pump installations. If the pump does not have a built-in check valve, a line check valve should be installed in the discharge line within 7.5 meters of the pump and below the draw down level of the water supply. For deeper settings, it is recommended that line check valves be installed per the manufacturer's recommendations.
Swing type check valves are not acceptable and should never be used with submersible motors/pumps. Swing type check valves have a slower reaction time which can cause water hammer (see below). Internal pump check valves or spring loaded check valves close quickly and help eliminate water hammer.
Check valves are used to hold pressure in the system when the pump stops. They also prevent backspin, water hammer and upthrust. Any of these can lead to early pump or motor failure.
NOTE: Only positive sealing check valves should be used in submersible installations. Although drilling the check valves or using drain-back check valves may prevent back spinning, they create upthrust and water hammer problems.
A. Backspin - With no check valve or a failed check valve, the water in the drop pipe and the water in the system can flow down the discharge pipe when the motor stops. This can cause the pump to rotate in a
reverse direction. If the motor is started while this is happening, a heavy strain may be placed across the pump-motor assembly. It can also cause excessive thrust bearing wear because the motor is not turning fast enough to ensure an adequate film of water between the thrust bearing and thrust shoes.
B. Upthrust - With no check valve, or with a leaking check valve, the unit starts under a zero head condition. This causes an uplifting or upthrust on the impeller-shaft assembly in the pump. This upward movement carries across the pump-motor coupling and creates an upthrust condition in the motor. Repeated upthrust can cause premature failure of both the pump and the motor.
C. Water Hammer - If the lowest check valve is more than 9.0 meters above the standing water level, or a lower check valve leaks and the check valve above holds, a partial vacuum is created in the discharge piping. On the next pump start, water moving at very high velocity fills the void and strikes the closed check valve and the stationary water in the pipe above it, causing a hydraulic shock.
This shock can split pipes, break joints and damage the pump and/or motor. Water hammer is an easily detected noise. When discovered, the system should be shut down and the pump installer contacted to correct the problem.
5
Application - All Motors
Wells-Large Diameter, Uncased, Top Feeding & Screened Sections
Franklin Electric submersible motors are designed to operate with a cooling flow of water over the motor.
If the pump installation does not provide the minimum flow shown in Table 6, a flow inducer sleeve (flow sleeve) must be used. The conditions requiring a flow sleeve are:
· Well diameter is too large to meet Table 6 flow requirements.
· Pump is in an open body of water. · Pump is in a rock well or below the well casing. · The well is "top-feeding". · Pump is set in or below screens or perforations.
Water Temperature and Flow
Franklin Electric submersible motors are designed to operate up to full load horsepower in water up to 30°C. A flow of 7.62 cm/sec for 4" motors rated 3 Hp and higher, and 15.24 cm/sec for 6 and 8 inch motors is required for proper cooling. Table 6 shows minimum flow rates, in l/m, for various well diameters and motor sizes.
If the motor is operated in water over 30°C, water flow past the motor must be increased to maintain safe motor operating temperatures. See HOT WATER APPLICATIONS on Page 7.
TABLE 6 Required Cooling Flow
Minimum l/m required for motor cooling in water up to 30°C
Casing or Sleeve I.D.
(mm)
4" Motor (3-10 HP) 7.62 cm/sec. l/m
6" Motor 15.24cm/sec
l/m
8" Motor 15.24cm/sec
l/m
102
4.5
-
-
127
26.5
-
-
152
49
34
-
178
76
95
-
203
114
170
40
254
189
340
210
305
303
530
420
356
416
760
645
406
568
1060
930
.25 ft/sec = 7.62 cm/sec 1 inch = 2.54 cm
.50 ft/sec = 15.24 cm/sec
Flow Inducer Sleeve
If the flow rate is less than specified or coming from above the pump, then a flow inducer sleeve must be used. A flow sleeve is always required in an open body of water. FIG 1 shows a typical flow inducer sleeve construction.
EXAMPLE: A six-inch motor and pump that delivers 200 l/m will be installed in a 254 mm well. From Table 6, 340 l/m would be required to maintain proper cooling. In this case adding an 203 mm or smaller flow sleeve provides the required cooling.
WORM GEAR CLAMPS
INTAKE
FLOW INDUCER SLEEVE
SUBMERSIBLE MOTOR
CENTERING BOL T
CENTERING BOLTS MUST BE LOCATED ON MOTOR CASTING. DO NOT LOCATE ON STATOR SHELL.
SAW CUTS
NOTCH OUT FOR CABLE GUARD
LOCK NUTS INSIDE SLEEVE
BOTTOM END VIEW
FIG. 1
CENTERING BOLT HOLE (3 REQUIRED)
6
Application - All Motors
Head Loss From Flow Past Motor
Table 7 lists the approximate head loss due to flow between an average length motor and smooth casing or flow inducer sleeve.
TABLE 7 Head Loss in Meters at Various Flow Rates
Motor Diameter
4"
4"
4"
6"
6"
6"
8"
8"
Casing ID in mm
102
127
152
152
178
203
206
254
Flow Rate in l/m
95 189 378 568 757 946 1136 1514 1893 2271 3028 3785
0.09
0.37
1.4
0.09
0.52
3.1
0.18
0.06
1.1
0.34
0.12
1.9
0.15
2.1
0.55
0.21
2.9
0.24
3.2
0.75
0.3
4.1
0.37
0.06
4.5
7.2
0.61
0.12
7.5
0.94
0.21
11.4
0.2
1.3
0.3
15.9
0.3
0.5
0.7
Hot Water Applications
When the pump-motor operates in water hotter than 30°C, a flow rate of at least .91 m/sec is required. When selecting the motor to drive a pump in over 30°C water, the motor horsepower must be de-rated per the following procedure.
1. Using Table 7A, determine pump l/m required for different well or sleeve diameters. If necessary, add a flow sleeve to obtain at least .91 m/sec flow rate.
TABLE 7A Minimum l/m Required for .91 m/sec Flow Rate
Casing or Sleeve I.D.
4" High Thrust Motor
6" Motor
8" Motor
mm
l/m
l/m
l/m
102
57
127
303
152
606
197
178
568
203
984
227
254
1970
1250
305
2460
356
3860
406
5530
7
Application - All Motors
2. Determine pump KW (HP) required from the pump manufacturer's curve.
3. Multiply the pump KW (HP) required by the heat factor multiplier from Table 8.
4. Select a rated KW (HP) motor that is at least the value calculated in Item 3.
Brake KW (Horsepower)
4.5 (6)
EXAMPLE
A
3.7 (5)
B
3.0 (4)
C
2.2 (3)
1.5 (2)
.75 (1)
0 0 18.9 37.9 56.8 75.7 94.6 113.6 132.5 155 174.4 193.8
Liters Per Minute FIG. 2 MANUFACTURER'S PUMP CURVE
TABLE 8 Heat Factor Multiplier at .91 m/sec Flow Rate
Maximum Water Temperature
1/3 - 5 HP .25 - 3.7 KW
7 1/2 - 30 HP 5.5 - 22 KW
60°C
1.25
1.62
55°C
1.11
1.32
50°C
1.00
1.14
45°C
1.00
1.00
40°C
1.00
1.00
35°C
1.00
1.00
Over 30HP Over 22 KW
2.00 1.62 1.32 1.14 1.00 1.00
Hot Water Applications - Example
EXAMPLE: A 6" pump end requiring 29.1 KW (39 HP) input will pump 51°C water in an 203 mm well at a delivery rate of 530 l/m. From Table 7A, a 152 mm flow sleeve will be required to increase the flow rate to at least .91 m/sec.
Using Table 8, the 1.62 heat factor multiplier is selected because the KW (HP) required is over 22 KW (30 HP) and water temperature is above 50°C. Multiply 29.1 KW x 1.62 (multiplier), which equals 47.1 KW (63.2 HP). This is the minimum rated full load horsepower usable at 21.9 KW (39 HP) in 51°C.
8
Application - All Motors
Drawdown Seals
Allowable motor temperature is based on atmospheric pressure or higher surrounding the motor. "Drawdown seals," which seal the well to the pump above it's intake
to maximize delivery, are not recommended, since the suction created can be lower than atmospheric pressure.
Grounding Control Boxes and Panels
The United States National Electrical Code requires that the control box or panel-grounding terminal always be connected to supply ground. If the circuit has no grounding conductor and no metal conduit from the box to supply panel, use a wire at least as large as line conductors and connect as required by the National Electrical Code, from the grounding terminal to the electrical supply ground.
Connect earth grounds to control boxes and panels per local and national codes or regulations.
WARNING: Failure to ground the control frame can result in a serious or fatal electrical shock hazard if a circuit fault occurs.
Grounding Surge Arrestors
An above ground surge arrestor must be grounded, metal to metal, all the way to the water strata for the lightning arrestor to be effective. GROUNDING THE ARRESTOR TO THE SUPPLY GROUND OR TO A DRIVEN GROUND ROD PROVIDES LITTLE OR NO PROTECTION FOR THE MOTOR.
Control Box and Panel Environment
Franklin Electric control boxes are designated IP 23. They are suitable for indoor and outdoor applications within temperatures of -10°C to 50°C. Operating control boxes below -10°C can cause reduced starting torque and loss of overload protection when overloads are located in control boxes.
Control boxes and panels should never be mounted in direct sunlight or high temperature locations. This will cause shortened capacitor life and unnecessary tripping
of overload protectors. A ventilated enclosure painted white to reflect heat is recommended for an outdoor, high temperature location.
A damp well pit, or other humid location, accelerates component failure from voltage breakdown and corrosion.
Control boxes with voltage relays are designed for vertical upright mounting only. Mounting in other positions will affect the operation of the relay.
Equipment Grounding
WARNING: Serious or fatal electrical shock may result from failure to connect the motor, control enclosures, metal plumbing and all other metal near the motor or cable to the power supply ground terminal using wire no smaller than motor cable wires.
The primary purpose of grounding the metal drop pipe and/or metal well casing in an installation is safety. It is done to limit the voltage between nonelectrical (exposed metal) parts of the system and ground, thus minimizing dangerous shock hazards. Using wire at least the size of the motor cable wires provides adequate currentcarrying capability for any ground fault that might occur. It also provides a low resistance path to ground, ensuring that the current to ground will be large enough to trip any overcurrent device designed to detect faults (such as a ground fault circuit interrupter, or GFCI).
Normally, the ground wire to the motor would provide the
primary path back to the power supply ground for any ground fault. There are conditions, however, where the ground wire connection could become compromised. One such example would be the case where the water in the well is abnormally corrosive or aggressive. In this example, a grounded metal drop pipe or casing would then become the primary path to ground. However, the many installations that now use plastic drop pipes and/or casings require further steps to be taken for safety purposes, so that the water column itself does not become the conductive path to ground.
When an installation has abnormally corrosive water AND the drop pipe or casing is plastic, Franklin Electric recommends the use of a GFCI with a 10 mA set-point. In this case, the motor ground wire should be routed through the current-sensing device along with the motor power leads. Wired this way, the GFCI will trip only when a ground fault has occurred AND the motor ground wire is no longer functional.
9
Application - Single-Phase Motors
3-Wire Control Boxes
Single-phase three-wire submersible motors require the use of control boxes. Operation of motors without control boxes or with incorrect boxes can result in motor failure and voids warranty.
Control boxes contain starting capacitors, a starting relay, overload protectors, and, in some sizes, running capacitors.
Potential (Voltage) Relays
Potential relays have normally closed contacts. When power is applied, both start and main motor windings are energized, and the motor starts. At this instant, the voltage across the start winding is relatively low and not enough to open the contacts of the relay.
As the motor accelerates, the increasing voltage across the start winding (and the relay coil) opens the relay contacts. This opens the starting circuit and the motor continues to run on the main winding alone, or the main plus run capacitor circuit. After the motor is started the relay contacts remain open.
CAUTION: Be certain that control box HP and voltage match the motor.
2-Wire Motor Solid State Controls
BIAC Switch Operation
When power is applied the bi-metal switch contacts are closed so the triac is conducting and energizes the start winding. As RPM increases, the voltage in the sensor coil generates heat in the bi-metal strip, causing the bi-metal strip to bend and open the switch circuit. This removes the starting winding and the motor continues to run on the main winding alone.
Approximately 5 seconds after power is removed from the motor, the bi-metal strip cools sufficiently to return to its closed position and the motor is ready for the next start cycle. If, during operation, the motor speed drops, the lowered voltage in the sensor coil allows the bi-metal contacts to close, and bring the motor back to operating speed.
Rapid Cycling
The BIAC starting switch will reset within approximately 5 seconds after the motor is stopped. If an attempt is made to restart the motor before the starting switch has reset, the motor may not start; however, there will be
current in the main winding until the overload protector interrupts the circuit. The time for the protector to reset is longer than the reset of the starting switch. Therefore, the start switch will have closed and the motor will operate.
A waterlogged tank will cause fast cycling. When a waterlogged condition does occur, the user will be alerted to the problem during the off time (overload reset time) since the pressure will drop drastically. When the waterlogged tank condition is detected the condition should be corrected to prevent nuisance tripping of the overload protector.
Bound Pump (Sandlocked)
When the motor is not free to turn, as with a sandlocked pump, the BIAC switch creates a "reverse impact torque" in the motor in either direction. When the sand is dislodged, the motor will start and operate in the correct direction.
CAUTION: Restarting the motor within 5 seconds after power is removed may cause the motor overload to trip.
10
Application - Single-Phase Motors
2- or 3-Wire Cable, 50 Hz (Service Entrance to Motor - Maximum Length In Meters & Feet)
Cable for submersible motors must be suitable for submerged operation, and adequate in size to operate within rated temperature and maintain adequate voltage at the motor. Cable may be twisted conductors with or without jacket, or flat molded type. Franklin 50HZ cable selections maintain motor voltage to at least 95% of supply voltage with maximum rated running amps, and maintain acceptable starting voltage and cable temperature.
Minimum Square Millimeter cable for each rating is based on IEC Publication 364-5-523 (1983 Edition). Jacketed cable is based on Table 52-B1, Installation Method C In Table Using Column C in Table 52-C3 (70°C). Individual conductor is based on Table 52-B2, Installation Method G using Column 6 In Table 52-C10 (70°C).
Minimum AWG Cable sizes are based on the National Electrical Code in Table 430-150 for 75°C Cable In 30°C Maximum Ambient. Use Larger Cable if Local Codes Or Higher Temperatures Require It. Lengths in Bold Meet IEC and NEC Ampacity only For Individual Conductor Cables in air or water, not in conduit.
Tables list the maximum recommended lengths in Meters for square millimeter copper cable sizes and in feet for AWG copper cable sizes. The single-phase tables apply to all three wire types, and control boxes where required, may be at any point in the cable length. The portion of cable from service entrance to a threephase controller should not exceed 25% of table maximum length to assure reliable starter operation.
