REDJACKET

Water Products

1 Service Manual
Submersible Pumps Jet Pumps

TABLE OF CONTENTS

Table of Contents
This manual covers single phase 4 submersible pumps and jet pumps. Submersibles: (Pages 1 48) Page Typical Systems ...................................................... 1-5 Troubleshooting ................................................... 6-11 Amprobe Instructions ........................................ 12 Ohmmeter Instructions ...................................... 13 A Capacitor Checkout .......................................... 14-15 B Relay Checkout ................................................. 16-19 C Overload Checkout ........................................... 20-21 Overload Kit ................................................... 21a-21b Red Jacket Control Box Tests ............................. 22-25 D Voltage Checkout ............................................. 26-27 E Electrical Short Checkout .................................. 28-29 F Motor Winding Resistance Checkout ................. 30-33 G Cable Checkout ................................................ 34-35 H Amperage Checkout ........................................ 36-40 I Pressure Switch Adjustment .............................. 41-42 J Pressure Tank Checkout ..................................... 43-44 Submersible Pump Disassembly ....................... 45-46 Submersible Pump Reassembly ........................ 47-48 Jet Pumps: (Pages 49 81) Typical Systems .................................................... 49-53 Troubleshooting .................................................. 54-61 1 Voltage Checkout ............................................. 62-63 2 Amperage Checks ............................................. 64-65 Ohmmeter Checks ........................................... 66-71 Wiring Diagrams .............................................. 72-75 3 Checking Suction Lift ........................................ 76-77 4 Pressure Control Valves ..................................... 78-79 Jet Pump Disassembly ........................................ 80 Jet Pump Reassembly ......................................... 81

Red Jacket Water Products is a licensed trademark. The ITT Engineered Blocks symbol are registered trademark and tradename of ITT Industries.

SUBMERSIBLES

Typical Submersible System . . .

Three-wire system illustrated using galvanized tank. RULE OF THUMB
1. Use same size or larger pipe as discharge on pump. 2. Always use a check valve for every 200 ft. of vertical pipe.

Disconnect Switch Control Box

Protected Power Supply Pressure Gauge To House Piping Shut-off Valve Union Drain Tap Pressure Relief Valve Air Escape Control Pressure Switch Line Check Valve with Snifter Union

Pitless Adapter Drain and Y Fitting

NOTE: Piping below the frost line is common in colder climate areas. In warm climates, the piping is often above ground and tank placement is often outside the house and/or inside a separate cover or housing. 1

SUBMERSIBLES

Typical Submersible System . . .

Two-wire system illustrated; using diaphragm type tank. RULE OF THUMB
1. Use same size or larger pipe as discharge on pump. 2. Always use a check valve for every 200 ft. of vertical pipe. To House Piping Protected Power Supply Disconnect Switch Shut-off Valve Union Pressure Switch Pressure Relief Valve Drain Tap Pitless Adapter Check Valve Frost Level Tank Tee Check Valve

On installations with a pitless adapter the top check valve should be below the pitless, not at the tank, as the discharge line should be pressurized back to the pitless. On installations with well seals or well pits it is allowable to locate the top check valve near the tank.

CAUTION
All electrical equipment must be connected to supply ground. Follow applicable code requirements.

Franklin Electric Control Box

TYPICAL SYSTEMS

Three-wire Single Phase Wiring Diagram:

Ground Breaker or Fuse Control Box Ground To Well

Pressure Switch

Standard Red Jacket Control Box

L1

L1 Black Red Yellow

Black

Red

L2

Yellow

L2

Standard Control Box

Deluxe Control Box with Watt-Knot Voltage Surge Protector

CAUTION
All electrical equipment must be connected to supply ground. Follow applicable code requirements.

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3 and 5 HP Red Jacket Control Box with Magnetic Contactor

Run Capacitor

WattKnot WHITE GROUND LEAD

Start Capacitor

5 Relay 1 2 Line 1 Red Yel Blk Ground Pressure Switch Circuit Breaker Line 2

Ground Box According to Local and National Codes

Level or Pressure Control

712 and 10 HP Red Jacket Control Box

TYPICAL SYSTEMS

Run Capacitor

Start Capacitor

Run Capacitor

Start Capacitor

5 6 Relay Line 1 Red Yel Blk Ground White Ground Lead

WattKnot

Circuit Breaker

Line 2

Ground Box According to Local and National Codes

See the Franklin Electric AIM (Application, Installation, Maintenance) Manual for F.E. control box data and schematics.

