Pentair Pentek P42B0005A2 Electronic Manual

pentek

®

ElEctroNics MaNual inStallatiOn

•

OPeratiOn

•

MaintenanCe

WWW.pUMpS.COM

Table of Contents

SECTION 1: General Safety Guidelines

SECTION 2: Nomenclature

2.1 Motors

2.2 Drives

2.3 Submersible Motor Controls

SECTION 3: Installation and Setup

3.1 General Installation Guidelines

3.2 Proper Grounding

3.3 Corrosive Water and Ground

3.4 Check Valves

3.5 Start-Up

SECTION 4: Electrical Power

4.1 Mixing Wire Size with Existing Installation

4.2 Wire Splicing

4.3 3-Phase Starters

4.4 Checking Motor Rotation

4.5 3-Phase Current Balancing

4.6 Transformer Sizing

4.7 Using a Generator

4.8 Special Applications

SECTION 5: XE Series 4” Submersible Motors

5.1 Motor Inspection

5.2 Testing

5.3 Storage and Transportation

5.4 4” Motor Specifications

5.5 4” Motor Dimensions

5.6 4” Motor Fuse Sizing

5.7 Cable Lengths

5.8 4” Motor Overload Protection

5.9 Motor Cooling

5.10 Starting Frequency

SECTION 6: Pentek ® 6” Submersible Motors


6.2 Testing

6.3 Storage and Drain/Fill Instructions

6.4 Motor Specifications

6.5 Motor Dimensions

6.6 Motor Fuse Sizing and Cable Selection

6.7 Overload Protection

6.8 Motor Cooling

6.9 Head Loss In Casing


6.11 Troubleshooting

SECTION 7: Hitachi ® 6” Submersible Motors


7.2 Testing

7.3 Storage and Drain/Fill Instructions

7.4 Motor Specifications

7.5 Motor Dimensions

7.6 Motor Fuse Sizing and Cable Selection

7.7 Overload Protection

7.8 Motor Cooling

7.9 Head Loss In Casing


7.11 Troubleshooting

SECTION 8: Pentek Intellidrive ™ Variable

Frequency Drives

8.1 General Safety

8.2 Description

8.3 Installation

8.4 Initial Startup Programming Procedure

8.5 Advanced Programming

8.6 I/O Connections

8.7 Wiring Sizing, Repair Parts, Specifications

8.8 Troubleshooting

8.9 Warranty

SECTION 9: PPC Series 50/60 Hz Variable

Frequency Drives

9.1 Pentek PPC-Series Drives

9.2 PPC3 Series Specifications

9.3 PPC5 Series Specifications

9.4 Wiring Connections

9.5 Transducer Connection

9.6 Pentek Assistant

9.7 Timer Function

9.8 Helpful Hints

9.9 PPC3 and PPC5 Tank Sizing

9.10 Reactors And Filters

SECTION 10: PPX NEMA Pump Panels

10.1 Description

SECTION 11: Submersible Motor Controls

11.1 How it Works

11.2 Specifications

11.3 Mounting and Installation

11.4 Wiring Connections and Replacement Parts

SECTION 12: Motor Protective Devices - 50/60 Hz

12.1 How They Work

12.2 Specifications

12.3 Mounting And Installation

12.4 Wiring Connections

SECTION 13: Troubleshooting

13.1 Pump And Motor Problem Analysis

13.2 Motor Troubleshooting Flow Charts

13.3 Testing Submersible Motor Insulation and Winding

Resistance

13.4 Smart Pump Protector Troubleshooting

13.5 Submersible Controls Troubleshooting

SECTION 14: Appendix

14.1 Installation Checklist

14.2 Choosing A Pump System

14.3 Sizing Submersible Pump, Motor, and Tanks

14.4 How to Select the Correct Pumping Equipment

14.5 Sizing Tanks

14.6 Record of Installation

Hitachi

®

is a registered trademark of Hitachi Industrial Equipment Systems Co., Ltd.

All other brand or product names are trademarks or registered trademarks of Pentair Ltd.

© 2013 PN793 (08/20/13)

2

SECTION 1: General Safety Guidelines

Important Safety Instructions

SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation, operation, and maintenance of the product.

Always refer to the equipment owner’s manual for safety information relevant to that product.

This is the safety alert symbol. When you see this symbol on your product or in this manual, look for one of the following signal words and be alert to the potential for personal injury!

indicates a hazard which, if not avoided, will result in death or serious injury.

indicates a hazard which, if not avoided, could result in death or serious injury.

indicates a hazard which, if not avoided, could result in minor or moderate injury.

NOTICE addresses practices not related to personal injury.

Carefully read and follow all safety instructions in this manual and on product.

Keep safety labels in good condition.

Replace missing or damaged safety labels.

Fatal Electrical Shock Hazard.

• Ground motor, controls, all metal pipe and accessories connected to the motor, to the power supply ground terminal. Ground wire must be at least as large as motor supply cables.

• Disconnect power before working on the system.

• Do not use the motor in a swimming area.

WARNING

Hazardous voltage. Can shock, burn, or cause death.

Ground pump before connecting to power supply.

Disconnect power before working on pump, motor or tank.

All work must be done by a trained and qualified installer or service technician.


2.1 Motors

Table 2-1: Motor Nomenclature

Sample:

P43B0010A2-01 is a PENTEK 4” Stainless Steel Motor

1 HP, 60 Hz., 230 V, 1 Ph., Rev. 1

Name Plate Example:

P 43 B 0 0 1 0 A 2 -01

Brand

P = PENTEK

Motor Size

42 = 4 inch, 2-wire

43 = 4 inch, 3-wire

Motor Material

B = All stainless steel

S = CBM

Horsepower

0005 = 1/2 HP

0007 = 3/4 HP

0010 = 1 HP

0015 = 1-1/2 HP

0020 = 2 HP

0030 = 3 HP

0050 = 5 HP

0075 = 7-1/2 HP

0100 = 10 HP

Frequency

A = 60 Hz.

B = 50 Hz.

C = 50/60 Hz.

Voltage

1 = 115 V, 1 Ph.

2 = 230 V, 1 Ph.

3 = 230 V, 3 Ph.

4 = 460 V, 3 Ph.

5 = 575 V, 3 Ph.

8 = 200 V, 3 Ph

Revision Code

3


2.2 Drives

Variable / High Speed Drive Nomenclature

The chart below shows the naming for a PPC5, 460 volt,

4 amp drive with a NEMA 1 enclosure.

Note that the output current (amps) of the control must be greater than or equal to the maximum rated motor current. Output of all drives is 3-phase power.

PID Variable Frequency Drive Nomenclature

PID – 10

Product Family

PID = Pentek IntelliDrive

HP Rating:

10 = up to 1 HP

20 = up to 2 HP

50 = up to 5 HP

2.3 Submersible Motor Controls

The chart below shows the naming for a Submersible

Motor control, Standard box, capacitor run, 5 horsepower,

230 volt single phase drive.

6021 0609

SMC - CR 50 2 1

Series

SMC_(Std.)

SMC5 (50 Hz)

Style

CR (Cap Run)

IR (Induction Run)

CRP (Cap Run with contactor)

HP x 10

05 (0.5 hp)

07 (.75 hp)

10 (1 hp)

15 (1.5 hp)

20 (2 hp)

30 (3 hp)

50 (5 hp)

Voltage

1 (115 v)

2 (230 v)

Phase

1 (Single)

4


3.1 General Installation Guidelines

• In order to avoid abrasion to the power and control cables, pad the top of the well casing (a rubber pad is recommended) where the cable will pass over it; use a cable reel for cable control.

• The unit must always be easy to rotate in the hoisting gear.

• Lay power and control cables out straight on the ground (no loops) before installation. Guide cables during lowering so that they are not stretched or squeezed while pump is being installed. Make sure that cable insulation is not nicked or damaged before or during installation. Never use the electrical cables to move the motor/pump.

• The pump and motor are heavy. Make sure that all connections are secure and that the hoisting gear is adequate to do the job before starting to lift pump.

Don’t stand under the unit. Don’t allow extra people into the area while hoisting the unit.

• If motor or pump/motor unit are attached to a supporting girder, do not remove girder until unit is vertical.

• Install pump at least 10’ (3m) below the lowest water level during pumping, but at least 6’ (2m) above the bottom of the well.

• 6” motors can be operated in vertical or horizontal

(when lead wire is at 12:00 position facing motor flange) positions.

• 4” motors can be operated in vertical or horizontal positions. Note that the thrust bearing will have shorter life in a non-vertical application. In such an installation, keep frequency of starts to less than

10 per day.

3.2 Proper Grounding

Hazardous voltage. Can shock, burn or cause death. Installation or service to electrical equipment should only be done by qualified electrician.

Control panels must be connected to supply ground

Proper grounding serves two main purposes:

1. It provides a path to ground in case of a ground-fault.

Otherwise the current would present a shock or electrocution hazard.

2. It protects equipment from electrical surges.

Use wire the same size as, or larger than motor’s current-carrying wires (consult Tables in the motor section).

Installations must comply with the National Electric Code as well as state and local codes.

All systems must have lightning (surge) protection with a secure connection to ground.

An above ground lighting (surge) protection must be grounded metal-to-metal and extend all the way to the water bearing layer to be effective. Do not ground the lightning (surge) protection to the supply ground or to a ground rod as this will provide little or no surge protection to the unit.

All motors are internally grounded and requires a 3 or

4-wire drop cable.

3.3 Corrosive Water and Ground

Some waters are corrosive, and can eventually corrode the ground wire. If the installation uses a metal well casing, any ground current will flow through it. In the case of plastic piping and casing, the water column would carry the current in a ground fault situation.

To prevent this, route the motor ground wire and the motor power leads through a GFCI with a 10 mA set point. In this way, the GFCI will trip when a ground fault has occurred AND the motor ground wire is no longer functional.

3.4 Check Valves

Check valve installation is necessary for proper pump operation. The pump should have a check valve on its discharge, or within 25 feet (7.62 m) of the pump. For very deep wells, locate a check valve at least every 200 feet

(61 m) vertical.

• Use only spring type or gravity-poppet check valves. Swing type valves can cause water hammer problems.

• Do not use drain-back style check valves (drilled).

Check valves serve the following purposes:

• Maintain Pressure: Without a check valve, the pump has to start each cycle at zero head, and fill the drop pipe. This creates upthrust in the motor, and would eventually damage both the pump and motor.

• Prevent Water Hammer: If two check valves are used, and the lower one leaks, then a partial vacuum forms in the pipe. When the pump next starts, the flow fills the void area quickly, and creates a shock wave that can break piping and damage the pump. If you get water hammer on pump start, this may be the cause.

• Prevent Back-Spin: Without a functioning check valve, upon shutoff, the water drains back through the pump, and cause it to rotate backwards. This can create excessive wear on the thrust bearing, and if the pump restarts as water is flowing down the pipe, it will put an excessive load on the system.

Installation and Setup

5

6


3.5 Start-Up

NOTICE: To avoid sand-locking pump, follow procedure below when starting pump for the first time. NEVER start a pump with discharge completely open unless you have done this procedure first.

1. Connect a pipe elbow, a short length of pipe and a gate valve to pump discharge at well head.

2. Make sure that controls will not be subjected to extreme heat or excess moisture.

3. Make sure power is OFF. DO NOT START PUMP YET.

4. Set gate valve on discharge 1/3 open; start pump.

5 Keep gate valve at this setting while water pumps out on ground. Let it run until water is clear of sand or silt. (To check solids in water, fill a glass from pump and let solids settle out).

6. When water is completely clear at 1/3 setting, open gate valve to approximately two-thirds open and repeat process.

7. When water is completely clear at 2/3 setting, open gate valve completely and run pump until water is completely clear.

8. Do not stop the pump until the water is clear.

Otherwise sand will accumulate in the pump stages which may bind or freeze the pump.

9. Remove gate valve and make permanent installation.

NOTICE: The motor may draw higher than normal current while the riser pipe is filling. After the riser pipe is full, the amp draw should drop back to less than the allowed current given on the motor nameplate.

When pump is in service, the amp draw must be approximately equal to or lower than the service factor amps given on the motor nameplate. If not, recheck entire installation and electrical hook-up to find out why amp draw is higher than normal.

Motor Torque

The motor exerts a strong torque force on the downpipe and any other supporting structures when it starts. This torque is usually in the direction that would unscrew right-hand threads (the motor’s reaction movement is clockwise as seen from above).

All pipe and pump joints must be tightened to safely handle the starting torque. Tighten all threaded joints to a minimum of 10 ft.-lb per horsepower. i.e. 20 HP = 200 ft.-lb; 50 HP = 500 ft.-lb.

Tack welding or strap welding may be required with higher horsepower pumps.


4.1 Mixing Wire Size with Existing

Installation

Using two different cable sizes.

Sometimes conditions make it desirable to use more than one size cable, such as replacing a pump in an existing installation.

For example: Installing a pump with a 4”, 5 HP, 230 volt, single phase motor, with the motor setting at 370’

(112.8 m) down the well and with 160’ (48.8 m) of #8 cable buried between the service entrance and the well head.

160 Ft. AWG 8

B. Cut off power supply wire ends. Match colors and lengths of wires to colors and lengths of motor leads.

C. Trim insulation back 1/2” (13mm) from supply wire and motor lead ends (Figure 4-2).

1/2"

(12.7mm)

Butt Connector

Figure 4-2: Insert Wires

D. Insert motor lead ends and supply wire ends into butt connectors. Match wire colors between supply wires and motor leads.

E. Using crimping pliers, indent butt connector lugs to attach wires (Figure 4-3).

Indent here

370 Ft.

Pump

Controls

Cable

Service Entrance

(Main Fuse Box

From Meter)

5 HP (4.9 kw)

230V 1Ph Motor

Figure 4-1: Mixing Wire Sizes: Example

5401 0412

In order to avoid replacing the buried cable, the question is: What size cable is required in the well? Calculate as follows:

1. According to Table 5-9, a total of 326’ (112.8 m) of #8 cable is the maximum length cable to power a 5 HP motor. The percent of this total that has been used by the 160’ (48.8 m) of cable in the buried run is:

160’ / 326’ = .49 or 49%.

2. With 49% of the allowable cable already used, 51% of the total length is left for use in the well. To avoid running a cable that is too small (gauge) and lowering the voltage to the motor, we have to find a cable size large enough so that 370’ (112.8 m) is less than 51% of the total length allowed for that size.

3. 370 ÷ 51% = 726 feet.

4. From Table 5-9 we find that the total allowable length for #4 cable is 809’ (246.6 m).

This is longer than needed. Therefore, #4 cable can be used for the 370’ (112.8 m) of cable in the well.

Any combination of sizes can be used, provided that the total percentage of the length of the two sizes of cable is not less than 100% of the allowed lengths.

4.2 Wire Splicing

Splice wire to motor leads. Use only copper wire for connections to pump motor and control box.

1. Taped splice (for larger wire sizes)

A. Stagger lead and wire length so that 2nd lead is

2” (50mm) longer than 1st lead and 3rd lead is

2” (50mm) longer than second.

Figure 4-3: Indent Connectors

F. Cut Scotchfil

™

electrical insulation putty into

3 equal parts and form tightly around butt

5185 1105 connectors. Be sure Scotchfil overlaps insulated part of wire.

G. Using #33 Scotch

®

tape, wrap each joint tightly; cover wire for about 1-1/2” (38mm) on each side of joint. Make four passes with the tape. When finished you should have four layers of tape tightly wrapped around the wire. Press edges of tape firmly down against the wire (Figure 4-4).

Completed splice

Figure 4-4: Wrap Splices

5186 1105

NOTICE: Since tightly wound tape is the only means of keeping water out of splice, efficiency of splice will depend on care used in wrapping tape.

NOTICE: For wire sizes larger than No. 8 (7mm

2

), use soldered joint rather than Scotchfil putty, Figure 4-5.

Figure 4-5: Twist Wires

Alternate method twist and solder

Scotchfil

™

is a trademark of 3M Company.

Scotch is a registered trademark of 3M Company.

5187 1105

7

8


2. Heat shrink splice (For wire sizes #14, 12 and 10 AWG

(2, 3 and 5mm

2

):

A. Remove 3/8” (9.5mm) insulation from ends of motor leads and power supply wires.

B. Put plastic heat shrink tubing over motor leads between power supply and motor.

C. Match wire colors and lengths between power supply and motor.

D. Insert supply wire and lead ends into butt connector and crimp. Match wire colors between power supply and motor. Pull leads to check connections.

E. Center tubing over butt connector and apply heat evenly with a torch (match or lighter will not supply enough heat, Figure 4-6).

Connector

L1

L2

L3

Low Voltage Control

This starter arrangement uses a transformer to allow the coil to be energized by a lower voltage. Note that the secondary circuit must be fused, and the coil sized for the secondary voltage.

Overload

Control

Coil

Control

Device

Thermal

Overload

Heaters

3-Phase

Motor

Heat shrink tubing

Figure 4-6: Heat-Shrink Tubing Applied

5188 1105

NOTICE: Keep torch moving. Too much concentrated heat may damage tubing.

4.3 3-Phase Starters

Starters are used to start the motor by engaging contacts that will energize each line simultaneously. The contacts are closed when the coil is energized.

Figures 4-7 through 4-9 show three types of starters used on the motors. The control device in the secondary circuit is typically a pressure switch. Other control could be provided by level control, timers or manual switches.

Line Voltage Control

This commonly-used control has a coil energized by line voltage. The coil voltage matches the line voltage.

Overload

Control

Figure 4-8: Low Voltage Control

Separate Voltage Control

This arrangement uses power from a separate source to energize the coil.

Separate

Voltage

Overload

Control

Coil

Control

Device

Thermal

Overload

Heaters

L1

L2

L3

3-Phase

Motor

Figure 4-9: Separate Voltage Control

Coil

Control

Device

Thermal

Overload

Heaters

L1

L2

L3

3-Phase

Motor

Figure 4-7: Line Voltage Control


4.4 Checking Motor Rotation

To check rotation before the pump is installed, follow these steps:

During testing or checking rotation (such as “bumping”

or “inching”) the number of “starts” should be limited to

3 and total run time of less than 15 seconds.

Bumping must be done while motor is in horizontal

position and followed by a full 15 minute cooling-off period before any additional “starts” are attempted.

Energize the motor briefly, and observe the direction of rotation.

It should be counterclockwise when viewed from the pump (shaft) end.

To check rotation after the pump is installed:

NOTICE: NEVER continuously operate a pump with the discharge valve completely closed

5402 0506

Figure 4-10: Motor Rotation

(dead head). This can overload the motor due to lack of cooling, or destroy the pump and will void the warranty.

After energizing the motor, check the flow and pressure of the pump to make sure that the motor is rotating in the correct direction. To correct a wrong rotation, switch any two of the three cable connections (three-phase motor only). The setting that gives the most flow and pressure is correct.

A cooling-off period of 15 minutes is required between starts.

Hazardous voltage. Disconnect power before working on wiring.

Input voltage, current and insulation resistance values should be recorded throughout the installation and should be used for preventive maintenance.

Electrical

Power

Supply

L3

L2

Here is an example of current readings at maximum pump loads on each leg of a three wire hookup. Make calculations for all three possible hookups.

A. For each hookup, add the readings for the three legs.

B. Divide each total by three to get average amps.

C. For each hookup, find current value farthest from average (Calculate the greatest current difference from the average).

D. Divide this difference by the average and multiply by

100 to obtain the percentage of unbalance.

Use smallest percentage unbalance, in this case

Arrangement 2 (Table 4.1).

Us e the Current-Balance worksheet located in the Installation Record

After trying all three lead hookups, if the reading furthest from average continues to show on the same power lead, most of the unbalance is coming from the power source.

Call the power company.

If the reading furthest from average changes leads as the hookup changes (that is, stays with a particular motor lead), most of the unbalance is on the motor side of the starter. This could be caused by a damaged cable, leaking splice, poor connection, or faulty motor winding.

Arrangement 1

Starter

T3

T2

Electrical

Power

Supply

To Motor

Arrangement 1

L3

L2

L1

Starter

T3

T2

T1

Arrangement 2

L3

L2

Starter

T2

T1

To Motor

Arrangement 3

L3

L2

Arrangement 2

Starter

T1

T3

L3

L2

L1

Starter

T2

T1

T3

4.5 3-Phase Current Balancing

Current Unbalance Test

Arrangement 1

Before checking for current unbalance, the pump must be started, and rotation direction determined.

T3

Determine current unbalance by measuring current in

Power each power lead. Measure current for all three possible hookups (Figure 4-11). Use example and worksheet on the Installation Checklist and Record in Section 12 to calculate current unbalance on a three phase supply system and retain for future reference.

NOTICE: Current unbalance between leads should not exceed 5%. If unbalance cannot be corrected by rolling the leads, locate the source of the unbalance.

L1 T1

Arrangement 2

Starter

L3

L2

L1

T2

T1

T3

L1

Arrangement 3

Starter

L3

L2

L1

T3

T1

T3

T2

L1

T2

Figure 4-11: 3-Phase Current Unbalance: Example

Arrangement 3

Starter

L3 T1

L2 T3

L1

T2

9


Use this worksheet to calculate current unbalance for our installation.

Table 4-1: Electrical Current Unbalance Example

EXAMPLE

Total Amps

Arrangement 1

Amps

L1–T1=17

L2–T2=15.3

L3–T3=17.7

50

Average Amps

From Average Amps

Deviation L1

Deviation L2

Deviation L3

% Current Unbalance

Largest Deviation

% Unbalance +

50 ÷ 3 = 16.7

0.3

1.4

1.0

1.4 ÷ 16.7

8.4%

4.6 Transformer Sizing

A full three-phase power supply is recommended for all three-phase motors and may consist of three individual transformers or one three-phase transformer.

“Open” delta or wye connections which use only two transformers can be used, but are more likely to cause unbalanced current problems. Transformer ratings should be no smaller than listed in Table 4-2 for supply power to the motor alone.

T1

T2

T3

Full 3-Phase (Delta)

T1 T2 T3

Wye or Open Delta 3-Phase

Figure 4-12: Three Phase Power

Transformers are rated by KVA capacity. This must be high enough capacity for the motor being installed. If the transformer capacity is too small, the motor will receive reduced voltage and may be damaged.

Any other loads in the system would be in addition to the motor alone.

Refer to Table 4-2. Note that the open delta configuration can only use 87% of the rated power of the two transformers.

Arrangement 2

Amps

L1–T3=16.7

L2–T1=16.3

L3–T2=17

50

50 ÷ 3 = 16.7

0.0

0.4

0.3

0.4 ÷ 16.7

2.4%

Arrangement 3

Amps

L1–T2=16.7

L2–T3=16

L3–T1=17.3

50

50 ÷ 3 =16.7

0.0

0.7

0.6

0.7 ÷ 16.7

4.2%

Table 4-2: Transformer Capacity

KVA Rating (smallest) For Each Transformer

HP kW

Required KVA

Open WYE or D

2 Transformers

WYE or D

3 Transformers

5

7.5

10

15

20

25

30

40

50

60

1/2

3/4

1

1-1/2

2

3

3.7

5.5

7.5

11.0

15.0

18.5

22.0

30.0

37.0

45.0

0.37

0.55

0.75

1.1

1.5

2.2

7.5

10.0

15.0

20.0

25.0

30.0

40.0

50.0

60.0

75.0

1.5

1.5

2.0

3.0

4.0

5.0

5.0

7.5

10.0

15.0

15.0

20.0

25.0

30.0

35.0

40.0

1.0

1.0

1.5

2.0

2.0

3.0

3.0

5.0

5.0

7.5

10.0

10.0

15.0

20.0

20.0

25.0

0.5

0.5

0.75

1.0

1.5

2.0

10


4.7 Using a Generator

40

50

60

10

15

20

25

30

1

1-1/2

2

3

5

7-1/2

Selecting a generator

Select a generator that can supply at least 65% of rated voltage upon start-up of the motor.

The chart shows ratings of generators, both externally and internally regulated. This chart is somewhat conservative. Consult the generator manufacturer if you are uncertain.

Table 4-3: Ratings of Generators

Motor

HP

1/2

3/4

Externally Regulated kW KVA

2.0

3.0

2.5

3.8

Internally Regulated kW KVA

1.5

2.0

1.9

2.5

30.0

40.0

60.0

75.0

100.0

100.0

150.0

175.0

4.0

5.0

7.5

10.0

15.0

20.0

37.5

50.0

75.0

94.0

125.0

125.0

188.0

220.0

5.0

6.3

9.4

12.5

18.8

25.0

15.0

20.0

25.0

30.0

40.0

50.0

60.0

75.0

2.5

3.0

4.0

5.0

7.5

10.0

Frequency

It is highly important that the generator maintain constant frequency (Hz), since the motor’s speed depends upon frequency.

A drop of just 1 to 2 Hz can noticeably lower pump performance. An increase of 1 to 2 Hz can cause overload conditions.

18.8

25.0

31.0

37.5

50.0

62.5

75.0

94.0

3.1

3.8

5.0

6.25

9.4

12.5

Voltage Regulation

There is a significant difference in the performance of internally and externally regulated generators.

An external regulator senses output voltage dips and triggers an increase in the voltage output of the generator.

An internal regulator, senses current and responds to increased current by supplying more voltage.

Generator Operation

Start the generator before starting the pump motor.

The pump motor must be stopped before turning off the generator.

If the generator runs out of fuel, and the pump is still connected, it will put excess strain on the thrust bearings as the generator slows.

Risk of electrocution. Use transfer switches when the generator is used as a backup to the power grid. Contact your power company or generator manufacturer for proper use of standby or backup generators.

4.8 Special Applications

Using Phase Converters

Phase converters allow three-phase motors to operate from one-phase supply. Various styles of phase converters are available. Many converters do not supply a properly balanced voltage, and using these will void the motor’s warranty unless approval is obtained first.

Guidelines For Phase Converters:

• Current unbalance must be less than 5%.

• Converter to be sized to service factor capacity

• Maintain motor cooling with a cooling flow of at least

3’ per second.

• Fuses and circuit breakers must be time-delay type.

Motor Starting with Reduced Voltage

Starting a motor with full voltage will bring it to full speed in less than 1/2 second. This can:

• Spike the load current, causing brief voltage dips in other equipment.

• Over-stress pump and piping components because of high torque.

• Cause water hammer.

Motor Starters (3-Phase Only)

Various types of motor starters are available.

Autotransformers are recommended because of reduced current draw.

When motor starters are used, they should supply a minimum of 55% of rated voltage for adequate starting torque.

11


5.1 Motor Inspection

Check the motor for damage in shipping.

Before installation, check the following.

• Check over all tools, especially the hoisting gear, for wear or damage before hoisting unit.

• Inspect the motor cable for any nicks or cuts.

• Verify that motor nameplate data matches registration card information exactly.

• Verify that motor nameplate voltage is correct for available power supply voltage. Voltage must not vary more than +/-10% from nameplate rated voltage.

• Verify that the well diameter is large enough to accommodate the motor/pump unit all the way to the pump setting depth.

• For installations with tight well casings, make sure that riser pipe flanges are recessed to protect the power and control cables from abrasion and squeezing during installation.

Heavy object. Lifting equipment must be capable of lifting motor and attached equipment.

• If the total length of the pump motor unit (without any riser pipe) exceeds 10’ (3m), the unit must be supported with a girder while hoisting. Do not remove supporting girder until unit is standing vertically in the hoist. Check for damage.

5.2 Testing

Insulation Resistance

To check for insulation resistance:

1. Disconnect power to the motor for this test.

2. Connect an Ohm meter (resistance in Ω) between the power leads and the motor ground or well casing.

20KΩ Damaged motor, possible result of lightning strike.

500KΩ Typical of older installed motor in well.

2 MΩ Newly installed motor

10 MΩ Used motor, measured outside of well

20 MΩ New motor without cable

5.3 Storage and Transportation

The motors are filled with a non-toxic, Propylene Glycol and water solution to prevent damage from freezing temperatures. The solution will prevent damage from freezing temperatures to -40˚F (-40˚ C). Motors should be stored in areas that do not go below this temperature.

The solution will become slushy between 0˚F (-17˚C) and

-40˚F (-40˚C) but no damage occurs. If this occurs, allow the motor to sit in the well for several minutes before operating.

Storage site should be clean, well vented, and cool.

Keep humidity at the storage site as low as possible.

Protect motor and cables from direct sunlight.

Protect power supply cables and control cables from moisture by taping the cable ends with electrician’s tape.

Do not kink power supply or control cables.

Take care when moving unit (packed or unpacked) with crane or hoisting gear not to knock it against walls, steel structure, floors, etc. Do not drop motor.

Do not lift motor or motor/pump unit by power supply or control cables.