TABLE 11 Single-Phase Maximum Length of Copper Cable (meters)
Motor Rating
Metric Cable Size - 70° C Insulation - Copper Wire - Square Millimeters
Volts KW
HP
1.5
2.5
4
6
10
16
25
35
50
.25
1/3
190
320
510
770
1260 1970 2960 3990 5340
.37
1/2
120
210
330
500
820
1290 1950 2640 3560
220 Volt 50Hz.
.55
3/4
80
140
230
350
580
900
1360 1830 2450
.75
1.0
60
110
180
270
440
690
1050 1430 1930
1.1
1.5
40
70
120
190
310
490
750
1020 1390
1.5
2.0
30
60
100
150
250
400
620
850
1180
2.2
3.0
20
40
60
100
170
270
410
560
770
3.7
5.0
0
0
40
60
110
170
260
370
520
1 Meter = 3.3 feet
70 6970 4680 3210 2550 1860 1590 1030 710
95 8750 5910 4020 3230 2380 2070 1320 930
TABLE 11A Single-Phase Motor Maximum Length of Copper Cable (feet)
Motor Rating
American Wire Gage, 75° C Insulation - AWG Cable in Feet
Volts KW HP
14
12
10
8
6
4
3
2
.25 1/3
900
1450 2310 3530 5480 8460
.37 1/2
580
940
1500 2310 3600 5580 6830 8470
220 Volt 50 Hz.
.55 3/4
400
660
1050 1610 2510 3890 4750 5880
.75 1.0
310
500
800
1240 1940 3010 3690 4580
1.1 1.5
210
350
560
870
1360 2130 2620 3270
1.5 2.0
170
280
450
710
1120 1770 2180 2730
2.2 3.0
110
190
300
470
750
1170 1440 1800
3.7 5.0
0
120
190
300
480
760
940
1180
1
7150 5610 4020 3390 2220 1480
0
8670 6840 4930 4180 2730 1830
00
8350 6060 5160 3360 2280
11
Application - Single-Phase Motors
Two different cable sizes can be used.
Depending on the installation, any number of combinations of cable may be used.
For example, in a replacement installation, the well already has 60 meters of buried 10 mm2 cable between the service entrance and the well head. The question is: What size cable is required in the well with a 3.7 KW (5 HP), 220 volt, single-phase motor setting at 70 meters?
1. From Table 11, a 3.7 KW (5 HP) motor can use up to 110 meters of 10 mm2 cable.
2. The application has 60 meters of buried 10 mm2 cable.
3. 60 meters ÷ 110 meters (max allowable) is equal to 54.5% of max allowable.
EXAMPLE: 3.7 KW (5 HP), 220 Volt, Single-Phase Motor
4. 100% - 54.5% = 45.5% remaining of another size cable.
5. 70 meters (well head to motor) is 45.5% of max allowable length of another cable size.
6. 70 meters ÷ .455 (45.5%) = 154 meters is max allowable.
7. 154 meters is less than or equal to what size cable in Table 11, under the 3.7 KW (5 HP) listing?
The table shows 10 mm2 is good for 110 meters, which is too short. 16 mm2 is good for 270 meters, therefore 16 mm2 can be used for the remaining 70 meters.
12
Application - Single-Phase Motors
TABLE 13 Single-Phase Motor Specifications ( 50 Hz), 2875 RPM, 1.0 Service Factor
Motor
Nameplate Rating
Full
Type Model
Load
Prefix
Watts
KW
HP
Volts
Line Volts
Amps
Line to Line (1) Resistance (Ohms)
Main
Start
Circuit Breakers or Fuse Amps
Efficiency % Power Factor % Locked
Typical Submersible
Rotor Amps
Nontime Delay Dual Element (Std.) Fuse or Time Delay
F.L. 3/4 1/2 F.L. 3/4 1/2
Circuit Breaker Fuse
220 220 3.9 610 6.3 - 7.7
-
62 59 51 73 64 53 25.0
15
5
244555 .37 1/2
230 230 4.1 630 6.3 - 7.7
-
59 55 47 68 60 50 26.1
15
5
4 Inch 2-Wire
220 220 6.0 880 3.7 - 4.6
-
63 59 52 70 62 53 30.0
20
7
244557 .55 3/4
230 230 6.5 920 3.7 - 4.6
-
61 56 48 67 59 49 36.6
20
7
220 220 7.3 1180 3.2 - 3.9
-
65 62 55 75 66 54 42.0
20
9
244558 .75 1
230 230 7.6 1200 3.2 - 3.9
-
63 59 52 71 63 52 43.9
20
9
220 220 10.6 1800 2.2 - 2.7
-
64 61 56 78 70 58 50.6
30
12
244359 1.1 1 1/2
230 230 10.8 1820 2.2 - 2.7
-
63 60 53 73 65 54 52.9
30
12
214553
220 220 2.9 440 9.2 - 11.2 38.6 - 47.2 58 53 45 69 60 50 12.0
15
3.5
.25 1/3
214573
240 240 2.6 440 10.8 - 13.3 40.0 - 48.9 58 53 45 69 60 50 11.0
15
3.5
4 Inch 3-Wire Cap. Start
214555
220 220 4.2 650 6.4 - 7.8 19.4 - 23.7 57 54 46 72 64 53 15.4
15
4.5
.37 1/2
214575
240 240 3.9 650 7.7 - 9.4 19.3 - 23.6 57 54 46 72 64 53 14.1
15
4.5
214557
220 220 6.3 940 3.8 - 4.6 14.7 - 18.0 59 55 47 69 60 50 23.0
15
7
.55 3/4
214577
240 240 5.8 940 4.6 - 5.6 14.6 - 17.9 59 55 47 69 60 50 21.1
15
7
214558
220 220 7.6 1200 3.2 - 3.9 12.8 - 15.7 62 59 52 73 65 53 29.1
20
9
.75 1
214578
240 240 7.0 1200 3.9 - 4.7 13.1 - 16.1 62 59 52 73 65 53 26.7
20
9
4 Inch 3-Wire Cap. Start-Cap. Run
224350
220 220 10.0 1690 2.4 - 2.9 6.4 - 7.8 67 63 55 79 63 55 40.6
20
12
1.1 1 1/2
224380
240 240 8.9 1690 2.9 - 3.6 8.9 - 10.9 67 63 55 79 63 59 37.2
20
12
224351
220 220 12.1 2160 2.0 - 2.5 8.0 - 9.7 69 67 60 85 77 65 54.3
30
15
1.5 2
224381
240 240 10.7 2160 2.2 - 2.6 6.5 - 7.9 69 67 60 85 77 65 51.1
30
15
224352
220 220 17.8 3270 1.1 - 1.4 3.7 - 4.5 68 66 63 85 77 65 87.5
50
25
2.2 3
224382
240 240 15.9 3270 1.3 - 1.7 4.4 - 5.4 68 66 63 85 77 65 81.7
50
25
224353
220 220 26.0 5150 .79 - .97 2.4 - 2.9 73 71 64 93 89 78 118
70
30
3.7 5
224383
240 240 23.4 5150 .94 - 1.15 2.8 - 3.5 73 71 64 93 89 78 109
70
30
(1) Main winding - yellow to black Start winding - yellow to red
Performance is typical, not guaranteed, at specified voltages and specified capacitor values.
Performance at voltage ratings not shown is similar, except amps vary inversely with voltage.
13
Application - Three-Phase Motors
TABLE 14 Three and Six Wire Cable, 50 Hz Service Entrance to Motor - Maximum Length in Meters 70°C
Motor Rating
Metric Cable Size, Square Millimeters, Copper Wire - 70°C Rated Insulation
220v 50Hz 3Ø 3 - Lead (230V may use 110% of table) (240V may use 119% of table)
Volts
KW HP 1.5 2.5 4 6 10 16 25 35 50 70 95 120 150 185 240 300 400 .37 1/2 300 510 820 1230 2010 3160 4810 6540 8890 .55 3/4 200 350 550 830 1370 2150 3280 4460 6060 8060 .75 1 160 270 430 650 1070 1680 2550 3470 4710 6250 7970 9510 1.1 1 1/2 110 190 300 450 750 1170 1790 2430 3310 4400 5620 6700 7790 8970 1.5 2 80 140 230 340 570 900 1380 1880 2570 3430 4410 5290 6180 7150 8470 9670 2.2 3 50 90 150 230 380 600 920 1270 1740 2330 3000 3610 4230 4910 5840 6700 7790 3 4 40 70 110 170 280 440 670 920 1270 1700 2180 2630 3080 3570 4240 4850 5630 3.7 5 30 50 90 130 220 360 550 750 1030 1390 1790 2150 2520 2930 3480 4000 4640 4 5 1/2 30 50 80 120 200 320 490 670 920 1240 1590 1910 2240 2590 3070 3520 4070 5.5 7 1/2 0 30 60 90 150 240 380 520 710 960 1240 1490 1750 2040 2430 2790 3250 7.5 10 0 0 40 60 110 170 270 370 500 680 870 1050 1230 1420 1690 1930 2230 11 15 0 0 0 40 80 120 190 270 370 500 650 790 930 1080 1290 1490 1740 15 20 0 0 0 0 60 90 150 200 280 380 500 610 720 840 1010 1170 1370 18.5 25 0 0 0 0 0 70 110 160 220 300 390 480 570 660 800 920 1090 22 30 0 0 0 0 0 60 100 130 190 260 330 400 480 560 670 780 910 .37 1/2 930 1550 2460 3670 6030 9460 .55 3/4 630 1050 1670 2500 4100 6440 9790 .75 1 490 820 1300 1950 3200 5020 7620 1.1 1 1/2 340 570 910 1360 2240 3520 5350 7280 9890 1.5 2 260 430 700 1040 1720 2700 4120 5630 7690 2.2 3 170 290 460 700 1150 1810 2770 3790 5190 6950 8950 3 4 120 210 340 510 840 1330 2030 2770 3790 5070 6530 7840 9190 3.7 5 100 170 270 410 680 1080 1650 2260 3090 4140 5340 6420 7540 8750 4 5 1/2 90 150 250 370 610 970 1480 2020 2770 3700 4750 5710 6680 7740 9180 5.5 7 1/2 70 110 190 280 470 740 1140 1560 2140 2870 3700 4460 5240 6090 7250 8330 9700 7.5 10 50 80 130 200 330 530 810 1110 1510 2030 2610 3130 3670 4250 5040 5770 6680 11 15 0 60 90 140 240 380 590 810 1120 1510 1950 2350 2770 3230 3860 4450 5200 15 20 0 0 70 110 180 290 450 620 860 1160 1500 1820 2150 2520 3020 3490 4110 18.5 25 0 0 0 80 140 230 350 490 680 910 1190 1440 1700 1990 2390 2770 3260 22 30 0 0 0 0 120 190 300 410 570 770 1000 1210 1440 1680 2010 2330 2740 30 40 0 0 0 0 0 140 220 310 420 570 740 900 1060 1230 1470 1700 1990 37 50 0 0 0 0 0 110 180 240 340 460 590 710 840 980 1170 1350 1580 45 60 0 0 0 0 0 0 150 200 280 380 490 600 700 820 980 1130 1330 55 75 0 0 0 0 0 0 120 170 240 330 420 510 610 710 860 990 1170 75 100 0 0 0 0 0 0 0 0 180 240 320 390 460 530 640 740 880 90 125 0 0 0 0 0 0 0 0 0 190 240 290 350 400 480 550 650 110 150 0 0 0 0 0 0 0 0 0 0 210 250 290 340 410 470 550 130 175 0 0 0 0 0 0 0 0 0 0 180 220 260 300 360 420 500 150 200 0 0 0 0 0 0 0 0 0 0 0 190 230 270 320 370 440
380v 50Hz 3Ø 3 - Lead (400V may use 110% of table) (415V may use 119% of table)
6 - Lead Wye - Delta
Motor Rating
Metric Cable Size, Square Millimeters, Copper Wire - 70°C Rated Insulation
220v 50Hz 3Ø 6 - Lead (230V = 110%) (240V = 119%)
380v 50Hz 3Ø 6 - Lead (400V may use 110% of table) (415V may use 119% of table)
Volts
KW HP 1.5 2.5 4 6 10 16 25 35 50 70 95 120 150 185 240 300 400
3.7 5 40 70 130 190 330 540 820 1120 1540 2080 2680 3220 3780 4390 5220 6000 6960 5.5 7 1/2 30 40 90 130 220 360 570 780 1060 1440 1860 2230 2620 3060 3640 4180 4870 7.5 10 10 30 60 90 160 250 400 550 750 1020 1300 1570 1840 2130 2530 2890 3340 11 15 0 30 40 60 120 180 280 400 550 750 970 1180 1390 1620 1930 2230 2610 15 20 0 0 30 40 90 130 220 300 420 570 750 910 1080 1260 1510 1750 2050 18.5 25 0 0 0 30 60 100 160 240 330 450 580 720 850 990 1200 1380 1630 22 30 0 0 0 0 60 90 150 190 280 390 490 600 720 840 1000 1170 1360 3.7 5 150 250 400 610 1020 1620 2470 3390 4630 6210 8010 9630 5.5 7 1/2 100 160 280 420 700 1110 1710 2340 3210 4300 5550 6690 7860 9130 7.5 10 70 120 190 300 490 790 1210 1660 2260 3040 3910 4690 5500 6370 7560 8650 11 15 40 90 130 210 360 570 880 1210 1680 2260 2920 3520 4150 4840 5790 6670 7800 15 20 30 60 100 160 270 430 670 930 1290 1740 2250 2730 3220 3780 4530 5230 6160 18.5 25 0 40 70 120 210 340 520 730 1020 1360 1780 2160 2550 2980 3580 4150 4890 22 30 0 0 70 100 180 280 450 610 850 1150 1500 1810 2160 2520 3010 3490 4110 30 40 0 0 0 70 130 210 330 460 630 850 1110 1350 1590 1840 2200 2550 2980 37 50 0 0 0 0 100 160 270 360 510 690 880 1060 1260 1470 1750 2020 2370 45 60 0 0 0 0 90 130 220 300 420 570 730 900 1050 1230 1470 1690 1990 55 75 0 0 0 0 0 120 180 250 360 490 630 760 910 1060 1290 1480 1750 75 100 0 0 0 0 0 90 130 190 270 360 480 580 690 790 960 1110 1320 90 125 0 0 0 0 0 0 100 150 210 280 360 430 520 600 720 820 970 110 150 0 0 0 0 0 0 0 120 180 240 310 370 430 510 610 700 820 130 175 0 0 0 0 0 0 0 0 150 210 270 330 390 450 540 630 750 150 200 0 0 0 0 0 0 0 0 130 180 240 280 340 400 480 550 660
1 Meter = 3.3 feet
Lengths in BOLD meet the IEC ampacity only for individual conductor cable in free air or water, not in conduit.
Ampacities are determined from IEC publication 364-5-523 (1983 edition).
Jacketed cable is based on Table 52-B1, Installation method C using Column C in Table 52-C3 (70°C).
Individual Conductor is based on Table 52-B2, Installation method G using Column 6 in Table 52-C10 (70°C).