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Troubleshooting
INDEX An amprobe and ohmmeter are essential for properly checking a system. Use of the amprobe is explained on page 12. Use of the ohmmeter is explained on page 13. Find the basic problem . . . for which numerous symptoms are listed and possible solutions are given for each: Page Pump Will Not Start ............................... 7 Pump Will Not Run ................................. 8 Pump Runs, But Little or No Water Delivered ................................ 9 Insufficient Tank Pressure ...................... 10 Pump Starts Too Frequently .................. 11

RULE OF THUMB
Remember, there may be other system problems caused by auxiliary controls not covered in this booklet.

IMPORTANT
This manual is intended ONLY for use by professionals familiar with NEC (National Electric Codes) electrical codes and hydraulic and safety procedures of pump installations. 6

TROUBLESHOOTING

Troubleshooting
Pump Will Not Start . . . If fuses and overload check okay . . . PROBLEM: ANSWER: 1. No power or See D page 26. incorrect voltage 2. Defective pressure Inspect points and switch replace switch if necessary. 3. Loose connection See E, F, G in control box, pages 28-35. cable or motor.

SUBMERSIBLES

Troubleshooting
Pump Will Not Run . . . If motor overload trips or fuses blow . . . PROBLEM: ANSWER: 1. Improper size fuses Replace with correct. 2. Wrong control box Replace with correct. 3. Incorrect voltage See D page 26. 4. Defective control box See A, B, C pages 14-21. 5. Loose connections See E page 28. in control box, Condition causes cable or motor improper resistance readings. 6. Cable insulation See G page 34. damaged or splice Condition causes may be open or improper resistance shorted readings. 7. Defective pressure Inspect points and/ switch or or replace switch if plugged tubing necessary. 8. Control box in hot Temperature not to environment exceed 122F (50C). 9. Pump bound by Pull pump and clean. abrasives See H page 36. Condition causes high amperage. 10. Motor shorted or See pages 30-33. grounded

TROUBLESHOOTING

Troubleshooting
Pump Runs, But . . . Little or no water delivered . . . PROBLEM: ANSWER: 1. Line check valve stuck Replace if defective. or installed backwards 2. Connections loose See wiring diagram or misconnected in in control box. control box 3. Incorrect voltage See D page 26. 4. Pump not submerged Check water level in well. 5. Leak in piping system Replace if necessary. 6. Worn pump Repair or replace water-end. 7. Worn motor Replace motor. 8. Suction screen or Pull pump and clean. impeller clogged 9. Broken pump shaft Replace. or coupling 10. Motor running Three phase backwards reverse 2 leads Single phase turn off for 20 seconds and restart

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Troubleshooting
Insufficient Tank Pressure . . . PROBLEM: 1. Improper pressure switch setting 2. Incorrect voltage 3. 4. 5. 6. ANSWER: See I page 41.

See D page 26. Repair or replace. Excessive pump wear Repair or replace. Leaks in piping system Repair or replace. Water level in well Drill a deeper well. too low Pump too small for Install a larger water depth horsepower pump.

10

Troubleshooting
Pump Starts Too Frequently . . . PROBLEM: 1. Waterlogged tank a. Galvanized ANSWER: Check tank for leaks. Check drain and Y fittings, snifter valve for proper operation. See J page 43. Replace if necessary. See I page 41. Repair or replace

TROUBLESHOOTING

b. Captive air type 2. Check valve stuck open 3. Improper pressure switch setting 4. Leaks in piping system 5. Pressure tank improperly sized

RULE OF THUMB
Must be sized to allow a minimum run time per cycle as follows: 1 3 112 HP = 1 minute run time 2 HP & larger = 2 minute run time

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Amprobe Instructions

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

AMPROBE/OHMMETER INSTRUCTIONS

The Ohmmeter is used for measuring the electrical resistance of a wire circuit. The unit of measurement is called an Ohm. 1. The knob at the bottom of the Ohmmeter is adjustable through six ranges: RX1 = Rx1 If your ohmmeter RX10 = R x 10 is digital readout RX100 = R x 100 type, refer to the RX1000 = R x 1,000 instructions that RX10K = R x 10,000 came with it. RX100K = R x 100,000 2. The round center knob is for the purpose of adjusting the instrument to zero (0) after clipping the two ohmmeter leads together. This must be done every time the range selection is changed. CAUTION
Use Ohmmeter only with power off. 13

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Capacitor Checkout

Capacitor with Ohmmeter

CAUTION
Discharge the capacitor before making this check. (A screwdriver can be used to make contact between capacitors posts.)

1. 2. 3. 4.

Disconnect leads to capacitor post. Setting: R x 1,000 Connect ohmmeter leads to capacitor posts. Reading: Pointer should swing toward zero, then back toward infinity.