12


5.4 4” Motor Specifications

Table 5-1: Single Phase Motor Specifications (115 and 230 Volt, 60 Hz, 3450 RPM)

Motor Type

Pentek

®

Part

Number Amps (Y/B/R)

Full Load

Y Only Watts Amps (Y/B/R)

P42B0010A2-01 7.9

1679 9.1

PSC

2-Wire

CSIR

3-Wire

CSCR

3-Wire

P42B0015A2-01

P42B0005A1-01

P42B0005A2-01

P42B0007A2-01

P42B0010A2-01

P42B0015A2-01

P42B0005A1

P42B0005A2

P42B0007A2

P43B0005A1-01

P43B0005A2-01

P43B0007A2-01

P43B0010A2-01

P43B0005A1

P43B0005A2

P43B0007A2

P43B0010A2

P43B0005A2-01

P43B0007A2-01

P43B0010A2-01

P43B0015A2-01

P43B0005A2

P43B0007A2

P43B0010A2

P43B0015A2

P43B0020A2

P43B0030A2

P43B0050A2

8.1/8.1/0

11.0/11.0/0

5.5/5.5/0

7.2/7.2/0

8.4/8.4/0

4.2/4.1/1.8

4.8/4.4/2.5

6.1/5.2/2.7

9.1/8.2/1.2

4.1/4.1/2.2

5.1/5.0/3.2

6.1/5.7/3.3

9.7/9.5/1.4

9.9/9.1/2.6

14.3/12.0/5.7

24/19.1/10.2

7.4

3.7

5.0

8.8/8.8/0

5.3/5.3/0

6.6/6.6/0

9.2

7.9

4.0

5.0

6.7

9.0

4.8

6.1

9.1

4.1

5.1

6.1

9.7

9.9

14.3

24.0

8.8

5.3

6.6

8.1

11.0

5.5

7.2

8.4

4.2

940

1165

1660

720

1000

1205

1215

733

745

1014

1267

7.15

1693

2170

3170

5300

845

834

1130

675

740

970

2108

910

845

1130

1500

2000

9.4/9.4/0

12.6/12.6/0

6.3/6.3/0

8.3/8.3/0

9.7/9.7/0

4.8/4.3/1.8

6.0/4.9/2.3

7.3/5.8/2.6

10.9/9.4/1.1

4.9/4.4/2.1

6.3/5.6/3.1

7.2/6.3/3.3

11.1/11.0/1.3

12.2/11.7/2.6

16.5/13.9/5.6

27.0/22.0/10.0

11.0

9.8

4.7

6.2

8.1

10.4

9.5

4.7

6.4

10.9/10.9/0

6.1/6.1/0

7.8/7.8/0

Service Factor

Y Only

6.0

7.3

10.9

4.9

6.3

7.2

11.1

12.2

16.5

27

10.9

6.1

7.8

9.4

12.6

6.3

8.3

9.7

4.8

1620

1021

1033

1381

1672

960

1088

1073

1459

980

1050

1350

Watts

1990

2520

1120

1050

1400

1800

2350

1270

1540

2130

955

1300

1530

2187

2660

3620

6030

13


Table 5-2: Three Phase Motor Specifications (230, 460, 200 and 575 Volt, 60 Hz, 3450 RPM)

Rating Full Load

Pentek ® Part

Number

HP kW Volts Hz

Service

Factor

Amps Watts

P43B0005A8

P43B0005A3 1/2 0.37

200

230 1.6

2.9

2.4

600

610

P43B0020A8

P43B0020A3

P43B0020A4

P43B0020A5

P43B0030A8

P43B0030A3

P43B0030A4

P43B0030A5

P43B0050A8

P43B0050A3

P43B0050A4

P43B0050A5

P43B0075A8

P43B0075A3

P43B0075A4

P43B0075A5

P43B0100A4

P43B0005A4

P43B0007A8

P43B0007A3

P43B0007A4

P43B0010A8

P43B0010A3

P43B0010A4

P43B0015A8

P43B0015A3

P43B0015A4

P43B0015A5

3/4

1

1-1/2

2

3

5

7-1/2

10

0.55

0.75

1.1

1.5

2.2

3.7

5.6

7.5

460

575

200

230

460

575

200

230

460

575

460

200

230

460

575

200

230

460

200

230

460

200

230

460

200

230

460

575

60

1.5

1.4

1.3

1.25

1.15

4.8

3.7

18.3

15.7

7.6

7.0

27.0

24.0

12.2

9.1

15.6

7.5

6.5

3.3

2.7

10.9

9.2

1.3

3.8

3.3

1.7

4.6

4.0

2.2

6.3

5.2

2.8

2

2920

2850

4850

4925

4810

5080

7600

7480

7400

7260

9600

2015

1990

2018

1610

2890

2880

610

812

850

820

1150

1090

1145

1560

1490

1560

1520

Maximum Load (SF Load)

Amps

5.3

4.1

20.2

17.5

8.5

7.6

30.0

26.4

13.5

10.0

17.2

8.8

7.6

3.8

3.3

12.0

10.1

3.4

2.9

1.5

4.5

3.9

2.0

5.5

4.7

2.5

7.2

6.1

3.2

2.4

Watts

3320

3240

5515

5650

5530

5750

8800

8570

8560

8310

11000

2490

2450

2470

2400

3290

3280

870

880

875

1140

1185

1140

1500

1450

1505

1950

1930

1980

1950

14


Table 5-3: Single Phase 4” Motor Electrical Parameters (115 and 230 Volt, 60 Hz, 3450 RPM, 2 and 3 wire)

Winding Efficiency % Power Factor %

Motor

Type

Pentek ® Part

Number Main

Resistance *

Start

Resistance

FL SF FL SF

Locked Rotor

Amps

KVA Code

P42B0005A1-01

P42B0005A2-01

1.4-2.0

6.1-7.2

42.1

45

54

58.5

99.6

92

99.9

97

28

16

H

J

PSC

2-Wire

CSIR

3-Wire

CSCR

3-Wire

2.6-3.3

2.0-2.6

2.1-2.5

4.2-4.9

2.6-3.6

2.2-3.2

1.6-2.3

1.6-2.2

1.1-1.4

0.62-0.76

4.2-5.2

1.9-2.3

1.0-1.4

5.1-6.1

2.6-3.3

2.0-2.6

5.9-6.9

4.2-5.2

1.8-2.4

1.3-1.8

4.5-5.2

3.0-4.8

0.9-1.6

4.2-4.9

2.6-3.6

2.2-3.2

5.1-6.1

P42B0007A2-01

P42B0010A2-01

P42B0015A2-01

P42B0005A1

P42B0005A2

P42B0007A2

P42B0010A2

P42B0015A2

P43B0005A1-01

P43B0005A2-01

P43B0007A2-01

P43B0010A2-01

P43B0005A1

P43B0005A2

P43B0007A2

P43B0010A2

P43B0005A2-01

P43B0007A2-01

P43B0010A2-01

P43B0015A2-01

P43B0005A2

P43B0007A2

P43B0010A2

P43B0015A2

P43B0020A2

P43B0030A2

P43B0050A2

86

86

81

76

85

86

80

94

99

65

61

64

66

54

58

61

66

77

69

71

69

62

65

68

67

69

72

71

59

58

61

62

61.5

64

62

58.5

64.5

66

62

66

68

52

56

62

66

68

72

71

58

59

57

52

60

63

51

50

55

59

54.5

50.5

50

56.5

49

50

55

10.4-11.7

9.3-10.4

10.0-10.8

17.4-18.7

11.8-13.0

11.3-12.3

7.9-8.7

10.8-12.0

2.0-2.5

1.36-1.66

2.5-3.1

12.4-13.7

10.4-11.7

9.3-10.4

5.7-7.0

17.4-18.7

11.8-13.0

11.3-12.3

12.4-13.7

61

59

62.5

61

62

65

98

99

97

96

97

98

99

85

95

97

98

87

85

90

92

69

71

72

75

87

96

99

78

75

76

91

F

H

K

J

M

N

M

J

F

H

M

L

L

L

J

G

E

32

41

49

22.3

32

41.2

47.8

49.4

76.4

101

21.7

42

44

21

32

41

49.6

22.3

32

41.2

21

18

24

44

36.4

19.5

24.8

* Main winding is between the yellow and black leads. Start winding is between the yellow and red leads.

15


Table 5-4: Three Phase Motor Electrical Parameters (230, 460, 200 and 575 Volt, 60 Hz, 3450 RPM)

Pentek ® Part

Number

Line to Line Resistance Ohms

FL

% Efficiency

SF

Locked Rotor Amps

62 68.5

P43B0005A8

P43B0005A3

P43B0005A4

P43B0007A8

P43B0007A3

4.1-5.2

5.72-7.2

23.6-26.1

2.6-3.0

3.3-4.3

61

69

66

68

74

71

22

17.3

9

32

27

P43B0007A4

P43B0010A8

P43B0010A3

P43B0010A4

P43B0015A8

P43B0015A3

P43B0015A4

P43B0015A5

P43B0020A8

P43B0020A3

P43B0020A4

P43B0020A5

P43B0030A8

P43B0030A3

P43B0030A4

P43B0030A5

P43B0050A8

P43B0050A3

P43B0050A4

P43B0050A5

P43B0075A8

P43B0075A3

P43B0075A4

P43B0075A5

P43B0100A4

0.4-0.8

.85-1.25

3.58-4.00

3.6-4.2

0.5-0.6

0.55-0.85

1.9-2.3

3.6-4.2

1.8-2.2

14.4-16.2

3.4-3.9

4.1-5.1

17.8-18.8

1.9-2.5

2.8-3-4

12.3-13.1

19.8-20.6

1.4-2.0

1.8-2.4

8.00-8.67

9.4-9.7

0.9-1.3

1.3-1.7

5.9-6.5

9.4-9.7

77

76

78

76

76

77

79

77

75

74

75

75

72

73

74

75

74

69

66

69

65

72

78

76

77

80

77

75

74

75

76

73

74

73.5

70

72

69

74

75

78

77

78

76

113

93

48

55

165

140

87

55

110

32.4

16.3

11.5

51

44

23

14

29

26.1

13

40

21.4

71

58.9

30

21.4

KVA Code

R

M

J

M

J

L

J

K

L

J

K

M

K

16


5.5 4” Motor Dimensions

Table 5-5: Single Phase Motor Dimensions (115 and 230 Volt, 60 Hz, 3450 RPM)

Motor Type

Pentek

®

Part

Number

HP kW

Inches

Length mm

P42B0005A1-01

1/2 0.37

10.5

267

4-Inch

2-Wire

P42B0005A2-01

P42B0007A2-01

P42B0010A2-01

P42B0015A2-01

P42B0005A1

P42B0005A2

3/4

1

1-1/2

1/2

0.55

0.75

1.1

0.37

11.9

12.5

14.2

11.0

302

318

361

279

3/4

1

1-1/2

0.55

0.75

1.1

4-inch

3-Wire

P42B0007A2

P42B0010A2

P42B0015A2

P43B0005A1-01

P43B0005A2-01

P43B0007A2-01

P43B0010A2-01

P43B0005A1

P43B0005A2

P43B0007A2

P43B0010A2

P43B0005A2-01

P43B0007A2-01

P43B0010A2-01

P43B0015A2-01

P43B0005A2

P43B0007A2

P43B0010A2

P43B0015A2

P43B0020A2

P43B0030A2

P43B0050A2

1/2

3/4

1

1/2

3/4

1

1/2

3/4

1

1-1/2

1/2

3/4

1

1-1/2

2

3

5

0.37

0.55

0.75

0.37

0.55

0.75

0.37

0.55

0.75

1.1

0.37

0.55

0.75

1.1

1.5

2.2

3.7

9.2

10.3

11.2

12.8

9.7

10.8

11.7

13.6

15.1

18.3

27.7

12.4

13.3

14.9

9.6

9.2

10.3

11.2

10.0

9.7

10.8

11.7

234

262

284

325

246

275

297

345

383

466

703

314

337

378

244

234

262

284

253

246

275

297

Lb

18.1

21.4

23.2

27.3

19.2

16.7

19.8

22.0

26.0

18.1

21.4

23.1

27.4

31.0

40.0

70.0

22.7

24.5

28.9

17.9

16.7

19.8

22.0

18.9

18.1

21.4

23.1

Weight

Kg

8.2

9.7

10.5

12.4

8.7

7.6

9.0

10.0

11.8

8.2

9.7

10.5

12.4

14.1

18.1

31.8

10.3

11.1

13.1

8.1

7.6

9.0

10.0

8.6

8.2

9.7

10.5

17


Table 5-6: Three Phase Motor Dimensions (230, 460, 200 and 575 Volt, 60 Hz, 3450 RPM)

Length

Pentek ® Part Number HP kW

Inches mm Lb

P43B0005A8

P43B0005A3

P43B0005A4

P43B0007A8

P43B0007A3

1/2

3/4

0.37

0.55

10

10.8

254

275

18.9

21.4

P43B0007A4

P43B0010A8

P43B0010A3

P43B0010A4

P43B0015A8

P43B0015A3

P43B0015A4

P43B0015A5

P43B0020A8

P43B0020A3

P43B0020A4

P43B0020A5

P43B0030A8

P43B0030A3

P43B0030A4

P43B0030A5

P43B0050A8

P43B0050A3

P43B0050A4

P43B0050A5

P43B0075A8

P43B0075A3

P43B0075A4

P43B0075A5

P43B0100A4

1

1-1/2

2

3

5

7-1/2

10

0.75

1.1

1.5

2.2

3.7

5.6

7.5

11.7

13.8

15.3

21.7

27.7

30.7

297

351

389

550

703

780

23.1

27.4

32

55

70

78

Weight

9.7

10.5

12.4

14.5

24.9

31.8

35.4

Kg

8.6

18


3.00 (7.62)

Shaft free end-play

.005 -.040 (.127 - 1.02)

1.508 (38.30)

1.498 (38.05)

All dimensions in inches (mm)

3.750 (95.2)

4” Motor

Length

14 Teeth 24/48 Pitch

30 Degee Pressure Angle

Min 0.50 (23.1) Full Spline

ANSI B92.1 Compliant

0.97 (24.6) max

0.79 (20.1) min

1.5 (38.1)max.

Figure 5-1: XE Series 4” Motor Dimensions – Single and Three Phase

0.6255 (15.89)

0.6245 (15.86)

Sand Boot

(4) 5/16 - 24

UNF-2A Threaded

Studs on 3” (76.2)

Dia. Circle

19


5.6 4” Motor Fuse Sizing

Table 5-7: SINGLE PHASE Motor Fuse Sizing (115 and 230 Volt, 60 Hz, 3450 RPM)

Fuse Sizing Based on NEC

Motor Type Pentek ® Part Number HP kW Volts

Standard Fuse Dual Element Time Delay Fuse

1/2 0.37

115 20

10

4-Inch

PSC

2-Wire

4-Inch

CSIR

3-Wire

4-Inch

CSCR

3-Wire

P42B0005A1-01

P42B0005A2-01

P42B0007A2-01

P42B0010A2-01

P42B0015A2-01

P42B0005A1

P42B0005A2

P42B0007A2

P42B0010A2

P42B0015A2

P43B0005A1-01

P43B0005A2-01

P43B0007A2-01

P43B0010A2-01

P43B0005A1

P43B0005A2

P43B0007A2

P43B0010A2

P43B0005A2-01

P43B0007A2-01

P43B0010A2-01

P43B0015A2-01

P43B0005A2

P43B0007A2

P43B0010A2

P43B0015A2

P43B0020A2

P43B0030A2

P43B0050A2

3/4

1

1-1/2

1/2

3/4

1

1-1/2

1/2

3/4

1

1/2

1/2

3/4

1

1-1/2

2

3

5

3/4

1

1/2

3/4

1

1-1/2

0.55

0.75

1.1

0.37

0.55

0.75

1.1

0.37

0.55

0.75

0.37

0.37

0.55

0.75

1.1

1.5

2.2

3.7

0.55

0.75

0.37

0.55

0.75

1.1

230

115

230

115

230

115

230

20

20

30

30

45

70

30

15

30

15

20

25

30

15

20

25

15

25

15

20

25

30

30

15

20

25

35

15

20

15

10

15

20

10

15

20

10

15

10

15

10

15

20

25

40

Circuit

Breaker

25

15

20

30

15

20

25

30

15

20

25

10

30

20

10

15

20

25

15

25

10

15

25

25

40

60

20


Table 5-8: THREE PHASE Motor Fuse Sizing (230, 460, 200 and 575 Volt, 60 Hz, 3450 RPM)

Fuse Sizing Based on NEC

Pentek ®

Part Number

HP kW Volts

Standard

Fuse

Dual Element Time Delay Fuse

P43B0005A8

P43B0005A3 1/2 0.37

200

230

10

6

6

6

P43B0020A8

P43B0020A3

P43B0020A4

P43B0020A5

P43B0030A8

P43B0030A3

P43B0030A4

P43B0030A5

P43B0050A8

P43B0050A3

P43B0050A4

P43B0050A5

P43B0075A8

P43B0075A3

P43B0075A4

P43B0075A5

P43B0100A4

P43B0005A4

P43B0007A8

P43B0007A3

P43B0007A4

P43B0010A8

P43B0010A3

P43B0010A4

P43B0015A8

P43B0015A3

P43B0015A4

P43B0015A5

3/4

1

1-1/2

2

3

5

7-1/2

10

0.55

0.75

1.1

1.5

2.2

3.7

5.6

7.5

15

10

60

45

25

20

80

70

40

25

45

25

15

15

10

35

25

6

3

3

15

15

10

6

20

15

10

6

460

575

200

230

460

575

200

230

460

575

460

200

230

460

575

200

230

460

200

230

460

200

230

460

200

230

460

575

10

10

35

30

15

15

50

45

25

20

25

6

6

15

15

20

15

6

6

3

10

10

6

3

10

10

6

3

15

10

50

40

20

20

70

60

35

25

35

20

20

10

10

30

25

Circuit

Breaker

10

6

6

3

3

10

10

10

6

15

15

6

6

21


5.7 Cable Lengths

Ta ble 5-9: Cable Lengths, SINGLE PHASE 115 and 230 Volt, 60 Hz, 3450 RPM, 2- and 3-wire Motors, 60° and 75° C.

Service Entrance to Motor: Maximum Length in Feet

Motor

Type

Pentek ® Part

Number

P42B0005A1-01

P42B0005A2-01

P42B0007A2-01

HP

1/2

3/4

Volt

115

230

14

112

464

353

12

178

739

562

10

284

1178

897

8

449

1866

1420

6

699

Wire Size, AWG

4

1114

3

1401

2903

2210

4628

3523

5818

4429

2

1769

7347

5594

1

2229

9256

7046

0

2814

11684

8895

00

3550

11222

PSC

2-Wire

P42B0010A2-01 1

P42B0015A2-01 1-1/2

P42B0005A1

P42B0005A2

1/2

P42B0007A2

P42B0010A2

3/4

1

115

230

271

211

115

466

342

241

430

335

183

742

545

383

686

535

293

1183

869

611

1087

847

463

1874

1376

968

1692

1318

721

2915

2141

1506

2697

2100

1150

4648

3413

2400

3390

2640

1445

5843

4291

3018

4281

3335

1825

7379

5419

3811

5394

4201

2299

9295

6826

4801

6808

5303

2902

11733

8617

6060

8590

6690

3662

10871

7646

115

6325

3192

CSIR

3-Wire

CSCR

3-Wire

P42B0015A2

P43B0005A1-01

P43B0005A2-01

P43B0007A2-01

P43B0010A2-01

P43B0005A1

P43B0005A2

P43B0007A2

P43B0010A2

P43B0005A2-01

P43B0007A2-01

1-1/2

1/2

3/4

1

1/2

P43B0010A2-01 1

P43B0015A2-01 1-1/2

P43B0005A2

P43B0007A2

1/2

3/4

P43B0010A2

P43B0015A2

1

1-1/2

P43B0020A2

P43B0030A2

P43B0050A2

3/4

1

1/2

3/4

2

3

5

230

115

230

300

201

447

348

304

197

180

133

199

101

359

281

233

87

348

264

226

457

365

478

320

711

553

484

314

286

211

317

160

571

447

371

138

553

420

359

726

581

762

510

1135

883

772

501

456

337

206

505

255

912

713

592

221

883

670

573

1158

927

1206

808

1797

1398

1223

793

722

534

326

801

404

1444

1129

937

349

1398

1061

908

1835

1468

1877

1257

2796

2175

1903

1234

1123

830

507

1246

629

2246

1757

1458

544

2175

1651

1413

2855

2284

2992

2004

4458

3467

3034

1968

1790

1324

809

1986

1002

3581

2800

2324

867

3467

2632

2252

4551

3641

3762

2519

5604

4359

3814

2474

2251

1664

1017

2496

1260

4502

3521

2921

1090

4359

3309

2831

5721

4577

4751

3182

7078

5505

4817

3124

2843

2102

1284

3153

1591

5685

4446

3689

1376

5505

4178

3575

7225

5780

5985

4008

8916

6935

6068

3936

3581

2648

1618

3972

2004

7162

5601

4648

1734

6935

5264

4504

9102

7281

7554

5059

11254

8753

7659

4968

4520

3342

2042

5013

2530

9040

7070

5867

2188

8753

6644

5685

11489

9191

8920

7402

2761

8383

7173

11596

9531

6383

11044

9663

6268

5703

4217

2577

* Table data are generated per NEC standards.

22


Ta ble 5-10: Cable Lengths, THREE PHASE 230, 460, 200 and 575 Volt, 60 Hz, 3450 RPM Motors, 60° and 75° C.

Service Entrance to Motor: Maximum Length in Feet

Pentek ® Part

Number

P43B0005A8

P43B0005A3

P43B0005A4

P43B0007A8

HP

1/2

Volt

200

230

460

200

14

657

756

2922

423

12

1045

1202

4648

674

10

1667

1917

7414

1074

8

2641

3037

1702

6

4109

4725

Wire Size, AWG

4

7532

3

9469

2648

2 1 0 00

3513 5601 7041 8892 P43B0007A3

P43B0007A4

P43B0010A8

P43B0010A3

P43B0010A4

P43B0015A8

P43B0015A3

P43B0015A4

P43B0015A5

P43B0020A8

P43B0020A3

P43B0020A4

3/4

1

1-1/2

2

230

460

200

230

460

200

230

460

575

200

230

460

P43B0020A5

P43B0030A8

P43B0030A3

P43B0030A4

P43B0030A5

3

575

200

230

460

575

1336

159

217

827

1660

P43B0050A8

P43B0050A3

P43B0050A4

P43B0050A5

5

200

230

460

575

94

125

516

721

64 P43B0075A8

P43B0075A3

200

230

7-1/2

P43B0075A4

P43B0075A5

460

575

325

548

P43B0100A4 10 460 255

* Table data are generated per NEC standards.

359

1370

2283

217

288

1153

562

2191

346

466

1753

265

571

2179

3631

344

459

1835

894

3486

551

742

2789

421

150

199

820

1147

101

2126

253

345

1315

2641

516

871

405

379

503

2072

2897

255

334

1305

2202

1024

870

1159

4635

5370

638

872

3323

6671

239

318

1308

1829

161

211

824

1390

647

912

3475

5792

549

732

2926

3390

403

551

2098

4212

1426

5560

879

1183

4448

672

2258

8806

1392

1874

7045

1064

1444

5504

2166

2915

1655

2246

1354

1803

7212

993

1357

5171

590

783

3224

4507

397

519

2030

3426

1593

3454

4648

2638

3581

2158

2874

1583

2163

940

1248

5140

633

827

3236

2540

4342

5843

3317

4502

2714

3613

1990

2719

1182

1569

796

1040

4068

3193

7379

5685

3427

4563

2513

3434

1493

1982

1005

1314

5138

4033

7162

4317

5748

3166

4326

1881

2496

1266

1655

6472

5080

9040

5449

7256

3996

5460

2374

3151

1598

2089

9155

6889

2995

3976

2017

2635

23


5.8 4” Motor Overload Protection

Single Phase Motors

Single phase motors have overload protection either in the motor or in the control box. Motors less than or equal to 1 HP have built-in protection. This automatic protection will continue to cycle under a locked or stalled rotor condition.

Single phase motors larger than 1 HP use overload protection located in the SMC (Submersible Motor

Controls) section. These are manual overloads and must be manually reset if an overload condition occurs.

5.9 Motor Cooling

Pentek

®

4” XE Series motors are designed to operate to a maximum SF (Service Factor) horsepower in water up to

86° F (30° C).

4” motors: Minimum cooling water flow 3 HP and over

I.D of casing

4

5

6

Flow GPM (LPM) required

1.2 (4.5

7 (26.5)

13 (49)

10

12

7

8

14

16

20 (76)

30 (114)

50 (189)

80 (303)

110 (416)

150 (568)

If the flow is less than specified, a flow-inducer sleeve can be installed, as shown in Figure 5-2. The sleeve will act like a smaller casing size to force flow around the motor to aid cooling.

5.10 Starting Frequency

Recommended motor starting frequency is shown below. Motor, pressure switch, tank, and pump life may be extended by limiting starts per hour and starts per day. Proper tank sizing is critical to control pump cycle times. Excessive or rapid cycling creates heat which can prematurely damage motors, switches, and controls.

HP

1/2 thru 3/4

1 thru 5

7.5 thru 200

4.2

Motor Starting Frequency

Single Phase

Starts/hr Starts/24hr Starts/hr Starts/24hr

12.5

300

12.5

300

100

4.2

Three Phase

100

A one (1) minute minimum run time for pumps and motors up to 1.5 HP and two (2) minutes for 2HP and larger motors is recommended to dissipate heat build-up from starting current.

Figure 5-2: Flow Inducer Sleeve

24

SECTION 6: Pentek

®

6” Submersible Motors



SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation, operation, and maintenance.

This is the safety alert symbol. When you see this symbol in this manual, look for one of the following signal words and be alert to the potential for personal injury!




NOTICE addresses practices not related to personal injury.

Carefully read and follow all safety instructions in this manual.

Keep safety labels in good condition. Replace missing or damaged safety labels.

California Proposition 65 Warning

This product and related accessories contain chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

APPLICATION LIMITS

Maximum Immersion Depth: 985 ft. (300 m)

Maximum Water Temperature: 95°F (35°C) pH content of the water: 6.5–8

Minimum Cooling Flow Rate: 0.5 feet per second (fps)

(0.15meters per second (mps)).

Required line voltage at the motor under operating conditions (±10%).

NOTICE When calculating voltage at the motor, be sure to allow for voltage drop in the cable.

The sum of the absolute values of the voltage and frequency must not vary from the sum of the nominal values by more than ±10%.

Operating with current unbalanced on the three legs of the circuit can overheat and damage the motor and will void the warranty. Current imbalance must not exceed

5% maximum.

Maximum Sand Content: 50ppm (max. size 0.1–0.25mm)

Maximum Chlorine Ion Content: 500ppm

6.2 Testing

ELECTRICAL

(See Table 1, Page 4, for Motor Electrical

Specifications)

1. Risk of electrical shock if the cable is

damaged. Inspect the motor cable for any nicks or cuts. Do not use the motor cable to pull, lift, or handle the motor. Protect the motor cable during storage, handling, moving, and installation of the motor.

2. Inspect the motor to determine that it is the correct horsepower, voltage, and size for the job and that there is no shipping damage. Verify that the motor nameplate voltage matches the available power supply voltage. The nameplate rated voltage must not vary more than ± 10% from the power supply voltage.

3. On all new installations and after the motor has sat idle for a long period of time, check the motor’s internal electrical resistance with a megohmmeter with lead wires connected. Prior to installation, the motor should have an insulation value of at least

500 megohms. After installation, the motor and power cable should have a minimum insulation value of 1 megohm. If the minimum values are below the listed values, contact the factory before starting the motor.

4. Fuses or circuit breakers and overload protection are required. Fuses or circuit breakers and overloads must be sized in accordance with National

Electrical Code (NEC) or Canadian Electrical Code

(CEC) requirements, as applicable, and with all applicable local codes and ordinances. See

Section 6 for these specifications.

5. Wire and ground the motor in accordance with

National Electrical Code (NEC) or Canadian

Electrical Code (CEC) requirements, as applicable, and with all applicable local codes and ordinances.

6.3 Storage and Drain/Fill Instructions

LIFTING

1. Heavy Object. Lifting equipment must be capable of lifting motor and attached equipment. Check over all tools, especially the hoisting gear, for wear or damage before hoisting the unit.

2. If the total length of the pump and motor unit (without any riser pipe attached) exceeds 10ft (3m), support the unit with a girder while hoisting (see Figure 1). Do not remove the supporting girder until the unit is standing vertically in the hoist. Check for damage.

25


®



Figure 1: When the pump and motor together

(without any riser pipe) are 10ft (3m) long or more, support the assembly before lifting to avoid bending it in the middle. Never try to lift the motor or pump by the motor cables.

Less Than 10 Ft (3 M) 10 Ft (3M) or More

Support the pump and motor!

10 Ft (3M) or More

Lack of support will destroy the motor!

MOTOR STORAGE AND INSTALLATION

1. The motor is filled at the factory with anti-freeze which will protect it in temperatures down to –22ºF

(-30ºC). Do not install, transport or store the motor below these temperatures if the motor is filled. If storage is necessary at temperatures below –22ºF

(-30ºC), drain the anti-freeze from the motor.

2. Verify that the motor is full before installing. If not, fill it with clean water (see below). Installing a motor that is not filled with liquid will void the warranty. Before installation, check all water fill and drain plugs, mounting bolts, and cable connections for tightness.

Refill the motor with clean water as follows:

A. Stand the motor on end (vertically) and remove the fill plug with a 5mm hexagonal nut driver.

B. Turn the motor shaft by hand while rocking the motor back and forth (see Figure 2).

C. Pour in clean water until the motor is as full as possible.

D. Repeat the turning/rocking procedure.

E. Check the liquid level. If necessary, add more clean water.

F. When the motor is full, re-install the fill plug.

Tighten it with the 5mm hexagonal nut driver.

Support motor while rocking to prevent motor from falling over.

A. Rock motor while turning shaft.

B. Fill motor; repeat rocking and filling until motor is full.

Figure 2: Rock Motor gently from side to side while turning shaft by hand (A), then fill with clean water (B).

Repeat until full.

26


®



NOTICE To avoid damaging the motor thrust bearing, do not hammer on the shaft, coupling, or slinger. Check the motor rotation by hand to make sure that it turns freely.

1. To avoid damage to the motor diaphragm, make sure that the bottom of the motor does not touch the dirt or mud at the bottom of the well. Install the motor at least 10’ above the well bottom.

2. To install the motor horizontally, lay it down with the lead wires at 12 o’clock when you are facing the motor shaft. To prevent any load on the shaft and bearings and to avoid any damaging vibrations to the motor, mount the motor solidly on the pump end and make sure that the pump and motor are accurately aligned.

3. Install the motor so that during operation water flows past all parts of it at a rate of at least 0.5 fps

(0.15 mps). If the well will not provide this flow, install a sleeve on the motor to channel water past it (see Figure 3). Do not try to operate the motor in mud or sand. To do so will damage the motor and void the warranty.

4. Electrical connections: Connect the three motor leads to the three hot motor leads (black, brown, and blue) in the incoming cable. Connect the ground wire (green and yellow) in accordance with

NEC or CEC requirements (as applicable) and in accordance with all applicable local codes and ordinances. Apply power momentarily to check rotation. If the motor runs backwards, interchange any two power leads to reverse direction of rotation.