14
Application - Three-Phase Motors
TABLE 15 Three and Six Wire Cable, 50Hz Service Entrance to Motor - Maximum Length in Feet
75°C
Motor Rating
AWG Wire Size, Copper Wire - 75°C Rated Insulation
MCM MCM MCM MCM
220v 50Hz 3Ø 3 - Lead (230V may use 110% of table) (240V may use 119% of table)
Volts
KW
HP 14 12 10 8
6
4
3
2
1
0 00 000 0000 250 300 350 400
0
1/2 1420 2290 3640 5620 8800
.55 3/4 960 1550 2470 3820 5980 9320
.75
1 750 1210 1930 2980 4660 7260 8920
1.1 1 1/2 520 840 1340 2080 3270 5090 6260 7790 9570
1.5
2 390 640 1030 1600 2510 3920 4830 6020 7420 9100
2.2
3 260 430 680 1070 1680 2630 3240 4050 5000 6150 7570 9180
3
4 190 310 500 780 1230 1920 2370 2960 3650 4490 5520 6690 8090 9280
3.7
5 150 250 400 630 1000 1560 1930 2410 2980 3660 4510 5470 6620 7600 8710 9810
4 5 1/2 130 220 360 570 890 1400 1730 2160 2660 3270 4030 4880 5890 6760 7730 8700 9520
5.5 7 1/2 100 170 270 430 680 1080 1330 1660 2060 2530 3120 3790 4590 5270 6050 6820 7480
7.5
10
0
0 190 300 480 760 940 1180 1460 1790 2210 2670 3230 3710 4240 4770 5230
11
15
0
0 0 220 350 560 690 870 1080 1330 1640 1990 2420 2780 3200 3610 3970
15
20
0
0 0 170 270 430 530 660 820 1020 1260 1530 1870 2150 2480 2800 3090
18.5 25
0
0
0
0 210 330 410 520 650 800 990 1210 1470 1700 1960 2220 2450
22
30
0
00
0 0 280 350 440 550 680 840 1020 1250 1440 1650 1870 2060
.37 1/2 4280 6880
.55 3/4 2900 4670 7140
.75
1 2260 3640 5780 8920
1.1 1 1/2 1580 2550 4050 6250 9780
1.5
2 1210 1940 3090 4790 7510
2.2
3 800 1300 2060 3210 5030 7870 9690
3
4 580 950 1510 2350 3690 5760 7090 8850
3.7
5 470 770 1220 1910 3000 4690 5780 7210 8900
4 5 1/2 420 690 1100 1710 2690 4200 5180 6460 7970 9780
5.5 7 1/2 320 520 840 1310 2060 3230 3990 4980 6150 7560 9320
7.5
10 230 370 600 930 1470 2300 2840 3540 4370 5360 6600 7990 9650
11
15 160 270 430 680 1070 1690 2080 2600 3220 3970 4900 5950 7230 8310 9550
15
20
0
0 330 520 820 1290 1590 1990 2470 3040 3760 4590 5580 6430 7410 8380 9230
18.5 25
0
0 260 410 640 1010 1250 1570 1950 2400 2970 3620 4410 5080 5860 6630 7310
22
30
0
0 0 340 540 860 1060 1330 1650 2030 2510 3060 3730 4290 4950 5590 6160
30
40
0
00
0 400 640 790 990 1230 1510 1870 2270 2760 3170 3650 4120 4530
37
50
0
00
0 0 510 630 790 980 1200 1490 1810 2200 2530 2910 3290 3610
45
60
0
00
0 0 420 520 660 820 1010 1240 1510 1840 2120 2440 2750 3030
55
75
0
00
00
0 450 560 700 860 1060 1300 1580 1820 2100 2380 2620
75
100 0
0
0
0
0
0
0
0 520 640 800 980 1190 1370 1580 1790 1970
90
125 0
0
0
0
0
0
0
0
0
0 620 750 920 1050 1210 1360 1500
110 150 0
0
0
0
0
0
0
0
0
0
0 640 770 890 1020 1160 1270
130 175 0
0
0
0
0
0
0
0
0
0
0
0 670 780 900 1020 1120
150 200 0
0
0
0
0
0
0
0
0
0
0
0 600 690 790 900 990
380v 50Hz 3Ø 3 - Lead (400V may use 110% of table) (415V may use 119% of table)
220v 50Hz 3Ø 6- Lead (230V = 110%) (240V = 119%)
Motor Rating
Volts
KW
3.7
5.5
7.5
11
15
18.5
22
3.7
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
130
150
HP
5 7 1/2
10 15 20 25 30 5 7 1/2 10 15 20 25 30 40 50 60 75 100 125 150 175 200
6 - Lead Wye - Delta
AWG Wire Size, Copper Wire - 75°C Rated Insulation
MCM MCM MCM MCM
14 12 10 8
6
4
3
2
1
0 00 000 0000 250 300 350 400
220 370 600 940 1500 2340 2890 3610 4470 5490 6760 8200 9930
150 250 400 640 1020 1620 1990 2490 3090 3790 4680 5680 6880 7900 9070
100 180 280 450 720 1140 1410 1770 2190 2680 3310 4000 4840 5560 6360 7150 7840
70 120 210 330 520 840 1030 1300 1620 1990 2460 2980 3630 4170 4800 5410 5950
0
0 150 250 400 640 790 990 1230 1530 1890 2290 2800 3220 3720 4200 4630
0
0 120 190 310 490 610 780 970 1200 1480 1810 2200 2550 2940 3330 3670
0
0
0 160 270 420 520 660 820 1020 1260 1530 1870 2160 2470 2800 3090
700 1150 1830 2860 4500 7030 8670
480 780 1260 1960 3090 4840 5980 7470 9220
340 550 900 1390 2200 3450 4260 5310 6550 8040 9900
240 400 640 1020 1600 2530 3120 3900 4830 5950 7350 8920
180 300 490 780 1230 1930 2380 2980 3700 4560 5640 6880 8370 9640
150 240 390 610 960 1510 1870 2350 2920 3600 4450 5430 6610 7620 8790 9940
0 190 330 510 810 1290 1590 1990 2470 3040 3760 4590 5590 6430 7420 8380 9240
0
0 240 370 600 960 1180 1480 1840 2260 2800 3400 4140 4750 5470 6180 6790
0
0
0 300 480 760 940 1180 1470 1800 2230 2710 3300 3790 4360 4930 5410
0
0
0 250 400 630 780 990 1230 1510 1860 2260 2760 3180 3660 4120 4540
0
0
0
0 340 540 670 840 1050 1290 1590 1950 2370 2730 3150 3570 3930
0
0
0
0
0 400 490 630 780 960 1200 1470 1780 2050 2370 2680 2950
0
0
0
0
0
0 390 490 610 750 930 1120 1380 1570 1810 2040 2250
0
0
0
0
0
0
0 400 510 630 780 960 1150 1330 1530 1740 1900
0
0
0
0
0
0
0
0 430 540 670 820 1000 1170 1350 1530 1680
0
0
0
0
0
0
0
0
0 480 600 730 900 1030 1180 1350 1480
380v 50Hz 3Ø 6 - Lead (400V may use 110% of table) (415V may use 119% of table)
1 Meter = 3.3 feet
Lengths in BOLD meet the IEC ampacity only for individual conductor cable in free air or water, not in conduit. Ampacities are determined from motor full load current Table 430-150 in the National Electrical Code.
15
Application - Three-Phase Motors
TABLE 16 Three-Phase Motor Specifications (50 Hz), 2875 RPM, 1.0 Service Factor
Circuit Breakers or Fuse Amps
Type
Motor Model Prefix
KW
Nameplate Rating HP Volts Amps
Full Load Watts
Line to Line (1) Resistance (Ohms)
Efficiency % Power Factor %
Locked Rotor Amps
F.L. 3/4 1/2 F.L. 3/4 1/2
Typical Submersible
Nontime Delay (Std.) Fuse or Circuit Breaker
Dual Element Time Delay Fuse
234551
220 1.8 550
16.4 - 20.0 67 65 59 78 70 57 7.3
15
2.5
4
.37 1/2
Inch 234561
380-415 1.1 550
55.3 - 67.5 67 65 59 78 70 57 4.3
15
1.2
234552
220 2.6 810
11.2 - 13.8 67 66 61 81 72 60 11
15
3
.55 3/4
234562
380-415 1.5 810
37.6 - 46.0 67 66 61 81 72 60 6.2
15
1.8
234553
220 3.5 1050
8.5 - 10.4 70 69 63 79 70 57 15
15
4
0.75 1
234563
380-415 2.0 1050 25.9 - 31.7 70 69 63 79 70 57 8.5
15
2.5
234554
220 5.2 1470
4.2 - 5.1 75 75 72 83 75 62 25
15
6
1.1 1 1/2
234524
380-415 3.0 1470 13.4 - 16.3 75 75 72 83 75 62 14
15
3
234355
220 6.9 2120
3.3 - 4.1 71 71 67 84 77 65 36
15
8
1.5 2
234325
380-415 4.0 2120
9.1 - 11.1 76 76 72 83 76 63 21
15
4.5
234356
220 10.4 3100
2.4 - 2.9 72 73 71 85 78 65 47
25
12
2.2 3
234326
380-415 6.0 3100
7.2 - 8.8 76 77 74 85 78 65 27
15
7
234394
220 12.4 4000
1.5 - 1.8 75 74 71 84 77 65 73
35
15
34
234395
380-415 7.3 4000
4.5 - 5.5 75 74 71 84 77 65 42
20
9
234357
220 15.5 5030
1.3 - 1.6 74 75 71 86 79 67 80
40
20
3.7 5
234327
380-415 9.0 5030
4.0 - 4.9 76 77 75 84 77 64 46
25
10
234396
220 17.0 5370
1.0 - 1.3 77 76 72 83 76 60 102
45
20
4 5 1/2
234397
380-415 10.4 5370
2.9 - 3.6 77 76 72 83 76 60 59
25
12
234358
220 22.8 7430
.82 - 1.0 75 76 73 86 79 68 120
60
30
5.5 7 1/2
234328
380-415 13.0 7430
2.5 - 3.1 78 79 78 86 79 66 70
35
15
234595 7.5 10 380-400 18.7 9720
1.6 - 2.0 76 76 73 82 74 61 99
50
25
Performance is typical, not guaranteed, at specified voltages. Performance of 1984 and older models, not listed is similar, but not identical.
16
Application - Three-Phase Motors
TABLE 17 Three-Phase Motor Specifications (50 Hz), 2875 RPM, 1.0 Service Factor
Type
6 Inch
8 Inch
Motor Model Prefix 236680 236610 236681 236611 236682 236612 236683 236613 236684 236614 236685 236615 236686 236616
236617
236618
236619
239600
239601
239602
239603
239604
239105
239106
239107
239108
Nameplate Rating
KW HP Volts
Line Volts
220 220
3.7
5
380
380 400
415
220 220
5.5 7 1/2 380
380 400
415
220 220
7.5 10 380
380 400
415
220 220
11 15 380
380 400
415
220 220
15 20 380
380 400
415
220 220
18.5 25 380
380 400
415
220 220
22 30 380
380 400
415
380
30 40 380 400
415
380
37 50 380 400
415
380
45 60 380 400
415
380
30 40 380 400
415
380
37 50 380 400
415
380
51 60 380 400
415
380
55 75 380 400
415
380
75 100 380 400
415
380
90 125 380 400 415
380
110 150 380 400
415
380
130 175 380 400
415
380
150 200 380 400
415
Amps
15.4 8.9 8.8 9.3 21.9 12.7 12.5 12.8 28.5 16.5 16.0 16.2 41.8 24.2 23.0 24.1 55.3 32.0 31.3 31.0 69.1 40.0 38.5 38.5 82.9 47.0 45.3 45.5 64.1 63.5 64.6 80.1 77.9 77.9 95.5 93.9 93.2 61.0 61.0 62.0 75.0 74.0 74.0 89.0 89.0 89.0 111.0 108.0 108.0 148.0 145.0 145.0 194.0 190.0 191.0 226.0 222.0 223.0 260.0 252.0 247.0 294.0 284.0 277.0
Full Load Watts
4850 4850 4900 4950 7175 7175 7100 7175 9450 9450 9450 9450 13750 13750 13750 13750 18200 18200 18500 18500 23000 23000 22700 22700 27250 27250 27000 27000 36000 36000 36000 45000 45000 45000 54000 54000 54000 34700 34700 34700 43000 43000 43000 51500 51500 51500 64000 64000 64000 85000 86000 86000 107000 107000 107000 127000 127000 127000 150000 148000 148000 170000 170000 170000
Line to Line (1) Resistance (Ohms) 1.3 - 1.6 3.9 - 4.8 .79 - .97 2.4 - 2.9 .63 - .77 1.9 - 2.4 .38 - .47 1.1 - 1.4 .26 - .33 .83 - 1.0 .20 - .25 .62 - .77 .16 - .21 .52 - .64
.34 - .42
.25 - .32
.22 - .27
.247 - .303
.185 - .226
.142 - .174
.106 - .130
.073 - .089
.055 - .067
.042 - .051
.042 - .052
.036 - .044
Performance is typical, not guaranteed, at specified voltages.
Locked rotor amps for Wye start 6 lead motors is 33% of value shown.
Performance also applies to 6 lead model numbers where not listed.
Six lead individual phase resistance = table X 1.5. 17
Efficiency %
F.L. 3/4 1/2
77 76 73 77 76 73 77 71 59 75 73 67 78 79 77 78 79 77 79 78 74 78 77 74 79 80 77 79 80 77 79 79 75 79 78 75 81 82 80 81 82 80 81 80 78 81 80 77 82 83 81 82 83 81 81 81 79 81 81 77 81 83 82 81 83 82 82 83 81 82 82 80 82 83 82 82 83 82 83 83 81 83 82 80 83 84 83 83 84 82 83 82 80 83 84 83 83 84 82 83 83 81 83 84 84 83 84 83 83 84 81 86 86 85 86 86 83 86 85 82 87 87 85 87 87 84 87 86 83 87 87 86 87 87 85 87 86 84 88 88 86 88 87 85 88 87 84 88 88 86 87 87 85 87 87 84 87 87 85 87 86 84 87 86 83 88 88 86 88 87 85 88 87 84 87 87 86 88 87 86 88 87 85 88 88 86 88 88 86 88 88 86
Power Factor %
F.L. 3/4 1/2
84 78 66 84 78 66 79 71 59 74 64 52 85 80 70 85 80 70 82 75 63 78 70 57 87 83 74 87 83 74 86 80 70 81 74 62 87 82 62 87 82 72 84 80 64 82 75 63 87 84 75 87 84 75 85 80 69 83 77 65 89 85 76 89 85 76 85 79 68 82 75 62 88 86 78 88 86 78 86 81 71 84 78 66 87 82 72 83 76 64 79 71 58 87 84 76 85 79 69 82 76 64 87 84 75 84 79 69 82 75 64 88 84 75 84 78 68 80 73 62 89 85 78 86 81 71 83 76 66 89 85 77 85 81 71 82 76 65 89 86 79 87 82 72 84 78 66 89 86 79 87 82 72 84 78 67 86 83 75 83 78 68 80 74 63 87 84 77 84 80 70 81 75 64 89 87 83 87 84 79 86 81 74 90 88 83 88 86 79 87 83 75
Locked Rotor Amps
68 39 42 43 105 61 64 66 143 83 83 91 218 126 125 133 283 164 170 174 340 197 206 215 440 255 268 278 362 382 397 395 417 434 478 506 526 397 418 433 507 534 654 612 645 669 819 862 895 1099 1157 1200 1265 1332 1382 1517 1597 1657 1651 1733 1803 1765 1858 1928
Circuit Breakers or Fuse Amps
Typical Submersible
Nontime Delay (Std.) Fuse or Circuit Breaker
40 25 25 25 60 35 35 35 75 45 45 45 110 60 60 60 150 80 80 80 175 100 100 100 225 125 125 125 175 175 175 200 200 200 250 250 250 175 175 175 200 200 200 250 250 250 300 300 300 400 400 400 500 500 500 600 600 600 700 700 700 800 800 800
Dual Element Time Delay Fuse
20 10 10 10 25 15 15 15 35 20 20 20 50 30 30 30 60 35 35 35 80 45 45 45 90 55 55 55 75 75 75 90 90 90 110 110 110 70 70 70 90 90 90 100 100 100 125 125 125 175 175 175 225 225 225 300 300 300 300 300 300 350 350 350
Application - Three-Phase Motors
Overload Protection of Three-Phase Submersible Motors
Motor Protection, Selection of Thermal Overload Relays
Characteristics of submersible motors differ from standard motors and special overload protection is required. In order to provide sufficient protection against overload and locked rotor, the relay has to be of the following characteristic:
· Conform to European standards e.g. VDE providing trip time <10 sec. at 500% IN (name plate current) based on cold bimetal
· Protection against single phasing
· Must trip at 120% IN (name plate current) · Temperature compensated to avoid nuisance tripping
The specific information can be obtained directly from the manufacturer's catalog. They are available from a Current/Time curve as shown on the right.
