Submersible_Pumps_5in_and_Larger_IOM_Manual

2.2 Assemble Pump End to Motor

Under no circumstance should the pump be run dry. Doing so may damage internal parts. We suggest you check the rotation on a three phase motor before assembling it to the water end (pump). All 4" and 6" single phase motors should rotate counterclockwise when viewed from the shaft end.

Rotation on three phase motors should match pump specifications. Due to the high-starting torque the motor should be secured in such a way as not to damage the motor but to hold the motor from spinning.

Remove the cable guard from the pump (water end). Install the motor shaft sand slinger if included with the water end in the motor mounting hardware package. Attach the water end to the motor. Align the wires in the cable guard and reinstall it to the water end.

2.3 Install Check Valve(s)

Discharge heads are threaded with NPT pipe threads. All models, without built-in check valves, require a spring loaded check valve within 25' (7.5m) of the pump discharge and below the drawdown level of the water supply. Motor manufacturers recommend additional check valves every 200' to 250' (70m) in the vertical discharge line. Check valves are used to hold pressure in the system and to prevent backspin, water hammer and upthrust.

Backspin is allowing water to flow back through the pump to drain the system. It causes the impellers and motor rotor to rotate in a reverse direction. This can cause premature thrust bearing wear and if the motor starts during backspin the shaft can be twisted or broken.

Water Hammer occurs when the lowest check valve is more than 30' above the standing water level or the lower check valve leaks and the check valve above holds. This creates a partial vacuum (void) in the discharge piping. On the next start, water moving at a very high velocity fills the void and strikes the closed check valve and the stationary water in the pipe above it, causing a hydraulic shock. This shock (water hammer) can split pipes, break joints, and damage the pump and motor. Water hammer is an easily detected noise. When discovered the pump should be immediately shut down and the installer contacted to resolve the problem.

Upthrust is an upward movement of the impellers and motor shaft. It is caused by starting the pump at zero head due to no check valve or a leaking check valve; or very low system head due to a high static water level. Repeated upthrust can cause premature failure of either or both the pump and the motor. See 4.2

2.4 Installing Pump in Well

If you are using a torque arrestor, install it per the manufacturer’s installation instructions. On top feeding wells or large diameter wells where water velocity will not cool the motor properly install a flow sleeve over the pump. See Table 3

– Required Cooling Flow.

Connect the discharge pipe to the pump discharge head.

Submersible pumps are capable of very high discharge pressures, consult with your pipe supplier to determine the best pipe material and schedule for each installation.

Lower the pump into the well. Set the pump at least 10' off the bottom but above the screens. Protect the wires from chafing on the well casing. Install a pitless adapter or similar device at the wellhead. Consult the fitting manufacturer or pitless supplier for specific installation instructions.

Using waterproof electrical tape, or wire ties, fasten the wires to the drop pipe at 10' intervals. Make sure that the tape does not loosen as it will block the pump suction if it falls down the well.

2.5 Pressure Relief Valve

Pressure relief valves are mandatory (required) on any system that is capable of producing over 100 psi or 230' TDH. In an area where a water leak or blow-off may damage property connect a drain line to the pressure relief valve. Run it to a suitable drain or an area where the water will not damage property.

2.6 Pressure Tank and Pressure Switch

(when used)

The pressure switch should be located at the tank cross tee on a single tank and as close to the center as possible on multiple tank installations. Multiple tank installations should have a manifold pipe 1½ to 2 times the size of the supply pipe from the pump. This is to reduce the friction head loss or pressure differential in the manifold. Excessive losses could cause switch chatter. There should be no filters, or high loss fittings between the switch and the tank(s). Wide open gate valves are allowed between the tank and switch.

2.7 Adjusting Tank Pre-Charge (when used)

Insure that the tank is empty of water. Use a high quality pressure gauge to check the tank pre-charge pressure. The pressure should be 2 psi below the pump cut-in (turn on) pressure. As an example, a 30-50 psi system would use a tank pre-charge of 28 psi.

Select an area where the temperature is above 34° F in which to install the tank, pressure switch, and pressure relief valve.

The tank should be located in an area where a leak will not damage property.

3.1 General

Note: Do not power the unit or run the pump until all electrical and plumbing connections are completed and the pump is filled with water.

Always follow the National Electric Code (N.E.C.) in the

U.S., or the Canadian Electrical Code in Canada, as well as all state, provincial, or local codes.

All electrical work must be performed by qualified personnel. Some local laws require installation by only

“licensed installers”.