Flow Inducer

Sleeve

10’ (3M) or more

Well

Water

Pump

Motor

NOT TO SCALE

Figure 3: If flow past motor is less than .5 fps (0.15 mps), install a flow inducer sleeve as shown. Flow must be at least .5 fps (0.15 mps) for adequate motor cooling. The flow inducer sleeve should not touch the side of the motor.

27


®


6.4 Motor Specifications

Ordering Information

Motor tyPe PhAse Note

PeNteK

Model # hP KW hZ Volts

6PM2-5-2 5 4 serVice FActor 1.00 serVice FActor 1.15 locKed

AMPs eFF.

%

P.F.

% AMPs eFF.

%

P.F.

% rotor

AMPs

15 .2

75 83 16.4 77 85 102.1

6” three

Motors are 60 hz only

6PM2-7-2 7-1/2 6

6PM2-10-2 10 8

6PM2-15-2 15 11

6MP2-20-2 20 15

6PM2-25-2 25 19

6PM2-30-2 30 22

6PM2-5-4 5

6PM2-7-4 7-1/2 6

6PM2-10-4 10 8

4

6PM2-15-4 15 11

Motors are dual rated

50 hz &

60 hz

6PM2-20-4 20 15

6MP2-25-4 25 19

6PM2-30-4 30 22

6PM2-40-4 40 30

6PM2-50-4 50 37

60 230

21.2 79 85 23.2 79 86 146.4

30.8 77 81 33.0 78 83 187.6

43.2 78 84 47.0 78 86 281.8

57.4 79 85 63.0 79 87 394.5

69 81 86 76.0 80 88 480.2

76.6 84 88 85.0 84 89 614.2

50 380 8.9 75 87

60 460 10.6 75 83 8.2 77 85

45.6

51.1

50 380 12.5 79 87

60 460 15.4 79 85 11.6 79 86

50 380 17.8 78 85

60 460 15.4

77 81 16.5 78 83

50 380 25.6 77 87 127

60 460 21.6 78 84 23.5 78 86 140.9

50 380 34 78 89 170.2

60 460 28.5 79 85 31.5 79 87 197.3

66.8

73.2

85.6

93.8

50 380 41 79 89 219

60 460 34.5 81 86 38.0 80 88 240.1

50 380

60 460

46

38

83 90

84 88 42.5 84 89

276.8

307.1

50 380 62.5 83 90 393.1

60 460 52.7 84 88 58.0 84 89 439.7

50 380 77.6

83 90 449.8

60 460 64.3

85 87 70.8

85 89 500.5

thrust loAd

KVA code

K

1763

J

3485

J

J

J

1763

3485

6182

K

K

K

J

J

J

J

J

K

K

J iNsulAtioN clAss

WiNdiNg resistANce

(ohM) rPM leNgth Weight iN MM lBs Kg

0.7873

3460 22.7 577 90 41

F

0.5389

3460 24.9 632 102 46

0.3964

3440 29.2 741.5 116 53

0.2782

3450 31.8 807.5 121 55

0.2101

3450 35.1 892.5 147 67

0.1605

3450 38.0 964.5 165 75

0.1445

3500 41.8 1,060.5 190 86

2.9674

2820

3460

22.7 577 90 41

1.9828

1.4648

0.9916

0.7192

2810

3450

2810

3450

2820

3460

2800

3440

24.9 632 102

29.2 741.5 116

31.8 807.5 131

35.1 892.5 147

46

53

55

67

0.5640

0.5036

0.3958

.3295

2860

3490

2840

3480

2820

3450

2880

3500

38.0 964.5 165

41.8 1060.5 190

47.1 1197

49.9 1267

209

75

86

95

292 132

6.5 Motor Dimensions

l1

Nominal diameter

Effective diameter

6"/152.4 mm

5.43"/138 mm

Shaft extension length 2.87" / 73 mm l

For lengths, refer to Ordering Information tables.

Dimensions are for estimating purposes only. d

28


®


6.6 Motor Fuse Sizing and Cable Selection

CABLE SELECTION

COPPER CABLE SIZE - From Main Breaker Panel to Motor (in feet)

60˚

VOLTS /

HZ

MOTOR

HP KW STD

FUSE

Dual

Element 14 12 10

THREE PHASE

8 6 4

AWG

3 2 1 0

MCM

00 000 0000 250 300 350 400 500

230 V

60 hz

460 V

60 hz or

380 V

50 hz

5 3.7

45

7.5 5.5

60

10 7.5

90

15 11 125

20 15 175

25 18.5 225

30 22 250

5 3.7

20

7.5 5.5

30

10 7.5

45

15 11 70

20 15 90

25 18.5 110

30 22 125

110

125

125

10

50

80

25

40

40

50

20

25

60

70

154

-

-

-

-

-

373 471 593 749 945 1193 1503 1775 2130 2490 2847 3543

617 982 1566 2480 3859 6152 7734 9767

436

307

-

-

245

174

-

-

-

-

391

277

-

-

620

438

965 1538 1933 2442 3076 3883 4899 6184 7791 9198

682 1087 1367 1726 2174 2745 3463 4372 5508 6502 7806 9124

308 479 764 961 1213 1529 1930 2434 3073 3872 4571 5488 6415 7334 9125

216 337 537 675 852 1073 1355 1709 2158 2719 3210 3853 4504 5149 6407

-

251 400 503 636 801 1011 1275 1610 2028 2394 2874 3360 3842 4780

-

332 417 527 664 838 1057 1334 1681 1985 2383 2785 3184 3962

694 1107 1753 2728 4349 5467 6904 8698

488

343

-

778 1233 1918 3057 3844 4854 6115 7719 9738

546 865 1347 2147 2699 3408 4293 5419 6837 8631

408 646 1005 1601 2013 2543 3203 4043 5101 6439 8113 9578

-

535

479

833 1328 1669 2108 2655 3351 4228 5338 6725 7939 9531

745 1187 1492 1884 2374 2997 3781 4773 6013 7099 8522 9961

40 30 150 100 546 870 1093 1381 1740 2196 2770 3497 4406 5202 6244 7299 8345 lengths only meet the us National electrical code ampacity requirements for individual conductors rated 60° c in free air or water, Not in magnetic enclosures, conduit or direct buried. refer to Nec table 310.15(B)(17) for more information.

-

-

-

-

CABLE SELECTION


VOLTS /

HZ

MOTOR

HP KW STD

FUSE

Dual

Element 14 12 10

THREE PHASE

8 6 4

AWG

3 2 1 0

MCM

75° C

00 000 0000 250 300 350 400 500

230 V

60 hz

460 V

60 hz or

380 V

50 hz

5 3.7

45

7.5 5.5

60

10 7.5

90

15 11 125

20 15 175

25 18.5 225

30 22 250

5 3.7

20

7.5 5.5

30

10 7.5

45

15 11 70

20 15 90

110

125

125

10

50

80

25

40

40

50

20

25

-

-

-

-

-

-

245

-

-

-

-

-

391 620 965 1538 1933 2442 3076 3883 4899 6184 7791 9198

277 438 682 1087 1367 1726 2174 2745 3463 4372 5508 6502 7806 9124

-

-

-

-

308 479 764 961 1213 1529 1930 2434 3073 3872 4571 5488 6415 7334 9125

-

-

-

337 537 675 852 1073 1355 1709 2158 2719 3210 3853 4504 5149 6407

-

-

-

400

-

503 636

617 982 1566 2480 3859 6152 7734 9767

801 1011 1275 1610 2028 2394 2874 3360 3842 4780

417 527 664 838 1057 1334 1681 1985 2383 2785 3184 3962

471 593 749 945 1193 1503 1775 2130 2490 2847 3543

-

-

436 694 1107 1753 2728 4349 5467 6904 8698

488 778 1233 1918 3057 3844 4854 6115 7719 9738

-

546 865 1347 2147 2699 3408 4293 5419 6837 8631

646 1005 1601 2013 2543 3203 4043 5101 6439 8113 9578

535 833 1328 1669 2108 2655 3351 4228 5338 6725 7939 9531 25 18.5 110

30 22 125

60

70

40 30 150 100 870 1093 1381 1740 2196 2770 3497 4406 5202 6244 7299 8345 lengths only meet the us National electrical code ampacity requirements for individual conductors rated 75° c in free air or water, Not in magnetic enclosures, conduit or direct buried. refer to Nec table 310.15(B)(17) for more information.

-

-

-

-

-

-

-

745 1187 1492 1884 2374 2997 3781 4773 6013 7099 8522 9961

29


®



CABLE SELECTION


MOTOR

VOLTS HP KW STD

FUSE

Dual

Element 14 12 10

THREE PHASE

8 6 4

AWG

3 2 1 0

MCM

60° C

00 000 0000 250 300 350 400 500

5 3.7

45 25 391 620 965 1538 1933 2442 3076 3883 4899 6184 7791 9198

230 V

60 hz

460 V

60 hz or

380 V

50 hz

7.5 5.5

60

10 7.5

90

15 11 125

20 15 175

25 18.5 225

30 22 250

5 3.7

20

7.5 5.5

30

10 7.5

45

15 11 70

20 15 90

25 18.5 110

30 22 125

40 30 150

125

125

10

20

40

50

80

110

25

40

50

60

70

100

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

277

-

-

-

-

-

-

-

-

-

-

593 749 945 1193 1503 1775 2130 2490 2847 3543

617 982 1566 2480 3859 6152 7734 9767

-

-

-

-

436 694 1107 1753 2728 4349 5467 6904 8698

778 1233 1918 3057 3844 4854 6115 7719 9738

546 865 1347 2147 2699 3408 4293 5419 6837 8631

-

-

-

438

-

682 1087 1367 1726 2174 2745 3463 4372 5508 6502 7806 9124

479 764 961 1213 1529 1930 2434 3073 3872 4571 5488 6415 7334 9125

-

537 675 852 1073 1355 1709 2158 2719 3210 3853 4504 5149 6407

-

-

503

-

636 801 1011 1275 1610 2028 2394 2874 3360 3842 4780

527 664 838 1057 1334 1681 1985 2383 2785 3184 3962

646 1005 1601 2013 2543 3203 4043 5101 6439 8113 9578

833 1328 1669 2108 2655 3351 4228 5338 6725 7939 9531

745 1187 1492 1884 2374 2997 3781 4773 6013 7099 8522 9961

1093 1381 1740 2196 2770 3497 4406 5202 6244 7299 8345 lengths meet the us National electrical code ampacity requirements for either individual conductors or jacketed rated 60° c cable and can be in conduit or direct buried. Flat molded and web/ ribbon cable are considered jacketed cable. refer to Nec table 310.15(B)(16) for more information.

* = motors are 8” diameter

CABLE SELECTION


MOTOR

VOLTS HP KW STD

FUSE

Dual

Element 14 12 10 8 6 4

AWG MCM

75° C

3 2 1 0 00 000 0000 250 300 350 400 500

THREE PHASE

230 V

60 hz

460 V

60 hz or

380 V

50 h

5 3.7

45

7.5 5.5

60

10 7.5

90

15 11 125

20 15 175

25 18.5 225

30 22 250

5 3.7

20

7.5 5.5

30

10 7.5

45

15 11 70

20 15 90

25 18.5 110

30 22 125

40 30 150

110

125

125

10

50

80

25

40

40

50

20

25

60

70

100

-

-

-

-

-

-

-

-

-

436 694 1107 1753 2728 4349 5467 6904 8698

488 778 1233 1918 3057 3844 4854 6115 7719 9738

-

-

-

245

-

-

-

-

-

-

-

-

391

-

546 865 1347 2147 2699 3408 4293 5419 6837 8631

646 1005 1601 2013 2543 3203 4043 5101 6439 8113 9578

535 833 1328 1669 2108 2655 3351 4228 5338 6725 7939 9531

-

-

620

-

965 1538 1933 2442 3076 3883 4899 6184 7791 9198

277 438 682 1087 1367 1726 2174 2745 3463 4372 5508 6502 7806 9124

-

-

-

-

308 479 764 961 1213 1529 1930 2434 3073 3872 4571 5488 6415 7334 9125

-

-

-

337 537 675 852 1073 1355 1709 2158 2719 3210 3853 4504 5149 6407

-

-

-

745 1187 1492 1884 2374 2997 3781 4773 6013 7099 8522 9961

-

400

-

503 636

617 982 1566 2480 3859 6152 7734 9767

801 1011 1275 1610 2028 2394 2874 3360 3842 4780

417 527 664 838 1057 1334 1681 1985 2383 2785 3184 3962

471 593 749 945 1193 1503 1775 2130 2490 2847 3543

870 1093 1381 1740 2196 2770 3497 4406 5202 6244 7299 8345 lengths meet the us National electrical code ampacity requirements for either individual conductors or jacketed rated 75° c cable and can be in conduit or direct buried. Flat molded and web/ ribbon cable are considered jacketed cable. refer to Nec table 310.15(B)(16) for more information.

30


®


6.7 Overload Protection

208 VAc

NeMA siZe

1

2

4

3

230-240 VAc

MAX hP oF coNtActor

7.5

10

25

40 discoNNect A

30

60

100

200

MAX totAl A oF PPX PANel

13.5

27

50

70

100

135 o/l curreNt rANge

6.5 – 13.5

13 – 27

25 – 50

35 – 70

65 – 135

65 – 135 cAtAlog

NuMBer

PPX-1A-13-30r

PPX-1A-27-30r

PPX-2A-50-60r

PPX-3A-70-100r

PPX-3A-135-100r

PPX-4A-135-200r diMeNsioNs h x W x d

34 x 21 x 7

34 x 21 x 7

34 x 21 x 7

47.5 x 25 x 9

47.5 x 25 x 9

47.5 x 25 x 9

Weight

(lBs.)

85

85

90

195

195

195

Note: For hPs with multiple part numbers, use motor amperage to select a panel.

NeMA siZe

2

1

3

460-480 VAc

MAX hP oF coNtActor

7.5

15

30 discoNNect A

30

60

100


13.5

27

50

70


6.5 – 13.5

13 – 27

25 – 50

35 – 70

65 – 135 cAtAlog

NuMBer

PPX-1B-13-30r

PPX-1B-27-30r

PPX-2B-50-60r

PPX-3B-70-100r

PPX-3B-135-100r diMeNsioNs h x W x d

34 x 21 x 7

34 x 21 x 7

34 x 21 x 7

47.5 x 25 x 9

47.5 x 25 x 9

Weight

(lBs.)

85

85

90

195

195


NeMA siZe

1

2

5

4

3

MAX hP oF coNtActor

10

25

50

100

200 discoNNect A

30

60

100

200

400


13.5

27

50

70

100

135


6.5 – 13.5

13 – 27

25 – 50

35 – 70

65 – 135

65 – 135 cAtAlog

NuMBer

PPX-1c-13-30r

PPX-1c-27-30r

PPX-2c-50-60r

PPX-3c-70-100r

PPX-3c-135-200r

PPX-4c-135-200r diMeNsioNs h x W x d

34 x 21 x 7

34 x 21 x 7

34 x 21 x 7

47.5 x 25 x 9

47.5 x 25 x 9

47.5 x 25 x 9

Weight

(lBs.)

85

85

90

195

195

195

130 – 270 PPX-5c-270-400r 52 x 22 x 10 285


575-600 VAc

NeMA siZe

2

1

5

4

3

MAX hP oF coNtActor

10

25

50

100

200 discoNNect A

30

60

100

200

400


13.5

27

50

70

100

135


6.5 – 13.5

13 – 27

25 – 50

35 – 70

65 – 135

65 – 135

130 – 270 cAtAlog

NuMBer

PPX-1d-13-30r

PPX-1d-27-30r

PPX-2d-50-60r

PPX-3d-70-100r

PPX-3d-135-100r

PPX-4d-135-200r

PPX-5d-270-400r diMeNsioNs h x W x d

34 x 21 x 7

34 x 21 x 7

34 x 21 x 7

47.5 x 25 x 9

47.5 x 25 x 9

47.5 x 25 x 9

52 x 22 x 10

Weight

(lBs.)

85

85

90

195

195

195

285


31


®



Submersible motors must have Class 10 overload protection that will disconnect the power within 10 seconds in the case of a locked rotor. To accomplish this, fixed-heater overloads are used. Refer to Section 10 for appropriate heaters.

The chart is based upon total line amps. Divide the motor amps by 1.732 when using a 6-lead motor with a Y-Delta

Starter. Notice: General Electric overload heaters are only usable with general electric overload relays. Do not adjust relays to exceed nameplate amps.


Pentek 6” motors are designed for minimum water flow of 0.5 ft. /sec. past the motor. Maximum water temperature is

95° F (35° C).

6” MOTORS: MINIMUM COOLING WATER FLOW

I.D of casing

6

7

8

10

12

14

16

Flow (GPM) required

9

25

40

85

140

200

280

If the flow is less than specified, a flow-inducer sleeve can be installed. This will act like a smaller casing size, and force flow around the motor to aid cooling. Always use a flow-inducer sleeve when the pump is in open water.

6.9 Head Loss In Casing

Use the chart below to account for the head loss around the pump.

Head loss in feet for flow past motor

6” Motors cAsiNg iNside diAMeter

7” gPM

300

400

500

600

100

150

200

250

6”

1.7

3.7

6.3

9.6

13.6

23.7

0.5

0.8

1.2

2.0

3.1

4.4

8”

0.2

0.4

0.7

1.0


To extend the life of the pump motor and control, limit the number of starts to 100 per 24 hours. If higher starting frequencies are necessary, consult your factory. To prevent overheating, run motor for a minimum of two minutes. For starting frequency, refer to section 5.10.

32


®


6.11 Troubleshooting

Problem

Motor does not start, but does not blow fuses or trip circuit breaker

Motor starts, but fuses blow or circuit breakers trip

Motor starts and runs, then blows fuse or trips circuit breaker

Possible Causes

Defective fuses or circuit breakers

Loose or corroded terminals

Damaged or defective connections

No incoming power

Solution

Replace fuses or circuit breakers.

Clean and tighten connections and motor lead terminals.

Repair or replace connections.

Contact power company.

Wrong voltage

Incorrect fuses or relay

Incorrect connections

Locked rotor or pump

Insufficient insulation on motor cables

Incoming voltage more than 10% high or low sand in well

Make sure that nameplate rated voltage matches nominal power supply, and that actual supply voltage is within ±10% of nameplate voltage.

Install correct fuses or relay.

Re-connect motor wires correctly.

Make sure that motor is at least 10ft above bottom of well, check well for sand.

Install new motor cables; recheck resistance with Megohmeter.

Confirm high or low voltage in motor cable, consult power company.

Pull the pump and clean the well.

Motor does not start, but fuse blows or circuit breaker trips

Locked rotor or pump Check for sand in well.

Make sure that motor is at least 10ft above the bottom of the well.

Pull pump and check for mechanical obstruction in the pump and for free rotation of the motor.

33

SECTION 7: Hitachi

®

6” and Larger Submersible Motors


The following conditions are stated to provide the owner with a list of criteria for maximum motor life and to assure motor warranty.

1. Maximum water temperature:

• A) 35°C (95°F): 6” (5~40HP) motors.

• B) 25°C (77°F): 6” (50,60HP), 8’’, 10”, 12’’ and 14” motors

2. PH content of the water between: 6.5 -8

3. Maximum chlorine content: 500 PPM

• Maximum Sulfuric acid iron content: 15 PPM

• Maximum Fluorine content: 0.8 PPM

• Maximum Electric conductivity: 118 μMHO/INCH

4. Maximum sand content: 50 PPM

5. Proper approved three phase overload protection.

See Table 13.

6. Proper fusing for motor circuit protection.

See Table C.

7. Proper line voltage during running conditions:

60Hz: 460V, 230V ±10%

50Hz: 380V ±10% at motor lead terminal. (Voltage drop of cable should be considered by user.)

Combination of voltage and frequency variation:

±10% (sum of absolute values of voltage and

frequency)

Current unbalance between legs should not exceed

5% of the average.

8. Proper sizing of motor (current, thrust, voltage, etc.) and a 10 feet clearance from the bottom of the well are required.

9. In the case of horizontal installation, the motor is to be rigidly aligned with the pump and firmly mounted to prevent any load on the shaft and bearings and to avoid any damaging vibrations to the motor.

10. The motor must always be immersed in water so that a flow velocity of cooling water at a rate of 0.5 feet per second flows past any and all parts of the motor.

The motor will not operate in mud or sand.

11. The power cables shall be sized large enough so that at rated current there will be less than a 5% voltage drop. See Table C. Cables must be waterproof submersible type.

12. For 3ø motor a balanced and properly sized transformer bank shall be provided. Improper electrical supply (for example, phase converter.

V-connection transformer, etc.) or connections will void the warranty

13. Single-phase protection is recommended for protection of the installation. Any failure due to single phasing of the incoming voltage causing the motor to fail will void the warranty.

Hitachi

®


14. Surge suppressors are recommended in the interest of protecting the control panel, as well a.s the insulation system of the motor. Any motor failure due to lightning or other Acts of God will void the warranty.

15. Provide waterproof insulation splices between all lead wires and well cables.

16. In the event that a reduced voltage starter is used to start the motor, the following should be verified:

• Correct quick trip, class 10 or better, ambient compensated overloads are incorporated.

• Proper short circuit protection is utilized.

• The torque required by the motor and pump package is attainable by this type starter.

• The lead arrangement of the motor is acceptable with the proposed starter load connections.

• Verify that if any time delay relays are used in switching contactors in and out, that the time settings do not exceed 2 seconds; this could damage the motor.

• lf a manual auto transformer starter is used, voltage should be minimum 60% of rated voltage, and switched to “Run”condition within 2 seconds. Double check Table B and C for correct protection.

17. Single-Phase Motors (5-15HP)

Proper connections and correct capacitors and relays are necessary for single-phase motor starting and running. Connection diagram: Sec Fig. 1.

Performance and recommendable capacitors: See

Table D.

7.2 Testing

1. Do not use lead wires to pull, lift or handle the motor.

The lead wires should be protected during storage, handling, moving and installation of the motor. 2)

2. Inspect the motor to determine that it is the correct

HP, voltage and size for the job and that there is no shipping damage.

3. The factory-installed water in the motor is supplied with anti-freeze capable of temperatures to

0°C(-22°F). Do not install, transport or store below these temperatures. If storage is necessary below these temperatures, drain the water from the motor.

4. After long periods of idleness and on all new installations, check the electrical resistance and megger the motor with lead wires connected: see table A. Prior to installation, the motor should have an insulation value of at least 50 megohms. After installation, motor and power cable should have a minimum insulation value of 1 megohm. If minimum values are not obtained, contact factory.

34


®


7.2 Testing

5. Verify motor is filled with clean water before installing. The warranty is void if this is not done.

Also check the tightness of all water filling and drain plugs, mounting bolts and cable connections.

6. Do not hammer the shaft, coupling or slinger since this may damage the thrust bearing. Check the rotation of the motor by hand to insure that it turns freely.

7. Do not drop the bottom end of the motor in the dirt or mud since this may plug up the diaphragm opening.

8. If motor is to be installed horizontal, make sure that the lead wires are at the 12 o’clock position when facing the motor shaft (in horizontal position).

NOTE:

There are no bearings that need oil or grease. The motor, being inaccessible, should be monitored through its electrical connections.

• A) Measure and record operating current and voltage.

• B) Measure and record the motor insulation resistance. Any resistance of less than 50 megohm

(5,000,000) for a new motor should be evaluated or checked further by a qualified service shop.

• Lightning arrestors and/or surge capacitors will help prevent damage to the control box, cables, and motor.

• Single-phase protection will help in preventing motor failure due to adverse incoming primary power.

• Based on the values obtained in A and B above and the output flow rates and pressures of the pump, a complete picture of total performance can be obtained. This can be used to determine any pump and motor maintenance and overhauling which might be required.

• If the motor is to be stored, protect the unit from freezing by storing in an area with a temperature higher than -30°C (-22° F).

7.3 Storage and Drain Fill Instructions

1. After energizing the motor, check the flow and pressure of the pump to make sure that the motor is rotating in the correct direction. To correct a wrong rotation, switch any two of the three cable connections. (Three-phase motor only)

2. When starting the pump for the first time, inspect the water for sand. If sand appears, then continue to pump till the water clears up; otherwise, sand will accumulate in the pump stages and will bind or freeze the moving parts if water is allowed to flow back down the well.

3. During testing or checking rotation (such as

“humping” or “inching”) the number of “starts” should be limited to 3, followed by a full 15 minute cooling-off period before any additional “starts’’ are attempted. Depending on the depth of the well and/or method of checking, these rotational checks or ‘’starts’’ may actually be full-fledged starts. If this is the case, then a full cooling-off period of 15 minutes is required between this type of start.

4. For automatic (pilot device) operation, the motor should be allowed to cool for 15 minutes between starts.

5. Input voltage, current and insulation resistance values should be recorded throughout the life of the installation and should be used as a from of preventive maintenance.

Hitachi 6” and Larger Motors

Hitachi

®


35


®



TABLE A. RESISTANCE DATA

Single Phase 2 Pole 230V/60Hz

Motor Size and Type HP

6”, C

“

“

“

5

7.5

10

15

R – Y

2.172

1.401

1.052

0.678

Resistance (Ω)

B – Y

0.512

0.400

0.316

0.230

R – B

2.627

1.774

1.310

0.850

Three Phase 2 Pole


“

“

“

“

“

“

8”,W

“

“

“

“

“

“

10”, W

“

“

12”, W

6”, C

“

“

“

“

“

“

“

“

“

“

25

30

30

40

50

60

40

50

60

75

100

125

150

175

200

250

300

7.5

7.5

5

5

10

10

15

15

20

20

25

460

230

460

460

“

“

“

“

“

“

“

“

“

“

“

“

“

Volt

230

460

230

460

230

460

230

460

230

460

230

0.666

0.166

0.554

0.446

0.388

0.388

0.372

0.331

0.278

0.218

0.164

Resistance (Ω)

.806

3.050

0.651

2.430

0.448

1.619

0.312

1.074

0.258

0.861

0.210

0.132

0.115

0.121

0.0929

0.0776

0.0386

Three Phase 4 Pole


8”, W

“

“

“

“

“

“

“

“

“

“

7.5

7.5

10

10

15

15

20

20

25

25

30

“

10”, W

“

“

“

“

12“, W

“

“

14“, W

30

40

50

60

75

100

125

150

175

200

250

“ 300 “

Values are for normal temp. 68° (20°) with motor lead wires.

LEAD WIRE COLOR

R: Red

Y: Yellow

B: Black

G: Green (6” only)

MOTOR TYPE

C: CANNED

W: WATER TYPE

460

230

460

460

“

“

“

“

“

“

“

Volt

230

460

230

460

230

460

230

460

230

460

230

0.171

0.138

0.119

0.0826

0.0552

0.0517

0.888

0.408

0.408

0.288

0.257

0.171

Resistance (Ω)

.564

2.178

0.564

2.178

0.399

1.519

0.399

1.519

0.242

0.888

0.242

Hitachi

®


36


®



Motor Dimensions

Materials of Construction

PARTS MATERIALS

Motor Sleeve

Castings

Fasteners

Stainless steel construction

Baked epoxy-coated gray iron

Stainless steel

Shaft

Flange

Rotor

Thrust Bearings

Mechanical Seal

NEMA splined stainless steel

NEMA standard type

Double epoxy-coated

Kingsbury-type 420 stainless steel

Nitrile rubber (NBR), grease packed

Diaphragm

Sand Cap

Sand Slinger

Nitrile rubber

Polyurethane

Stainless steel

Lead Wire (or Cable) Double-insulated, heat and water-resistant,

167°F/75°C, 600V d l1 l diAMeter hP KW Volts Ph hZ

6 5 3.7

200 3 60

6 5 3.7

230 1 60

6

6

6

6

5 3.7

5 3.7

7.5

5.5

7.5

5.5

230

460

200

230

6

6

6

6

6

6

6

6

7.5

5.5

7.5

5.5

10

10

10

10

15

15

7.5

7.5

7.5

7.5

11

11

230

460

200

230

230

460

200

230

6

6

6

6

6

6

6

6

8

6

8

6

6

6

15

15

20

20

20

30

30

30

15

25 18.5

25 18.5

40

50

60

11

11

15

15

25 18.5

22

22

22

30

37

45

230

460

200

230

460

230

460

200

460

460

460

200

230

460

*Models are 8" motors with 6" pump connection.