Time in sec.
20
10 4 2 1 2.5
Overload setting, DOL and Y start
For DOL, max. at full current IN shown on nameplate. For Y, relay must be incorporated in the delta circuit for adequate protection on Y start and set at IN x 0.58. Recommended setting for all applications is the measured current value at duty point.
Setting > IN is not allowed.
3 3.5 4 4.5 5 6 7 8 9 10 Multiple of IN (name plate current)
18
Application - Three-Phase Motors
Subtrol-Plus
Subtrol-Plus is a Franklin Electric protection device for 6" and 8" motors that uses microprocessor technology to detect overload, underload, overheat, and rapid cycling. When one of these faults occurs, Subtrol-Plus shuts down the motor and visually displays the fault condition. Some additional features are automatic restart, field adjustable trip settings, and external alarm/back-up system connection.
Subtrol-Plus is supplied as an easy-to-install kit, which fits virtually any three-phase pump panel. Subtrol-Plus calibrates to a particular motor through the use of a rating insert.
Subtrol-Plus easy-to-install kit
Power Factor Correction
In some installations, power supply limitations make it necessary or desirable to increase the power factor of a submersible motor. The table lists the capacitive KVAR required to increase the power factor of large Franklin three-phase submersible motors to the approximate values shown at maximum input loading.
Capacitors must be connected on the line side of the overload relay, or overload protection will be lost.
TABLE 19 KVAR Required 50 Hz
Motor
KVAR Required for P.F. of:
KW
HP
0.90
0.95
1.00
3.7
5
.8
1.5
3.1
5.5
7 1/2
1.0
2.1
4.5
7.5
10
.8
2.2
5.3
11
15
1.1
3.3
7.8
15
20
1.8
4.3
9.6
18.5
25
3
6.5
14
22
30
3
7.5
17
30
40
5
10
22
37
50
5
12
27
45
60
5
13
30
55
75
5
15
37
75
100
4
18
46
90
125
18
35
72
110
150
18
38
82
130
175
13
37
88
150
200
10
37
95
Values listed are total required (not per phase).
19
Application - Three-Phase Motors
Three-Phase Starter Diagrams
Three-phase combination magnetic starters have two distinct circuits: a power circuit and a control circuit.
The power circuit consists of a circuit breaker or fused line switch, contacts, and overload heaters connecting incoming power lines L1, L2, L3 and the three-phase motor.
The control circuit consists of the magnetic coil, overload
contacts and a control device such as a pressure switch. When the control device contacts are closed, current flows through the magnetic contactor coil, the contacts close, and power is applied to the motor. Hands-Off-Auto switches, start timers, level controls and other control devices may also be in series in the control circuit.
Line Voltage Control
This is the most common type of control encountered. Since the coil is connected directly across the power lines, L1 and L2, the coil must match the line voltage.
L1 L2 L3 FUSES
PRESSURE SWITCH OR OTHER CONTROL DEVICE
O.L. CONTACTS
COIL
CONTACTS
OVERLOAD HEATERS AND/OR
SUBTROL PLUS
MOTOR
FIG. 7
Low Voltage Transformer Control
This control is used when it is desirable to operate push buttons or other control devices at some voltage lower than the motor voltage. The transformer primary must match the line voltage and the coil voltage must match the secondary voltage of the transformer.
L1 L2 L3
FUSES CONTACTS
TRANSFORMER
FUSE
PRESSURE SWITCH OR OTHER CONTROL DEVICE
O.L. CONTACTS
COIL
OVERLOAD HEATERS AND/OR SUBTROL PLUS
MOTOR
FIG. 8
L1 L2 L3
External Voltage Controls
Control of a power circuit by a lower circuit voltage can also be obtained by connecting to a separate control voltage source. The coil rating must match the control voltage source, such as 115 or 24 volts.
FUSES CONTACTS
PRESSURE SWITCH OR OTHER CONTROL DEVICE
O.L. CONTACTS
COIL
TO SEPARATE CONTROL VOLTAGE SOURCE
OVERLOAD HEATER AND/OR
SUBTROL DEVICE
MOTOR
FIG. 9
20
Application - Three-Phase Motors
Three-Phase Power Unbalance
A full three-phase supply is recommended for all threephase motors, consisting of three individual transformers or one three-phase transformer. So-called "open" delta or wye connections using only two transformers can be used, but are more likely to cause problems, such
as poor performance, overload tripping or early motor failure due to current unbalance.
Transformer rating should be no smaller than listed in Table 4 for supply power to the motor alone
FIG. 10 FULL THREE-PHASE
FIG. 11 OPEN DELTA
Three-Phase Power Unbalance
1. Established correct motor rotation by running in both directions. Change rotation by exchanging any two of the three motor leads. The rotation that gives the most water flow is always the correct rotation.
2. After correct rotation has been established, check the current in each of the three motor leads and calculate the current unbalance as explained in 3 below.
If the current unbalance is 2% or less, leave the leads as connected.
1st Hook Up
L1 L2 L3
T2
T1
T3
2nd Hook Up
L1 L2 L3
T1
T3
T2
3rd Hook Up L1 L2 L3 supply
starter
T3
T2
T1
motor
If the current unbalance is more than 2%, current readings should be checked on each leg using each of three possible hook-ups. Roll the motor leads across the starter in the same direction to prevent motor reversal.
3. To calculate percent of current unbalance:
A. Add the three line amps values together.
EXAMPLE:
T1 = 51 amps T2 = 46 amps + T3 = 53 amps
Total = 150 amps
T3 = 50 amps T1 = 49 amps + T2 = 51 amps
Total = 150 amps
T2 = 50 amps T3 = 48 amps + T1 = 52 amps
Total = 150 amps
B. Divide the sum by three, yielding average current.
C. Pick the amp value which is furthest from the average current (either high or low).
D. Determine the difference between this amp value (furthest from average) and the average.
E. Divide the difference by the average. Multiply the result by 100 to determine percent of unbalance.
150 = 50 amps
3 50 - 46 = 4 amps
4 = .08 or 8% 50
150 = 50 amps
3
150 = 50 amps
3
50 - 49 = 1 amp 50 - 48 = 2 amps
1 = .02 or 2% 50
2 = .04 or 4% 50
4. Current unbalance should not exceed 5% at full load. If the unbalance cannot be corrected by rolling leads, the source of the unbalance must be located and corrected. If, on the three possible hookups, the leg farthest from the average stays on the same
Phase designation of leads for CCW rotation viewing shaft end.
To reverse rotation, interchange any two leads.
Phase 1 or "A"- Black, T1, or U1
power lead, most of the unbalance is coming from the power source. However, if the reading farthest from average moves with the same motor lead, the primary source of unbalance is on the "motor side"
Phase 2 or "B"- Yellow, T2, or V1 Phase 3 or "C"- Red, T3, or W1 NOTICE: Phase 1, 2 and 3 may not be L1, L2 and L3.
of the starter. In this instance, consider a damaged
cable, leaking splice, poor connection, or faulty
motor winding.
21
Submersible Pump Installation Check List
1. Motor Inspection q A. Verify that the model, HP or KW, voltage, phase and hertz on the motor nameplate match the installation requirements. q B. Check that the motor lead assembly is not damaged. q C. Measure insulation resistance using a 500 or 1000 volt DC megohmmeter from each lead wire to the motor frame. Resistance should be at least 200 megohms without drop cable. q D. Keep a record of motor model number, HP or KW, voltage, and serial number (S/N). (S/N is stamped in shell above the nameplate. A typical example, S/N 98A18 01-0123)
2. Pump Inspection q A. Check that the pump rating matches the motor q B. Check for pump damage and verify that the pump shaft turns freely.
3. Pump/Motor Assembly q A. If not yet assembled, check that pump and motor mounting faces are free from dirt, debris and uneven paint thickness. q B. Pumps and motors over 3.7 KW (5 HP) should be assembled in the vertical position to prevent stress on pump brackets and shafts. Assemble the pump and motor together so their mounting faces are in contact and then tighten assembly bolts or nuts evenly to manufacturer specifications. q C. If accessible, check that the pump shaft turns freely. q D. Assemble the pump lead guard over the motor leads. Do not cut or pinch lead wires during assembly or installation.
4. Power Supply and Controls q A. Verify that the power supply voltage, hertz, and KVA capacity match motor requirements. q B. Verify control box KW (HP) and voltage matches motor (3-wire only). q C. Check that the electrical installation and controls meet all safety regulations and match the motor requirements, including fuse or circuit breaker size and motor overload protection. Connect all metal plumbing and electrical enclosures to the power supply ground to prevent shock hazard. Comply with national and local codes.
5. Lightning and Surge Protection q A. Use properly rated surge (lightning) arrestors on all submersible pump installations. Motors 3.7 KW (5 HP) and smaller, which are marked "Equipped with Lightning Arrestors", contain internal arrestors. q B. Ground all above ground arrestors with copper wire directly to the motor frame, or to metal drop pipe or casing which reaches below the well pumping level. Connecting to a ground rod does not provide good surge protection.
6. Electrical Drop Cable q A. Use submersible cable sized in accordance with local regulations and the cable charts, see Pages 11 and 14 & 15. Ground motor per national and local codes. q B. Include a ground wire to the motor and surge protection, connected to the power supply ground if required by codes. Always ground any pump operated outside a drilled well.
7. Motor Cooling q A. Ensure at all times the installation provides adequate motor cooling; see Page 6 for details.
8. Pump/Motor Installation q A. Splice motor leads to supply cable using electrical grade solder or compression connectors, and carefully insulate each splice with watertight tape or adhesive-lined shrink tubing, as shown in motor or pump installation data. q B. Support the cable to the delivery pipe every 3 meters with straps or tape strong enough to prevent sagging. Use padding between cable and any metal straps. q C. A check valve in the delivery pipe is recommended. More than one check valve may be required, depending on valve rating and pump setting; see Page 5 for details. q D. Assemble all pipe joints as tightly as practical, to prevent unscrewing from motor torque. Torque should be at least 13.57 N-m per HP. q E. Set the pump far enough below the lowest pumping level to assure the pump inlet will always have at least the Net Positive Suction Head (NPSH) specified by the pump manufacturer. Pump should be at least 3 meters from the bottom of the well to allow for sediment build up. q F. Check insulation resistance as pump/motor assembly is lowered into the well. Resistance may drop gradually as more cable enters the water, but any sudden drop indicates possible cable, splice or motor lead damage; see Page 33.
Form No. 3656 10.03
Submersible Pump Installation Check List
9. After Installation q A. Check all electrical and water line connections and parts before starting the pump. q B. Start the pump and check motor amps and pump delivery. If normal, continue to run the pump until delivery is clear. If three-phase pump delivery is low, it may be running backward. Rotation may reversed (with power off) by interchanging any two motor lead connections to the power supply. q C. Check three-phase motors for current balance within 5% of average, using motor manufacturer instructions. Imbalance over 5% will cause higher motor temperatures and may cause overload trip, vibration, and reduced life. q D. Verify that starting, running and stopping cause no significant vibration or hydraulic shocks. q E. After at least 15 minutes running time, verify that pump output, electrical input, pumping level, and other characteristics are stable and as specified.
Date _____________________ Filled In By ____________________________________________________
Notes____________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________
Submersible Motor Installation Record
RMA No. _____________
INSTALLER'S NAME ___________________________
OWNER'S NAME _____________________________________
ADDRESS ___________________________________ ADDRESS __________________________________________
CITY __________________ STATE_____ ZIP________
CITY ____________________ STATE_____ ZIP_____________
PHONE (____) _____________ FAX (____) _________
PHONE (____) ________________ FAX (____)______________
CONTACT NAME ______________________________
CONTACT NAME _____________________________________
WELL NAME/ID _______________________________
DATE INSTALLED _____________ DATE FAILED __________
WATER TEMPERATURE _______________°C
Motor:
Motor No. _____________________ Date Code ___________________ KW _________ Voltage _________ Phase _________
Pump:
Manufacturer __________________ Model No. __________ Curve No. __________ Rating: ________ l/m@ ________m TDH NPSH Required ____________ m NPSH Available__________ m Actual Pump Delivery__________l/m@ __________ PSI Operating Cycle _________________ON (Min./Hr.) ___________________ OFF (Min./Hr.) (Circle Min. or Hr. as appropriate) YOUR NAME ____________________________________________________________________ DATE ______/______/______
WELL DATA:
Total Dynamic Head _________________m Casing Diameter___________________ mm
Drop Pipe Diameter _________________mm Static Water Level ___________________m
Drawdown (pumping) Water Level_______m Checkvalves at __________&__________&
__________&__________m
Solid
Drilled
Pump Inlet Setting __________________m Flow Sleeve: ____No____ Yes, Dia. _____mm
Casing Depth_______________________m
Well Screen
Perforated Casing
From______to_____ft. & ______to______m
Well Depth__________________________m
Form No. 2207 10.03
TOP PLUMBING: Please sketch the plumbing after the well head (check valves, throttling valves, pressure tank, etc.) and indicate the setting of each device.
Submersible Motor Installation Record
Power Supply:
Cable: Service Entrance to Control ____________m _______ mm2/MCM
Copper Jacketed
Aluminum Individual Conductors
Cable: Control to Motor ____________m________mm2/MCM
Copper Jacketed
Aluminum Individual Conductors
SERVICE ENTRANCE
Transformers:
KVA __________ #1 __________ #2 __________ #3
Initial Megs (motor & lead) T1________T2_______T3________
Final Megs (motor, lead & cable) T1______T2______T3______
Incoming Voltage:
No Load L1-L2______ L2-L3_______L1-L3_______ Full Load L1-L2______ L2-L3_______L1-L3_______
Running Amps:
HOOKUP 1: Full Load L1______L2_______L3_______ %Unbalance______
HOOKUP 2: Full Load L1______L2_______L3_______ %Unbalance______
HOOKUP 3: Full Load L1______L2_______L3_______ %Unbalance______
Ground Wire Size ___________________mm2/MCM Motor Surge Protection Yes No
PUMP
P U
PANEL
M
P
M O T O R
CONTROL PANEL:
Panel Manufacturer_________________________________ Short Circuit Device
Circuit Breaker Rating________Setting______ Fuses Rating___________ Type___________
Standard
Delay
Starter Manufacturer________________________________
Starter Size ________________________________________
Type of Starter Full Voltage
Autotransformer
Other:___________Full Voltage in _____sec.