14

Capacitor Checkout

A. CAPACITOR CHECKOUT

Quick-Disconnect Control Box

RULE OF THUMB
To recheck, reverse the OHMMETER LEADS.

15

SUBMERSIBLES

Franklin Electric Relay Checkout for to 1 HP QD Control

1 3

Boxes Relay with Ohmmeter A. Blue Relay - Solid State 1 3 1 HP QD Control Boxes Used from 1994 until present time:

Step 1, Triac Test 1. Meter setting: R x 1,000. 2. Connections: Cap and B terminal. 3. Correct meter reading: Infinity for all models.

Step 2, Coil Test 1. Meter setting: R x 1. 2. Connections: L1 and B. 3. Correct meter reading: Zero ohms for all models.

16

B. SINGLE PHASE FRANKLIN ELEC. CONTROL BOX RELAY CHECKOUT

B. Black Solid State Switch 1 3 1 HP QD Control Boxes Used from 1985 until 1994 Step 1, Triac Test Step 2, Coil Test 1. Meter setting: 1. Meter setting: R x 1. R x 1,000. 2. Connections: 2. Connections: R (Start) terminal Y (Common) and L2. and orange lead 3. Correct meter on start switch. reading: Zero 3. Correct meter ohms for all reading: Infinity models. for all models. C. Current (Amperage) Relay 1 3 1 HP QD Control Boxes Klixon relays have 4 terminals, # starts with 155252, used until January, 1985 Step 1, Coil Test 1. Meter setting: R x 1. 2. Connections: #1 & #3. 3. Correct meter reading: Less than 1 ohm for all models. Step 2, Contact Test 1. Meter setting: R x 1,000 2. Connections: #2 & #4. 3. Correct meter reading: Infinity for all models.

17

SUBMERSIBLES

F.E. Relay Checkout Continued

D. Potential (Voltage) Relay 112 15 HP, Integral HP Control Boxes GE relays have 3 terminals, # starts with 155031 Step 1, Coil Test 1. Meter setting: R x 1,000. 2. Connections: #2 & #5. 3. Correct meter readings: For 115 Volt Boxes: .7 1.8 (700 to 1,800 ohms). For 230 Volt Boxes 4.5 7.0 (4,500 to 7,000 ohms). Step 2, Contact Test 1. Meter setting: R x 1. 2. Connections: #1 & #2. 3. Correct meter reading: Zero for all models.

Contactor Checkout
Checkout procedure for Integral HP and other Contactors Contactor Coil Test (Disconnect lead from one side of coil) 1. Meter setting: R x 100 2. Connections: Coil terminals 3. Correct meter reading: 180 to 1,400 ohms Contactor Contact Test 1. Meter Setting: R x 1 2. Connections: L1 & T1 or L2 & T2 3. Manually close contacts 4. Correct meter reading: Zero ohms
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B. CONTACTOR AND FRANKLIN ELECTRIC SERVICE BOX CHECKOUT

Additional information on troubleshooting and replacement parts for Franklin Electric Single Phase Control Boxes is available in the F.E. Application-Installation-Maintenance Manual (AIM Manual). It is available online at www.franklin-electric.com or call the Franklin Electric Technical Hotline @ 800-348-2420. The AIM is also included in the Technical Section of our Water Products catalogs. A new QD diagnostic tool: the QD service box is available from Franklin Electric. It can be used to check voltage and current while the motor is running. Order it from www.franklin-electric.com using a credit card.

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SUBMERSIBLES

Franklin Electric Overload Checkout . . .

Overload Protector with Ohmmeter 1. Setting: R x 1. 2. Connect leads to black wire and blue wire. 3. Reading: 0.5 ohm maximum.

Capacitor Relay

L2 L1

OHMS

Rx1

R x 100 R x 10 Rx1

ZERO OHMS

13
R x 1000 R x 10K R x 100K

to 1 HP Quick-Disconnect Control Box

See Overload Kit Instructions page 21a. FRANKLIN MOTOR PROTECTION

Before 1985 Motor Control Box 20 No overload in Motor Jan.-July 1985 Overload in Motor After July 1985 Overload in Motor

Overload in Overload in No Overload Control Box Control Box in Control Box

F.E. Overload Checkout . . .