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

1

3

3

3

1

3

3

3

1 cAtAlog

NuMBer

6hit2-5-8

6hit2-5-1

60

60

60

60

6hit2-5-2

6hit2-5-4

6hit2-7-8

6hit2-7-1

60

60

60

60

60

60

60

60

6hit2-7-2

6hit2-7-4

6hit2-10-8

6hit2-10-1

6hit2-10-2

6hit2-10-4

6hit2-15-8

6hit2-15-1

60

60

60

60

60

60

60

60

6hit2-15-2

6hit2-15-4

6hit2-20-8

6hit2-20-2

6hit2-20-4

6hit2-25-8

6hit2-25-2

6hit2-25-4

60

60

60

6hit2-30-8

6hit2-30-2

6hit2-30-4

60 6hit2-40-4

60 86hit2-50-4*

60 86hit2-60-4* serVice

FActor

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

1.15

WiNgiNg resistANce

(ohMs) r-y, B-y, r-B, 2.172,

0.512, 2.627

0.806

3.05

r-y, B-y, r-B, 1.401,

0.400, 1.774

0.651

2.43

r-y, B-y, r-B, 1.052,

0.316, 1.310

0.448

1.619

r-y, B-y, r-B, 0.678,

0.230, 0.850

0.312

1.074

0.258

0.861

0.21

0.666

0.166

0.554

0.358

0.331

0.278

serVice

FActor iNPut AMPs

19.5

27.5

33

16.5

53.5

85

46

23

69.5

60

30

87.5

76

38

61

73

90

104

94

47

26

13

37.2

58

17

8.5

28.5

41

29

14.5

47.4

72

42

21

61.2

54

27

77.3

68

34

56

65

80

91.8

82

41

22

11

33.3

50

15

7.5

25.4

36 rAted iNPut

AMPs

17.5

24

Hitachi Control Boxes

T ype 1 NEMA Enclosure

In-Panel Circuit Breaker

Magnetic Contactor

Terminal Blocks for External Controls

UL Recognized hP

5

7.5

10

15

KW

3.7

5.5

7.5

11 leNgth

(l2)

22.95"

26.97"

22.95"

22.95"

24.80"

29.92"

24.80"

24.80"

26.97"

29.92"

26.97"

26.97"

29.92"

33.46"

29.92"

29.92"

31.5"

31.5"

31.5"

36.22"

36.22"

36.22"

38.19"

39.19"

38.19"

40.55"

45.28"

48.03" shAFt eXteNsioN

(l1)

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87"

2.87" thrust cAPAcity Weight

3,500 95

3,500 110

3,500

3,500

3,500

3,500

3,500

3,500

3,500

3,500

3,500

3,500

3,500

3,500

3,500

3,500

3,500

5,000

5,000

5,000

3,500

3,500

3,500

3,500

3,500

3,500

3,500

3,500

110

110

128

148

137

137

161

161

161

128

128

137

187

353

408

176

176

176

99

99

110

128

95

95

99

128 diAMeter

(d)

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

7.52"

7.52"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

5.5"

Ph

1

1

1

1

Volts

230

230

230

230 cAtAlog NuMBer hit-5cBd hit-7.5cBd

hit-10cBd hit-15cBd

Hitachi

®


37



®



l1

Materials of Construction

PARTS MATERIALS

Housing Baked epoxy-coated gray iron

Fasteners

Shaft

Rotor

Thrust Bearings

Mechanical Seal

Diaphragm

Sand Slinger

Lead Wire (or Cable)

Stainless steel

Splined or keyed stainless steel

Double epoxy-coated

Kingsbury-type 420 stainless steel

Nitrile rubber (NBR), grease packed

Nitrile rubber

Baked epoxy-coated gray iron

Double-insulated, heat and water-resistant,

167°F/75°C, 600V l d

Motor diAMeter

10

12

10

10

10

10

10

10

10

14

14

12

12

8

8

8

8

8

8

8

8

8

8

8

8*

8*

8

8 hP

125

200

250

150

60

75

40

50

100

200

300

250

300

75

100

125

150

40

50

25

30

60

15

20

50

60

7.5

10

KW Volts Ph

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

90

150

185

110

45

55

30

37

75

150

225

185

225

55

75

90

110

18.5

22

30

37

45

11

15

37

45

5.5

7.5

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460

460 hZ rPM

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

1800

3600

3600

1800

1800

1800

1800

1800

1800

1800

3600

1800

1800

3600

3600

3600

3600

1800

1800

3600

3600

3600

3600

3600

1800

1800

1800

1800 leNgth

(l) shAFt eXteNsioN

(l1) diAMeter

(d)

8.52

8.52

8.52

10.53

8.52

8.52

8.52

8.52

8.52

10.53

10.53

12.6

12.6

7.52

7.52

7.52

7.52

7.52

7.52

7.52

7.52

7.52

5.5

5.5

7.52

7.52

7.52

7.52

5

5

5

5

4

4

5

4

4

5

5

5

5

4

4

4

4

4

4

4

4

4

2.875

2.875

4

4

4

4

49.21

49.21

59.84

59.84

69.68

69.68

69.68

79.53

56.3

68.11

78.75

68.31

76.18

44.09

44.09

44.09

46.44

49.19

53.15

53.8

66.14

70.08

45.28

48.03

32.4

32.4

41.34

41.34

cAtAlog

NuMBer

10hit4-40-4

10hit4-50-4

10hit4-60-4

10hit4-75-4

10hit4-100-4

10hit4-125-4

10hit2-200-4

10hit2-250-4

12hit4-150-4

12hit4-200-4

12hit2-300-4

14hit4-250-4

14hit4-300-4

86hit2-50-4

86hit2-60-4

8hit4-7-4

8hit4-10-4

8hit4-15-4

8hit4-20-4

8hit4-25-4

8hit4-30-4

8hit2-40-4

8hit2-50-4

8hit2-60-4

8hit2-75-4

8hit2-100-4

8hit2-125-4

8hit2-150-4

*Motor is 8" diameter, but constructed to operate with a 6" liquid end.

** 8" motors with 6" flange when using stainless steel bolts have a thrust rating of 5,000 lbs. A thrust value of 10,000 lbs. can be obtained using grade-8 heat-treated stainless steel bolts.

thrust cAPAcity

10,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000 **5,000

10,000 **5,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000

10,000

Weight

794

816

948

959

507

507

639

639

794

1235

1455

1698

1940

463

518

595

661

342

342

320

353

408

157

182

298

298

320

320

Hitachi

®


38


®


7.5 Motor Dimensions

Spline Data

15 Teeth

16/32 Pitch

ANSI B92.1 Compliant

Min. 0.95 (24.13) Full Spline

1.000 (25.4)

0.999 (25.375)

(4) 1/2 - 20

UNF-2B Threaded

Studs on 4.375 (111.1) Dia.

Bolt Circle

5.51

(139.95)

3.000 (76.2)

2.997 (76.12)

1.811 (45.99)

0.987 (25.987)

0.982 (24.943)

2.875 (73.03)

2.860 (72.64)

Shaft free end-play

0.016-0.154 (4.06 - 3.91)

All dimensions in inches (mm) Length


Hitachi

®


39

SECTION 7: Cable Selection Guide

Hitachi

®

6”– 8” Submersible Motors


CABLE SELECTION


VOLTS /

HZ

MOTOR

HP KW STD

FUSE

Dual

Element 14 12 10

THREE PHASE

8 6

5 4 45 25

4

AWG

3 2 1 0

MCM

60˚

00 000 0000 250 300 350 400 500

149 237 378 598 931 1484 1865 2356 2967 3746 4726 5966 7516 8873

230 V

60 hz

460 V

60 hz

8 6 60

10 8 80

15 11 125

20 15 150

25 19 200

30 22 225

40* 30 300

5 4 20

8 6 30

10 8 40

15 11 60

20 15 80

25 19 100

30 22 110

40 30 150

40* 30 150

50 37

50* 37

60 45

60* 45

75 55

100 75

125 93

175

175

225

225

250

350

450

150 111 500

35

45

70

90

100

125

175

10

15

20

30

45

50

60

80

80

100

100

125

125

150

200

250

275 to Nec table 310.15(B)(17) for more information.


-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

247

-

-

-

-

-

-

-

-

-

-

-

-

-

-

391

-

-

609

-

-

-

-

-

970 1220 1540 1940 2449 3090 3901 4914 5802 6965 8142 9308

308 479 764 961 1213 1529 1930 2434 3073 3872 4571 5488 6415 7334 9125

221 344 548 689 871 1097 1384 1746 2205 2778 3279 3937 4602 5261 6546

-

264 420 528 667 841 1061 1339 1690 2130 2514 3018 3528 4034 5019

-

332 417 527 664 838 1057 1334 1681 1985 2383 2785 3184 3962

-

-

-

-

-

-

337

-

-

-

426

595 947 1511 2393 3723 5935 7461 9422

675 852 1073 1355 1709 2158 2719 3210 3853 4504 5149 6407

705 890 1121 1415 1785 2254 2839 3352 4024 4704 5378 6691

735 926 1168 1474 1861 2344 2768 3323 3884 4441 5525

-

-

-

537

-

-

677

-

855 1079 1359 1605 1926 2252 2575 3203

328 413 522 659 831 1047 1236 1484 1735 1984 2468

389 619 988 1564 2434 3880 4878 6161 7761 9797

307 488 778 1233 1918 3057 3844 4854 6115 7719 9738

-

350 558 884 1376 2193 2757 3482 4387 5537 6986 8819

-

428 678 1055 1682 2114 2670 3363 4245 5356 6761 8518

535 833 1328 1669 2108 2655 3351 4228 5338 6725 7939 9531

433 673 1073 1349 1704 2147 2710 3419 4316 5437 6419 7706 9008

-

-

-

-

-

-

-

-

519 827 1040 1313 1654 2088 2634 3325 4189 4946 5937 6940 7935 9873

502 801 1007 1271 1601 2022 2550 3220 4056 4789 5749 6720 7683 9559

-

-

639 803 1014 1277 1612 2034 2568 3235 3819 4585 5359 6127 7623

691 869 1097 1382 1745 2201 2779 3501 4133 4961 5799 6631 8250

878 1108 1399 1762 2081 2498 2920 3338 4153

893 1127 1420 1676 2012 2352 2689 3346

1162 1371 1646 1924 2200 2737 lengths only meet the us National electrical code ampacity requirements for individual conductors rated 60° c in free air or water, Not in magnetic enclosures, conduit or direct buried. refer

Hitachi

®


40


Hitachi

®



CABLE SELECTION


VOLTS /

HZ

MOTOR

HP KW STD

FUSE

Dual

Element 14 12 10

THREE PHASE

8 6

5 4 45 25

4

AWG

3 2 1 0

MCM

75° C

00 000 0000 250 300 350 400 500

149 237 378 598 931 1484 1865 2356 2967 3746 4726 5966 7516 8873

230 V

60 hz

460 V

60 hz

8 6 60

10 8 80

15 11 125

20 15 150

25 19 200

30 22 225

40* 30 300

5 4 20

8 6 30

10 8 40

15 11 60

20 15 80

25 19 100

30 22 110

40 30 150

40* 30 150

50 37

50* 37

60 45

60* 45

75 55

100 75

125 93

175

175

225

225

250

350

450

150 111 500

35

45

70

90

100

125

175

10

15

20

30

45

50

60

80

80

100

100

125

125

150

200

250

275 to Nec table 310.15(B)(17) for more information.


-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

155 247 391 609 970 1220 1540 1940 2449 3090 3901 4914 5802 6965 8142 9308

220

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

195 308 479 764 961 1213 1529 1930 2434 3073 3872 4571 5488 6415 7334 9125

350

-

-

-

-

-

595 947 1511 2393 3723 5935 7461 9422

389 619 988 1564 2434 3880 4878 6161 7761 9797

307 488 778 1233 1918 3057 3844 4854 6115 7719 9738

558

428

-

-

-

-

-

-

-

-

-

221

-

-

-

-

-

-

-

-

344

-

-

639 803 1014 1277 1612 2034 2568 3235 3819 4585 5359 6127 7623

433 691 869 1097 1382 1745 2201 2779 3501 4133 4961 5799 6631 8250

-

-

-

-

548

264 420 528 667 841 1061 1339 1690 2130 2514 3018 3528 4034 5019

208 332 417 527 664 838 1057 1334 1681 1985 2383 2785 3184 3962

268

-

-

-

-

-

689

337

537 675 852 1073 1355 1709 2158 2719 3210 3853 4504 5149 6407

561 705 890 1121 1415 1785 2254 2839 3352 4024 4704 5378 6691

582

-

-

-

871 1097 1384 1746 2205 2778 3279 3937 4602 5261 6546

426

735

-

-

537

-

677

926 1168 1474 1861 2344 2768 3323 3884 4441 5525

696 878 1108 1399 1762 2081 2498 2920 3338 4153

708 893 1127 1420 1676 2012 2352 2689 3346

-

855 1079 1359 1605 1926 2252 2575 3203

328 413 522 659 831 1047 1236 1484 1735 1984 2468

884 1376 2193 2757 3482 4387 5537 6986 8819

678 1055 1682 2114 2670 3363 4245 5356 6761 8518

338 535 833 1328 1669 2108 2655 3351 4228 5338 6725 7939 9531

-

433 673 1073 1349 1704 2147 2710 3419 4316 5437 6419 7706 9008

519 827 1040 1313 1654 2088 2634 3325 4189 4946 5937 6940 7935 9873

502 801 1007 1271 1601 2022 2550 3220 4056 4789 5749 6720 7683 9559

922 1162 1371 1646 1924 2200 2737 lengths only meet the us National electrical code ampacity requirements for individual conductors rated 75° c in free air or water, Not in magnetic enclosures, conduit or direct buried. refer


Hitachi

®


41


Hitachi

®



CABLE SELECTION


MOTOR

VOLTS HP KW STD

FUSE

Dual

Element 14 12 10

THREE PHASE

8 6

5 4 45 25 -

4

AWG

3 2 1 0

MCM

60° C

00 000 0000 250 300 350 400 500

378 598 931 1484 1865 2356 2967 3746 4726 5966 7516 8873

230 V

60 hz

460 V

60 hz

8 6 60

10 8 80

15 11 125

20 15 150

25 19 200

30 22 225

40* 30 300

5 4 20

8 6 30

10 8 40

15 11 60

20 15 80

25

30

40

50

60

75

19

22

30

40* 30

37

50* 37

45

60* 45

55

100 75

125 93

100

110

150

150

175

175

225

225

250

350

450

150 111 500

35

45

70

90

100

125

175

10

15

20

30

45

50

60

80

80

100

100

125

125

150

200

250

275

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

391

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

609

479

-

-

-

-

-

-

-

-

-

-

-

-

-

970 1220 1540 1940 2449 3090 3901 4914 5802 6965 8142 9308

764

548 689 871 1097 1384 1746 2205 2778 3279 3937 4602 5261 6546

-

-

-

-

-

-

-

-

-

-

-

961 1213 1529 1930 2434 3073 3872 4571 5488 6415 7334 9125

528 667 841 1061 1339 1690 2130 2514 3018 3528 4034 5019

595 947 1511 2393 3723 5935 7461 9422

-

619 988 1564 2434 3880 4878 6161 7761 9797

778 1233 1918 3057 3844 4854 6115 7719 9738

558 884 1376 2193 2757 3482 4387 5537 6986 8819

-

678 1055 1682 2114 2670 3363 4245 5356 6761 8518

-

833 1328 1669 2108 2655 3351 4228 5338 6725 7939 9531

-

1073 1349 1704 2147 2710 3419 4316 5437 6419 7706 9008

1040 1313 1654 2088 2634 3325 4189 4946 5937 6940 7935 9873

1007 1271 1601 2022 2550 3220 4056 4789 5749 6720 7683 9559

-

-

-

-

-

-

-

-

-

-

web/ribbon cable are considered jacketed cable. refer to Nec table 310.15(B)(16) for more information.


527

-

-

-

-

-

-

-

-

-

664

-

838 1057 1334 1681 1985 2383 2785 3184 3962

677 855 1079 1359 1605 1926 2252 2575 3203

-

-

831 1047 1236 1484 1735 1984 2468

1277 1612 2034 2568 3235 3819 4585 5359 6127 7623

1097 1382 1745 2201 2779 3501 4133 4961 5799 6631 8250

-

-

-

-

1355 1709 2158 2719 3210 3853 4504 5149 6407

1415 1785 2254 2839 3352 4024 4704 5378 6691

-

-

-

1474 1861 2344 2768 3323 3884 4441 5525

-

-

-

-

-

1762 2081 2498 2920 3338 4153

-

-

-

2012 2352 2689 3346

2200 2737 lengths meet the us National electrical code ampacity requirements for either individual conductors or jacketed rated 60° c cable and can be in conduit or direct buried. Flat molded and

Hitachi

®


42


Hitachi

®



CABLE SELECTION


MOTOR

VOLTS HP KW STD

FUSE

Dual

Element 14 12 10

THREE PHASE

8 6

5 4 45 25

4

AWG

3 2 1 0

MCM

75° C

00 000 0000 250 300 350 400 500

237 378 598 931 1484 1865 2356 2967 3746 4726 5966 7516 8873

230 V

60 hz

460 V

60 hz

8 6 60

10 8 80

15 11 125

20 15 150

25 19 200

30 22 225

40* 30 300

5 4 20

8 6 30

10 8 40

15 11 60

20 15 80

25 19 100

30 22 110

40 30 150

40* 30 150

50 37 175

50* 37 175

60 45 225

60* 45 225

75 55 250

100 75 350

125 93 450

150 111 500

150

200

250

275

100

100

125

125 -

-

-

-

-

-

-

-

-

-

-

-

80

80

50

60

30

45

15

20

100

125

175

10

70

90

35

45

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

247

-

-

-

-

-

-

-

-

-

-

-

-

-

-

391

308

-

-

-

-

609

479

-

-

-

970 1220 1540 1940 2449 3090 3901 4914 5802 6965 8142 9308

764

344 548 689 871 1097 1384 1746 2205 2778 3279 3937 4602 5261 6546

420 528 667 841 1061 1339 1690 2130 2514 3018 3528 4034 5019

-

-

-

961 1213 1529 1930 2434 3073 3872 4571 5488 6415 7334 9125

417

-

-

527

-

595 947 1511 2393 3723 5935 7461 9422

664

537 677 855 1079 1359 1605 1926 2252 2575 3203

-

838 1057 1334 1681 1985 2383 2785 3184 3962

659 831 1047 1236 1484 1735 1984 2468

-

-

389 619 988 1564 2434 3880 4878 6161 7761 9797

488 778 1233 1918 3057 3844 4854 6115 7719 9738

-

558 884 1376 2193 2757 3482 4387 5537 6986 8819

678 1055 1682 2114 2670 3363 4245 5356 6761 8518

535 833 1328 1669 2108 2655 3351 4228 5338 6725 7939 9531

-

-

-

-

-

673 1073 1349 1704 2147 2710 3419 4316 5437 6419 7706 9008

827 1040 1313 1654 2088 2634 3325 4189 4946 5937 6940 7935 9873

801 1007 1271 1601 2022 2550 3220 4056 4789 5749 6720 7683 9559

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

803 1014 1277 1612 2034 2568 3235 3819 4585 5359 6127 7623

869 1097 1382 1745 2201 2779 3501 4133 4961 5799 6631 8250

-

-

-

-

-

890 1121 1415 1785 2254 2839 3352 4024 4704 5378 6691 web/ribbon cable are considered jacketed cable. refer to Nec table 310.15(B)(16) for more information.


-

-

-

-

1073 1355 1709 2158 2719 3210 3853 4504 5149 6407

-

-

-

-

1168 1474 1861 2344 2768 3323 3884 4441 5525

-

-

-

-

-

1399 1762 2081 2498 2920 3338 4153

-

1420 1676 2012 2352 2689 3346

1646 1924 2200 2737 lengths meet the us National electrical code ampacity requirements for either individual conductors or jacketed rated 75° c cable and can be in conduit or direct buried. Flat molded and


Hitachi

®


43


®



208 VAc

NeMA siZe

4

3

2

1 7.5

10

25

40 discoNNect A

30

60

100


6.5 – 13.5

13 – 27

25 – 50

35 – 70

65 – 135

65 – 135 cAtAlog

NuMBer

PPX-1A-13-30r

PPX-1A-27-30r

PPX-2A-50-60r

PPX-3A-70-100r

PPX-3A-135-100r

PPX-4A-135-200r diMeNsioNs h x W x d

34 x 21 x 7

34 x 21 x 7

34 x 21 x 7

47.5 x 25 x 9

47.5 x 25 x 9

47.5 x 25 x 9

Weight

(lBs.)

85

85

90

195

195

195


230-240 VAc

MAX hP oF coNtActor


13.5

27

50

70

100

135

NeMA siZe

1

3

2

460-480 VAc

MAX hP oF coNtActor

7.5

15

30 discoNNect A

30

60

100


13.5

27

50

70


6.5 – 13.5

13 – 27

25 – 50

35 – 70

65 – 135 cAtAlog

NuMBer

PPX-1B-13-30r

PPX-1B-27-30r

PPX-2B-50-60r

PPX-3B-70-100r

PPX-3B-135-100r diMeNsioNs h x W x d

34 x 21 x 7

34 x 21 x 7

34 x 21 x 7

47.5 x 25 x 9

47.5 x 25 x 9

Weight

(lBs.)

85

85

90

195

195


NeMA siZe

1

5

4

3

2

MAX hP oF coNtActor

10

25

50

100

200 discoNNect A

30

60

100

200

400


13.5

27

50

70

100

135


6.5 – 13.5

13 – 27

25 – 50

35 – 70

65 – 135

65 – 135

130 – 270 cAtAlog

NuMBer

PPX-1c-13-30r

PPX-1c-27-30r

PPX-2c-50-60r

PPX-3c-70-100r

PPX-3c-135-200r

PPX-4c-135-200r

PPX-5c-270-400r diMeNsioNs h x W x d

34 x 21 x 7

34 x 21 x 7

34 x 21 x 7

47.5 x 25 x 9

47.5 x 25 x 9

47.5 x 25 x 9

52 x 22 x 10

195

195

195

285

Weight

(lBs.)

85

85

90


575-600 VAc

NeMA siZe

5

4

3

2

1

MAX hP oF coNtActor

10

25

50

100

200 discoNNect A

30

60

100

200

400


13.5

27

50

70

100

135


6.5 – 13.5

13 – 27

25 – 50

35 – 70

65 – 135 cAtAlog

NuMBer

PPX-1d-13-30r

PPX-1d-27-30r

PPX-2d-50-60r

PPX-3d-70-100r

PPX-3d-135-100r diMeNsioNs h x W x d

34 x 21 x 7

34 x 21 x 7

34 x 21 x 7

47.5 x 25 x 9

47.5 x 25 x 9

Weight

(lBs.)

85

85

90

195

195

65 – 135

130 – 270

PPX-4d-135-200r

PPX-5d-270-400r

47.5 x 25 x 9

52 x 22 x 10

195

285


Hitachi

®


44


®



Submersible motors must have Class 10 overload protection that will disconnect the power within 10 seconds in the case of a locked rotor. To accomplish this, fixed-heater overloads are used. Refer to Section 10 for appropriate heaters.

The chart is based upon total line amps. Divide the motor amps by 1.732 when using a 6-lead motor with a Y-Delta

Starter. Notice: General Electric

®

overload heaters are only usable with General Electric overload relays. Do not adjust relays to exceed nameplate amps.


Hitachi 6” motors are designed for minimum water flow of 0.5 ft. /sec. past the motor. Maximum water temperature is

95° F (35° C).

6” MOTORS: MINIMUM COOLING WATER FLOW

I.D of casing

6

7

8

10

12

14

16

Flow (GPM) required

9

25

40

85

140

200

280

If the flow is less than specified, a flow-inducer sleeve can be installed. This will act like a smaller casing size, and force flow around the motor to aid cooling. Always use a flow-inducer sleeve when the pump is in open water.

7.9 Head Loss In Casing

Use the chart below to account for the head loss around the pump.

Head loss in feet for flow past motor

6” Motors cAsiNg iNside diAMeter

7” gPM

300

400

500

600

100

150

200

250

6”

1.7

3.7

6.3

9.6

13.6

23.7

0.5

0.8

1.2

2.0

3.1

4.4

8”

0.2

0.4

0.7

1.0



To extend the life of the pump motor and control, limit the number of starts to 100 per 24 hours. If higher starting frequencies are necessary, consult your factory. To prevent overheating, run motor for a minimum of two minutes. For starting frequency, refer to section 5.10.

General Electric

®

is a registered trademark of General Electric Company.

45


®



Problem

Motor does not start but does not blow fuses or relay

Possible Causes

No power supply

Fuses or relay blow when motor starts

Defective connections

Incorrect voltage

Incorrect fuses or relay

Defective capacitors

Wrong connections

Motor runs for a while and then blown fuses or relay.

Low voltage or high voltage

Defective capacitors

Different control box for the motor

Defective starting voltage relay

Pump is sand clogged

Overheated protector

Solution

Replace fuses, breakers or check for loose or corroded connections and motor lead terminals

Correct connections

Apply correct voltage. Voltage must be plus or minus 10% of rated

(Nameplate)

Replace with proper fuses and relay

Replace with proper capacitors

Correct wrong connections or short circuit.

Locked rotor conditions

Correct pump or well conditions

Insulation resistance down

Check the line and correct

Apply rated voltage

Replace with proper capacitors

Replace with proper control box

Replace with proper relay

Pull pump and clean well

Shield the control box from heat source

46

SECTION 8: Pentek Intellidrive

™

Variable Frequency Drives

8.1 General Safety


SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation, operation, and maintenance of the Pentek

Intellidrive Variable Frequency Drive (VFD).

This is the safety alert symbol. When you see this symbol on your Pentek Intellidrive or in this manual, look for one of the following signal words and be alert to the potential for personal injury!




NOTICE addresses practices not related to personal injury.

Carefully read and follow all safety instructions in this manual and on the Pentek Intellidrive.

Keep safety labels in good condition. Replace missing or damaged safety labels.

California Proposition 65 Warning

This product and related accessories contain chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Risk of high-voltage electrical shock

from EMI/RFI filter inside drive. Can shock, burn or kill if the front cover of the Pentek Intellidrive is open or removed while power is connected to the Drive or the Drive is running. The front cover of the Drive must be closed during operation.

• Make all wiring connections, then close and fasten the cover before turning on power to drive.

• NEVER open the box when power is connected to

Drive.

• Before doing any service or maintenance inside

Drive or when connecting or disconnecting any wires inside Drive:

1. DISCONNECT power.

2. WAIT 5 minutes for retained voltage to discharge.

3. Open box.

• Before starting any wiring or inspection procedures, check for residual voltage with a voltage tester.

• NEVER connect power wiring to Drive before mounting the box.

• NEVER handle or service Drive with wet or damp hands. Always make sure hands are dry before working on Drive.

• NEVER reach into or change the cooling fan while power is applied to Drive.

• NEVER touch the printed circuit board when power is applied to Drive.

Risk of fire. Can cause severe injury, property damage or death if installed with incorrect or inadequate circuit breaker protection. To ensure protection in the event of an internal fault in the

Pentek Intellidrive, install the Drive on an independent branch circuit protected by a circuit breaker (see

Table 2 for circuit-breaker sizing), with no other appliances on the circuit.

Risk of burns. The Drive can become hot during normal operation. Allow it to cool for

5 minutes after shut-down and before handling it to avoid burns.

NOTICE To avoid damage to Drive or problems with

Drive:

• Connect output cables to 3-wire 1-phase and

3-phase submersible motors as follows:

Red to R, Yellow to Y, Black to B.

Any other order will reverse the motor rotation and may damage the motor.

• Connect output cables to 2-wire 1-phase submersible motors as follows:

Connect to Y and B only.

Connect Ground to green screw.

• Above ground 3-phase motors may have different lead colors. Generally connect output leads as follows:

R to L1, Y to L2, B to L3.

Verify rotation after startup.

• Do not modify equipment.

• Do not use power factor correction capacitors as they will damage both motor and Pentek Intellidrive.

• Do not remove any parts unless instructed to do so in Owner’s Manual.

• Do not use a magnetic contactor on Drive for frequent starting/stopping.

• Do not install or operate Drive if it is damaged or parts are missing.

• Before starting Drive that has been in storage, always inspect it and test operation.

• Do not carry out a megger (insulation resistance) test on the control circuit of the Drive.

• Do not allow loose foreign objects which can conduct electricity (such as screws and metal fragments) inside Drive box at any time. Do not allow flammable substances (such as oil) inside Drive box at any time.

• Ground Drive according to the requirements of the

National Electrical Code Section 250, IEC 536 Class

1, or the Canadian Electrical Code (as applicable) , and any other codes and ordinances that apply.

• All installation, service work, and inspections must be done by qualified electrician.

47


™


8.2 Description

Specifications/Ratings

Input Voltage ...................... 1-Phase 230VAC Nominal (190–265VAC)

Input Frequency .....................................................................50/60Hz

Ambient Temperate Range .................... -4 to 122 °F (-20° to 50 °C)

Output Connections .........................3-Phase, 3-Wire/1-Phase or

1-Phase/2-Wire

Max Motor Cable Length .................................................... 1,000 feet

Enclosure ........................................................................................3R

Table 1 - Specifications with above ground motors not rated for a Variable

Frequency Drive, maximize motor life by limiting lead length to 25 ft. Refer to pump Owner’s Manual and the

National Electrical Code for proper wire size.

Each carton contains:

• Pentek Intellidrive Variable Frequency Drive

• Pressure Transducer

• 10’ Pressure Transducer Cable

• Quick Start Guide

Model Motor Type

HP

Range

Input

Voltage

Maximum

Output

AMPS

Enclosure

Type

PIDXX

PID10

PID20

PID50

2-WIRE* 1-PHASE

3-WIRE* 1-PHASE 0.5–1 HP

3-PHASE

2-WIRE* 1-PHASE 0.5–1.5 HP

3-WIRE* 1-PHASE

3-PHASE

0.5–2 HP

3-PHASE

2-WIRE

3-WIRE

0.5–5 HP

0.5 - 1.5

0.5-2

190V –

265V

9.5A

7.5A

5A

11A

13.5A

8.5A

18A

11A

13.5A

NEMA 3R outdoor

Product Family

PID - PENTEK INTELLIDRIVE

HP Range

10 = up to 1.0 HP

20 = up to 2.0 HP

50 = up to 5.0 HP

* Select drives by S.F. amps of pump motor.

The Pentek Intellidrive is specifically designed to operate 4” submersible pumps and 3-phase above ground pumps in water well and residential booster applications. Each Drive is rated for maximum output amp rating. Any use of Drive outside of intended design parameters will void warranty. If Drive is used

The PID10 will operate a 1-Phase 2-Wire, 1-Phase

3-Wire, and 3-Phase motor up to 1HP.

The PID20 will operate a 1-Phase 2-Wire up to 1.5HP and a 1-Phase 3-Wire or 3-Phase motor up to 2HP.

The PID50 will operate a 1-Phase 2-Wire up to 1.5HP,

1-Phase 3-Wire up to 2HP, or 3-Phase motor up to 5HP.

Figure 1 - A typical residential installation layout

Gnd

PENTEK

INTELLIDRIVE™

Gnd

48

(3 phase only)

Transducer; install in straight pipe downstream of tank, at least one foot away from pipe fittings on each side.

6004 0509


™


Transducer

The Pentek Intellidrive uses a 4-20mA, 0-100PSI pressure transducer to control motor speed (max is 300 PSI transducer).

The transducer (see Figure 1) senses pressure in the pipe and converts it to an electrical signal.

The Drive senses and processes the signal in the

PID (Proportional, Integration, Derivative) control.