Heater Manufacturer________________________________ Number______________Adjustable Set at ________amps.
Subtrol-Plus No Yes Registration No. __________
If yes, Overload Set? No Yes Set at _______amps. Underload Set? No Yes Set at _______amps.
Controls are Grounded to:
Well Head
Motor
Rod
Power Supply
Variable Frequency Drives:
Manufacturer_________________ Model ______________ Output Frequency: _________ Hz Min _________ Hz Max
Cooling Flow at Min. Freq. ___________________________ Cooling Flow at Max. Freq.__________________________
Approved Overload: Built-in ________ External Model: (per above) Cables: (per above) Set Amps __________
Start Time ____________sec. Stop Mode Coast __________sec. Ramp __________ sec.
Output filter ___________ Reactor _______________%
Make __________ Model ___________ None
Maximum Load Amps:
Drive Meter Input Amps Line 1 __________ Line 2 __________ Line 3 __________ Drive Meter Output Amps Line 1 __________ Line 2 __________ Line 3 __________ Test Ammeter Output Amps Line 1 __________ Line 2 __________ Line 3 __________ Test Ammeter Make ________________________ Model ________________________
Submersible Motor Booster Installation Record
Submersible Motor Booster Installation Record Date ______ /______ / _______ Filled In By ____________________________________ RMA No. __________________
Installation
Owner/User __________________________________________________ Telephone (________) __________________________ Address __________________________________________________ City ____________________________________________ State_____________________________ Postal Code/Zip_________________ Country__________________________________ Installation Site, If Different ___________________________________________________________________________________ Contact ______________________________________________________ Telephone (________) __________________________ System Application__________________________________________________________________________________________ ___________________________________________________________________________________________________________ System Manufactured By_____________________________ Model _________________ Serial No. _____________________ System Supplied By___________________________________ City _________________________________________________ State_____________________________ Postal Code/Zip________________ Country__________________________________
Motor
Model No. ____________________________ Serial No. ______________________________ Date Code ___________________
Horsepower/kW______________ Voltage ______________
Single-Phase Three-Phase
Motor Diaphragm Height__________________ in mm Motor Shaft Height__________________ in mm Slinger Removed? Yes No Check Valve Plug Removed? Yes No Motor Dia. _________in Does Motor Have a Deionized Fill Solution: Yes No
Pump
Manufacturer _____________________________ Model ____________________________ Serial No. _____________________ Stages __________________ Diameter____________________ Flow Rate Of _______________ GPM At _____________TDH Booster Case Internal Diameter _______________________ Material Construction ____________________________________
Controls and Protective Devices
Subtrol? Yes No
If Yes, Warranty Registration No.________________________________________________
If Yes, Overload Set? Yes No ______ Set At ______________________________
Reduced Voltage Starter?
Underload Sets?
Yes No ______ Set At ______________________________
Yes q No If Yes, Type ______________________________________________________
Mfr.______________________ Starting______________%Full Voltage Ramp up to Full Voltage In _______________ Sec.
Variable Frequency Drive?
Yes No If Yes, Mfr. _____________________________ Model__________________
Accel. Time 0 to 30Hz:_____________ Sec. Max Freq.____________Volt/Hz
Decel. Time 30 to 0Hz:_____________ Sec. Min Freq._____________Volt/Hz
Volt/Hz Profile: _____________________________________________________________________________________________
Magnetic Starter/Contactor Mfr. ___________________________ Model ______________________Size_________________
Overload Mfr. ________________________________________________________ Ambient Compensated Yes No
Overload Class 10 Rated Yes No Htr No._______________ If Adjustable Overload Set At__________________
Circuit Protection Fuse Breaker Mfr.______________________ Size________________ Type__________________
Lightning/Surge Arrestor Mfr. _____________________________ Model ____________________________________________
Controls Are Grounded to __________________ with No. ________ Wire
Submersible Motor Booster Installation Record
Inlet Feed Water Temp Control Required Mfr._____________________________ Model _____________________________
Set At ________ °F °C Delay_____ Sec.
Inlet Pressure Control Required Ea. Mtr. Mfr.______________ Model _____________ Set_________ PSI Delay_____ Sec.
Outlet Flow Control Required Ea. Mtr. Mfr______________ Model ____________ Set________ GPM Delay_____ Sec.
Outlet Pressure Control Required Ea. Mtr. Mfr.______________ Model ____________ Set__________ PSI Delay_____ Sec.
Inlet Flow Control (Optional) If Yes,
Flushing
Mfr.______________ Model ____________ Set___
GPM Delay_____ Sec.
Is there a flushing cycle? Yes
No
If Yes, Flushing Occurs:
Pre-Operation
Yes No If Yes, _______________ Duration in Min. _________ GPM or ________ PSI
Post-Operation Chemicals
Yes No If Yes, _______________ Duration in Min. _________ GPM or ________ PSI Yes q No If Yes, list _________________________________________________________
Motor Duty Cycle: Starts Per 24hrs ___________Time Between Shutdown & Start-up _______________________________
Insulation Check
Initial Megs: Motor & Motor Lead Only Installed Megs: Motor, Motor Lead, & Cable Motor Phase to Phase Resistance
Voltage To Motor
T1_________ T2________ T3_________ T1_________ T2________ T3_________ T1-T2 ________ T1-T3 ________ T2-T3________
Non-Operating: Operating At Rated Flow ___________ GPM Operating At Open Flow ____________GPM
Amps To Motor
T1-T2_________ T1-T2_________ T2-T3_________ T1-T2_________ T1-T2_________ T2-T3_________ T1-T2_________ T1-T2_________ T2-T3_________
Operating At Rated Flow ___________ GPM Operating At Open Flow ____________GPM
Current System Reading
T1 _________ T2 ________ T1 _________ T2 ________
T3 _________ T3 _________
Inlet Pressure __________PSI Outlet Pressure __________ PSI Water Temperature _______ °F °C
Warranty on three-phase motors is void unless Subtrol or proper quick trip ambient compensated protection is used on all three (3) motor lines.
If you have any questions or problems, call the Franklin Electric Toll-Free Hot Line: 1-800-348-2420
Comments:_________________________________________________________________________________________________ ___________________________________________________________________________________________________________ ___________________________________________________________________________________________________________ ___________________________________________________________________________________________________________ ___________________________________________________________________________________________________________ Please attach a sketch of the system
Form No. 3655 10.03
Application - Three-Phase Motors
Three-Phase Motor Lead Identification
90° Lead Spacing
T5-V2 (YELLOW)
T6-W2 (RED)
CHECK VALVE OR PIPE PLUG ON RIGHT SIDE FACING MOTOR SHAFT
T4-U2 (BLACK)
T2-V1 (YELLOW)
T3-W1 (RED)
T1-U1 (BLACK)
LEADS LOCATED HERE ONLY FOR 3 LEAD (DOL) MOTORS
Line Connections -- Six Lead Motors
Connections for across-the-line starting, running, and any reduced voltage starting except WYE-DELTA type starters.
L1
L2
L3
WYE-DELTA starters connect the motor as shown below during starting, then change to the running connection shown at the left.
L1
L2
L3
T1
T6
T2
T4
T3
T5
U1
W2
V1
U2
W1
V2
T1
T2 T3
T4 T5 T6
U1
V1 W1
U2 V2 W2
Each motor lead is numbered with two markers, one near each end. To reverse rotation, Interchange any two line connections.
22
Application - Three-Phase Motors
Reduced Voltage Starters
All Franklin three-phase submersible motors are suitable for full-voltage starting. Under this condition the motor speed goes from zero to full speed within a half second or less. The motor current goes from zero to locked rotor amps, then drops to running amps at full speed. This may dim lights, cause momentary voltage dips to other electrical equipment, and shock load power distribution transformers.
In some cases the power companies may require reduced-voltage starters to limit this voltage dip. There are also times when reduced-voltage starters may be desirable to reduce motor starting torque thus reducing the stress on shafts, couplings, and discharge piping. Reduced-voltage starters also slow the rapid acceleration of the water on start up to help control up thrust and water hammer.
Reduced-voltage starters may not be required if the maximum recommended cable length is used. With maximum recommended cable length there is a 5% voltage drop in the cable at running amps, resulting in about 20% reduction in starting current and about 36% reduction in starting torque compared to having rated voltage at the motor. This may be enough reduction in starting current so that reduced-voltage starters are not required.
Three-Lead Motors: Autotransformer or solid-state reduced-voltage starters may be used for soft-starting standard three-phase motors.
When autotransformer starters are used, the motor should be supplied with at least 55% of rated voltage to ensure adequate starting torque. Most autotransformer
starters have 65% and 80% taps. Setting the taps on these starters depends on the percentage of the maximum allowable cable length used in the system. If the cable length is less than 50% of the maximum allowable, either the 65% or the 80% taps may be used. When the cable length is more than 50% of allowable, the 80% tap should be used.
Solid-state starters cannot be used with Subtrol-Plus unless a bypass contactor is installed across the starter. Consult the factory for details.
Six-Lead Motors: Wye-Delta starters are used with six-lead Wye-Delta motors. All Franklin 6" and 8" Three-phase motors are available in six-lead Wye-Delta construction. Consult the factory for details and availability. Part winding starters are not compatible with Franklin Electric submersible motors and should not be used.
Wye-Delta starters of the open-transition type, which momentarily interrupt power during the starting cycle, are not recommended. Closed-transition starters have no interruption of power during the start cycle and can be used with satisfactory results.
Reduced-voltage starters have adjustable settings for acceleration ramp time, typically preset at 30 seconds. They must be adjusted so the motor is at full voltage within THREE SECONDS MAXIMUM to prevent excessive radial and thrust bearing wear.
If Subtrol-Plus is used the acceleration time must be set to TWO SECONDS MAXIMUM due to the fast reaction time of the Subtrol-Plus.
In-line Booster Pump Systems
Franklin Electric's submersible motors are acceptable for 3. booster pumps, up to 93kW (125HP) motor shaft output, using an open or closed system flow sleeve provided the following conditions are taken into consideration in the system design.
Design And Operational Requirements
1. Non-Vertical Operation: Vertical Shaft-up (0°) to Horizontal (90°) operation is acceptable as long
4.
as the pump transmits "down-thrust" to the motor
within 3 seconds after start-up and continuously
during operation. However, it is best practice to
provide a positive slope whenever it is possible, even 5.
if it is only a few degrees.
2. Motor, Sleeve, and Pump Support System: The booster sleeve I.D. must be sized according to the motor cooling and pump NPSHR requirements. The support system must support the motor's weight, prevent motor rotation and keep the motor and pump aligned. The support system must also allow for thermal axial expansion of the motor without creating binding forces. 23
Motor Support Points: A minimum of two support points are required on the motor. One in the motor/ pump flange connection area and one in the bottom end of the motor area. The motor castings, not the shell area, are recommended as support points. If the support is a full length support and/or has bands in the shell area, they must not restrict heat transfer or deform the shell.
Motor Support Material and Design: The support system should minimize turbulence, vibration, and flow restrictions. The support materials and locations must not inhibit the heat transfer away from the motor.
Motor and Pump Alignment: The maximum allowable misalignment between the motor, pump, and pump discharge is 0.025 inch per 12 inches of length (2mm per 1000mm of length). This must be measured in both directions along the assembly using the motor/pump flange connection as the starting point. The booster sleeve and support system must be rigid enough to maintain this alignment during assembly, shipping, operation and maintenance.
Application - Three-Phase Motors
In-line Booster Pump Systems (continued)
6. Motor Fill Solution Exchange To Deionized Water: Refilling of the motor with Deionized (DI) water should be done only if the application absolutely requires it. Applications requiring DI water must comply with the below derating chart. The exchange of the motor fill solution must be done by an approved Franklin Electric service shop or representative. The motor must be permanently stamped with a "D" closely behind the Serial Number located above the motor nameplate. The maximum pressure that can be applied to the motor internal components during the flushing and refilling process is 7 psi (0.5 bar).
Pump Load Multiplier For Motor Nameplate Rating
Deionized Water Fill Derating 8" Encapsulated Motor
1.8
1.7
1.6
1.5
1.4
1.3 1.00 Service Factor 1.2
1.1
1.15 S.F.
1
30
25
20
15
10
Feed Water Temperature (°C)
First: Determine maximum Feed Water Temperature that will be experienced in this application.
Second: Determine the Pump Load Multiplier from the appropriate Service Factor curve. (Typical 1.15 Service Factor is for 60Hz ratings & 1.00 Service Factor ss for 50Hz ratings.)
Third: Multiply the Pump Load Requirement by the Pump Load Multiplier to determine the Minimum Motor Nameplate Rating.
Fourth: Select a motor with an equal or higher motor nameplate rating.
7. Motor Alterations - Sand Slinger & Check Valve Plug: On 6" and 8" motors, the rubber sand slinger located on the shaft must be removed. The pipe plug covering the check valve must be removed from Niresist and 316 SS motors.
8. Frequency of Starts: Fewer than 10 starts per 24-hour period are recommended. Allow at least 20
minutes between shutdown and start-up of the motor.
9. Controls - Soft Starters and VFDs: Reduced voltage starters and variable speed drives (inverter drives) may be used with Franklin three-phase submersible motors to reduce starting current, upthrust, and mechanical stress during startup. The guidelines for their use with submersible motors are different than with normal air cooled motor applications. Refer to the Franklin Electric Application, Installation and Maintenance (AIM) Manual Reduced Voltage Starters section or Variable Speed Submersible Pump Operation, Inverter Drives sections for specific details.
10. Motor Overload Protection: Submersible motors require properly sized ambient compensated Class 10 quick-trip overloads per the Franklin's AIM Manual guidelines to protect the motor. Class 20 or higher overloads are NOT acceptable. Franklin's Subtrol-Plus is strongly recommended for all large submersibles since it is capable of sensing motor heat without any additional wiring to the motor. Applications using Soft Starters with a Subtrol-Plus require a start-up bypass - consult the factory for details. Subtrol-Plus can not be used in applications using a VFD control.
11. Motor Surge Protection: Properly sized, grounded and dedicated motor surge arrestors must be installed in the supply line of the booster module as close to the motor as possible. This is required on all systems including those using soft-starters and variable speed drives (inverter drives).
12. Wiring: Franklin's lead assemblies are only sized for submerged operation in 30ºC or less water and may overheat and cause failure or serious injury if operated in air. Any wiring not submerged must meet applicable national and local wiring codes and Franklin Cable Chart Table 24. (Notice: wire size, wire rating and insulation temperature rating must be known when determining its suitability to operate in air or conduit. Typically, for a given size and rating, as the insulation temperature rating increases its ability to operate in air or conduit also increases.)