C. FRANKLIN ELECTRIC CONTROL BOX OVERLOAD CHECKOUT

For 112 HP (and Larger) Control Box . . . 1. Set Ohmmeter at R x 1 2. Connect the Ohmmeter leads to Terminal #1 and #3 on each Overload Protector. 3. Reading should be not more than 0.5 Ohms maximum on the scale. Integral HP Control Box

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FRANKLIN ELECTRIC OVERLOAD KIT INSTALLATION

FRANKLIN ELECTRIC OVERLOAD KIT INSTALLATION INSTRUCTIONS To add an overload assembly to a Q-D box with a Blue Q-D relay produced in February, 1992 (B92) or later. This will provide protection for a super stainless motor produced in May, 1989 (E89) and earlier.
CAPACITOR ORANGE

BLUE RED YELLOW

BLACK

CONNECTION LABEL

OVERLOAD KIT RATINGS AND PART NUMBERS RATING O.L. KIT # 1 3 115V 305 100901 1 3 230V 305 100902 1 2 115V 305 100903 1 2 230V 305 100904 3 4 230V 305 100905 1 230V 305 100906
21a

FRANKLIN ELECTRIC OVERLOAD KIT INSTALLATION INSTRUCTIONS

1. Disconnect power to the control box. 2. Remove control box cover. Disconnect yellow and orange leads and discard. 3. Install new connection label supplied with overload kit over the connection label. 4. Loosen screw on QD relay, hold down bracket. Slide overload bracket between QD relay and bracket. Tighten screw. 5. Connect overload assembly as follows; A) Yellow overload lead to L2 terminal; B) Yellow overload lead to Y (comm) terminal; C) Orange overload lead to empty capacitor terminal; D) Orange overload lead to cap terminal on QD relay. 6. Replace cover on control box and reconnect power. NOTES: See overload checkout page 20. QD control boxes produced after August 1985, (H85) do not contain an overload in the capacitor. On-winding thermal overloads were added to three-wire motors rated 1 3 1 HP in April 1985, (D85). If a control box dated August 1985, (H85) or later is applied with a motor dated December 1984, (M84) or earlier, overload protection can be provided by adding an overload kit to the control box. Franklin Electric, ph. 800-348-2420, produced two QD style control boxes; a Black Solid State QD and a new Blue Relay Control Box which has a sealed blue relay inside. The Solid State QD box uses a single overload protector. The Blue Relay Box requires a new double overload protector. The parts are identified in your Repair Part Price Book under the Capacitor/Overload or QD Relay heading. The Solid State control box part no. ends with . . . 10. The Relay box part no. ends with . . . 15. 21b

FRANKLIN ELECTRIC OVERLOAD KIT INSTALLATION

SUBMERSIBLES

Standard Red Jacket Control Box Tests

Single Phase Control Box 13, 12, 34, 1, 112, 2 HP
Proper Indication A Relay Coil L2, Red 2.5-4.5 (230V) .5-1.5 (115V) Notes 1 and 2 Remove Metal Case Run Capacitor before proceeding if installed B Run Capacitor Individual R x 10K Needle swings Terminals to right and drifts back to left Notes 3 and 5 C Start Capacitor Red, Black R x 1000 Needle swings Overload relay to right and Contacts drifts back to left Notes 4 and 5 Reinstall all components before proceeding D Ground Test Ground and R x 100K No indication ( ) all other terminals, one by one If all the above tests have been OK, replace voltage relay (possible welded contacts or out of calibration). 1. Control box terminals, except relay terminals, as indicated. 2. Will not always indicate relay out of calibration or welded contacts. 3. Indicates capacitor will take charge, but not always indicate aged capacitor. Infinity ( ) reading with no needle swing indicates an open capacitor or overload circuit breaker. Check individually with tests 4 and 1 at component terminals. Zero (0) reading indicates shorted capacitor. 4. Check each capacitor individually by removing all wires from at least one terminal. 5. Always reverse ohmmeter leads between each reading as capacitor will take a charge, but not always indicate an aged capacitor. 22 Test Component Terminals Meter Setting R x 1000

Red Jacket 3, 5, 712 and 10 HP Control Box Check with Ohmmeter

Start Relay 1. 3 & 5 HP Terminals 2-5 2. 3 & 5 HP Terminals 1-2 3. 712 & 10 HP Terminals 5-6 4. 712 & 10 HP Terminals 1-6 Contactor 1. 3 HP Coil Terminals 2. 5 HP Coil Terminals 3. 712 HP Coil Terminals 4. 10 HP Coil Terminals 5. Contact Terminals (both pair) Reading 5.0-6.7 0 2.5-4.5 0 Ohm Setting R x 1000 Rx1 R x 1000 Rx1