When operating in AUTOSTART mode, the Drive increases and decreases the speed of the pump motor as needed to maintain constant pressure in the piping system.

Keypad

The keypad programs the Drive, monitors the status of the pump, and displays faults if they occur. Each button has a unique function, as described in Figure 2. The LCD display shows a text display of the status of the Drive’s operation.

Other LEDs light up to indicate when certain buttons are pressed or certain events occur.

Fan

The Drive uses a thermostatically controlled internal fan which operates automatically when necessary to cool the Drive components.

Changes internal pressure setpoint from 15 PSI to transducer max -3PSI

(default is 60

PSI).

Runs the Drive at 45Hz (with no pressure control) to allow installer to pump out well.

Changes display to previous screen.

Selects menu items and confirms numeric value changes.

Power is ON to Drive.

Drive is in Warning Mode (TPM); refer to

Troubleshooting section.

A fault has occurred.

Displays Drive’s current operating condition and changes display parameters.

Stops the motor.

Figure 2 - Pentek Intellidrive keypad functions

Views and changes parameters.

Shows last 15 faults.

With code, locks and unlocks password protected keys.

Toggles between English, Spanish, and

French (default is English).

Left and right arrows move cursor.

Up and down arrows scroll through menus and change numeric values.

Resets fault that stopped Drive/pump.

Checks for line fill, then starts pump in constant pressure mode.

49


™


8.3 Installation

Table 2 - Circuit breaker and wire sizes

Motor

2-wire

3-wire

3 phase

Drive

Model

PID10

PID20

PID10

PID20

PID10

PID20

PID50

Volts

230

Motor HP

1

1-1/2

2

1/2

3/4

1/2

3/4

1

1-1/2

1/2

3/4

1

1-1/2

2

3

5

Wire Size*

Input Output

14 14

12

10

14

12

10

14

12

10

6

12

10

14

12

10

14

12

10

8

Circuit

Breaker**

15

20

25

15

25

15

20

25

30

50

Generator (kVA)***

3.5

5.3

5.8

2.1

2.8

5.3

2.3

3.0

2.2

3.1

4.4

3.4

4.4

5.5

7.3

12.6

* AWG will change depending on the length of wire. See Tables 3-6.

** With properly-sized circuit breakers, the Drive is protected from short circuit on the input and the output. There is no risk of fire or electrical shock due to a short circuit. The Drive has NEC Class 10 overload protection.

*** Minimum 240V generator size.

NOTICE Information in Tables 3-6 applies ONLY to Pentek

®

motors. For other motors, refer to motor manufacturer specifications for wire sizing.

Table 3 - Service Entrance to Drive - 1 Phase, 2-Wire 40°C Ambient, and 5 percent Voltage Drop,

60C and 75C Insulation (copper only).

Volts

Motor Rating

HP SFA

1/2 4.7

14 AWG

447 (136)

12 AWG

Maximum Cable Length in feet (M)

712 (217)

10 AWG

1000 (305)

8 AWG

–

6 AWG 4AWG

230

2

3

5

3/4

1

6.2

8.1

1 1/2 10.4

12.2

10.1

17.5

341(104)

261(79)

203 (62)

173 (53)

209 (64)

121(37)

542 (165) 864 (263) 1000 (305)

415 (126) 661 (202) 1000 (305)

323 (98)

192 (59)

515 (157)

275 (84) 439 (134)

333 (101) 530 (162)

306 (93)

816 (249) 1000 (305)

696 (212)

840 (256)

485 (148)

–

1000 (305)

1000 (305)

754 (230)

–

1000 (305)

50


™


Table 4 - AWG Wire Sizing, Drive to 1-Phase, 2-Wire Motor, 40°C Ambient, and 5 percent Voltage Drop,



Motor P/N

P42B0005A2-01

P42B0007A2-01

P42B0010A2-01

P42B0015A2-01

Volts

Motor Rating

HP

1/2

3/4

230

SFA

4.7

6.2

1 8.1

1 1/2 10.4

14 AWG

447 (136)

12 AWG

712 217)

10 AWG

1000 (305)

8 AWG

–

341 (104) 542 (165) 864 (263) 1000 (305)

261 (80)

203 (62)

415 (126)

323 (98)

661 (201)

515 (157)

1000 (305)

816 (249)

6 AWG

–

1000 (305)

Table 5 - AWG Wire Sizing, Drive to 3-Wire, 1-Phase Motor, 40°C Ambient, and 5 percent Voltage Drop,



Motor P/N

P43B0005A2-01

P43B0007A2-01

Volts

Motor Rating

HP

1/2

3/4

SFA

4.8

6

14 AWG

440 (134)

352 (107)

12 AWG

560 (171)

10 AWG

700 (213) 1000 (305)

8 AWG

–

893 (272) 1000 (305)

6 AWG

–

P43B0010A2-01

P43B0015A2-01

P43B0020A2-01

230 1 7.3

1 1/2 10.9

2 12.2

289 (88)

194 (59)

173 (53)

460 (140)

308 (94)

275 (84)

734 (224) 1000 (305)

492 (150) 778 (237) 1000 (305)

439 (134) 696 (212) 1000 (305)

Table 6 - AWG Wire Sizing, Drive to 3-Phase Motor, 40°C Ambient, and 5 percent Voltage Drop, 60C and 75C Insulation (copper only).

Motor P/N

P43B0005A3

P43B0007A3

P43B0010A3

P43B0015A3

P43B0020A3

P43B0030A3

P43B0050A3

Motor Rating

Volts HP SFA

1/2

3/4

2.9

3.9

230

1

1 1/2

2

3

5

4.7

6.1

7.6

10.1

17.5

14 AWG 12 AWG

728 (222) 1000 (305)

541 (165) 861 (262)


10 AWG 8 AWG 6 AWG

–

1000 (305) –

_ 449 (137)

346 (105)

278 (85)

209 64)

715 (218)

551 (168)

442 (135)

333 (101)

1000 (305)

878 (268)

705 (215)

530 (162)

306 (93)

1000 (305)

1000 (305)

840 (256)

485 (148)

1000 (305)

754 (230)

4 AWG*

_

1000 (305)

*

Installations that require wire gauge larger than 6 AWG will require an external junction box. Run

6 AWG wire from the Drive into the junction box, then make external connections with wire nuts to appropriately sized wire.

51


™


Mounting the Drive

To mount the Drive as shown in Figure 6, follow this procedure:

1. First, remove the cover by backing out screw at bottom of front cover.

2. Push on backplate with thumbs while pulling the cover toward you with index fingers, creating a gap. See Figures 3 and 4.

5. Ensure the Drive’s ventilation holes are not blocked and there is enough space around it to allow free air flow (minimum

3” clearance on top, bottom, and sides).

See Figure 6. Once the Drive is mounted, electrical wiring can be connected.

Figure 3 - Separate cover and backplate

Gap

Figure 4 - Gap between cover and backplate

3. Pull bottom of cover towards you; lift up on cover and remove. See Figure 5.

Typical

230VAC

Circuit

Breaker

(Double

Width)

5997 0412

Figure 6 - Attaching Drive to wall

6. To reattach the Drive cover, hook the top of it on backplate (be sure to leave a gap). Lower bottom of cover into place. Push cover evenly against backplate, eliminating the gap. See

Figure 7.

Figure 5 - Pull out bottom of cover

4. With the cover removed, permanently mount the Drive using the top slotted hole, plus either the three bottom holes (for flat surface mounting) or the center bottom hole (for attaching to a post or stud) . See Figure 6.

52

Figure 7 - Reattaching Drive cover

7. Replace screw at bottom of front cover.


™


Wiring

To allow for ease of wiring, the enclosure wiring area is free of electronics other than the terminals. Conduit holes and knockouts are located so that the wire can be fed straight through to the connectors, with minimal bending.

The terminals accept 6-14 AWG wire.

Installations that require larger wire gauge than

6 AWG will require an external junction box. Run

6 AWG wire from the Drive into the junction box, then make external connections with wire nuts to appropriately sized wire.

NOTICE For convenience in wiring, the input and motor terminals unplug from the box. Pull them down to remove them for ease of access, as shown in Figure 8.

Verify that the terminal connectors are completely seated when you replace them. It is best practice to connect all output wires (larger wire gauge) first, then all input wires.

Pump Connections

If the Pentek Intellidrive is used with above ground motors not rated for Variable Frequency Drive use, maximize motor life by limiting lead length to 25 ft. Refer to the pump owner’s manual, the

National Electrical Code, and local codes for proper wire size.

The output of the Drive is single phase (2-wire or

3-wire) or 3-phase, depending on motor selection during startup.

The output power terminals (motor wire connections) are located on the lower right side of the Drive and are labeled R (Red), Y (Yellow), and

B (Black). See Tables 2 through 6 for suggested wire sizes.

NOTICE 2-wire 1-phase connect to Y + B, not R + B.

Feed the motor cable through the 3/4” conduit hole on the bottom right side and into the appropriate terminals. If the wire is large enough to require a larger conduit hole, remove the

1-1/4” knockout and use the appropriate conduit connections. Attach the motor ground wire to the grounding screw, located to the upper right of the terminal block. Attach the motor power wires to the terminals as shown in Figure 9.

NOTICE Drive does not sense motor temperature and will not protect motor from over heating.

Figure 9 - Basic Wiring Connections for Startup

53


™


Pressure Tank Recommendations

Minimum tank size is two gallons. Use a precharged pressure tank with Drive, as shown in

Figure 1. The tank size must equal at least 20 percent of the pump’s rated flow in gallons per minute (GPM), but cannot be less than two gallons capacity. For example, a pump rated at 7 GPM would require a tank of two gallons capacity or larger. A pump rated at 50 GPM would require a 10 gallon tank or larger. Tanks larger than 10 gallons can be used, but may require adjustment of Wake

Delay parameter.

Transducer Connections

A 0-100 PSI 4-20 mA transducer is provided with Drive. Install the transducer downstream of tank, as shown in Figure 1. Install transducer in a tee in a straight section of pipe with at least 1 foot of straight pipe on each side of the tee (i.e., all fittings must be at least 1 foot away from transducer).

Feed transducer cable through the open 1/2” conduit hole on bottom of the Drive enclosure.

As shown in Figure 9, connect the red wire of the transducer cable to AI+, connect black wire to AI–, and connect the green cable shield to the metal cable shield screw.

Table 7 - Control Pressure Set Point and Tank

Pre-Charge Pressure Values (PSI).

Pressure

Point

Setting

(PSI)

Precharge

Pressure

(PSI)

Pressure

Point

Setting

(PSI)

Precharge

Pressure

(PSI)

25

30

35

40

18

21

25

28

65

70

75

80

46

49

53

56

45

50

55

60

(Default)

32

35

39

42

85

90

95

–

60

63

67

NOTICE Set pressure tank’s pre-charge to 70 percent of the system operating pressure. When using an external set point as well as an internal set point, pre-charge tank to 70 percent of the lower setpoint of the two. Some applications may require a different percentage when determining the setpoint.

To connect the transducer wires:

1. Strip wire ½ inch

2. Push spring terminal up with finger or slotted screwdriver

3. Insert wires from bottom

4. Release spring terminal

Input Power Connections

The input power terminals are located on the lower left side and are marked L1 and L2 (see

Figure 9). There is a ground screw for the input ground wire to the right of the connector (torque to 10 in lb). Feed wire through the 3/4” conduit hole on the bottom left side and into appropriate terminals. If wire is large enough to require a larger conduit hole, remove the 1-1/4” knockout and use appropriate conduit connections.

To determine the correct wire sizes for installation, see Table 3.

NOTICE The Pentek Intellidrive only accepts 230V single phase input power. If incoming power does not match this, have a qualified electrician alter supply voltage to 230V/1Ph before connecting it to the Drive. See specifications ratings in Section 8.2.

54


™


8.4 Initial Startup and Programming

Procedures

Ensure that the cover is installed before operating the Pentek Intellidrive.

Most installations will only require the initial startup settings. However, the installer may need to set additional parameters. Information about accessing all parameters, explanations of their functions, and procedures for changing parameter values, will be found later in this section.

1. Program the Drive: Apply power to the

Pentek Intellidrive. Setup Guide will appear in the display. Follow keypress sequence shown in

Figure 10.

NOTICE If Setup Guide does not appear, refer to

Drive Reset Procedure, Figure 20.

1 Phase

Apply 230V to Drive

Enter Motor Phase

(1 Phase or 3 Phase)

Connection Type

(2 Wire or 3 Wire)

Press Enter

3 Phase

Motor Type

Subm or Above Gnd

Service Factor Amps

To maximize pump performance, be sure to enter the correct Service Factor Amps (SF

Amps) in the Pentek Intellidrive.

• Entering SF Amps higher than the motor rating lets the Drive supply more amps to the motor than the motor is designed for and may allow the motor to overheat (see Table 8).

• Entering SF Amps lower than the motor rating limits the output amps to less than the motor is designed for and will reduce the performance of the pump.

• For any 1-Phase 3-Wire motor, the correct

Service Factor Amp rating for the Drive is Cap

Start/Cap Run amps (see Table 8). This may not match the motor nameplate, which (for a

Single Phase, 3-Wire motor) will generally be

Cap Start/ Induction Run Amps.

• For any 3-Phase or 1 Phase, 2-Wire motor, use the motor nameplate Service Factor

Amp rating.

NOTICE Pentek ® submersible motors may differ from motors of the same horsepower from other manufacturers. For 1-Phase,

3-Wire motors from all other submersible motor manufacturers, enter the motor manufacturer’s CS/CR service factor amps for

your motor. For 3-Phase or 2-Wire 1-Phase motors, use the motor nameplate amp value.

Also see Retro Fit Applications.

Press Enter

Enter Service

Factor Amps

2. Select 80 Hz Operation, if necessary (See 60 Hz to 80 Hz Operation for more information):

A. Press MAIN MENU button.

B. Follow the keypress sequence shown in

Figure 11.

Press Enter

Press MAIN MENU button

Set Time

Press Enter

Set Date

Press Enter

Press Enter

Setup Complete

6566 0512

Use arrows to scroll to Motor

Press Enter

Use arrows to select

Max Frequency

Press Enter

Use arrows to select 80 Hz

Figure 10 - Drive Setup Guide.

Press Enter to save

55


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3. Pump out well (if necessary):

Direct pump’s discharge to appropriate location not connected to system and press Pump Out.

Drive will ask “Is a valve open?” Change “No” to “Yes”, press enter. The pump will run at 45 Hz.

Adjust frequency as appropriate:

A. Press ENTER

B. Change frequency value

Table 8 - Pentek Motor Service Factor Amps

Motor

Type

2-Wire

CS/CR

3-Wire

3-Phase

PENTEK ® Part

Number

P42B0005A2-01

P42B0007A2-01

P42B0010A2-01

P42B0015A2-01

P42B0005A2

P42B0007A2

P42B0010A2

P42B0015A2

P43B0005A2-01

P43B0007A2-01

P43B0010A2-01

P43B0015A2-01

P43B0005A2

P43B0007A2

P43B0010A2

P43B0015A2

P43B0020A2

P43B0005A3

P43B0007A3

P43B0010A3

P43B0015A3

P43B0020A3

P43B0030A3

P43B0050A3

Rating @

230V

HP

1/2

3/4

1

1-1/2

1/2

3/4

1

1-1/2

1/2

3/4

2

1/2

3/4

1

1-1/2

2

3

5

1

1-1/2

1/2

3/4

1

1-1/2

Service

Factor

Amps

4.7

6.2

8.1

10.4

4.7

6.4

9.1

11.0

4.8

6.0

12.2

2.9

3.9

4.7

6.1

7.6

10.1

17.5

7.3

10.9

4.9

6.3

7.2

11.1

pressure functions are not working, there is no sleep or Dry Run Protection which can cause very high pressure if flow is restricted.

4. Verify installation: Make sure that the system has properly-sized, pressure-relief valve and pressure tank.

Make sure pressure tank’s precharge is correct.

See Table 7.

Make sure pump discharge is connected to system.

5. System Start:

A. Open valves at the ends of lines so that air will escape during pressurization.

B. Press Auto Start; close valves at the ends of lines after all air has escaped.

C. The system goes into Constant Pressure

Operation as soon as the transducer registers the Dry Run Sensitivity parameter

(default is 10 PSI). If system pressure does not reach that PSI value within 3 minutes, the Drive will stop. Press Auto Start again to restart line fill. If longer priming or line fill time is required, adjust Fill Time parameter.

See Table 9.

Changing a Parameter Value

This procedure works for ANY parameter.

A. Press MAIN MENU button.

B. Follow the keypress sequence shown in

Figure 12:

A shorthand way to remember this is:

• Press ENTER to change a value

Use arrows to find parameter

Press Enter

Use arrows to change value

Press Enter to save

NOTICE Above ground pumps should run at 60

Hz for this step (until pump is primed). Then adjust frequency as necessary.

C. Press ENTER again.

Run the Drive in this mode until the well discharge runs clear, then press STOP button to stop Drive.

Risk of explosion. In Pump Out mode, pump runs at a constant speed. All

56

• Press ENTER again to save it

• If new value is not saved, any screen change will result in the loss of the new value.

Table 9 lists all available commands and parameters for the Pentek Intellidrive.


™


60 Hz to 80 Hz Operation

When installing the Pentek Intellidrive with a motor and liquid end of the same HP rating, operate it at 60 Hz (the default value). The Drive can be operated at frequencies of up to 80 Hz when the installation uses a 3-phase motor

2 times the size of the pump. For example, a

1 HP pump with a 2 HP 3-phase motor. This combination will equal the performance of a conventional 2 HP pump.

Press Main Menu and follow the keypress sequence shown in Figure 11. Be sure to press ENTER to save the new Max Frequency selected. The Drive will now use the new value selected.

NOTICE The Drive will not allow the output amps to go above the Service Factor Amps selected on the keypad. Because of this, some 80 Hz operations may be limited. This protects the motor and may be a common occurrence in a

80Hz operation.

8.5 Advanced Programming

Keypad Lock - Password

The password locks or unlocks the blue buttons on keypad. All Pentek Intellidrive units are shipped from factory with the default password 7777. It can be changed to any other 1 to 4 digit number.

To reset password to a unique password for unit, unlock keypad (see below) and follow the keypress sequence shown in Figure 12 to make the change.

If installer does not press the password button, then the keypad will automatically lock 60 minutes after the Drive is powered up. The time out period is adjustable (see Table 9).

To unlock keypad press Password, use directional arrows to select numeric code and press ENTER.

NOTICE For more detailed information on keypad functions, see Figure 2.

Pump Out Operation

Press Pump Out. The Drive will start pump in a constant speed mode (default 45 Hz). The pump will run until STOP or Auto Start are pushed.

If speed change is necessary, press enter, to highlight value use arrows to change value then press enter to save.

Setting the Pressure

NOTICE Default pressure setting is 60 PSI. If this value is changed, adjust tank pressure accordingly

(see Table 7).

There are three ways to change the pressure setpoint:

1. While running the pump

• Follow keypress sequence shown in Figure

13 to make desired change. This parameter allows either Internal or External Setpoint to be changed, depending on which one is referenced at the time the change is made.

2. Via the PSI Preset (Figure 14)

3. Via the Main Menu (Main Menu/Settings/

Setpoint/Internal Setpoint)

Press Auto Start if pump is not running

Verify

“Running Fixed Press” displayed on screen

Press Enter

Use arrows to change the value

Press Enter to Save

6568 0512

Figure 13 - Change PSI Setpoint while running pump.

Press PSI Preset

Press Enter

Use arrows to change the value

Press Enter to Save

6569 0512

Figure 14 - Change PSI Internal Setpoint using PSI Preset.

57


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Table 9 - Main Menu and Parameters

Menu

Settings

Time/Date

PID Control

Sleep

Parameter

Hour Format

Time

Date

Proportional

Gain

Integration

Time

Derivation

Time

Derivative

Limit

Boost

Differential

Boost Delay

Unit of

Measure

Hours

HH:mm

MM/DD/YYYY

Default

12Hr

Value

Min.

Max.

Description

12Hr 24Hr Selects 12 or 24 hour time scale.

1:00 AM

1/1/12

1

–

24

–

Sets current time. Used for time stamp in fault log.

Sets current date. Used for date stamp in fault log.

–

Milliseconds

Milliseconds

–

PSI

MM:SS

1500

500 ms

60 ms

120

3 PSI

1 Min

0

20 ms

0 ms

0

3 PSI

30 Sec

10000

65000 ms

10000 ms

2000

10 PSI

5 Min

Sets the PID controller gain. Used in conjunction with all PID Control parameters to control how fast or slow the Drive reacts to pressure changes.

Sets the PID controller integration time. Used in conjunction with all

PID Control parameters to control how fast or slow Drive reacts to pressure changes.

Sets PID controller derivation time. Used in conjunction with all

PID Control parameters to control how fast or slow Drive reacts to pressure changes.

Sets derivative filter time constant for PID controller.

First part of Boost Process.

Pressure boost that happens before it goes to Wake Delay.

The time Drive takes to start

Boost Process after system has stabilized.

Wake Up

Differential

PSI

Password

Wake Delay

Password

Time Out

Password

MM:SS

HrHr:mm

–

5 PSI

15 Sec

5 PSI 15 PSI Pressure amount below setpoint

3 Sec 2 Min

Second part of the Boost Process.

The time it takes to ramp down pressure during the Boost Process.

1 Hr

7777

1 Min

0000

6 Hr

Amount of time it takes to lock keypad (after last button is pressed).

9999 Password used to unlock keypad.

58


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Table 9 - Continued

Menu

Settings

Parameter

Setpoints

Sub Menu

Motor

Sensor

Internal

Setpoint

External

Setpoint

Parameter

Motor Phase

Connection

Type

Motor Type

Service Factor

Amps

Min Frequency

Max

Frequency

Max Sensor

Value

Unit of

Measure

PSI

PSI

Unit of

Measure

_

–

–

A

Hz

Hz

PSI

Value

Default Min Max

60 PSI

40 PSI

15 PSI

15 PSI

Description

Max

Sensor

Value minus

3 PSI.

Max

Sensor

Value minus

3 PSI.

Main pressure setpoint used. Sets main system operational pressure.

This parameter is accessed here, through PSI Preset button, or by pressing Enter button while in

Constant Pressure operation.

Second pressure setpoint. When another pressure setting is desired other than Internal Setpoint.

Additional programming needed in

I/O section. Requires an external switch or timer to wired to I1 or

I2 terminals. It is only active when there is voltage present

I1 terminals

Default Max Min Description

1

3 wire

Subm

00.0 A

1

3 wire

Subm

00.0 A

1 above

Min Hz

3

2 wire

Above

Gnd

Per drive and motor

30 Hz 30 Hz 1 below

60 Hz

100 PSI

80 Hz

10 PSI 300 PSI

Selects phase of motor to be operated. An additional sub menu will appear, based on phase selection, to select proper motor type.

Wire type for 1 phase motor operation only. Can only access by first setting Motor Phase parameter to 1 Phase.

Motor type for 3 phase motor operation only. Can only access by first setting Motor Phase parameter to 3 Phase.

Service factor amps (max. load) of motor the Drive is operating. Sets maximum allowed amps at output of Drive. See Table 8 for values.

Minimum frequency (speed) motor will run.

Maximum frequency (speed) motor will run. Up to 80Hz is only available on only when Motor

Phase is set to 3 and motor type is

Sub.

Maximum pressure value of transducer sensor used with Drive.

Only change if different transducer is used with Drive, other than 100

PSI max scale.

59


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Table 9 - Continued

Menu or

Sub Menu

Parameter

Ex Runtime

Excessive

Runtime

Detection

Excessive

Runtime Hours

Auto Restart

Delay

Number of

Resets

Unit of Measure

_

Hours

Minutes

–

Dry Run

I/O

Over Press

No Ground

Reset

Detection Time

Sensitivity

Fill Time

Digital Input 1

Digital Input 2

Relay Output

Over Pressure

No Ground

Detection

Factory Reset

SW Update Software Update

M:SS

PSI

M:SS

–

–

PSI

–

–

–

Value

Default Min Max

Description

Enabled Disabled Enabled

Enables or disables Excessive Runtime

Detection.

24

10 Min

3

15 Sec

10

1 M

Unused

Unused

80 PSI

Enabled Disabled Enabled

No

1

3 Min

0

5 Sec

0

15 S

–

–

15 PSI

No

100

60 Min

5

10 Min

300

10 M

–

–

97 PSI

Yes

Number of hours Drive can run before it faults on Excessive Runtime.

Time Drive waits to restart pump when

Dry Run is detected.

Number of tries Drive attempts to restart pump when Dry Run condition is detected.

Time the Drive takes to recognize Dry

Run condition.

Pressure value that Dry Run condition is detected at. Dry Run fault will occur if this pressure cannot be met within

Detection Time window. Lower pressure

= less sensitivity.

Time allowed to fill (prime) pipes during

Auto Line Fill process. Relates to Dry

Run Sensitivity value. (Time starts after

55 Hz is reached).

Selects operation of Drive when terminal I1 or I2 is used. Select between

Unused, Run Enabled, Ext Fault, and

Setpoint. The Drive will respond to selected command when voltage is present at I1 or I2 terminal.

Selects the operation of Drive when terminal O1 is used. Select between

Unused, Run, and Fault. The Drive closes the Relay when Run or Fault is selected.

Sets Over Pressure Warning value.

Change if higher than 80 PSI system pressure is needed.

Selects whether Ground Detection parameter is Enabled or Disabled. If

Disabled is selected, it will revert back to Enabled after 72 hours. Warning LED will flash entire time it is Disabled.

Resets all parameters to factory defaults. Displays Setup Guide after it is complete. Software version displayed here. Does not clear fault log.

Disabled Disabled Enabled Used to update software, if necessary.

60


™


8.6 I/O Connections

The I/O terminals are located in the center of the wiring compartment, as shown previously in

Figure 9.

The Digital Input connections (I1 and I2) are used to control the Drive based on the state of an external device, such as a flow switch, moisture sensor, alternator, or other device. Programming is needed to activate any of these functions (see Table 9).

The Output Relay (O1) is used to control an external device based on two states of Drive; either Running the pump or Faulted. Programming is needed to activate any of these functions (see Table 9).

Cable Installation

Three 1/2” conduit knockouts are provided on the bottom of the Drive enclosure for the I/O wires.

Break out the closest 1/2” knockout and route the wires through. Use a cord grip to prevent the wire from rubbing and causing a short.

NOTICE Never run low voltage I/O wire through the same conduit hole as the 230V input wires or motor wires.

To connect the external wires to the terminals:

1. Strip wire ½ inch

2. Push spring terminal up with finger or slotted screwdriver

3. Insert wires from bottom

4. Release spring terminal

Connection Examples

Figures 15-18 show various connection schemes for typical applications. Table 10 describes each

I/O terminal, including purpose and rating.

115 VAC or

230 VAC or

240 VAC

+

-

Figure 16 - Example external Input with external supply

Figure 17 - Example Output relay with internal

24 volt supply

6541 0412

6542 0412

Figure 15 - Example Input with internal 24 volt supply

+

-

115 VAC or

230 VAC

6540 0412

240 VAC

Figure 18 - Example Output with external supply

61

6541 0412


™


Table 10 - I/O Function, Connections, Ratings

Label Function

AI+ Positive connection for transducer

AINegative connection for transducer

V+

V-

I1+

I1-

I2+

I2-

O1+

O1+

P

N

Positive side of 24 volt power supply.

Used to power external devices.

Negative side of 24 volt power supply.

Used to power external devices.

Positive (dry contacts) connection of

Digital Input 1. Connect when using an external device to control Drive.

Negative (dry contacts) connection of


Positive (dry contacts) connection of


Negative (dry contacts) connection of


Output relay (dry contacts) connection.

Programmed to close when pump is

Running or Faulted.

Output relay (dry contacts) connection.

Programmed to close when pump is

Running or Faulted.

Positive connection of an RS-485 communication device (see Figure 19).

Negative connection of an RS-485 communication device (see Figure 19).

Connection

Red transducer wire

Black transducer wire

Positive side of 24V external device, i.e., flow switch, moisture sensor, alternator, etc. Need to complete the circuit with V-.

See Figures 15 and 17.

Typically to I1-, I2-, or O1-. Used with a flow switch, moisture sensor, alternator, etc. Need to complete the circuit with V+.

See Figures 15 and 17.

From an external device i.e., flow switch, moisture sensor, alternator, etc.

Requires complete circuit connection with I1-. See Figures 15 and 16.

Can be from V- or from the negative side of an external power supply. Requires complete circuit connection with I1+. See

Figures 15 and 16.

From an external device, i.e., flow switch, moisture sensor, alternator, etc.

Requires complete circuit connection with I2-. See Figures 15 and 16.

Can be from V- or from the negative side of an external power supply. Requires complete circuit connection with I2+. See

Figures 15 and 16.

Rating

24 Volt

(supplied)

40mA maximum output

Accepts 24VDC and up to

230VAC

Positive wires of an external device. See

Figures 17 and 18.

Positive wires of an external device. See

Figures 17 and 18.

Accepts up to 5 Amps at

24VDC and

8 Amps at up to

230VAC

Positive wire from RS-485 device.

Negative wire from RS-485 device.

Per RS-485

Standard

62


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RS-485 Communications

RS-485 is a US-based telecommunications standard for binary serial communications between devices. It is the protocol, or set of specifications, that needs to be followed to allow devices that implement the standard to speak to each other. A fully compliant RS-485 port is included in the Pentek Intellidrive system to permit serial connections among more than two devices on an RS-485 compliant network. Figure

19 shows two-wire connection to the Drive.

01+ 01- I1+ I1- I2+ I2- V+ V- AI+ AI- P N SD CARD

Figure 19 - Example RS-485 Connection

8.7 Wiring Sizing, Repair Parts,

Specifications

6544 0412

Lightning/Surge Protection

Lightning arrestors or other surge suppressing devices can be used with this product. MOV (Metal

Oxide Varistor), SOV (Silicon Oxide Varistor).