TABLE 24 Franklin Cable chart (See 12. Wiring)
Cable Temp. Rating ( ºC )
75
90
135
Motor Nameplate Rated Amps Full Load 3-Lead (DOL) 6-Lead (Y-) 3-Lead (DOL) 6-Lead (Y-)
3-Lead (DOL)
6-Lead (Y-)
#10 AWG
In Air
40A 69A 44A 76A 63A
In Conduit
28A 48A 32A 55A
46A
109A 80A
#8 AWG
In Air
56A 97A 64A 111A 74A
In Conduit
40A 69A 44A 76A
51A
127A 88A
#6 AWG
In Air
76A 132A 84A 145A 104A
In Conduit
52A 90A 60A 104A
74A
180A 129A
Based on 30°C maximum ambient with cable length of 100 feet or less
24
#4 AWG
In Air
100A 173A 112A 194A 145A
In Conduit
68A 118A 76A 132A
98A
251A 170A
#2 AWG
In Air
136A 236A 152A 263A 185A
In Conduit
92A 159A 104A 180A
126A
320A 219A
Source of Cable Ampacity
US N.E.C., 2002 edition, Tables 310.16 & 310.17
US N.E.C., 2002 edition, Tables 310.16 & 310.17 Standard AAR (American Association of Railroads)
RP-585
Application - Three-Phase Motors
In-line Booster Pump Systems (continued)
13. Check Valves: Spring-loaded check valves must be used on start-up to minimize motor upthrusting, water hammer, or in multiple booster (parallel) applications to prevent reverse flow.
14. Pressure Relief Valves: A pressure relief valve is required and must be selected to ensure as the pump approaches shut-off that it never reaches the point that the motor will not have adequate cooling flow past it.
15. System Purge (Can Flooding): An air bleeder valve must be installed on the booster sleeve so that flooding may be accomplished prior to booster startup. Once flooding is complete, the booster should be started and brought up to operating pressure as quickly as possible to minimize the duration of an upthrust condition.
16. System Flush Must Not Spin Pump: Applications may utilize a low flow flushing operation. Flow through the booster sleeve must not spin the pump impellers and the motor shaft. If spinning takes place, the bearing system will be permanently damaged and the motor life shortened. Consult the booster pump manufacturer for maximum flow rate through the pump when the motor is not energized.
17. Open Atmosphere Booster Pump Systems: When an open booster is placed in a lake, tank, etc. that is open to atmospheric pressure, the water level must provide sufficient head pressure to allow the pump to operate above its NPSHR requirement at all times and all demand or seasonal levels. Adequate inlet pressure must be provided prior to booster start-up.
Continuous Monitoring System Requirements Four Factors Minimum
1. Water Temperature: Feed water on each booster must be continuously monitored and not allowed to exceed 86°F (30°C) at any time. IF THE INLET
TEMPERATURE EXCEEDS 86°F (30°C), THE SYSTEM MUST SHUTDOWN IMMEDIATELY TO PREVENT PERMANENT MOTOR DAMAGE. If feed water temperatures are expected to be above 86°F (30°C), the motor must be derated. See Franklin's AIM Manual Hot Water Applications section for derating guidelines. (The high temperature feed water derating is in addition to any DI water derating if one was required.)
2. Inlet Pressure: The inlet pressure on each booster must be continuously monitored and not allowed to drop below 20 PSIG at any time. If the pump's specified Net Positive Suction Head Requirement (NPSHR) is greater than 20 PSIG, increase the inlet pressure requirement to the greater value. Adequate inlet pressure must be provided prior to booster start-up. IF THE INLET PRESSURE DROPS BELOW THE INLET PRESSURE REQUIREMENT, THE SYSTEM MUST SHUTDOWN IMMEDIATELY TO PREVENT PERMANENT MOTOR DAMAGE. NOTE: Motors where the inlet pressure exceeds 500 PSI must undergo special high pressure testing. Consult factory for details and availability.
3. Discharge Flow: The flow rate for each pump must not be allowed to drop below the motor minimum cooling flow requirement. IF THE MOTOR MINIMUM COOLING FLOW REQUIREMENT IS NOT BEING MET, THE SYSTEM MUST BE SHUTDOWN IMMEDIATELY TO PREVENT PERMANENT MOTOR DAMAGE.
4. Discharge Pressure: The discharge pressure must be monitored to maintain a down thrust load toward the motor within 3 seconds after start-up and continuously during operation. IF THE MOTOR DISCHARGE PRESSURE IS NOT ADEQUATE TO SUPPLY DOWN THRUST, THE SYSTEM MUST BE SHUTDOWN IMMEDIATELY TO PREVENT PERMANENT MOTOR DAMAGE.
Variable Speed Submersible Pump Operation, Inverter Drives
Franklin three-phase submersible motors are operable from variable frequency inverter drives when applied within guidelines shown below. These guidelines are based on present Franklin information for inverter drives, lab tests and actual installations, and must be followed for warranty to apply to inverter drive installations. Franklin two-wire and three-wire single-phase submersible motors are not recommended for variable speed operation.
WARNING: There is a potential shock hazard from contact with insulated cables from a PWM drive to the motor. This hazard is due to high frequency voltage content of a PWM drive output.
Load Capability: Pump load should not exceed motor nameplate service factor amps at rated voltage and frequency.
Frequency Range: Continuous between 30 Hz and rated frequency (50 or 60 Hz). Operations above rated frequency require special considerations, consult factory for details.
Volts/Hz: Use motor nameplate volts and frequency for the drive base settings. Many drives have means to increase efficiency at reduced pump speeds by lowering motor voltage. This is the preferred operating mode.
Voltage Rise-time or dV/dt: Limit the peak voltage to the motor to 1000V and keep the rise-time greater than 2 µsec. Alternately stated: keep dV/dt < 500V/µsec. See Filters or Reactors.
25
Application - Three-Phase Motors
Variable Speed Submersible Pump Operation, Inverter Drives (continued)
Motor Current Limits: Load no higher than motor nameplate service factor amps. For 50 Hz ratings, nameplate maximum amps are rated amps. See Overload Protection below.
Motor Overload Protection: Protection in the drive (or separately furnished) must be set to trip within 10 seconds at 5 times motor maximum nameplate amps in any line, and ultimately trip within 115% of nameplate maximum amps in any line.
Subtrol-Plus: Franklin's Subtrol-Plus protection systems ARE NOT USABLE on VFD installations.
Start and Stop: One second maximum ramp-up and ramp-down times between stopped and 30 Hz. Stopping by coast-down is preferable.
Successive Starts: Allow 60 seconds before restarting.
Filters or Reactors: Required if all three of the following conditions are met: (1) Voltage is 380 or greater and (2) Drive uses IGBT or BJT switches (rise-times < 2 µsec) and (3) Cable from drive to motor is more than 15.2 m. A low-pass filter is preferable. Filters or reactors should be selected in conjunction with the drive manufacturer and must be specifically designed for VFD operation.
Cable Lengths: Per Franklin's cable tables unless a reactor is used. If a long cable is used with a reactor, additional voltage drop will occur between the VFD and the motor. To compensate, set the VFD output voltage higher than the motor rating in proportion to the reactor impedance (102% voltage for 2% impedance, etc.).
Motor Cooling Flow: For installations that are variable-flow, variable-pressure, minimum flow rates must be maintained at nameplate frequency. In variableflow, constant pressure installations, minimum flow rates must be maintained at the lowest flow condition. Franklin's minimum flow requirements for 4" motors : 7.26 cm/sec. and for 6" and 8" motors: 15.24 cm/sec.
Carrier Frequency: Applicable to PWM drives only. These drives often allow selection of the carrier frequency. Use a carrier frequency at the low end of the available range.
Miscellaneous: Franklin three-phase motors are not declared "Inverter Duty" motors per NEMA MG1, Part 31 standards. However, Franklin's submersible motors can be used with VFDs without problems and/or warranty concerns provided these guidelines are followed.
26
Installation - All Motors
4" Super Stainless - Dimensions
(Standard Water Well)
.76 R MAX
5/16- 24 UNF-2B MOUNTING STUDS
37.6 MAX
12.7 MIN. FULL SPLINE
38.30 38.05
27.7
4.09 MAX LEAD
23.1
BOSS HEIGHT
95.3 DIA.
L*
4" High Thrust - Dimensions
(Standard Water Well)
.76 R MAX
5/16 - 24 UNF-2B MOUNTING STUDS
37.6 MAX
12.7 MIN. FULL SPLINE
38.30 38.05
27.7 23.1 4.09 MAX LEAD BOSS HEIGHT
95.3 DIA.
L*
6" - Dimensions
(Standard Water Well)
15 TOOTH 12.7 DIAMETRAL PITCH
23.9 MIN. FULL SPLINE
76.200 76.124
25.400 25.387
DIA.
73.03 72.87
1/2- 20 UNF-2B MOUNTING HOLES
6.35 6.10
CHECK VALVE
L*
8" - Dimensions
(Standard Water Well)
23 TOOTH 12.7000 DIAMETRAL PITCH
SHAFT DIA 38.10 38.075
114.55 114.30
127.00 126.92
M8 x 31.8-6G GROUND SCREW
190.5 DIA MAX
42.9 MIN FULL SPLINE
23 TOOTH 12.7000 DIAMETRAL PITCH
127.00 126.92
101.60 101.35
6.10
SHAFT DIA 38.10 38.075
114.55 114.30
CHECK
VALVE
WATER WELL MODELS
MOUNTING HOLES
CLEARANCE FOR 16mm BOLTS
PIPE PLUG
STAINLESS
STEEL MODELS
L*
M8 x 31.8-6G GROUND
SCREW
195.6 DIA MAX
42.9 MIN FULL SPLINE
101.60 101.35
6.10 CHECK VALVE
L*
138.2 DIA.
158.8
177.8 FINNED
69.9 FINNED
Dimensions in mm unless otherwise noted
40 to 100 HP
125 to 200 HP
* Motor lengths and shipping weights are available on Franklin Electric's web page (www.franklin-electric.com) or by calling Franklin's submersible hotline (800-348-2420)
27
Installation - All Motors
Tightening Motor Lead Connector Jam Nut
4" Motors: 20 to 27 N-m (15 to 20 ft-lb.)
6" Motors: 68 to 81 N-m (50 to 60 ft-lb.)
8" Motors with 1-3/16" to 1-5/8" Jam Nut: 68 to 81 N-m (50 to 60 ft-lb.)
8" Motors with 4 Screw Clamp Plate: Apply increasing torque to the screws equally in a criss-cross pattern until 9.0 to 10.2 N-m (80 to 90 inlb.) is reached.
Jam nut tightening torques recommended for field assembly are shown. Rubber compression set within
the first few hours after assembly may reduce the jam nut torque. This is a normal condition which does not indicate reduced seal effectiveness. Retightening is not required, but is permissible and recommended if original torque was questionable.
A motor lead assembly should not be reused. A new lead assembly should be used whenever one is removed from the motor, because rubber set and possible damage from removal may prevent proper resealing of the old lead.
All motors returned for warranty consideration must have the lead returned with the motor.
Pump to Motor Coupling
Assemble coupling with non-toxic FDA approved waterproof grease such as Mobile FM102, Texaco CYGNUS2661, or approved equivalent. This prevents abrasives from entering the spline area and prolongs spline life.
Shaft Height and Free End Play
TABLE 28
Motor 4" 6"
8" Type 1 8" Type 2 8" Type 2.1
Normal Shaft Height 38.1 mm 73.0 mm 101.5 mm 101.5 mm 101.5 mm
Dimension Shaft Height
38.30 38.05
mm
73.02 72.88
mm
101.60 101.35
mm
101.60 101.35
mm
101.60 101.35
mm
Free End Play
Min.
Max.
.25 mm 1.14 mm
.75 mm 1.25 mm
.20 mm .50 mm
.89 mm 1.52 mm
.75 mm 2.03 mm
If the height, measured from the pump-mounting surface of the motor, is low and/or end play exceeds the limit, the motor thrust bearing is possibly damaged, and should be replaced.
Submersible Leads and Cables
A common question is why motor leads are smaller than specified in Franklin's cable charts.
The leads are considered a part of the motor and actually are a connection between the large supply wire and the motor winding. The motor leads are short and there is virtually no voltage drop across the lead.
In addition, the lead assemblies operate under water, while at least part of the supply cable must operate in air. Lead assemblies running under water operate cooler.
CAUTION: Lead assemblies on submersible motors are suitable only for use in water and may overheat and cause failure if operated in air.
28
Installation - All Motors
Splicing Submersible Cables
When the drop cable must be spliced or connected to the motor leads, it is necessary that the splice be watertight. This splice can be made with commercially available potting, heat shrink splicing kits, or by careful tape splicing.
Tape splicing should use the following procedure.
A) Strip individual conductor of insulation only as far as necessary to provide room for a stake type connector. Tubular connectors of the staked type are preferred. If connector outside diameter (OD) is not as large as cable insulation, build up this area with rubber electrical tape.
B) Tape individual joints with rubber electrical tape, using two layers, with the first layer extending two
inches beyond each end of the conductor insulation end, and the second layer extending two inches beyond the ends of the first layer. Wrap tightly, eliminating air spaces as much as possible.
C) Tape over the rubber electrical tape with #33 Scotch electrical tape, (3M) or equivalent, using two layers as in step "B" and making each layer overlap the end of the preceding layer by at least two inches.
In the case of a cable with three conductors encased in a single outer sheath, tape individual conductors as described, staggering joints.
Total thickness of tape should be no less than the thickness of the conductor insulation.
STAKED CONNECTOR
2"
2"
2"
RUBBER TAPE
FIG. 12
2" PVC ELECTRICAL TAPE
29
Maintenance - All Motors
System Troubleshooting
Motor Does Not Start
Possible Cause
Checking Procedures
Corrective Action
A. No power or incorrect voltage. Check voltage at line terminals The
Contact power company if voltage
voltage must be ±10% of rated voltage. is incorrect.
B. Fuses blown or circuit breakers tripped.
Check fuses for recommended size
Replace with proper fuse or reset
and check for loose, dirty or corroded circuit breakers.
connections in fuse receptacle. Check for
tripped circuit breakers.
C. Defective pressure switch.
Check voltage at contact points. Improper contact of switch points can cause voltage less than line voltage.
Replace pressure switch or clean points.
D. Control box malfunction.
For detailed procedure, see pages 34-35. Repair or replace.
E. Defective wiring
Check for loose or corroded connections Correct faulty wiring or connections. or defective wiring.
F. Bound pump. G. Defective cable or motor.
Check for misalignment between pump and motor or a sand bound pump. Amp readings will be 3 to 6 times higher than normal until the overload trips.
Pull pump and correct problem. Run new installation until the water clears.
For detailed procedure, see pages 32-34. Repair or replace.
Motor Starts Too Often Possible Cause
A. Pressure switch.
B. Check valve - stuck open.
C. Waterlogged tank. D. Leak in system.
Checking Procedures
Check setting on pressure switch and examine for defects. Damaged or defective check valve will not hold pressure.
Check air charge.
Check system for leaks.
Corrective Action Reset limit or replace switch.
Replace if defective.
Repair or replace. Replace damaged pipes or repair leaks.
30
Maintenance - All Motors
System Troubleshooting
Motor Runs Continuously Possible Cause
A. Pressure switch.
B. Low water level in well.
Checking Procedures
Check switch for welded contacts. Check switch adjustments.