We suggest using only copper wire. Size wire from the charts found in our ITT MAID, Motor Application & Installation

Manual, or an N.E.C.( National Electric Code) manual. If discrepancies exist the N.E.C. in the U.S., and in Canada the

Canadian Electrical Code prevails.

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3.2 Splice Drop Cable to Motor Leads

When the drop cable must be spliced or connected to the motor leads it is necessary that the splice be watertight. The splice can be done with heat shrink kits, compression fittings, or waterproof tape. Match motor leads and drop cable by color codes or identify drop cable wires to insure a proper connection at the control box.

A. Heat Shrink Splice Instructions

To use a typical heat shrink kit: strip ½" from the motor wires and drop cable wires, it is best to stagger the splices.

Place the heat shrink tubes on the wires. Place the crimps on the wires and crimp the ends. Slide the heat shrink tubes over the crimps and heat from the center outward.

The sealant and adhesive will ooze out the ends when the tube shrinks. The tube, crimps, sealant, and adhesive create a very strong, watertight seal. Overheating may burn the heat shrink tubes.

B. Taped Splice Instructions

1) Strip individual conductor of insulation only as far as necessary to provide room for a stake type connector.

Tubular connectors of the staked type are preferred. If connector O.D. is not as large as cable insulation, build-up with rubber electrical tape.

2) Tape individual joints with rubber electrical tape, using two layers; the first extending two inches beyond each end of the conductor insulation end, the second layer two inches beyond the ends of the first layer. Wrap tightly, eliminating air spaces as much as possible.

3) Tape over the rubber electrical tape with #33 Scotch electrical tape, or equivalent, using two layers as in step

“B” and making each layer overlap the end of the preceding layer by at least two inches.

C. Compression Splice Kits

Consult instructions supplied with compression splice kits or consult your local supplier.

3.3 Mounting the Motor Control Box

Single phase 3-wire control boxes are suitable for vertical mounting in indoor or outdoor locations. They will operate at temperatures between 14ºF ( -10º C) and 122º F (50º C).

Select a shaded, dry place to mount the box. Insure that there is enough clearance for the cover to be removed.

3.4 Verify Voltage

Insure that motor nameplate voltage and power supply voltage are the same. Three-phase starter coils are very voltage sensitive, always verify actual supply voltage with a voltmeter. High or low voltage will damage motors and controls and is not covered under warranty.

3.5 Turn Supply Power Off

Use a disconnect switch where required by code. Turn the circuit breaker OFF and lock-out the disconnect switch in the OFF position to prevent accidentally starting the pump before you are ready.

3.6 Make Connection to Single Phase (1Ø)

Control Box or Three Phase (3Ø) Starter

DANGER

Do not power the unit or run the pump until all electrical and plumbing connections are completed. Exception – to verify 3 phase motor rotation, it is acceptable to power the motor before it is attached to the water end to verify correct rotation. After checking rotation lock-out disconnect or circuit breaker in OFF position!

Verify that the disconnect or breaker is OFF before making any connections to the power supply. Always follow the

National Electric Code (N.E.C.) in the U.S., or the Canadian

Electrical Code in Canada, as well as all state, provincial, or local codes.

A. Single Phase (1Ø) Three-Wire Control Box Wiring

CAUTION

Connect the color coded motor leads to the motor control box terminals –

Y (yellow), R (red), and B (black); and the Green or bare wire to the green ground screw.

Connect wires between the Load terminals on the pressure switch and control box terminals L1 and L2. Run a ground wire between the switch ground and the control box ground. See Fig. 7 or 8

B. Three Phase (3Ø) Starter Wiring

CAUTION

Connect the motor leads to T1, T2, and T3 on the 3 phase starter. Connect the ground wire to the ground screw in the starter box. Follow starter manufacturers instructions for connecting pressure switch (where used) to starter. See Fig. 9 or 10

3.7 Make Power Supply Connection

CAUTION

Provide a separate fused or circuit breaker protected branch circuit for the pump. Install a main disconnect switch in full view and easily accessible from the pressure switch and tank location.

Single phase:

With pressure switch – make the connection from the pressure switch Line terminals to the disconnect switch (where used) and then to the circuit breaker panel.

Without pressure switch – make the connection from the control box L1 and L2 terminals to the disconnect switch

(where used) and then to the circuit breaker panel.

Three phase - make the connections between L1, L2, L3, and ground on the starter to the disconnect switch and then to the circuit breaker panel.

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