Accessories

Part Description

Alternating Control Panel

Moisture Sensor

Surge Protection Kits

300 PSI Transducer

Flow Switch

1

1

Qty

1

1

1

Part Number

VFD-ALT

VFD-WS

VFD-SGA

U17-2000

U17-1999

Retrofit Applications

When retrofitting an installation with the Pentek

Intellidrive, most of the preceding text can be applied. As a convenience, the recommended

Service Factor Amps for non-Pentek

®

motors is provided in Table 11. Always verify Service Factor

Amp values from current manufacturer literature.

Table 11 - Service Factor Amps @ 230V

Motor Type

2-Wire

CS/CR 3-Wire

3-Phase

HP

2

3

5

2

1/2

3/4

1

1-1/2

1/2

3/4

1

1-1/2

1/2

3/4

1

1-1/2

Service Factor Rating, in Amps

CentriPro ® ¹

Franklin

Electric

®

²

4.7

6.4

9.1

N/A

11.0

4.9

6.3

7.2

4.3

5.7

7.1

11.5

11.1

12.2

2.9

3.9

4.7

6.1

13.2

2.9

3.8

4.7

5.9

7.6

10.1

17.5

8.1

10.9

17.8

¹ CentriPro SFA data was taken from the March 2012 BMAID manual on 4/2012.

² Franklin Electric SFA data was taken from the 7/2011 Franklin

Electric AIM manual on 4/2012.

NOTICE The Pentek Intellidrive will not operate

Franklin Electric 2-wire motors.

Repair Parts

Qty

1

Part Number

PID-CON2

Part Description

Input Terminal Block Connector

Output Terminal Block

Connector

Cooling Fan

Pressure Transducer

10’ Transducer Cable

25’ Transducer Cable*





Keypad

* Purchase Separately

1

1

1

1

1

1

1

1

1

1

PID-CON3

PID-FAN-R

U17-1561-R

U18-1593

U18-1594

U18-1595

U18-1596

U18-1597

U18-1598

PID-HMI-R

CentriPro

®

is a registered trademark of Fluid Handling LLC.

Franklin Electric

®

is a registered trademark of Franklin Electric Co. Inc.

All other brand or product names are trademarks or registered trademarks of Pentair Ltd.

63


™



Fault

Over Current

Over Voltage

Possible Causes

Shorted output

Locked rotor

Damaged wire insulation

Internal Drive short

Power cycling on and off

Solution

Check for any shorts in motor cables.

Check for debris in pump.

Check motor wire insulation with a megger.

With power to Drive off, measure outputs with ohmmeter to detect short.

Check for a generator or switching on input line.

High line voltage

Low line voltage

Temporary loss of power

Measure incoming line voltage to Drive; should be between 190V and 265V.

Under Voltage

Excessive load current

Loss of a motor phase

Power was removed from

Drive

Exceeding Service Factor

Amps

Check for local power outage.

Check motor is correctly sized for the application.

Check correct voltage is present on all motor leads.

Check correct voltage is present on all input lines.

Check Service Factor Amps entered are correct.

Check pump and motor are correct.

Check Service Factor Amps entered and are correct.

Cannot Start Motor

No Service Factor Amps value entered

There is an open (connection) in motor wires

Locked rotor

Check resistance of all motor wires is correct.

Dry Run

Ground Fault

System Not Grounded

Operation at open discharge

Drive cannot read transducer signal

Possible leak

Dry running pump

Ground wire shorted to motor phase

Long motor cable length

Ungrounded Drive

Pull pump check for debris in pump.

May need to reduce Dry Run Sensitivity pressure or apply back pressure on transducer.

Check linearity of transducer, as it may be damaged. See Troubleshooting Guide for more information.

Check for pipe break or large leak.

Check water level in well.

Check the ground wire for short to motor phase wire or check insulation integrity with a megger.

If motor cable length is more than 1000 ft a reactor or filter may be needed to limit capacitance between motor wires.

Ground Detect parameter can be disabled, but will reactivate after 72 hours.

*For additional Troubleshooting information, please visit www.sta-rite.com/resources/images/16455.pdf for a downloadable guide.

64


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Fault

Open Transducer

Shorted Transducer

Over Temperature

Excessive Runtime

Internal Fault

Hardware Fault

External Fault

Low Amps

Possible Causes

Intermittent connection

Open Connection

Drive cannot read transducer signal

Transducer wires crossed

Possible failed transducer

Short in transducer wires

Possible failed transducer

Excessive heating in drive

Leak detected

Application calls for long run times

Internal voltages are out of range

Internal hardware failure

Solution

Check all transducer wires are securely connected or for damaged cable insulation.

Check for proper wiring of all transducer wires and verify cable connector securely attached to transducer.

Check electrical system for ground loops or no ground connection.

Check red is in AI+ and black is in AI-.

Check linearity of transducer; see

Troubleshooting Guide for more information.

Check for shorted transducer wire or damaged insulation.

Check linearity of transducer; see

Troubleshooting Guide for more information.

Check ambient temperature is not above

50°C (122°F).

Check for inoperable or unobstructed fan.

Check vents are not obstructed.

Check for leaks in pipe system.

Extend Excessive Runtime Hours limitation.

Disable Excessive Runtime Fault.

Drive will auto reset and attempt to clear fault. Fault Reset can be pressed to clear fault as well. Then try to operate pump. If fault continues Drive may need replacement.

Fault Reset can be pressed to clear fault.

Then try to operate pump. If fault continues

Drive may need replacement.

Check external device.

Must press Fault Reset to clear.

The external device detected fault condition and closed the

I1 or I2 input

Under-sized pump

Low current draw from pump

Thermal protector open in motor (3 wire)

Missing motor phase

Increase Minimum Speed to 35 Hz.

Wait 20 minutes then restart pump.

Check all motor connections at the Drive.

65


™


Warning

Warning LED flashing

Jam Warning

Over Pressure Warning

Drive Reset Procedure

Follow the keypress sequence shown at right to test the Drive.

Possible Causes

Ungrounded Drive, with ground detection parameter disabled (will operate for 72 hours and then fault).

Debris in pump stopping motor from turning (locked rotor).

Pressure rising above Over

Pressure setting.

Solution

Verify ground wire is connected on both incoming voltage side and motor side of

Drive.

With the power disconnected, use an ohmmeter to verify which pipe the Drive’s transducer is connected to. Also verify that the input ground wire is at the same potential, e.g., has approximately the same ohm reading.

Verify the input ground is connected all the way back to electrical panel.

Drive tries to free debris in pump by reversing or pulsing motor.

Drive stops and waits 1 minute, then checks that pressure is below the Setpoint pressure. Below it restarts, if not checks again in another minute. Can increase overpressure value.

Press Password button

Figure 20 - Drive Reset Procedure

Enter Passwword

(Default is 7777)

Press Enter

Press Main Menu button

Press up or down arrow until Reset appears

Press Enter to Edit

Change “No” to “Yes”

Press Enter

66

NOTICE In a domestic environment, this product may cause radio interference which may require supplementary mitigation measures.

6566 0612


™


8.9 Warranty

Limited Warranty

Pentair warrants to the original consumer purchaser (“Purchaser” or “You”) of the products listed below, that they will be free from defects in material and workmanship for the Warranty Period shown below.

Product

Water Systems Products — jet pumps, small centrifugal pumps, submersible pumps and related accessories

Pentek Intellidrive

Pro-Source ® Composite Tanks

Pro-Source Steel Pressure Tanks

Pro-Source Epoxy-Line Tanks

Sump/Sewage/Effluent Products

Warranty Period whichever occurs first:

12 months from date of original installation,

18 months from date of manufacture

12 months from date of original installation, or


5 years from date of original installation



12 months from date of original installation, or


Our warranty will not apply to any product that, in our sole judgment, has been subject to negligence, misapplication, improper installation, or improper maintenance. Without limiting the foregoing, operating a three phase motor with single phase power through a phase converter will void the warranty. Note also that three phase motors must be protected by three-leg, ambient compensated, extra-quick trip overload relays of the recommended size or the warranty is void.

Your only remedy, and Pentair’s only duty, is that Pentair repair or replace defective products (at Pentair’s choice). You must pay all labor and shipping charges associated with this warranty and must request warranty service through the installing dealer as soon as a problem is discovered. No request for service will be accepted if received after the Warranty Period has expired. This warranty is not transferable.

PENTAIR IS NOT LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT DAMAGES WHATSOEVER.

THE FOREGOING LIMITED WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES,

INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE

FOREGOING LIMITED WARRANTIES SHALL NOT EXTEND BEYOND THE DURATION PROVIDED HEREIN.

Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts, so the above limitations or exclusions may not apply to You. This warranty gives You specific legal rights and You may also have other rights which vary from state to state.

This Limited Warranty is effective June 1, 2011 and replaces all undated warranties and warranties dated before June 1, 2011.

PENTAIR

293 Wright Street • Delavan, WI 53115

Phone (262) 728-5551 • Fax (262) 728-7323

67

SECTION 9: PPC Series 50/60 Hz Variable Frequency Drives

9.1 Pentek

®

PPC-Series Drives

The Pentek Pump Controllers (PPC5 and PPC3 series) are pre-jumpered and include the Pentek Assistant, which simplifies programming and setup for constant pressure applications. The Pentek Assistant sets various parameters to Pentek defaults which are described in this manual. The Pentek Assistant also prompts the user for application-specific information.

For PPC3 and PPC5 troubleshooting, please refer to the

ABB ACS350 or ACS550 manual as appropriate.

9.2 PPC3 Series Specifications

4.7

6.7

7.5

9.8

17.6

24.6

31.0

46.2

Three-phase PPC3 drives can be operated on single phase when the output amps are derated by 50%.

Table 9-1: Three-Phase/208-230V Output

Output

Amps

Input

Phase

Input

Voltage

Enclosure

Rating

(NEMA)

Catalog

Number

4.7

6.7

7.5

9.8

1

PPC3-1-4A7-1

PPC3-1-6A7-1

PPC3-1-7A5-1

PPC3-1-9A8-1

3

200-240 1

PPC3-2-4A7-1

PPC3-2-6A7-1

PPC3-2-7A5-1

PPC3-2-9A8-1

PPC3-2-17A6-1

PPC3-2-24A6-1

PPC3-2-31A0-1

PPC3-2-46A2-1

8.8

12.5

15.6

23.1

31.0

38.0

44.0


Output

Amps

Input

Phase

Input

Voltage

Enclosure

Rating

(NEMA)

2.4

3.3

4.1

5.6

Catalog

Number

PPC3-4-2A4-1

PPC3-4-3A3-1

PPC3-4-4A1-1

PPC3-4-5A6-1

3 380-480 1

PPC3-4-8A8-1

PPC3-4-12A5-1

PPC3-4-15A6-1

PPC3-4-23A1-1

PPC3-4-31A0-1

PPC3-4-38A0-1

PPC3-4-44A0-1

NOTICE: For detailed specifications see users manual.

9.3 PPC5 Series Specifications


Output

Amps

4.6

6.6

Input

Phase

Input

Voltage

Enclosure

Rating

(NEMA)

1

12

1

12

Catalog

Number

PPC5-2-4A6-1

PPC5-2-4A6-12

PPC5-2-6A6-1

PPC5-2-6A6-12

7.5

11.8

16.7

24.2

30.8

46.2

59.4

74.8

88.0

114

3 208-240

1

12

1

12

1

12

1

12

1

12

1

12

1

12

1

12

1

12

1

12

143

178

221

248

1

PPC5-2-7A5-1

PPC5-2-7A5-12

PPC5-2-11A-1

PPC5-2-11A-12

PPC5-2-16A-1

PPC5-2-16A-12

PPC5-2-24A-1

PPC5-2-24A-12

PPC5-2-30A-1

PPC5-2-30A-12

PPC5-2-46A-1

PPC5-2-46A-12

PPC5-2-59A-1

PPC5-2-59A-12

PPC5-2-74A-1

PPC5-2-74A-12

PPC5-2-88A-1

PPC5-2-88A-12

PPC5-2-114A-1

PPC5-2-114A-12

PPC5-2-143A-1

PPC5-2-178A-1

PPC5-2-221A-1

PPC5-2-248A-1

NOTICE: For detailed specifications see users manual.

For single phase input, derate the output amps by 50%.

68


Table 9-4: 3-Phase/380-460V Output

Output

Amps

Input

Phase

Input

Voltage

Enclosure

Rating

(NEMA)

1

3.3

4.1

6.9

12

1

12

1

12

1

8.8

11.9

15.4

12

1

12

1

12

1

23

31

38

3 400-480

12

1

12

1

12

1

44

59

72

12

1

12

1

12

1

77

96

12

1

12

124

157

180 1

195

245

Catalog

Number

PPC5-4-3A3-1

PPC5-4-3A3-12

PPC5-4-4A1-1

PPC5-4-4A1-12

PPC5-4-6A9-1

PPC5-4-6A9-12

PPC5-4-8A8-1

PPC5-4-8A8-12

PPC5-4-11A-1

PPC5-4-11A-12

PPC5-4-15A-1

PPC5-4-15A-12

PPC5-4-23A-1

PPC5-4-23A-12

PPC5-4-31A-1

PPC5-4-31A-12

PPC5-4-38A-1

PPC5-4-38A-12

PPC5-4-44A-1

PPC5-4-44A-12

PPC5-4-59A-1

PPC5-4-59A-12

PPC5-4-72A-1

PPC5-4-72A-12

PPC5-4-77A-1

PPC5-4-77A-12

PPC5-4-96A-1

PPC5-4-96A-12

PPC5-4-124A-1

PPC5-4-157A-1

PPC5-4-180A-1

PPC5-4-196A-1

PPC5-4-245A-1

Table 9-5: 3-Phase/575V Output

Output

Amps

Input

Phase

Input

Voltage

Enclosure

Rating

(NEMA)

1

2.7

3.9

6.1

12

1

12

1

12

1

9

11

17

12

1

12

1

12

1

22

27

32

3 575

12

1

12

1

12

1

41

52

62

12

1

12

1

12

1

77

99

125

12

1

12

1

12

1

144

12

Catalog

Number

PPC5-5-2A7-1

PPC5-5-2A7-12

PPC5-5-3A9-1

PPC5-5-3A9-12

PPC5-5-6A1-1

PPC5-5-6A1-12

PPC5-5-9A0-1

PPC5-5-9A0-12

PPC5-5-11A-1

PPC5-5-11A-12

PPC5-5-17A-1

PPC5-5-17A-12

PPC5-5-22A-1

PPC5-5-22A-12

PPC5-5-27A-1

PPC5-5-27A-12

PPC5-5-32A-1

PPC5-5-32A-12

PPC5-5-41A-1

PPC5-5-41A-12

PPC5-5-52A-1

PPC5-5-52A-12

PPC5-5-62A-1

PPC5-5-62A-12

PPC5-5-77A-1

PPC5-5-77A-12

PPC5-5-99A-1

PPC5-5-99A-12

PPC5-5-125A-1

PPC5-5-125A-12

PPC5-5-144A-1

PPC5-5-144A-12

69


9.4 Wiring Connections

Three phase input power is connected to U1, V1, and W1.

If single phase input is used connect to U1 and W1. The neutral and ground leads must be connected to drive terminal PE. Motor leads are connected to U2, V2, and

W2. The motor ground must be connected to terminal

GND. For detailed instructions, see Owner’s Manual.

Analog I/O Digital Inputs

9.5 Transducer Connection

The Pentek

®

Assistant defaults to a 4-20mA transducer connected to AI2. The transducer is used to provide pressure feedback to the drive. Transducers offered by Pentek have either a red or brown power lead. The red or brown lead should be connected to the +24V power connection.

Transducers offered by Pentek have either a blue or black output lead. The blue or black lead should be connected to terminal 5. The Pentek U17-1286R transducer utilizes shielded cable. The bare lead may be covered with green shrink-wrap tubing. The bare lead is cable shielding, and should be connected to terminal 1. The translucent lead is unused, and should be tied off and insulated.

Relay Output

Digital Output

5405 0506

U1/L V1-N W1 BRK BRK U2 V2 W2

Line Input

U1, V1, W1

Output to Motor

U2, V2, W2

Figure 9-1 Typical Connections to PPC3

Line Input

U1, V1, W1

5406 0506

Figure 9-2 Typical Connections to PPC5

Power

Output to Motor

U2, V2, W2

Ground

Figure 9-3 PPC3 Transducer Connection.

DIP Switches

Jumper Board

+24 volt

Power

Connection

4 - 20 ma Output

Power Lead

Figure 9-4 PPC5 Transducer Connection.

70


9.6 Pentek

®

Assistant

Table 9-6: PPC3 Parameters Changed Relative to PID Control Defaults

Parameter Code

1002 Ext2 Commands

1102 EXT1/EXT2 Sel

1301 Minimum AI1

1601 Run Enable

1805 DO Signal

1806 DO On Delay

1806 DO On Delay

1807 DO Off Delay

2001 Minimum Speed

2001 Minimum Speed

2002 Maximum Speed

2202 Accel Time 1

2202 Accel Time 1

3001 AI<Min

3003 External Fault 1

3006 Mot Therm Time

3006 Mot Therm Time

3007 Mot Load Curve

3007 Mot Load Curve

3013 Underload Function

3014 Underload Time

3022 AI2 Fault Limi

3201 Superv 1 Param

3202 SuperV 1 Lim Lo

3203 SuperV 1 Lim Hi

Pentek Code

Keypad

EXT2

20%

Not Sel

Superv1 Over

10 Seconds (Above Ground)

60 Seconds (Submersible)

2 sec

0 (Above Ground)

User Defined (Submersible)

Sync

5 sec (Above Ground)

1 sec(Submersible)

Fault

DI5

500 sec (Above Ground)

350 sec (Submersible)

100% (Above Ground)

112% (Submersible)

Fault

10 sec

10%

Output Freq per 9907 per 9907

Parameter Code

3401 Signal 1 Param

3405 Output 1 Unit

3408 Signal 2 Param

3412 Output 2 Unit

3415 Signal 3 Param

3419 Output 3 Unit

4001 Gain

4002 Integration Time

4006 Units

4010 Set Point Sel

4022 Sleep Selection

4024 PID Sleep Delta

4027 PID Param Set

4101 Gain

4102 Integration Time

4106 Units

4109 100% value

4110 Set Point Sel

4111 Internal Setpoint

4122 Sleep Selection

4123 PID Sleep Level

4124 PID Sleep Delay

4125 Wake-Up Deviation

10 sec

DI3

1.0

1.0 Sec

PSI

Per 4009

Internal

Per 4011

Internal

Per 4023

10 sec

Per 4025

Pentek Code

Current

A

Speed

RPM

PID 1 FBK

PSI

1.0

1.0

PSI

Internal

Internal

9.6.1 Description of Information Required by the Pentek Assistant

9905 Motor Nom Voltage: This is the nominal voltage stated on the motor nameplate. If the motor is rated for operation at multiple voltages, select the voltage nearest the utility voltage. Ensure the motor connections correspond to the voltage selected.

9906 Motor Nom Current: This is the nominal current found on the motor nameplate. Do not use service factor amps.

9907 Motor Nom Freq: This is the nominal frequency found on the motor nameplate.

9908 Motor Nominal Speed: This is the nominal speed found on the motor nameplate. Use the number on the motor nameplate. Do not enter 3600, 1800, etc.

9909 Motor Nom Power: This is the nominal horsepower found on the motor nameplate. Do not include service factor unless the service factor is greater than 1.15.

2001 Min Speed (Required for Subs only): This is the minimum speed the motor is allowed to run. This minimum is set to prevent damage to the motor thrust bearings. Refer to motor literature to determine setting.

4011 Internal Setpoint: This is the pressure that the system will maintain.

4009 100% Value: This is the full scale reading of the transducer. The 100% Value of a 200PSI transducer is 200PSI.

4023 PID Sleep Level: Operation below this rpm will cause the drive to stop. Must never be below the shut-off head RPM.

4025 Wake-Up Dev: This is the pressure drop that will trigger the drive to restart. For example, if the set point is

60 PSI and the Wake-Up Deviation is 10 PSI, the drive will restart at 50 PSI.

71


Table 9-7: PPC5 Parameters Changed Relative to PID Control Defaults

Parameter Code

1002 EXT2 Commands

1102 EXT1/EXT2 SEL

1301 Minimum AI1

1401 RELAY OUTPUT 1

1404 RO 1 ON DELAY

1405 RO 1 OFF DELAY

1601 Run Enable

1605 USER PAR SET CHG

2001 Minimum Speed

2002 MAXIMUM SPEED

2202 ACCELER TIME

3001 AI<MIN FUNCTION

3003 EXTERNAL FAULT 1

3004 EXTERNAL FAULT 2

3006 MOT THERM TIME

3007 MOT LOAD CURVE

3013 UNDERLOAD FUNC

3014 UNDERLOAD TIME

3022 AI2 FAULT LIMIT

3201 SUPERV 1 PARAM

3202 SUPERV 1 LIM LO

3203 SUPERV 1 LIM HI

3401 SIGNAL 1 PARAM

Pentek

®

Code

8-Keypad

EXT2

20%

SUPERV1 OVER

10 S (above ground)

60 S (submersible)

2 S

Not SeL

3-DI3

User defined (above ground)

0 (submersible)

SYNC

15 SEC (above ground)

1 SEC (submersible)

1-FAULT

1-DI6

5-DI5

500 SEC (above ground)

350 SEC (submersible)

100% (above ground)

112% (submersible)

1-FAULT

10S

10%

103-OUTPUT FREQ

60

60

104-CURRENT

Parameter Code

3402 SIGNAL 1 MIN

3404 OUTPUT 1 DSP FORM

3405 OUTPUT 1 UNIT

3408 SIGNAL 2 PARAM


3412 OUTPUT 2 UNIT

3415 SIGNAL 3 PARAMETER


3419 OUTPUT 3 UNIT

4001 GAIN

4002 INTEGRATION TIME

4006 UNIT

4010 SET POINT SEL

4011 INTERNAL SETPOINT

4016 ACT1 INPUT

4017 ACT2 INPUT

4022 SLEEP SELECTION

4024 PID SLEEP DELAY

4027 PID 1 PARAM SET

4102 INTEGRATION TIME

4106 UNIT

4109 100% Value

4110 SET POINT SEL

4111 INTERNAL SETPOINT

4122 SLEEP SELECTION

4123 PID SLEEP LEVEL

4124 PID SLEEP DELAY

4125 WAKE-UP DEV

Pentek Code

0

5-+0.0

1 – AMPS

102-SPEED

4-+0

7 – RPM

128-PID 1 SETPNT

1 - ± 0.0

25 – PSI

1.0

2.0

25 – PSI

0 – KEYPAD

USER DEFINED

1-AI2

1-AI2

7 – INT

10 SEC

3-DI3

1.0S

25-PSI per 4009

19-INTERNAL

PER 4011

7-INT per 4023

10SEC per 4025

9.6.2 Mounting and Installation

Startup the Pentek Assistant

Apply power to the unit, and follow the steps in section

9.6.3 after the Drive’s screen is lit.

9.6.3 Using the Pentek Assistant

Apply power to the unit and follow the steps in Section

9.6.4 for changing operation parameters, use the steps below to run the Pentek Assistant.

1. Use the MENU key to access the Menu List.

2. Select Assistants

3. Select Pentek Assistant.

4. Follow the screen instructions to configure the system.

72


9.6.4 Step By Step Programming

Instructions

STEP 1

Initial Startup Panel Display

Upon initial drive power-up the installer will be prompted to run the Pentek

®

Assistant. Scroll to YES and then select OK. Wait while the program loads. On subsequent startups, the Pentek Assistant can be found in the

ASSISTANTS menu.

STEP 4

Motor Current Screen

Enter the motor current from the motor nameplate

(not maximum amps). Scroll to select the current and press SAVE unless it is a submersible (more than 1.15).

REM PAR EDIT

9906 MOTOR NOM CURR

3.8 A

EXIT 00:00 SAVE REM CHOICE

Do you want to run the PENTEK assistant?

Yes

No

EXIT 00:00 OK

STEP 2

Motor Selection Screen

Scroll to select the type installation and then press OK.

Please Select Mtr Type

Above Ground

Submersible

EXIT 00:00 OK

STEP 5

Motor Frequency Screen

Enter the motor frequency (Hz) from the motor nameplate. Scroll to select the frequency and select

SAVE.

REM PAR EDIT

9907 MOTOR NOM FREQ

60.0 Hz

EXIT 00:00 SAVE

STEP 3

Motor Voltage Screen

The screen shows motor voltage. Scroll to select the correct voltage for your motor as stated on the motor nameplate. This sample shows 460 volts. Press SAVE.

STEP 6

Motor Speed Screen

Enter the motor speed (RPM) from the motor nameplate.

Scroll to select the speed and press SAVE. The sample here shows 3450 RPM.

REM PAR EDIT

9905 MOTOR NOM VOLT

460 V

EXIT 00:00 SAVE

REM PAR EDIT

9908 MOTOR NOM SPEED

3450 rpm

EXIT 00:00 SAVE

73


STEP 7

Motor Horsepower Screen

Enter the motor horsepower (HP) from the motor nameplate. Scroll to select the horsepower and press

SAVE. The sample here shows 3.0 HP.

STEP 10

Transducer 100% Value

Enter the transducer’s full range value which should be stated on the transducer body. Scroll to select the pressure and then press SAVE. The sample here shows

100 PSI.

REM PAR EDIT

9909 MOTOR NOM POWER

3.0 hp

EXIT 00:00 SAVE

REM PAR EDIT

4009 100% VALUE

100.0 PSI

EXIT 00:00 SAVE

STEP 8

For Submersible Pumps Only

Enter the minimum speed allowed by the motor vendor

(consult motor literature). This is to prevent motor bearing damage.

REM PAR EDIT

2001 MIN SPEED

0 RPM

EXIT 00:00 SAVE

STEP 9

Scroll To Select Constant Pressure Point

Example shows 40 PSI.

REM PAR EDIT

4011 INTERNAL SET PNT

40 PSI

EXIT 00:00 SAVE

NOTICE: DO NOT choose maximum pressure.

range: 0... 10 bar / 145 psi max. pressure: 25 bar / 362.5 psi

UE: 80...330 VDC

OUT: 4...20mA Load <(N-8V) /0.02A

Use this Full Range Value

Do NOT use Maximum Pressure

STEP 11

PID Sleep Level Screen

Enter the PID sleep level. This is a motor speed setting.

If the motor speed falls below this RPM, the PID sleep function will be enabled. This is a Drive-assigned value.

For additional information, refer to the PPC5 Users

Manual. Scroll to select the speed and then press SAVE.

The sample here shows 3000 RPM.

Burn Hazard. If the sleep level is set too low, the pump my run without flow. This can boil water inside the pump, causing dangerously high pressure and temperature.

REM PAR EDIT

4023 PID SLEEP LEVEL

3000 rpm

EXIT 00:00 SAVE

74


STEP 12

Wake up Deviation Screen

Enter the wake-up deviation. This is the amount pressure drops (PSI) below the pressure set point before the drive restarts. This sample is waiting to be set and shows

0 PSI.

REM PAR EDIT

4025 WAKE-UP DEV

0.0 PSI

EXIT 00:00 SAVE

STEP 15

Check For System Harmonics

While the pump is running, scroll motor speed up to check for harmonics. Verify that harmonics do not exist above the PID sleep level.

STEP 16

Stop The Pump

Press the STOP button.

STEP 13

Assistant Compete

This ends setup of the Pentek

®

Assistant. The following steps complete the setup of the pump system.

STEP 17

Change To Remote Operation

Press the Loc / Rem button to change to remote control.

PENTEK Assistant

Complete

EXIT 00:00 OK

STEP 14

Check Motor Rotation

Press the Local/Remote button to change to local control.

Check above-ground motors by viewing shaft rotation.

For submersible (3-phase) motors, start and check performance. Reverse any two power leads and check again. The lead arrangement with best performance is correct.

LOC

DIR

0.0 A

0 rpm

0.0 PSI

00:00

100 RPM

MENU

STEP 18

Test System Setup

Press start to operate the pump. Test system to ensure proper system response and sleep function. Adjust group 40 parameters as needed.

NOTICE: The upper left hand corner of the display shows whether the drive is in local or remote control. In LOC mode the drive holds a constant speed which can be adjusted using the up/down buttons. The speed which will be held is in the upper right hand corner. In REM mode the drives holds a constant pressure.

TIP: For common parameters and menu items, use the

Help key ? to display descriptions.

If you encounter Alarms or Faults, use the Help key or refer to the Diagnostic section of the ABB User’s Manual.

75


9.7 Timer Function

The Pentek ® PPC Series controller includes four timer functions. Each timer function can include up to four daily

/ weekly start and stop times.

The following example show the parameter changes required to use PID Set 2 on Monday, Wednesday, and

Friday from 8:00AM to 10:00AM.

Parameter Setting

3601 – Timers Enable . . . . . . . . . . . . . . . . . . 7 – Enabled

3602 – Start Time 1 . . . . . . . . . . . . . . . . . . . . . . . 8:00AM

3603 – Stop Time 1. . . . . . . . . . . . . . . . . . . . . . . 10:00AM

3604 – Start Day 1 . . . . . . . . . . . . . . . . . . . . . . 1-Monday

3605 – Stop Day 1 . . . . . . . . . . . . . . . . . . . . . . . 1-Monday

3606 – Start Time 2 . . . . . . . . . . . . . . . . . . . . . . . 8:00AM

3607 – Stop Time 2. . . . . . . . . . . . . . . . . . . . . . . 10:00AM

3608 – Start Day 2 . . . . . . . . . . . . . . . . . . . 3-Wednesday

3609 – Stop Day 2 . . . . . . . . . . . . . . . . . . . 3 – Wednesday

3610 – Start Time 3 . . . . . . . . . . . . . . . . . . . . . . . 8:00AM

3611 – Stop Time 3. . . . . . . . . . . . . . . . . . . . . . . 10:00AM

3612 – Start Day 3 . . . . . . . . . . . . . . . . . . . . . . . . 5-Friday

3612 – Stop Day 3 . . . . . . . . . . . . . . . . . . . . . . . . . 5-Friday

3626 – Timer Func1SCR . . . . . . . . . . . . 7 = P3 +P2 + P1

4027 – PID 1 Param Set. . . . . . . . . 8 = Timer Function 1

9.8 Helpful Hints

Alarm 2025 upon startup

This is a normal alarm, and occurs whenever motor data is changed. The alarm shows for about 15 seconds while the drive performs a motor calibration.