Pump may exceed well capacity. Shut off pump, wait for well to recover. Check static and drawdown level from well head.
Corrective Action
Clean contacts, replace switch, or adjust setting.
Throttle pump output or reset pump to lower level. Do not lower if sand may clog pump.
C. Leak in system.
Check system for leaks.
Replace damaged pipes or repair leaks.
D. Worn pump.
Symptoms of worn pump are similar to those of drop pipe leak or low water level in well. Reduce pressure switch setting, if pump shuts off worn parts may be the fault.
Pull pump and replace worn parts.
E. Loose coupling or broken Check for loose coupling or damaged shaft. motor shaft.
Replace worn or damaged parts.
F. Pump screen blocked. Check for clogged intake screen.
Clean screen and reset pump depth.
G. Check valve stuck closed. Check operation of check valve.
Replace if defective.
H. Control box malfunction. See pages 34-35 for single-phase.
Repair or replace.
Motor Runs But Overload Protector Trips
Possible Cause
Checking Procedures
Corrective Action
A. Incorrect voltage.
Using voltmeter, check the line terminals.
Contact power company if voltage
Voltage must be within ± 10% of rated voltage. is incorrect.
B. Overheated protectors.
Direct sunlight or other heat source can raise Shade box, provide ventilation or control box temperature causing protectors to move box away from source. trip. The box must not be hot to touch.
C. Defective control box.
For detailed procedures, see pages 34-35.
Repair or replace.
D. Defective motor or cable. For detailed procedures, see pages 32-34.
Repair or replace.
E. Worn pump or motor.
Check running current, See pages 13, 16 & 17. Replace pump and/or motor.
31
Maintenance - All Motors
TABLE 32 Preliminary Tests - All Sizes Single and Three-Phase
"Test"
Procedure
What it Means
Insulation Resistance
1. Open master breaker and disconnect all leads from control box or pressure switch (QD type control, remove lid) to avoid electric shock hazard and damage to the meter.
2. Set the scale lever to R X 100K and set the ohmmeter on zero.
3. Connect one ohmmeter lead to any one of the motor leads and the other lead to the metal drop pipe. If the drop pipe is plastic, connect the ohmmeter lead to ground.
1. If the ohms value is normal (Table 33), the motor is not grounded and the cable insulation is not damaged.
2. If the ohms 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.
Winding 1. Open master breaker and disconnect all leads from control 1. If all ohms values are normal (Tables 13, 16 & 17), the
Resistance
box or pressure switch (QD type control, remove lid) to avoid electric shock hazard and damage to the meter.
motor windings are neither shorted nor open, and the cable colors are correct.
2. Set the scale lever to R X 1 for values under 10 ohms. For 2. If any one value is less than normal, the motor
values over 10 ohms, set the scale lever to R X 10. "Zero"
is shorted.
the ohmmeter.
3. If any one ohm value is greater than normal, the
3. On 3-wire motors measure the resistance of yellow to black
winding or the cable is open, or there is a poor cable
(Main winding) and yellow to red (Start winding).
joint or connection.
On 2-wire motors measure the resistance from line to line.
Three-phase motors measure the resistance line to line for all three combinations.
4. If some ohms values are greater than normal and some less on single-phase motors, the leads are mixed. See Page 34 to verify cable colors.
L1 L2 R Y B
ATTACH THIS LEAD TO WELL CASING OR
DISCHARGE PIPE
CONNECT THIS LEAD TO GROUND
RED YELLOW BLACK
{ TO
POWER SUPPLY
GROUND L1
L2
POWER MUST BE SHUT OFF
FIG. 13
BLACK YELLOW
RED GROUND
TO PUMP
{
OHMMETER SET AT R X 100K
L1 L2 R Y B
{ TO
POWER SUPPLY
GROUND L1
L2
POWER MUST BE SHUT OFF
FIG. 14
RED YELLOW BLACK
BLACK YELLOW
RED GROUND
TO PUMP
{
OHMMETER SET AT R X 1
32
Maintenance - All Motors
Insulation Resistance Readings
TABLE 33 Normal Ohm and Megohm Valves Between All Leads and Ground
Condition of Motor and Leads
Ohms Value
A new motor ( without drop cable ).
200,000,000 ( or more )
A used motor which can be reinstalled in well.
10,000,000 ( or more )
Motor in well. Readings are for drop cable plus motor.
New motor
2,000,000 ( or more )
Motor in good condition.
500,000 - 2,000,000
Insulation damage, locate and repair
Less than 500,000
MEGOHM Value 200 ( or more ) 10 ( or more )
2.0 ( or more ) 0.5 - 2.0 Less than .5
Insulation resistance varies very little with rating. Motors of all HP, voltage, and phase rating have similar values of insulation resistance.
Table 33 is based on readings taken with a megohm meter with a 500VDC output. Readings may very using a lower voltage ohmmeter, consult Franklin Electric if readings are in question.
Resistance of Drop Cable (Ohms)
The values below are for copper conductors. If aluminum conductor drop cable is used, the resistance will be higher. To determine the actual resistance of the aluminum drop cable, divide the ohm readings from this chart by 0.61. This chart shows total resistance of cable from control to motor and back.
Winding Resistance Measuring
The winding resistance measured at the motor should fall within the values in tables 13, 16, & 17. When measured through the drop cable, the resistance of the drop cable must be subtracted from the ohmmeter readings to get the winding resistance of the motor. See table below.
Drop Cable Resistance DC Resistance in Ohms per 100 ft. of wire (two conductors) @ 10°C
AWG or MCM Wire Size (Copper)
14
12
10
Ohms
0.544 0.338 0.214
8 0.135
6 0.082
4 0.052
3 0.041
2 0.032
1 0.026
1/0 0.021
2/0 0.017
3/0 0.013
4/0 0.010
250
300
350
400
500
600
700
0.0088 0.0073 0.0063 0.0056 0.0044 0.0037 0.0032
Drop Cable Resistance DC Resistance in Ohms per 100 meters of wire (two conductors) @ 10°C
Square millimeter (Copper)
1.5
2.5
4
6
Ohms
2.630 1.576 0.977 0.651
10 0.374
16 0.238
25 0.153
35 0.108
50 0.075
70 0.053
95 0.040
120 0.031
150 0.025
185 0.021
240 0.016
33
Maintenance - Single-Phase Motors & Controls
Identification Of Cables When Color Code Is Unknown (Single-Phase 3-Wire Units)
If the colors on the individual drop cables cannot be found with an ohmmeter, measure:
Cable 1 to Cable 2 Cable 2 to Cable 3 Cable 3 to Cable 1
Find the highest resistance reading. The lead not used in the highest reading is the yellow lead. Use the yellow lead and each of the other two leads to get two readings:
Highest is the red lead. Lowest is the black lead.
EXAMPLE: The ohmmeter readings were:
Cable 1 to Cable 2--6 ohms Cable 2 to Cable 3--2 ohms Cable 3 to Cable 1-- 4 ohms
The lead not used in the highest reading (6 ohms) was
Cable 3--Yellow
From the yellow lead, the highest reading (4 ohms) was
To Cable 1--Red
From the yellow lead, the lowest reading (2 ohms) was
To Cable 2--Black
Single-Phase Control Boxes
Checking and Repairing Procedures (Power On)
WARNING: Power must be on for these tests. Do not touch any live parts.
A. VOLTAGE MEASUREMENTS Step 1. Motor Off 1. Measure voltage at L1 and L2 of pressure switch or line contactor. 2. Voltage Reading: Should be ±10% of motor rating. Step 2. Motor Running 1. Measure voltage at load side of pressure switch or line contactor with pump running. 2. Voltage Reading: Should remain the same except for slight dip on starting. Excessive voltage drop can be caused by loose connections, bad contacts, ground faults, or inadequate power supply. 3. Relay chatter is caused by low voltage or ground faults.
B. CURRENT (AMP) MEASUREMENTS
1. Measure current on all motor leads.
2. Amp Reading: Current in red lead should momentarily be high, then drop within one second to values on Page 13. This verifies relay operation. Current in black and yellow leads should not exceed values on Page 13.
3. Relay failures will cause red lead current to remain high and overload tripping.
4. Open run capacitor(s) will cause amps to be higher than normal in the black and yellow motor leads and lower than normal in the red motor lead.
5. A bound pump will cause locked rotor amps and overload tripping.
6. Low amps may be caused by pump running at shutoff, worn pump, or stripped splines.
7. Failed start capacitor or open relay are indicated if the red lead current is not momentarily high at starting.
CAUTION: The tests in this manual for components such as capacitors, and relays should be regarded as indicative and not as conclusive. For example, a capacitor may test good (not open, not shorted) but may have lost some of its capacitance and may no longer be able to perform its function.
To verify proper operation of relays, refer to operational test procedure described above in Section B-2.
34
Maintenance - Single-Phase Motors & Controls
Ohmmeter Tests
QD Control Box (Power Off) A. START CAPACITOR
1. Meter Setting: R x 1,000. 2. Connections: Capacitor terminals. 3. Correct meter reading: Pointer should swing
toward zero, then back to infinity. B. POTENTIAL (VOLTAGE) RELAY
Step 1. Coil Test 1. Meter setting: R x 1,000.
2. Connections: #2 & #5. 3. Correct meter readings:
For 220-240 Volt Boxes 4.5-7.0 (4,500 to 7,000 ohms).
Step 2. Contact Test 1. Meter setting: R x 1. 2. Connections: #1 & #2. 3. Correct meter reading: Zero for all models.
Ohmmeter Tests
Integral Horsepower Control Box (Power Off) A. OVERLOADS (Push Reset Buttons to make sure
contacts are closed.) 1. Meter Setting: R x 1. 2. Connections: Overload terminals. 3. Correct meter reading: Less than 0.5 ohms.
B. CAPACITOR (Disconnect leads from one side of each capacitor before checking.) 1. Meter Setting: R x 1,000. 2. Connections: Capacitor terminals. 3. Correct meter reading: Pointer should swing toward zero, then drift back to infinity, except for capacitors with resistors which will drift back to 15,000 ohms.
C. RELAY COIL (Disconnect lead from Terminal #5) 1. Meter Setting: R x 1,000. 2. Connections: #2 & #5. 3. Correct meter readings: 4.5-7.0 (4,500 to 7,000 ohms) for all models.
D. RELAY CONTACT (Disconnect lead from Terminal #1) 1. Meter Setting: R x 1. 2. Connections: #1 & #2. 3. Correct meter reading: Zero ohms for all models.
CAUTION: The tests in this manual for components such as capacitors, and relays should be regarded as indicative and not as conclusive. For example, a capacitor may test good (not open, not shorted) but may have lost some of its capacitance and may no longer be able to perform its function.
To verify proper operation of relays, refer to operational test procedure described on Page 34, Section B-2.
35
Maintenance - Single-Phase Motors & Controls
QD Control Box Parts List
TABLE 35 Q.D. Control Box Components 50Hz.
Model
KW
HP
Volts
Relay
2803530115 0.25
1/3
220
155031112
2803550115 0.37
1/2
220
155031112
2803570115 0.55
3/4
220
155031112
2803580115 0.75
1
220
155031112
Same parts are used on Suffix 101 Control Boxes. The replacement kit for relay 155031112 is 305213912.
Capacitor
275461123 275461123 275461108 275461106
Capacitor Rating
43-53 Mfd. 220v 43-53 Mfd. 220v 59-71 Mfd. 220v 86-103 Mfd. 220v
CapacitorOverload Asm.
151033957 151033957 151033906 151033918
Overload
155250101 155250101 155250102 155250103
Capacitor Replacement Kit
Capacitor
Kit
275461106 275461108 275461123
305205906 305205908 305205923
Cap/Overload asm. replacement kit
Assembly
Kit
151033906 151033918 151033957
305218906 305218918 305218957
Integral HP Control Box Parts List
TABLE 35A Control Box Components, 1.1 KW and larger 50Hz.
Model
KW
HP
Volts
Relay (1)
Start
2823508110 1.1 2823518110 1.5 2823528110 2.2
1 1/2 2 3
220
155031112
One 275464113 105-126 Mfd. 220v
220
155031112
One 275468115 189-227 Mfd. 220v
220
155031112
One 275468119 270-324 Mfd. 220v
2822539010 3.7
5
220
155031112
Two 275468115 189-227 Mfd. 220v
(1) Relay Replacement Kit 305213912
Run
One 155328102 10 Mfd. 370v
One 155328103 20 Mfd. 370v
One 155327102 35 Mfd. 370v
One 155327101 30 Mfd. 220v
One 155327109 45 Mfd. 220v
Capacitor Replacement Kit
Capacitor
Kit
155327101 155327102 155327109 155328102 275464113 275468115 275468119
305203901 305203902 305203909 305204902 305207913 305208915 305208919
Overload Replacement Kit
Capacitor
Kit
275406102 275406107 275411102 275411106 275411107 275411114
305214902 305214907 305215902 305215906 305215907 305215914
36
Overloads
275411114
275411102 run, 275411106 start 275406107 run, 275411107 start
275406102 run, 275411102 start
Maintenance - Single-Phase Motors & Controls
Control Box Wiring Diagrams
GND
CAPACITOR
GREEN
O.L. PROT.
32 1
BLACK
B(MAIN)
ORANGE YELLOW
5 RELAY 1
2 RED
YELLOW
GREEN
YELLOW 150617101 REV. 21
BLUE
Y (MOTOR LEADS)
R(START)
BLUE
L2
L1
(LINE LEADS)
1/3 - 1 HP 4" 280 35_ 0115
RUN CAPACITOR 155328102 10 MFD 370V
BLK
ORG
START CAP. 275464113 105-126 MFD.
220V
BLK RED
5 RELAY 155031112 12
YEL RED
RED
BLK
YEL
GROUND LEAD
LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER, AND OTHER CONTROL IF USED.
L1 L2 YEL BLK RED
YEL
BLK
3 BLU
12 OVERLOAD 275411114
GROUND TO LEAD MOTOR
1 1/2 HP 282 350 8110
37
Maintenance - Single-Phase Motors & Controls
START CAPACITOR 275468115 189-227 MFD 220V
RUN CAPACITOR 155328103 20 MFD 370V
BLK ORG
RED
5 RELAY
155031112 12
YEL RED
YEL BLK RED
GROUND
L1
LEAD
LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER, AND OTHER CONTROL IF USED.
13
MAIN OVERLOAD 275411102
BLU BLK
L2 YEL BLK RED
YEL
13 BLK
START OVERLOAD 275411106
BLK
GROUND LEAD
TO MOTOR
2 HP 282 351 8110
START CAPACITOR 275468119 270-324 MFD 330V
RUN CAPACITOR 155327102 35 MFD 370V
3 HP 50 Hz
BLK ORG
RED
5 RELAY
155031112 12
YEL RED
START CAPACITOR 275468115 189-227 MFD 220V
ORG
ORG BLK
RUN CAP 155327101 30 MFD 370V
5 RELAY 155031112 12
START CAP. 275468115 189-227 MFD 220V
BLK RED
RUN CAP 155327109 45 MFD 370V
YEL
RED
BLK LIGHTNING ARRESTOR (IF USED)
YEL BLK RED
YEL BLK RED
GROUND
L1
LEAD
LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER, AND OTHER CONTROL IF USED.