Fault 14 External Fault 1

External fault 1 is triggered when the VFD’s output frequency exceeds motor nameplate frequency for more than 10 seconds. The ON delay parameter controls the time delay for this fault. If the system includes a large tank, or requires more time to reach the setpoint, increase parameter 1404 (PPC5) or 1806 (PPC3).

This fault is designed to protect against loss of prime, broken shafts, etc. To disable this fault, adjust parameter

2002 Maximum speed, to the motor nameplate rpm.

Sleep

The Pentek drive monitors pump speed to determine demand. The pump is shut off when the rpm goes below parameter 4023: PID Sleep Level. Always set parameter

4023 high enough to trigger sleep mode during low demand conditions. Note that the shut-off head at parameter 4023: RPM, must be higher than the pressure set-point.

The pressure setpoint can be determined by slowly closing the discharge valve to confirm that the RPM decreases to a level that triggers the sleep mode. The discharge head can also be found by using the BEC2 program on the BEC2.net website.

Systems that use small tanks, or have a flat performance curve, may cycle rapidly at intermediate flows. Correct this by increasing Parameter 4024: PID Sleep Delay.

DO NOT increase parameter 4024 to a level that will cause the pump to run with no demand. The water in the pump can overheat.

Sleep Options

Other devices such as flow or float switches can be used to trigger sleep mode. Parameter 4022 determines the method to trigger sleep mode. These options can be used for pump up, pump down, and other on/off applications.

Multiple Systems / Setpoints

The Pentek PPC Series Controller includes (2) independent process control sets (groups 40 and 41).

Group 41 parameters can be selected using Digital Input

(DI3). When first set-up, groups 40 and 41 are identical.

A set can be changed later with parameters for a second process.

Constant Flow

After running the Pentek Assistant, the drive can be configured for constant flow by adjusting parameters

4006: Units, and 4009: 100% Value.

Constant Flow Example 1:

Using a 4-20ma velocity meter with a range of

0 to 10 ft/sec. We want the display to be ft/sec.

Set 4006 to ft/sec

Set 4009 to 10


Same setup as example 1, but we have a 4” pipe and want the display to be gpm.

Set 4006 to gpm

Set 4009 to 393 (this is the flow in a 4” pipe which results in a 10 ft/sec velocity).


Using a 4-20ma flow meter with a range of 0 to 100 gpm.

We want the display to be gpm.

Set 4006 to gpm

Set 4009 to 100

76


9.9 PPC3 and PPC5 Tank Sizing

These instructions are only for systems that require tanks. Pressure tanks are generally required to maintain system pressure during periods of low or no demand.

Tank pre-charge must be less than the pressure set point

– wake up deviation.

Tank can be sized using Boyle’s law (V1 x P1 = V2 x P2).

Units are in gallons and PSI.

Typically tanks are sized for approximately 20% of pump capacity. For example, a 150 gpm pump typically requires

30 gallon total tank size.

Drawdown =

Total Tank Size x (Precharge+14.7)

__

Total Tank Size x (Precharge+14.7)

(Setpoint+14.7 – Wake Up Deviation) (Setpoint+14.7)

Reactors

9.10 Reactors And Filters

Variable frequency drives produce voltage spikes that are a function of voltage rise-time and length of motor cable.

In extreme cases peak voltage may exceed three times the nominal operating voltage.

Reactors

A reactor is a resistance and inductance device that reduces voltage spikes. It does this by both increasing the voltage rise-time and improving the impedance match of the cable and motor.

Filters

A filter combines a reactor with a capacitor network. The capacitors absorb a portion of the voltage spikes. This further reduces the peak voltage seen at the motor.

When to Use a Reactor or Filter

The chart below is a general guideline when choosing between using a filter or reactor.

Motor Type

NEMA Above-Ground

Std. Efficiency

NEMA Above-Ground

Premium Efficiency

Submersible up to 50’

Lead Length

50’ to 150’ 150’ to 1000’

230 V 460V 230V 460V 230V 460V

-

-

R

R

-

R

R

F

F F

Open Design

230 or 460 V

Model

KDRA1P

DDRA2P

KDRA3P

KDRA4P

KDRB1P

KDRD1P

KDRD2P

KDRD3P

KDRD4P

KDRC1P

KDRF1P

KDRF2P

KDRF3P

KDRH1P

KDRI1P

KDRI2P

KDRG1P

Filters

NEMA 1

230 or 460 V

Model

KDRA1PC1

KDRA2PC1

KDRA3PC1

KDRA4PC1

KDRB1PC1

KDRD1PC2

KDRD2PC2

KDRD3PC2

KDRD4PC2

KDRC1PC2

KDRF1PC3

KDRF2PC3

KDRF3PC4

KDRH1PC4

KDRI1PC4

KDRI2PC4

KDRG1PC4

R = Reactor F = Filter

The following list indicates a greater need for filters and reactors:

• Long motor leads are used

• Standard efficiency or submersible motors are used.

• The cost of replacing the motor is prohibitive.

• Using a submersible motor with a voltage rating greater than 230V.

• The quality and/or age of the motor is unknown.

• Condition of wiring and/or power quality is unknown.

NEMA 1, 230, 460 or 575 V

Model

KLC4BE

KLC6BE

KLC8BE

KLC12BE

KLC16BE

KLC25BE

KLC35BE

KLC45BE

KLC55BE

KLC80BE

KLC110BE

KLC130BE

KLC160BE

KLC200BE

KLC250BE

21

27

34

40

52

65

Rated

Amps

3.4

4.8

7.6

11

14

77

96

124

156

180

240

NEMA 1, CUL Listed

Model

KLCUL4BE

KLCUL6BE

KLCUL8BE

KLCUL12BE

KLCUL16BE

KLCUL25BE

KLCUL35BE

KLCUL45BE

KLCUL55BE

KLCUL80BE

KLCUL110BE

KLCUL130BE

KLCUL160BE

KLCUL200BE

KLCUL250BE

NEMA 1

575 V

Model

KDRA31PC1

KDRA35PC1

KDRA33PC1

KDRA34PC1

KDRA36PC1

KDRD31PC2

KDRD32PC2

KDRD35PC2

KDRD33PC2

KDRD34PC2

KDRC31PC2

KDRF31PC3

KDRF32PC3

KDRF33PC4

KDRH31PC4

KDRI31PC4

KDRI32PC4

KDRG31PC4

35

45

55

80

110

130

160

200

250

Rated Amps

8

12

4

6

16

25

62

77

99

125

144

192

242

17

22

27

32

41

52

Rated

Amps

2.7

3.9

6.1

9

11

77


10.1 Description

The PPX series of pump control panels consist of a manually operated fusible disconnect switch and a magnetic contactor with a solid-state overload housed in a NEMA enclosure. The fusible disconnect switch provides motor branch short-circuit protection. The contactor is proven in field applications where wide voltage fluctuations may occur. The overload relays provide motor overload protection.

The rainproof enclosure allows all routine operations to be performed from the outside without opening the door.

The fusible disconnect switch handle is mechanically interlocked with the enclosure door to prevent opening the door before the handle is moved to the OFF position.

For better access during repair or inspection, the cover may be removed by lifting the door upward and outward.

A latch is provided to prop the door open on windy days.

The overload relay incorporates a dial for field adjustment of tripping current.

Figure 10-1: Typical NEMA Enclosure

Install in conformance with National Electrical Code and all local codes. Branch circuit protection must be provided.

These controllers have all components arranged for easy access from the front. The circuits are relatively simple and circuit components are selected for trouble-free operation. Periodically, depending on the environment and duty, the panel should be inspected and cleaned.

Inspect all devices for loose bolts and nuts.

78


Table 10-1: NEMA Full-voltage Combination Starters

NEMA size Disconnect Amps Max Total Amps

208V

1

2

3

4

30

60

100

200

13.5

27

50

70

100

135

230-240V

1

2

3

30

60

100

13.5

27

50

70

100

460-480V

1

2

3

4

5

30

60

100

200

400

13.5

27

50

70

100

135

270

575-600V

Overload Current Range (Amps)

6.5-13.5

13-27

25-50

35-70

65-135

65-135

6.5-13.5

13-27

25-50

35-70

65-135

6.5-13.5

13-27

25-50

35-70

65-135

65-135

130-270

Part Number

PPX-1A-13-30R

PPX-1A-27-30R

PPX-2A-50-60R

PPX-3A-70-100R

PPX-3A-135-100R

PPX-4A-135-200R

PPX-1B-13-30R

PPX-1B-27-30R

PPX-2B-50-60R

PPX-3B-70-100R

PPX-3B-135-100R

PPX-1C-13-30R

PPX-1C-27-30R

PPX-2C-50-60R

PPX-3C-70-100R

PPX-3C-135-200R

PPX-4C-135-200R

PPX-5C-270-400R

1

2

3

4

5

30

60

100

200

400

13.5

50

70

100

135

270

6.5-13.5

13-27

25-70

35-70

65-135

65-135

130-270

PPX-1D-13-30R

PPX-1D-27-30R

PPX-2D-50-60R

PPX-3D-70-100R

PPX-3D-135-100R

PPX-4D-135-200R

PPX-5D-270-400R

Includes complete starter with fusible switch, H-O-A selector switch, START push button, and electronic overload protection in Type 3R enclosure. Fuses are not included.

79


L1A L2A

CCF

L3A

PFR

L1B

UVR

L3B

UVR or PFR

1

IL

HAND

SEL SW

OFF

AUTO 2

START PB

3

M

M

5

OL

9

Figure 10-2: Typical PPX NEMA Size 1 through 5 Schematic

Diagram

REMOTE

DEVICE

Key:

M = Motor Contactor

IL = Indicating Light

OL = Overload

CCF = Control Circuit Fusing

PFR = Phase Failure Relay

UVR = Undervoltage Relay

Dotted Line Box = If Used

6405 0311

80


20.94

(531.8)

9.00

(228.6)

4 POINT

MOUNTING

FOR 3/8”

BOLTS

ON

32.25

(819.2)

30.4

(863.6)

32.32

(821.0)

27.50

(698.5)

50 O

SPACE

AVAILABLE FOR

MODIFICATIONS

OFF

16.0

(406.4)

2 POINT

MOUNTING

FOR 5/8” BOLTS

(IF USED)

1.19

(30.2)

2.25

(57.2)

7.00

(177.8)

29.25

(743.0)

Figure 10-3: NEMA Sizes 1 and 2 Wide-Type Enclosures ; 85 lbs. (Size 1), 90 lbs. (Size 2)

Outlines, Dimensions in in. (mm), and Weights (lbs) - For Estimating Only

6406 0311

24.81

(630.2)

9.00

(228.6)

4 POINT

MOUNTING

FOR 3/8”

BOLTS

ON

47.38

(1203.5)

45.75

(1162.0)

44.75

(1136.0) 35.0

(889.0)

50 O

OFF

42.38

(1076.3)

SPACE

AVAILABLE FOR

MODIFICATIONS

2 POINT

MOUNTING

FOR 5/8” BOLTS

(IF USED)

1.19

(30.2)

20.0

(508.0)

2.25

(57.2)

8.63

(219.1)

Figure 10-4: NEMA Sizes 3 and 4 Wide-Type Enclosures ; 195 lbs .

6407 0311

81


20.94

(531.8)

4 POINT

MOUNTING

FOR 3/8”

BOLTS

ON

50

O

52.0

(1320.8)

49.38

(1254.3)

50.38

(1279.7)

SPACE

AVAILABLE FOR

MODIFICATIONS

13.50

(342.9)

17.00

(431.8)

2 POINT

MOUNTING

FOR 5/8” BOLTS

(IF USED)

1.19

(30.2)

OFF

22.0

(558.8)

4.19

(106.4)

10.0

(254.0)

47.0

(1193.8)

Figure 10-5 NEMA Size 5 Wide-Type Enclosures; 285 lbs

Outlines, Dimensions in in. (mm), and Weights (lbs) - For Estimating Only

6408 0311

82


11.1 How it Works

Submersible Motor Controls act as an above ground control system for you submersible motor. They provide easy access to the “brains” of your motor, so you can monitor, adjust and perform maintenance without removing the motor.

There are three main groups of motor controls. Each of these controls has a slightly different function, although all serve the main purpose of providing control for the motor.

Capacitor Start / Induction Run (CSIR)

A CSIR control uses a starting capacitor and a switch.

When voltage is first applied, the switch is closed and the start capacitor is in the circuit. This provides extra torque to bring the motor up to speed. The switch is often referred to as a potential relay. The relay’s coil senses voltage across the windings. When the windings get close to full speed, they magnetize the coil and physically breaks the connection to the start windings. This takes not only the start windings out of the circuit, but the starting capacitor as well. The motor then runs on the main winding alone.

Capacitor Start / Capacitor Run (CSCR)

A CSCR control functions very similar to a CSIR control except that in addition to the starting capacitor, it also uses a running capacitor. This allows the start winding to act as an auxiliary winding during operation. This smooths out operation of the motor and provides greater efficiency and a reduction in vibration and noise.

Plus Series Controls

The Pentek ® PLUS series controls combine a CSCR design and a control circuit to provide not only starting power to the motor, but a switch to turn the control on and off. The switch takes the form of a magnetic contactor that uses a coil that physically closes the contacts when energized. The contactor allows the installer to use a pressure switch with a lower current rating, since it is not switching the full amperage of the motor.

11.2 Specifications

All Pentek Submersible Motor Controls are rated for

Indoor or Outdoor use and employ NEMA 3R enclosures.

They are rain-tight and resistant to weathering and corrosion.

The controls are rated for operation in temperatures up to 50° C (122° F). DO NOT locate the control box in direct sunlight.

The terminals can accept up to #4 AWG copper wire rated for at least 75° C. Internal wiring conforms to appliance wiring standards UL 1015 which is resistant to acids, oils, alkalies, moisture and fungus.

Pentek Submersible Motor controls are agency recognized and tested to rigorous safety standards.

For specific ratings of individual components please see the repair parts portion of the manual.

11.3 Mounting and Installation

• Mount the control boxes to a secure backing.

• Mount controls vertical and plumb.

• In order to maintain NEMA 3R, plug all unused openings.

83


60 Hz.

11.4 Wiring Connections and Replacement Parts

1/2 to 1 HP Capacitor Start, Induction Run

1/2 - 1 HP

OR

RD

Use only copper conductors

1

2

Relay

5

Start Capacitor

BK

Main (B)

YL

Y

Motor Leads

Start (R) L2

Line In

Mo dels SMC-IR0511, SMC-IR0521, SMC-IR0721 and SMC-IR1021

L1

4773 0311

1-1/2 HP Capacitor Start, Capacitor Run

NOTICE: Attach installation wiring to the top of the terminal strip. Schematics may show otherwise for clarity.

1.5 HP Std

Start

Capacitor

Installation wiring should be installed into the top of the terminal block

HP Description

1/2 Start Capacitor, 250 µF, 125v



1 Start Capacitor, 105 µF, 270v

230V Relay

115V Relay

Part Number

U17-1429-R

U17-1423-R

U17-1424-R

U17-1425-R

U17-1592-R

U17-1593-R

BL

1/2 to 1 HP Capacitor Start, Capacitor Run

1/2 to 1 HP

BK

OR 1

Relay

Start

Capacitor

BK

Main (B)

2

YL

Y

Motor Leads

5

RD

Start (R)

Use only copper conductors

BK

RD

Run

Capacitor

L2

Line In

L1

3

4776 0311

Part Number

U17-1313-R

U17-1592-R

U17-1430-R

U17-1438-R

84

HP Description



1 Start Capacitor, 86 µF, 270v

1/2 Run Capacitor, 15 µF, 370v

3/4 Run Capacitor, 23 µF, 370v

1 Run Capacitor, 23 µF, 370v

All Relay

Part Number

U17-1422-R

U17-1423-R

U17-1424-R

U17-1419-R

U17-1292-R

U17-1292-R

U17-1592-R

Model SMC-CR1521

Description

Overload Protector

Relay

Start Capacitor, 105 µF, 330v

Run Capacitor, 10 µF, 370v


60 Hz.

2 and 3 HP Standard

2 & 3 HP Std

2 and 3 HP Plus

2 and 3 HP Plus

Run

Capacitor

Start

Capacitor

Installation wiring should be installed into the top of the terminal block

Attach Installation wiring to top of terminal block

BL

3

3

Models SMC-CR2021 and SMC-CR3021

Description

Start Capacitor,105 µF, 330v, 2 HP

Start Capacitor, 208 µF, 330v, 3 HP

Run Capacitor, 20 µF, 370v, 2 HP


Main Overload Protector, 2 HP


Start Overload Protector, 2 HP


Relay - 2 HP

Relay - 3 HP

5339 0311

Part Number

U17-1430-R

U17-1428-R

U17-1440-R

U17-1443-R

U17-1319-R

U17-1322-R

U17-1320-R

U17-1323-R

U17-1592-R

U17-1432-R

Models SMC-CRP2021 and SMC-CRP3021

Description

Start Capacitor,105 µF, 330v, 2 HP

Start Capacitor, 208 µF, 330v, 3 HP







Relay - 2 HP

Relay - 3 HP

Magnetic Contactor

5341 0311

Part Number

U17-1430-R

U17-1428-R

U17-1440-R

U17-1443-R

U17-1319-R

U17-1322-R

U17-1320-R

U17-1323-R

U17-1592-R

U17-1432-R

P17-954-R

85


60 Hz.

5 HP Standard

5 HP Std

5 HP Plus

5 HP Plus


Start

Capacitor

Run Capacitors


P.S.

BL

3

Model SMC-CR5021

Description

Start Capacitors, 270 µF, 330v

Run Capacitor, 80 µF, 370v

Main Overload Protector

Start Overload Protector

Relay

5340 0311

Part Number

U17-1437-R

U17-1502-R

U117-1456A-R

U17-1321-R

U17-1432-R

Model SMC-CRP5021

Description

Start Capacitors, 270 µF, 330v

Run Capacitor, (2) 40 µF, 370v

Magnetic Contactor

Main Overload Protector

Start Overload Protector

Relay

Run Capacitors

5342 0311

Part Number

U17-1437-R

U17-1442-R

P17-953-R

U117-1456B-R

U17-1321-R

U17-1432-R

86


12.1 How They Work

Pentek ® motor protectors are designed to protect single phase pumps from dry run, dead head, jammed impeller, and over & under voltage conditions.

A calibration adjustment allows the motor protector to be calibrated to specific pumping applications, thereby reducing the possibility of false or nuisance tripping. A micro drive based voltage and current sensing circuit monitors for power fluctuations, over-current, and undercurrent conditions. When an abnormality, such as loss of suction, is detected, the motor protector deactivates its output relay and immediately disconnects the pump motor. The motor protector then activates its user-

12.2 Specifications

Parameter

1 Phase Line Voltage (±10%)

Load Range

Frequency

Power Consumption (Maximum)

Operating Temperature

Electrostatic Discharge (ESD)

Output Contact Rating (SPST)

Weight

Enclosure

Current Transformer Ratio selectable “Restart Delay” (Dry run recovery) timer.

When the timer counts to zero or power is removed and reapplied, the motor protector reactivates its output relay and turns the pump back on.

An infrared LED communicates directly with a hand-held diagnostics tool called the Informer (sold separately). The

Informer displays 16 parameters including calibration point, trip point, running points, and last fault.

NOTICE: The use of flow restrictors or unusually high head pressures at the time of calibration may interfere with the detection of dead head conditions.

SPP-111P

1/3 - 1/2 HP

(.25 - .37 kW)

115 VAC

SPP-111P-3RL

1/2 HP @ 115 VAC

(17 AMPS MAX)

.63 lbs (.28 kg)

None

N/A

1/3 - 1 HP

(.33-.75 kW)

SPP-233P

230 VAC

1/3 - 3 HP

.25 - 2.24 kW)

-40° to 158° F (-40° to +70° C)

IEC 1000-4-2, Level 2, 4kV Contact, 6 kV Air

1 HP @ 115 VAC

(17 AMPS MAX)

1 HP @ 240 VAC

(17 AMPS MAX)

3 HP @ 240 VAC

(17 AMPS MAX)

1.6 lbs (.73 kg) w/enclosure

NEMA 3R

N/A

SPP-231P

1/3 - 1 HP

(.25 - .75 kW)

50-60 Hz

5 W

.63 lbs (.28 kg)

None

N/A

SPP-235P-XX

1.6 lbs (.73 kg)

5 - 15 HP

(3.73 - 11.19 kW)

480 VA @ 240 VAC

N/A

NEMA 3R w/ LENS

SPP-235-75 – 50:5

SPP-235-100 - 75:5

SPP-235-150 -

100:5

Operating Points

Overload

Underload (Dry Run)

Overvoltage Trip Point

Undervoltage Trip Point

Nu mber of Restarts allowed in a 60 sec.

Period before lockout (Rapid Cycle

Timer)

Trip Delay Time (Overload)

Trip Delay Time (Dry Run)

Restart Delay Time

Overvoltage/Undervoltage Delay

Al l other faults (Dry Run Rec. Timer)

Terminal

Wire Gauge

Maximum Torque

132.5 VAC

95 VAC

N/A

125 % of Calibration Point

~80% of Calibration Point

265 VAC

190 VAC

4

5s

2s

5s

2-225 min

12-22

7 in-lbs

87


12.3 Mounting And Installation

Mount the Pentek ® Motor Protector in a convenient location in or near the motor control panel. If the location is wet or dusty, then the Pentek Motor Protector should be mounted in a NEMA 3R, 4, or 12 enclosure.

12.4 Wiring Connections

1. Connect one line from the fused disconnect to the

Motor protector’s “L1 IN” terminal. Run a wire from the “L1 OUT” terminal to the other in-line controls such as a pressure or float switch. See Figure 10-1.

2. Connect the other line from the fused disconnect to

Motor Protector “L2 IN” terminal. Run a wire from the

“L2 OUT” terminal to the other in-line controls such as pressure or float switches. See Figure 12-1.

NOTICE: The Motor Protector may not detect a dead head

(blocked pipe) condition on applications where the pump is undersized for a given motor or flow restrictors are used on high stage pumps or low yield wells.

GND L2 L1

RUN

LIGHT

50

2

CAL

100

150

225

RESET

CAL

LIGHT

Fused

Disconnect

Submersible Pump Protector

L1 IN

L1 OUT L2 IN L2 OUT

GND L2 L1

Fused

Disconnect

GND

L2

L1

RUN

LIGHT

Pressure

Switch

2

50

CAL

100

150

225

RESET


L1 IN

L1 OUT L2 IN L2 OUT

CAL

LIGHT

4“ Plus 3-Wire

Control Box

SW

SW

Figure 12-2: “Plus” Control Box Connection for

SPP233

GND L2

L1

50

2

CAL

100

150

225

RESET

RUN

LIGHT

CAL

LIGHT

Fused

Disconnect


L1 IN

L1 OUT L2 IN L2 OUT

Motor

GND

L2

L1

Alternate Pressure Switch

Location When Rapid Cycle

Protection is not needed

Pressure

Switch

Standard 3-Wire

Control Box

1/3 to 3 HP

L1

L2

GND

Pressure

Switch

Alternate Pressure Switch

Location When Rapid Cycle

Protection is not needed

Figure 12-3: 2-Wire Connection for SPP233

5204

5201

Motor

Figure 12-1: SPP233 Standard Control Box Connection

Calibration/Settings

NOTICE: Calibrate the Motor Protector during normal pumping conditions.

1. Turn the RESTART DELAY / CALIBRATION adjustment fully counter-clockwise to the “CAL.” position.

2. Apply power to the Motor Protector. The pump motor should be running at this point.

3. The Motor Protector is being calibrated when the

CAL. LIGHT turns on (approximately 5 seconds).

Within 10 seconds, proceed to step 4.

4. Set the RESTART DELAY / CALIBRATION adjustment to the desired Restart Delay (Dry Well Recovery Time).

If you leave the RESTART DELAY / CALIBRATION adjustment in the “CAL.” position, the unit will trip off and stay off. Turn the adjustment out of the “CAL.” position to start the pump.

Manual Reset Mode: If the RESTART DELAY /

CALIBRATION adjustment is set to “RESET”, the Motor protector is in Manual Reset mode. After the Motor

Protector shuts down due to a voltage or load problem, the RESTART DELAY / CALIBRATION adjustment must be rotated out of the “RESET” position to restart the pump.

NOTICE: Any restart delay can be by-passed by rotating the RESTART DELAY / CALIBRATION adjustment to the “RESET” position and back to the desired Restart

Delay setting.

Rapid Cycling Protection: Rapid cycling is defined as more than four restarts in a 60 second period. The Motor

Protector will lockout upon detecting a rapid cycling condition until power is removed and re-applied to the

L1 IN and L2 IN terminals. See Diagnostics Table for instructions to diagnose a rapid cycling fault.

88


13.1 Pump And Motor Problem Analysis

Problem

Overloads Trip.

Fu ses Blow or

Breaker Trips.

Lo w or No Water

Production.

Possible Cause

Pump Won’t Start.

No voltage (check with voltmeter).

Typically will be no startup noise.

Locked pump.

Low or high voltage.

Check And Restore

1. Main power supply off.

2. Blown fuse or tripped circuit breaker.

3. Wiring damage, loose connection.

4. Burnt contactor points.

1. Check for sand in system.

2. Crooked well (submersible)

1. Check with voltmeter. (±10% of nameplate voltage). Request power company correct problem.

2. Determine if wire size is correct for voltage and amperage.

1. Improve cooling for motor and controls.

2. Use ambient compensated overloads.

Hi gh ambient temperature or direct sunlight.

In correct pump sizing – mismatched motor.

High cycling rate.

Plugged inlet.

1. Check pump (gpm) make sure near B.E.P. - “Best Efficiency

Point”.

2. Recheck pump and motor model numbers prior to installation.

Keep a written record.

1. Pressure control equipment malfunction.

2. Hole in piping system.

3. Pressure/storage tank failure.

Damaged motor control.

Check components per troubleshooting.

Short or Ground.

1. Fuses give superior protection and should be used in preference to circuit breakers when possible.

2. Inspect wiring for visible signs of heat damage (discoloration, damage to insulation).

3. Disconnect power and check with ohmmeter or megohmmeter to ground.

Improper sizing.

No rotation.

Restriction in piping.

Consult manufacturer’s information / sizing chart for proper size and replace as required.

1. Motor not turning (see “Pump won’t start” above.

2. Broken shaft coupling. Ammeter will show “low” amps.

1. Check valve sticking.

2. Check valve installed backward.

3. Broken check valve poppet or flapper lodged in piping system downstream.

1. Intake screen encrusted with minerals.

2. Insufficient clearance between pump and well casing for high capacity pump. Calculate intake velocity and limit to less than

5 feet per second.

89


Pump And Motor Problem Analysis (Continued)

Problem

Lo w or no water production

(continued)

Pu mp runs all the time.

Possible Cause

Well drawdown.

Well collapsed.

Pump selection.

Hole in well piping.

Wrong rotation.

Improper sizing.

Ho le in distribution piping.

Drawdown.

Control equipment.

Check And Restore

1. Install air line upon reinstalling unit if not already present for measuring depth with tire pump and gage.

2. Measure dynamic (drawdown) level with string or resistance meter.

3. Select different pump if appropriate.

1. Unit is pumping dirty or sandy water.

2. Lift with pump hoist, check pull weight and resistance

1. Recheck operating conditions by comparing to pump curve.

2. Operate within ±5 percentage points of efficiency from B.E.P.

1. Listen for sucking sound at well head when pump shuts off.

2. Well pipe empties when submersible pump is pulled from well.

1. Three phase motor - exchange any two of the three leads in the three phase motor starter panel.

2. Single phase motor - recheck motor and control panel wiring diagrams. Change wiring as appropriate.

3. Proper rotation for motors for sub. and centrifugal pumps with

CW rotation is CCW when looking at the shaft end of the motor.

4. Make a visual flow check or observe flow meter. Amperage is not a reliable indicator of wrong rotation.

Consult manufacturer’s performance charts or curves.

1. Observe pressure loss with system shut off.

2. Look for wet spot or depression along pipe path.

1. Check for surging, irregular amperage readings with amprobe.

2. Look for bursts of air in water.

3. Listen for surging sounds in piping.

1. Control equipment incorrectly selected or installed.

2. Welded electrical contact points.

3. Pressure switch supply pipe/tube plugged with rust/scale/ice.

Hazardous pressure and risk of explosion and

scalding. If pump is running continuously at no flow (with discharge shut off), water may boil in pump and piping system. Under steam pressure, pipes may rupture, blow off of fittings or blow out of pump ports and scald anyone near.

90


Pump And Motor Problem Analysis (Continued)

Problem

Pu mp runs all the time (continued)

Electric shock.

Am meter reads high on two leads, zero on the 3rd.

Ov erload trip – ammeter reads high on all leads.

Possible Cause Check And Restore

Pump wear.

1. Check amperage - generally lower unless severe bearing damage has occurred.

Gr ounded wiring or motor.

2. Verification may require removal of pump for service and visual inspection.

1. PROCEED WITH CAUTION!

2. Remove rings and other jewelry from hands before working with live power circuits.

3. Wear insulated boots and gloves.

4. Disconnect the power, check with ohmmeter.

Moisture.

5. Progressively check wire at each splice point (or obvious damage point).

6. When ground disappears, the fault is behind the point of discovery.

7. Check motor leads to motor shell with cable splice removed to determine if ground fault is in motor or supply cable.

Protect motor, motor starter and control devices from condensation or direct water spray.

Th ree phase motor “single phasing”.

Bi nding or dragging.

Po wer supply problems.

1. One power lead is not live or online.

2. Check with local utility company to see if having problems.

3. Check local power installation for transformer problems.

4. Will not be able to observe this condition very long. Very destructive to motor windings. Motor stator will soon be destroyed if single phasing protection is not installed.