13
MAIN OVERLOAD 275406107
BLU BLK
L2 YEL BLK RED
YEL
13 BLK
START OVERLOAD 275411107
BLK
GROUND
LEAD
TO
MOTOR
3 HP 282 352 8110
GROUND LEAD
L1 L2 YEL BLK RED
LINE POWER FROM TWO POLE FUSED SWITCH OR CIRCUIT BREAKER, AND OTHER CONTROL IF USED.
YEL
BLU BLK
12
MAIN OVERLOAD 275406102
BLK
31
GROUND
START
LEAD
OVERLOAD
275411102
TO MOTOR
5 HP 282 353 9010
38
Maintenance - Electronic Products
Pumptec-Plus
Pumptec-Plus is a pump/motor protection device designed to work on any 220V single-phase induction motor (PSC, CSCR, CSIR, and split-phase) ranging in size from 1/2 to 5 horsepower. Pumptec-Plus uses a micro-computer to continuously monitor motor power and line voltage to provide protection against dry well, water logged tank, high and low voltage and mud or sand clogging.
Pumptec-Plus - Trouble During Installation
Symptom
Possible Cause
Solution
Unit Appears Dead (No Lights)
No Power to Unit
Check wiring. Power supply voltage should be applied to L1 and L2 terminals of the Pumptec-Plus.
In some installations the pressure switch or other control device is wired to the input of the Pumptec-Plus. Make sure this switch is closed.
Flashing Yellow Light
Unit Needs To Be Calibrated
Miscalibrated
Pumptec-Plus is calibrated at the factory so that it will overload on most pump systems when the unit is first installed. This overload condition is a reminder that the Pumptec-Plus unit requires calibration before use. See step 7 of the installation instructions.
Pumptec-Plus should be calibrated on a full recovery well with the maximum water flow. Flow restrictors are not recommended.
Flashing Yellow Light During Calibration
Two Wire Motor
Step C of the calibration instructions indicate that a flashing green light condition will occur 2 to 3 seconds after taking the SNAPSHOT of the motor load. On some two-wire motors the yellow light will flash instead of the green light. Press and release the reset button. The green should start flashing.
Flashing Red and Yellow Lights
Power Interruption
During the installation of Pumptec-Plus power may be switched on and off several times. If power is cycled more than four times within a minute Pumptec-Plus will trip on rapid cycle. Press and release the reset button to restart the unit.
Float Switch
A bobbing float switch may cause the unit to detect a rapid cycle condition on any motor or an overload condition on two wire motors. Try to reduce water splashing or use a different switch.
The line voltage is over 242 volts. Check line voltage. Report high line High Line Voltage voltage to the power company.
Flashing Red Light
Unloaded Generator
If you are using a generator the line voltage may become too high when the generator unloads. Pumptec-Plus will not allow the motor to turn on again until the line voltage returns to normal. Over voltage trips will also occur if line frequency drops too far below 50 Hz.
Solid Red Light
Low Line Voltage The line voltage is below 198 volts. Check line voltage.
Loose Connections Check for loose connections which may cause voltage drops.
Loaded Generator
If you are using a generator the line voltage may become too low when the generator loads. Pumptec-Plus will trip on undervoltage if the generator voltage drops below 198 volts for more than 2.5 seconds. Undervoltage trips will also occur if the line frequency rises too far above 50 Hz.
39
Maintenance - Electronic Products
Pumptec-Plus
Pumptec-Plus - Troubleshooting After Installation
Symptom
Possible Cause
Solution
Dry Well Blocked Intake
Wait for the automatic restart timer to time out. During the time out period, the well should recover and fill with water. If the automatic reset timer is set to the manual position, then the reset button must be pressed to reactivate the unit.
Clear or replace pump intake screen.
Solid Yellow Light
Blocked Discharge Remove blockage in plumbing. Check Valve Stuck Replace check valve.
Broken Shaft
Replace broken parts.
Machine gun rapid cycling can cause an underload condition. Severe Rapid Cycling See flashing red and yellow lights section below.
Worn Pump
Replace worn pump parts and recalibrate.
Yellow Flashing Light
Stalled Motor Float Switch
Repair or replace motor. Pump may be sand or mud locked.
A bobbing float switch can cause two-wire motors to stall. Arrange plumbing to avoid splashing water. Replace float switch.
Solid Red Light
Ground Fault Low Line Voltage
Check insulation resistance on motor and control box cable.
The line voltage is below 198 volts. Pumptec-Plus will try to restart the motor every two minutes until line voltage is normal.
Check for excessive voltage drops in the system electrical Loose Connections connections (i.e. circuit breakers, fuse clips, pressure switch, and
Pumptec-Plus L1 and L2 terminals). Repair Connections.
Flashing Red Light
The line voltage is over 242 volts. Check line voltage. Report high High Line Voltage line voltage to the power company.
Rapid Cycle
The most common cause for the rapid cycle condition is a waterlogged tank. Check for a ruptured bladder in the water tank. Check the air volume control or snifter valve for proper operation. Check setting on the pressure switch and examine for defects.
Flashing Red and Yellow Lights
Leaky Well System Replace damaged pipes or repair leaks. Stuck Check Valve Failed valve will not hold pressure. Replace Valve.
Float Switch
Press and release the reset button to restart the unit. A bobbing float switch may cause the unit to detect a rapid cycle condition on any motor or an overload condition on two wire motors. Try to reduce water splashing or use a different switch.v
40
Maintenance - Electronic Products
CP Water System, SubDrive 75 & 150
The Franklin Electric CP (Constant Pressure) Water System is a variable-speed water system that utilizes a variable-speed drive system to deliver water at a constant pressure.
WARNING: Serious or fatal electrical shock may result from failure to connect the motor, CP Water Controller, metal plumbing and all other metal near the motor or cable to the power supply ground terminal using wire no smaller than motor cable wires. To reduce the risk of electrical shock, disconnect power before working on or around the water system. Capacitors inside the CP Water Controller can still hold a lethal voltage even after power has been removed. Allow 10 minutes for dangerous internal voltage to discharge. Do not use motor in swimming areas.
CP Water System Troubleshooting Should an application or system problem occur, a built-in diagnostics will protect the system. The "FAULT" light on the front of the CP Water Controller will flash a given number of times indicating the nature of the fault. In some cases, the system will shut itself off until corrective action is taken. Fault codes and their corrective actions are listed below. See Subdrive Installation Manual for installation data.
# of Flashes
1
Fault
Possible Cause
Motor underload
Overpumped or dry well. Worn pump. Broken motor shaft. Blocked pump or screen.
Corrective Action
Wait for well to recover and automatic restart timer to time out. If the problem does not correct, check motor and pump. See description on "smart reset" at the end of the installation manual.
Low line voltage
2
Undervoltage
Check for loose connections. Check line voltage. Report low voltage to the power company. Unit will start automatically when proper power is supplied.
3
Locked pump
Motor/pump misaligned.
Unit will attempt to free a locked pump. If
Abrasive/sand-bound pump. unsuccessful, check the motor and pump.
4
NOT USED
Loose connections.
Check motor wiring. Make certain all connections
5
Open circuit
Defective motor or cable.
are tight. Make certain proper motor is installed.
*Cycle input power to reset.
6
Short Circuit
Defective cable, splice, or motor.
Check motor wiring. *Cycle input power to reset.
7
Overheated controller
High ambient temperature. This fault automatically resets when temperature
Direct sunlight.
returns to a safe level.
*"Cycle input power" means turn the power off until both lights fade off and apply power again.
41
Maintenance - Electronic Products
Pumptec
Pumptec is a load sensing device that monitors the load on submersible pump/motors. If the load drops below a preset level for a minimum of 4 seconds the Pumptec will shut off the motor. The Pumptec is designed for use on Franklin Electric 2- and 3-wire motors (1/3 to 1 1/2 HP) 220V. The Pumptec is not designed for Jet Pumps.
Symptom
Checks or Solution
Pumptec trips in about 4 sec. with some water delivery.
A. Is the voltage more than 90% of nameplate rating?
B. Are the pump and motor correctly matched?
C. Is the Pumptec wired correctly? Check the wiring diagram and pay special attention to the positioning of the power lead.
Pumptec trips in about 4 sec. with no water delivery.
A. The pump may be airlocked. If there is a check valve on top of the pump, put another section of pipe between the pump and the check valve.
B. The pump may be out of water. C. Check the valve settings. The pump may be dead-heading. D. Pump or motor shaft may be broken. E. Motor overload may be tripped. Check the motor current (amperage).
Pumptec will not time-out and reset.
A. Check switch position on the side of the circuit board in Pumptec. Make sure the switch is not set between settings.
B. If the reset time switch is set to manual reset (position 0), Pumptec will not reset. (Turn power off for 5 sec., then back on to reset.)
The pump/motor will not run at all.
A. Check voltage. B. Check wiring. C. Bypass Pumptec by connecting L2 and the motor lead with a jumper. If
motor does not run, the problem is not Pumptec. D. Check that Pumptec is installed between the control switch and motor.
Pumptec will not trip when the pump breaks suction.
A. Be sure you have a Franklin motor.
B. Check wiring connections. Is power lead connected to the correct terminal? Is motor lead connected to correct terminal?
C. Check for ground fault in the motor and excessive friction in the pump.
D. The well may be "gulping" enough water to keep Pumptec from tripping. It may be necessary to adjust Pumptec for these extreme applications. Call the Franklin Electric Submersible Service Hotline at 800-348-2420 for information.
E. Does the control box have a run capacitor? If so, Pumptec will not trip (except with Franklin 1 1/2 HP motors).
Pumptec chatters when running.
A. Check for low voltage.
B. Check for water logged tank. Rapid cycling for any reason can cause the Pumptec relay to chatter.
C. Make sure the L2 and motor wires are installed correctly. If they are reversed, the unit can chatter.
42
Maintenance - Electronic Products
Subtrol-Plus
Subtrol-Plus -Troubleshooting After Installation
Symptom
Possible Cause or Solution
Subtrol-Plus Dead
When the Subtrol-Plus reset button is depressed and released, all indicator lights should flash. If line voltage is correct at the Subtrol-Plus and the L1, L2, L3 terminals, and the reset button does not cause lights to flash, Subtrol-Plus receiver is malfunctioning.
Green Off Time Light Flashes
The green light will flash and not allow operation unless both sensor coils are plugged into the receiver. If both are properly connected and it still flashes, the sensor coil or the receiver is faulty. An ohmmeter check between the two center terminals of each sensor coil connected should read less than 1 ohm, or coil is faulty. If both coils check good, receiver is faulty.
Green Off Time Light On
The green light is on and the Subtrol-Plus requires the specified off time before the pump can be restarted after having been turned off. If the green light is on except as described, the receiver is faulty. Note that a power interruption when the motor is running will initiate the delay function.
Overheat Light On
This is a normal protective function which turns off the pump when the motor reaches maximum safe temperatures. Check that amps are within the nameplate maximum on all three lines, and that the motor has proper water flow past it. If overheat trip occurs without apparent motor overheating, it may be the result of an arcing connection somewhere in the circuit or extreme noise interference on the power lines. Check with the power company or Franklin Electric. A true motor overheat trip will require at least five minutes for a motor started cold. If trips do not conform to this characteristic, suspect arcing connections, power line noise, ground fault, or SCR variable speed control equipment.
Overload Light On Underload Light On
This is a normal protective function, protecting against an overload or locked pump. Check the amps in all lines through a complete pumping cycle, and monitor whether low or unbalanced voltage may be causing high amps at particular times. If overload trip occurs without high amps, it may be caused by a faulty rating insert, receiver, or sensor coil. Recheck that the insert rating matches the motor. If it is correct, carefully remove it from the receiver by alternately lifting sides with a knife blade or thin screwdriver, and make sure it has no pins bent over. If the insert is correct and its pins are okay, replace receiver and/or sensor coils.
This is a normal protective function.
A. Make sure the rating insert is the correct for the motor.
B. Adjusting the underload setting as described to allow the desired range of operating conditions.
Note that a DECREASE in underload setting is required to allow loading without trip.
C. Check for drop in amps and delivery just before trip, indicating pump breaking suction, and for unbalanced line current.
D. With the power turned off, recheck motor lead resistance to ground. A grounded lead can cause underload trip.
43
Maintenance - Electronic Products
Subtrol-Plus
Subtrol-Plus -Troubleshooting After Installation (Continued) Symptom
Possible Cause or Solution
Tripped Light On
Whenever the pump is off as a result of Subtrol-Plus protective function, the red tripped light is on. A steady light indicates the Subtrol-Plus will automatically allow the pump to restart as described, and a flashing light indicates repeated trips, requiring manual reset before the pump can be restarted. Any other red light operation indicates a faulty receiver. One-half voltage on 460V will cause tripped light on.
Control Circuit Fuse Blows
With power turned off, check for a shorted contactor coil or a grounded control circuit lead. The coil resistance should be at least 10 ohms and the circuit resistance to panel frame over 1 megohm. A standard or delay-type 2 amp fuse should be used.
Contactor Will Not Close
If proper voltage is at the control coil terminals when controls are operated to turn the pump on, but the contactor does not close, turn off power and replace the coil. If there is no voltage at the coil, trace the control circuit to determine if the fault is in the Subtrol-Plus receiver, fuse, wiring, or panel operating switches. This tracing can be done by first connecting a voltmeter at the coil terminals, and then moving the meter connections step by step along each circuit to the power source, to determine at which component the voltage is lost.
With the Subtrol-Plus receiver powered up, with all leads disconnected from the control terminals and with an ohmmeter set at R X 10, measure the resistance between the control terminals. It should measure 100 to 400 ohms. Depress and hold in the reset button. The resistance between the control terminals should measure close to infinity.
Contactor Hums or Chatters
Check that coil voltage is within 10% of rated voltage. If voltage is correct and matches line voltage, turn off power and remove the contactor magnetic assembly and check for wear, corrosion, and dirt. If voltage is erratic or lower than line voltage trace the control circuit for faults similar to the previous item, but looking for a major drop in voltage rather than its complete loss.
Contactor Opens When Start Switch
is Released
Check that the small interlocks switch on the side of the contactor closes when the contactor closes. If the switch or circuit is open, the contactor will not stay closed when the selector switch is in HAND position.
Contactor Closes But Turn off power. Check the contactor contacts for dirt, corrosion, and proper closing when Motor Doesn't Run the contactor is closed by hand.
Signal Circuit Terminals Do Not Energize
With the Subtrol-Plus receiver powered up and all leads disconnected from the Signal terminals, with an ohmmeter set at R X 10, measure the resistance between the Signal terminals. Resistance should measure close to infinite. Depress and hold in the reset button, the resistance between the signal terminals should measure 100 to 400 ohms.
44
Notes
45
TOLL FREE HELP FROM A FRIEND 1-800-348-2420
1-260-827-5102 FAX
Phone Franklin's toll free SERVICE HOTLINE for answers to your installation questions on submersible pump motors. When you call, a Franklin expert will offer assistance in troubleshooting submersible systems and provide immediate answers to your motor application questions. Technical support is also available online. Visit our website at:
www.franklin-electric.com
Franklin Electric
Bluffton, Indiana 46714
M-1311
Acrobat Distiller 6.0.1 for Macintosh
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