5. This problem usually requires a replacement motor.

6. Determine source, install or replace protective gear.

1. High volume of sand or other abrasives in well. Check by observing water output.

2. Severe damage to motor thrust bearing due to cavitation or abrasives.

Usually very noisy.

3. Damage to motor control system.

1. Check with voltmeter while pump is running for ±10% voltage variance.

2. Extreme grounding of motor or supply cable. Check with ohmmeter or megohmmeter.

3. Poor wiring connections. Check splice, and terminal screws for looseness. Watch for discolored cable.

91


13.2 Motor Troubleshooting Flow Charts

Troubleshooting Flow Chart

Follow the arrow from the symptom on the left, to the inspection in the middle box.

If the middle box describes to symptom, proceed to the box on the right for the solution.

Motor Does

Not Start

No power or Incorrect Voltage.

Using voltmeter, check the line terminals.

Voltage must be +/- 10% of rated voltage.

YES

NO

Fuse blown or circuit breakers tripped.

Check fuses for correct size. Check for loose, dirty or corroded connections in fuse holder. Check for tripped fuses.

YES

NO

Contact power company if voltage is incorrect.

Replace with proper fuse or reset circuit breaker.

Defective Pressure Switch.

Check voltage at contact points. Improper contact of switch points can cause lower voltage.

YES

NO

Replace pressure switch.

Defective Wiring.

Check for loose or corroded connections.

Check motor lead terminals with voltmeter for voltage.

Check resistance of the lines with an ohmmeter (POWER OFF!)

YES

Correct faulty wiring or connections.

NO

Bound Pump.

Locked rotor condition can result from misalignment between pump and motor, or sand-bound pump. Amp readings will be

3 to 6 times higher than normal.

YES

Repair or replace pump assembly.

92


Motor Troubleshooting Flow Charts (continued)


(Continued)



Motor Starts

Too Often

Pressure switch.

Check pressure switch settings, and examine for damage or defects. Is the switch damaged or set wrong?

YES Reset or replace switch.

NO

Check valve stuck open.

Damaged or defective check valve will not hold pressure. Is water draining back into the well?

NO

YES

Waterlogged tank (air supply).

Check air charging system for proper operation. Is there inadequate air in tank?

YES

Replace check valve.

Correct or replace air system.

NO

Leak in System.

Check system for leaks. Are leaks found?

YES

Replace damaged pipes or repair leaks.

93




(Continued)



Motor runs continuously

Pressure switch.

Are switch contacts “welded” in the closed position, or set too high?

YES Replace pressure switch

NO

Low well level.

Pump may exceed well capacity. Shut off pump, and wait for well to recover. Check static and drawdown levels from well head.

Does water level recover to original level?

YES

NO

Leak in system.

Check system for leaks. Are leaks found?

YES

NO

Worn pump.

Symptoms are similar to a leak in a downpipe, or low water level in the well. Reduce pressure switch setting. If pump shuts off worn parts may be at fault. Is sand found in the tank?

YES

NO

Loose or broken motor shaft.

Little or no water will be delivered if the coupling between the motor and pump shaft is loose. A jammed pumps may have caused the motor shaft to shear off.

YES

NO

Throttle pump output or reset pump to lower level.

Do not lower into sand.

Replace damaged pipes or repair leaks.

Pull pump and replace or repair.

Pull pump, replace or repair damaged parts.

Pump screen blocked.

Restricted flow may indicate a plugged intake screen. Pump may be in mud / sand.

YES

NO

Check valve stuck closed.

No water will flow past a check valve in the closed position.

YES

Clean screen and reset at less depth. May need to clean the well.

Replace check valve

94




(Continued)



Motor runs but overload protector trips

Incorrect voltage

Using voltmeter, check the line terminals.

Is the voltage more than +/- 10% of rated voltage?

YES Contact power company.

NO

Overheated protectors.

Direct sunlight or other heat source can heat up the control box and cause protectors to trip. Is control box in the sunlight or hot to touch?

NO

YES

Worn pump or motor.

Check motor running current. Is it higher than nameplate amps?

YES

NO

Shade control box, provide ventilation or move box away from heat sorce.

Replace pump end and / or motor.

Incorrect wire size.

Check wire size and run-length with wire size chart. Is it sized too small?

YES

Replace wire with correct size.

95


13.3 Testing Submersible Motor

Insulation and Winding

Resistance

Insulation Resistance

1. Turn off power!

2. Set the ohmmeter to RX100K ohms.

3. Zero the ohmmeter.

4. Connect one lead to the metal drop pipe (or to ground if the pipe is plastic).

5. Connect the other lead to any motor lead.

6. Check each power lead.

7. Compare results to the following table.

Resistance Indicates

20K ohm

500K ohm

2 M ohm

10 M ohm

20 M ohm

Damaged motor, possible result of lightning strike.

Typical of older installed motor in well.

Newly installed motor

Used motor, measured outside of well

New motor without cable

Winding Resistance

1. Turn off power!

2. Set the ohmmeter to RX1 ohm range. For values over

10, use the RX10 ohm scale.

3. Zero the ohmmeter.

4. Compare results to resistance shown in motor specifications table.

Three Phase Motors

Measure each line to each other (three readings).

Compare these to the line-to-line resistance shown in motor specification table.

• If all leads measure within the table specifications, the leads and motor are okay.

• If a lead shows a higher resistance, then there is an open in the cable or winding. Check for secure cable connections.

• If a lead shows lower resistance, then there is a short circuit in the cable or winding.

Single Phase Motors: 3-wire

• Measure the main winding (black to yellow).

• Measure the start winding (red to yellow).

• Compare these readings with the motor specification table.

• If the readings vary widely (some high, some low), the leads may be switched. Confirm that the cable colors are correct.

Single Phase Motors: 2-wire

• Measure the resistance between the two lines.

• Compare the reading with the motor specification table.

• If the reading shows a high resistance, there may be an open in the cable or motor. Check for secure cable connections.

• If the reading shows very low resistance, there may be a short in the cable or motor.

96


13.4 Smart Pump Protector Troubleshooting

RUN Light

On Steady

On Steady

Off

Off

Blinking

Off

Blinking alternately with the CAL. Light

Blinking alternately with the RUN Light

Blinking in unison with the CAL. Light

CAL. Light

Off

On Steady

On Steady

Off

Off

Blinking

Blinking in unison with the RUN Light

Problem Or Function

RUN: Pump is running, no problems in operation.

Corrective Action

None

CAL: The motor protector is in the calibration process None

CAL COMPLETE: The motor protector is calibrated,

RESTART DELAY / CALIBRATION pot was left in “CAL.” position. Pump is off.

Pump will restart as soon as the RESTART DELAY /

CALIBRATION pot is rotated out of the “CAL.” position.

OFF / MANUAL RESTART: The motor is not running.

Either the Motor protector has tripped on dry run, dead head, or overload while the RESTART DELAY

/ CALIBRATION pot was in the “RESET” position, or source power is not present.

DRY RUN / DEAD HEAD: The motor protector has shut the pump off due to a dry run or dead head condition.

The unit is timing through the restart delay and will try to restart.

If pot is in the “RESET” position, rotate out of that position. If the “CAL” light blinks, check for an overload condition. If the RUN” light blinks, look for a dry run or dead head condition. If no lights come on, check incoming power for adequate voltage.

Check for restricted flow or inadequate supply of liquid.

OVERLOAD: The motor protector has shut the pump off due to an overload condition. The unit is timing through the restart delay and will try to restart if line voltage is at an acceptable level.

VOLTAGE FAULT: The motor protector is preventing the pump from starting due to voltage problems. The voltage is being monitored and the unit will remain in this mode until the voltage is at an acceptable level.

RAPID CYCLE: The motor protector has shut down on rapid cycling. Power must be removed and reapplied to reset the unit.

Check for low or high voltage or jammed pump impeller. If these conditions do not exist, recalibrate the unit while it is drawing higher amps (Amps should not exceed SFA).

If the unit remains in this state for more than 5 seconds, check for high or low voltage.

Check for broken bladder on the pressure tank (if used), or check for defective pressure or float switch.

97


13.5 Submersible Controls

Troubleshooting

Individual Component Diagnostics

Potential Relays

Using ohm meter - Coil Resistance (2 to 5) should measure according to the specification printed on the wiring diagram.

Using ohm meter - Contact resistance (1 to 2) should measure close to zero; higher values indicate deterioration of the contacts.

When the SMC first starts a faint click should be heard very shortly after the pump activates

Start Capacitor

Using a capacitor meter – measured capacitance should be within +20% of the rating printed on the capacitor (or consult parts list for ratings).

Using ohm meter – the meter should quickly show low resistance (ohms) and move slowly to show higher resistance. Resistance should not be zero or open.

Physical Inspection – A foul smell or a buildup of black soot indicates that a start capacitor has vented usually because of heat or prolonged use.

Run Capacitor

Using a capacitor meter – measured capacitance should be within +/- 6% of the rating printed on the capacitor (or consult parts list for ratings).

Using ohm meter – the meter should quickly show low resistance (ohms) and move slowly to show higher resistance. Resistance should not be zero or open.

Physical Inspection – Run capacitors have a built in fail safe device that disconnects the capacitor in case of overheat, in the case of such an event the capacitor will bulge.

Overloads

Push overload to ensure that it is reset.

Using ohm meter – connection resistance should measure close to zero.

Magnetic Contactor

Using ohm meter – Coil Resistance should measure per specification on wiring diagram.

Using ohm meter – Resistance between T1 & L1 and T2 &

L2 should measure close to zero with contacts manually closed. Greater values indicates degradation of contacts.

Physical Inspection – Contacts should be free to move up and down.

Measurements while running

Small Box – Measurements cannot be taken while running, line voltage can be monitored with the cover off, by placing a voltmeter across L1 & L2. Winding resistance can be taken while motor is connected and should correspond to manufacturers specification.

Fatal electrical shock hazard. Only qualified persons should perform the following procedure.

Medium and Large Box - To take measurements while running, remove the cover. Turn on the pump and allow to cycle as usual. L1 to L2 should measure 230V +/- 10%, it should not dip during operation. A clamp-on ammeter can be used to measure amp draw along any number of circuits.

The larger yellow wire or main leads can be used to measure amp draw of the system, draw should spike and then come in less than 1 second. Orange lead amp draw should start out high and then drop out to become zero. If the reading stays high there is a relay problem.

The voltage between Red and Yellow should measure approximately 330V - higher values indicate no load; lower values indicate the motor (CSCR or PSC only) is not up to speed. Note that winding resistance cannot be measured while the motor is attached to the control box.

98


Submersible Controls Troubleshooting

Problem

Pump fails to turn ON – no amp draw.

Motor draws amps significantly higher than service factor.

Overload trips within

10 seconds of Startup.

Overload Trips After

10 seconds of Startup.

Pump performance is low.

Start capacitor vents contents.

Possible Cause

Damaged magnetic contactor, specifically the coil.

Damaged pressure switch.

Loose connection.

Miswired motor (e.g. Red and Black swapped).

Voltage outside of operational norms.

Drop cable too small.

Locked (stalled) rotor condition.

Miswired control.

Corrective Action

Plus Series only - replace coil.

All models - replace pressure switch.

Check to ensure that all connections are made and all screws tightened to 20 in-lbs.

Check winding resistance.

Damaged motor.

Damaged relay (welded contacts, bad coil).

Replace relay.

Wrong Control (e.g. 2 HP used on a 1 HP pump).

Install correct control.

Bad run capacitor (blown).

Replace run capacitor.

Verify motor wiring.

Verify incoming voltage.

Replace drop cable with proper size wire for installation.

Check installation.

Mis-matched motor & liquid end.

Wrong control used on motor.

Check to ensure connections match wiring diagram.

Verify installation.

Replace with correct control.

Damaged relay.

Damaged Start Capacitor.

Rapid cycle.

High ambient.

Check per above.

Check per above.

Check installation.

Do not mount in direct sunlight, provide proper ventilation.

Check per above.

Check per above.

Damaged Run Capacitor.

Chattering Relay/Bad Coil makes a clicking noise during operation.

Wiring too small for current/drop length.

Wrong control used on motor.

Installation/liquid end problem.

Damaged motor.

Check installation.


Check per installation manual.

Verify and replace.

Voltage outside of operational norms.

Drop cable too small for run length.

Wire too small for drop length.

Check with voltmeter.

Check installation.

Damaged or Incorrect Run Capacitor.

Wrong control used.

Check per above.


Line voltage outside of operational norms.

Verify incoming voltage.

Damaged relay.

Check and replace the relay or wires if they failed.

Use a low-voltage relay.

99


14.1 Installation Checklist

This checklist can be used to preview and verify steps in the installation of Pentek ® equipment. Refer to appropriate section of the manual for more information.

Electrical Power

❏ Verify that the electrical service transformers KVA rating is adequate per the Table 4-2.

❏

Verify that motor voltage and frequency on the nameplate match the power supply voltage.

❏ Verify that fuse sizes are appropriate for the installation

❏

Verify that the pump, casing and power supply are all grounded.

❏ Inspect lightning arrestors for proper sized wire and grounding. Do not rely solely on a grounding rod in the earth.

❏ Verify that the cable size from the power supply box to the pump is the correct size. See tables in section 5-4.

Motor

❏ Lead Condition.

❏ Check insulation resistance.

❏

Verify nameplate information for the service needed.

❏ Verify that the motor is correctly sized to pump.

❏ Verify that fuses, heaters and other electrical components are appropriate for the amp load.

❏

Fluid level.

Pump and Motor Assembly

❏ Verify pump shaft rotation.

❏

Verify that the pump rating matches the site requirements.

❏ Visually inspect pump and motor for electrical lead condition and splice condition.

Installation

❏ Verify that the pipe joints are tight.

❏ Verify that check valves have been installed.

❏

Verify that the cable is supported with straps or tape at least every 10 feet (3.05 m).

❏ Pump cooling.

❏ Start the pump and observe any noise, vibration, leaks or overheating.

❏ Verify that the pump performance is as specified, that the electrical current is balanced and within specifications.

Check Valves

Check valve installation is necessary for proper pump operation. The pump should have a check valve on its discharge, or within 25 feet (7.62 m) of the pump. For very deep wells, locate a check valve at least every

200 feet (61 m).

• DO NOT install the check valve midway between the pump and the ground surface. Vibration in the piping will resonate and may damage or destroy the piping or pump. Adjust check valve spacing to avoid a mid-point placement.

• Use only spring type check valves. Swing type valves can cause water hammer problems.

• Do not use drain-back style check valves (drilled).

Check valves serve the following purposes:

• Maintain Pressure: Without a check valve, the pump has to start each cycle at zero head, and fill the down pipe. This creates upthrust in the motor, and would eventually damage both the pump and motor.

• Prevent Water Hammer: If two check valves are used, and the lower one leaks, then a partial vacuum forms in the pipe. When the pump next starts, the flow fills the void area quickly and creates a shock wave that can break piping and damage the pump.

• Prevent Back-Spin: Without a functioning check valve, upon shutoff, the water drains back through the pump, and cause it to rotate backwards. This can create excessive wear on the thrust bearing, and if the pump restarts as water is flowing down the pipe, it will put an excessive load on the pump.

100


14.2 Choosing A Pump System

A typical well application can be set up using one of three electrical configurations for single-phase power. The samples below are based upon a system using a 1.5 HP,

20-22 gpm pump, with 400 feet of wire from electrical disconnect to the motor. All configurations shown are suitable methods for residential applications.

Control Box

Electrical Disconnect

(3-wire Models)

Ventilated

Well Cap

Submersible

Cable

Union

Relief

Valve

Pitless

Adapter

Check

Valve

Gate Valves

Add Torque Arrestor

(especially needed with plastic pipe)

Tape Cable

To Pipe

Pre-charged Tank

Pressure Switch

Pressure Gauge

To House Service

Pump

Motor

“Good” System

Features

• Pressure Switch

• Wire, (10-2 w/ground)

• 1.5 HP, 20-22 gpm pump

• 1.5 HP, 2-wire motor

• 85 gal. Tank

• Optional Motor Protection (SPP-233P)

Benefits

• Cost

• Simple to use

• PENTEK PSC motor offers lower operating cost

“Better” System

Features

• Control Box

• Pressure Switch


• 1.5 HP, 20-22 gpm pump

• 1.5 HP, 3-wire motor

• 85 gal. Tank

• Optional Motor Protection (SPP-233P)

Benefits

• Capacitors and switches can be replaced without removing pump

• CSCR control offers higher efficiency

• Higher starting torque than 2-wire

“Best” System

Features

• VFD

• Pressure Transducer


• 1.5 HP, 20-22 gpm pump

• 1.5 HP, 3-Phase motor

• 6 gal. Tank

Benefits

• “City-like” pressure

• Lower operating costs

• Soft start/stop

• Motor protection built into VFD

101


14.3 Sizing Submersible Pump, Motor, and Tanks

Sizing a Submersible Pump

The following steps should be taken relative to properly sizing the system.

1. Determine gpm of system and well.

2. Size of well casing and type.

3. Determine service pressure requirements.

4. Determine voltage and phase.

5. Determine discharge pipe size.

6. Calculate friction head loss.

7. Determine (total discharge) head.

8. Select the submersible pump for the above criteria, and appropriate controls for the pump.

9. Select the proper size tank for minimum one minute pump run time.

10. For starting frequency, refer to Section 5.10.

11. Determine the distance from the service entrance panel to the pump motor.

12. Determine the size wire required based on the motors maximum load amps and the distance from the service entrance to the motor.

14.4 How to Select the Correct

Pumping Equipment

Friction

Loss

Service

Pressure

Figure 12-1: Common Pump Terminology

102

Horizontal

Pipe Run

Elevation

Standing

Water

Level

Drawdown

Pump

Setting

Submergence

Head

5183 0512


The answer to four basic questions will help select the proper pump.

1. What is the size of the well? The inside diameter of the well must be known so that the proper size pump and drop pipe can be determined.

2. What is the submergence? The vertical distance in feet from the pump to the water level while the pump is operating (see Figure 12-1). If the pump is installed away from the well and is on higher ground, this elevation must also be included. This must not be confused with the standing water level.

3. What should the average discharge pressure be?

Usual average discharge pressure is 50 lbs. – half way between the 40 lbs. to 60 lbs. switch setting of most water systems. More pressure is needed when the tank is installed away from the pump and at a higher level, or when house or yard fixtures are above the pump and tank, and a larger pump must be used.

4. What capacity is required? The discharge capacity of the pump in gallons per minute that is needed for satisfactory service. The pump should have enough capacity so that it can deliver the total water requirement in 2 hours of continuous operation. See

Table 12-1 for average water requirements.

Installation Terminology

Standing or Static Water Level – distance from top of well to natural water level when pump is not operating.

Drawdown Distance – distance water level drops while pump is operating.

Drawdown or Pumping Water Level – standing water level plus drawdown.

Submergence – distance submersible pump intake screen is installed below drawdown level.

Elevation – vertical distance between top of well and service inlet.

Pump Setting – distance from top of well to pump inlet screen.

Service Pressure – pressure required (in PSI) at service inlet.

Friction Loss – loss of pressure due to friction of water flowing through pipe and fittings.

Head – discharge head (in feet) delivered when pump is operating at desired capacity.

Horizontal Pipe Run – horizontal distance between service inlet and well.

“Top of Well” also means “Pitless Adapter Level” or well exit.

“Service Inlet” also means “Storage Tank Inlet”.

Selecting a Pump

TIP: PSI can be converted to equivalent feet of head by multiplying by 2.31.

i.e. 60 psi = 138.6 feet of head

To choose a motor for your submersible pump you first must know:

• Flow required in Gallons per Minute

• Total head (Pumping level, friction losses and service pressure required)

Friction loss must be calculated, and depends upon total length, diameter and type of pipe plus additions for each fitting (valves, elbows...) in the line.

Refer to the product catalog for friction loss charts.

Table 12-1: Average Water Requirements

Av erage Water Requirements For

General Service Around The Home

And Farm

Each person per day, for all purposes . . . . . . . 50 gal.

Each horse, dry cow or beef animal. . . . . . . . . 12 gal.

Each milking cow . . . . . . . . . . . . . . . . . . . . . . . . 35 gal.

Each hog per day . . . . . . . . . . . . . . . . . . . . . . . . . 4 gal.

Each sheep per day . . . . . . . . . . . . . . . . . . . . . . . 2 gal.

Each 100 chickens per day . . . . . . . . . . . . . . . . . 4 gal.

Av erage Amount Of Water Required By

Various Home And Yard Fixtures

Drinking fountain, continuously

flowing . . . . . . . . . . . . . . . . 50 to 100 gal. per day

Each shower bath. . . . . . . . . . . . . . . . . . . Up to 60 gal.

To fill bathtub . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 gal.

To flush toilet . . . . . . . . . . . . . . . . . . . . . . . . .2.5-6 gal.

To fill lavatory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 gal.

To sprinkle 1/4” of water on each

1000 square feet of lawn . . . . . . . . . . . . . . . 160 gal.

Dishwashing machine, per load . . . . . . . . . . . . . 3 gal.

Automatic washer, per load . . . . . . . . . . Up to 50 gal.

Regeneration of domestic water softener 50-100 gal.

Av erage Flow Rate Requirements By

Various Fixtures

(gpm equals gal. per minute, gph equals gal. per hour)

Fixture

Shower

Bathtub

Toilet

New (at 60 PSI)

2.5 gpm

3 gpm

1.6 gpm

Older Style

4 to 6 gpm

4 to 8 gpm

4 to 5 gpm

Lavatory

Kitchen sink

2.5 gpm

2.2 gpm

1 to 3 gpm

2 to 3 gpm

1/2” hose and nozzle . . . . . . . . . . . . . . . . . . . . 200 gph

3/4” hose and nozzle . . . . . . . . . . . . . . . . . . . . 300 gph

Lawn sprinkler . . . . . . . . . . . . . . . . . . . . . . . . . 120 gph

103


EXAMPLE

Assume we want 16 GPM at 60 PSI from a pump drawdown level (pumping level) 100 feet below the service inlet.

We have a 35 foot horizontal run of 1 1/4” plastic pipe with two gate valves and four 90° elbows.

To find the Friction losses we must refer to friction loss charts for pipe and fittings.

We find:

• 135 feet of pipe for the total pipe run (100 + 35).

• 10 equivalent feet of pipe for the gate valves (2 x5)

• 28 equivalent feet of pipe for the elbows (7x 4)

Add these for the total equivalent length of pipe = 173

• In the friction loss charts, find the loss of head for

173 feet of 1 1/4” pipe at 16 gpm. (3.96 per 100’) = 3.96 x 1.73 = 6.8 (round to 7.0)

Add: 7 Friction loss

100 Pumping level

139 60 PSI service pressure required (60 x 2.31=138.6. Round to 139)

= 246 Total Dynamic Head.

From this sample curve we would choose the

1 1/2 HP pump.

Locate a pump with a best efficiency point near the desired flow rate (16 GPM) that meets the total head requirements (246 TDH).

Selecting a pump in this manner gives you the most efficient pump for your application.

0

CAPACITY LITRES PER MINUTE

25 50 75 100

600

175

500

400

300

1-1/2 HP

1 HP

2 HP

150

125

100

75

14.5 Sizing Tanks

Tank should be sized to accomodate starting frequency in

Section 5.10.

Refer to the dealer catalog for tank selection. Otherwise, the following procedure can be used.

Drawdown based on Boyle’s Law

Procedure:

1. Identify drawdown multiplier relating to specific application.

2. Insert multiplier (X) into the following formula:

Pump GPM x Min Run Time = Minimum Tank

Multiplier (X) Capacity Required

Example: An example of a 20 GPM pump with a minimum run time of 1 minute, installed on a

50 - 70 PSIG system pressure range:

20 GPM x 1 minute

.24 (factor)

= 83.3 minimum U.S.

gallon tank capacity

30

40

50

60

70

80

90

100

NOTICE: Drawdown will be affected by operating temperature of the system, accuracy of the pressure switch and gauge, the actual pre-charge pressure and the rate of fill.

Table 12-2: Drawdown Volume Multiplier

(Approximate)

Pump Off

Pressure

PSI 10 20

Pump Start Pressure – PSI

30 40 50 60 70 80

20 0.26

0.41

0.22

0.37

0.18

0.46

0.31

0.15

0.40

0.27

0.13

0.47

0.35

0.24

0.12

0.42

0.32

0.21

0.11

0.48

0.38

0.29

0.19

0.10

0.44

0.35

0.26

0.17

Ta nk sizing for Variable Frequency Drives

Variable Frequency Drives (VFD) may require slightly different methods for figuring tank size. Refer to

Section 8 for VFD information.

200

50

100

25

30

0

0 5 10 15 20 25

CAPACITY GALLONS PER MINUTE

Sample Pump Curve

104


14.6 Record of Installation

Outside Power:

Transformer 1

Transformer 2

Transformer 3

KVA

KVA

KVA

Cables

From Service Entrance to Pump Control:

Size

Length

AWG/MCM

ft.

Temp. Rating °F / °C (circle one)

Check appropriate boxes

❏ Copper ❏ Aluminum

❏ Jacketed ❏ Individual Conductors

From Pump Control to Motor:

Size AWG/MCM

Length

Temp. Rating

ft.

°F / °C (circle one)

Check appropriate boxes

❏ Copper ❏ Aluminum

❏ Jacketed ❏ Individual Conductors

Pump Motor Control Panel

Manufacturer / Model

Circuit Protection:

❏ Circuit Breaker:

❏ Fuse

❏

Std.

Starter

Manufacturer

Type

❏

Autotransformer

❏ Full Voltage

❏ Other

Time to full voltage

Amps

❏

Delay

Size

sec.

Amps

Heaters

Manufacturer

Qty: Amp setting

Installation Data

Controls grounded to:

❏

Motor

❏

Well Head

❏

Power Supply

❏

Buried Rod

Grounding wire size

Date

Location

Motor serial number:

AWG / MCM

T1 T2 T3

Service

Entrance

Pump

Control

Transformers

Pump

Assembly

Motor Current - Balance Worksheet

Arrangement 1

Amps

L1–T1 =

L2–T2 =

L3–T3 =

Total Amps

Average Amps

From Average Amps

Deviation L1

Deviation L2

————

————

———— Deviation L3

% Current Unbalance

Largest Deviation

% Unbalance + %

Arrangement 2

Amps

L1–T3 =

L2–T1 =

L3–T2 =

————

————

————

%

Arrangement 3

Amps

L1–T2 =

L2–T3 =

L3–T1 =

————

————

————

%

105


Record of Installation

Installer

Address

City

Phone

E-mail

Who to contact?

Owner

Address

City

Phone

E-mail

Who to contact?

Installation

Well Identification

Water Temperature

Date Installed

Signature

Pump Information

Model

State

Fax

State

Fax

GPM

PSI

Date code

Motor Nameplate Information

Manufacture

Model

HP

Voltage

Phase

Max Amps

Date code

Serial Number

Zip

Zip

@ft. TDH

VFD (Variable Frequency Drive)

Information

Drive Manufacturer

Model Number

❏ Input Filters

❏ Output Filters

Down Pipe Dia.

Casing Dia.

Static Water Level.

Total Dynamic Head

Drawdown Water Level.

Check Valve Locations

Perforated Casing

From

To

Well Screen

From

To

Pump Inlet depth

Flow Sleeve Dia.

Casing Depth

Well Depth

106

NOTES

NOTES

293 Wright Street, Delavan, Wi 53115 WWW.PUMPS.COM

Ph: 262-728-5551 OrDerS FaX: 262-728-7323

Because we are continuously improving our products and services, Pentair reserves the right to change specifications without prior notice.

© 2013 Pentair ltd. all rights reserved.

PN793 (08/20/13)

Pentair Pentek P42B0005A2 Electronic Manual

pentek

®

ElEctroNics MaNual inStallatiOn

•

OPeratiOn

•

MaintenanCe

SECTION 14: Appendix

Important Safety Instructions

All work must be done by a trained and qualified installer or service technician.

2.1 Motors

Sample:

P43B0010A2-01 is a PENTEK 4” Stainless Steel Motor

1 HP, 60 Hz., 230 V, 1 Ph., Rev. 1

Brand

Motor Size

Motor Material

Horsepower

Frequency

Voltage

Revision Code

2.2 Drives

Variable / High Speed Drive Nomenclature

PID Variable Frequency Drive Nomenclature

2.3 Submersible Motor Controls

3.1 General Installation Guidelines

3.2 Proper Grounding

3.3 Corrosive Water and Ground

3.4 Check Valves

3.5 Start-Up

Motor Torque

4.1 Mixing Wire Size with Existing

Installation

Using two different cable sizes.

4.2 Wire Splicing

Low Voltage Control

4.3 3-Phase Starters

Line Voltage Control

Separate Voltage Control

4.4 Checking Motor Rotation

Us e the Current-Balance worksheet located in the Installation Record

4.5 3-Phase Current Balancing

Current Unbalance Test

EXAMPLE

4.6 Transformer Sizing

4.7 Using a Generator

Selecting a generator

Frequency

Voltage Regulation

Generator Operation

4.8 Special Applications

Using Phase Converters

Guidelines For Phase Converters:

Motor Starting with Reduced Voltage

Motor Starters (3-Phase Only)

5.1 Motor Inspection

5.2 Testing

Insulation Resistance

5.3 Storage and Transportation

5.4 4” Motor Specifications

5.5 4” Motor Dimensions

4” Motor

Length

5.6 4” Motor Fuse Sizing

5.7 Cable Lengths

5.8 4” Motor Overload Protection

Single Phase Motors

5.9 Motor Cooling

5.10 Starting Frequency

6.1 Motor Inspection

California Proposition 65 Warning

6.2 Testing

6.3 Storage and Drain/Fill Instructions

6.3 Storage and Drain/Fill Instructions

A. Rock motor while turning shaft.

B. Fill motor; repeat rocking and filling until motor is full.

6.3 Storage and Drain/Fill Instructions

6.4 Motor Specifications

6.5 Motor Dimensions