RED JACKET CONTROL BOX CHECK

8 8 4 8.5

R x 100 R x 100 R x 100 R x 10 R x 100k

Circuit Breaker 1. Check for continuity between the top and bottom terminals on the R x 1 scale. Check with switch in both the ON and OFF position. (In ON position, meter will read zero ohms.) (In OFF position, meter will read infinity.) Capacitors Must be checked individually R x 1000 1. Meter must deflect then drift back slowly to infinity. No deflection means capacitor is open. Steady low reading means capacitor is shorted. 23

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4 10 HP Red Jacket Control Box Start Relay Chart

Control Box No. S33NO S33N1 S50N0 S50N1 S75N1 S100N1 S150N1 200T1 300T1 500T1 756R1 1006R1 Part No. 710691 710701 710691 710701 710701 710701 710701 710701 711421 711421 711181 711171 PickDrop Voltage Voltages Coil Up -Out Volts Max. Max. Resistance Min. Min. 139 153 15 47 8.8 RX 100 130 259 288 35 94 3.9 RX 1K 253 139 153 15 47 8.8 RX 100 130 259 288 35 94 3.9 RX 1K 253 259 288 35 94 3.9 RX 1K 253 259 288 35 94 3.9 RX 1K 253 259 288 35 94 3.9 RX 1K 253 259 288 35 94 3.9 RX 1K 253 261 290 50 100 5.8 RX 1K 332 261 290 50 100 5.8 RX 1K 332 259 288 35 94 3.9 RX 1K 253 259 288 35 94 3.9 RX 1K 253

Notes: 1. Pick-up and drop-out voltage minimum and maximum are with relay at cold condition. 2. Coil resistance in ohms 10%.

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4 10 HP Red Jacket Control Box Start Capacitor Chart

Control Box Part No. S33N0 S33N1 S50N0 S50N1 S75N1 S100N1 S150N1 200T1 300T1 500T1 756R1 1006R1 U-CB0 U-CB1 Part No. 111761 111771 111781 111771 111791 112121 112121 114021 123001 123001 (2) 124871 (2) 123271 111761 12663-1 MFD Rating 161-139 53-64 189-227 53-64 64-77 88-108 88-108 108-130 165-198 165-198 243-292 324-389 161-193 64-77 Voltage AC 125 330 125 330 330 330 330 330 330 330 330 330 125 330

RED JACKET CONTROL BOX CHECK

2 10 HP Red Jacket Control Box Run Capacitor Chart

Control Box Part No. S50N0 S50N1 S75N1 S100N1 S150N1 200T1 300T1 500T1 756R1 756R1 Part No. 122511 122511 122511 122511 122511 122531 124891 124901 (2) 124811 (2) 124751 MFD Rating 10 10 10 10 10 15 35 60 35 50 Voltage AC 370 370 370 370 370 370 370 370 440 370 25

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Voltage Checkout

To Check Voltage with Franklin Electric Q.D. Type Control Box 1. Remove cover to break all motor connections. CAUTION
L1 and L2 are still connected to power.

2. To check VOLTAGE: Use voltmeter on L1 and L2 as shown. 3. When checking voltage, all other major electrical appliances (that could be in use at the same time) should be running. 4. If readings are not within the limits (see chart), call your power supplier. Voltage Limits Measured Volts Nameplate Min. Max. 115V 1 105 125 208V 1 188 228 230V 1 210 250

26

Voltage Checkout

D. VOLTAGE CHECKOUT

Also see QD service box on page 19.

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Electrical Short Checkout . . .

Measuring Insulation Resistance 1. Set the scale lever to R x 100K and adjust to 0. CAUTION
Open (turn off) master breaker and disconnect all leads from control box or pressure switch (Q-D type control, remove lid) to avoid damage to meter or electric shock hazard.

2. Connect an ohmmeter lead to any one of the motor leads and the other to the metal drop pipe. If the drop pipe is plastic, connect the ohmmeter lead to the metal well casing or ground wire.

OHMS

R x 100K Drop Cable with Ground Wire

R x 100 R x 10 Rx1

ZERO OHMS

R x 1000 R x 10K R x 100K

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Table 1 Normal Ohm and Megohm Values (Insulation Resistance) Between All Leads and Ground
Insulation resistance does not vary with rating. All motors of all HP, voltage and phase rating have similar values of insulation resistance. Condition of Motor and Leads A new motor (without drop cable). A used motor which can be reinstalled in the well. Motor in Well. Ohm readings are for drop cable plus motor. A new motor in the well. A motor in the well in reasonably good condition. A motor which may have been damaged by lightning or with damaged leads. Do not pull the pump for this reason. A motor which definitely has been damaged or with damaged cable. The pump should be pulled and repairs made to the cable or the motor replaced. The motor will not fail for this reason alone, but it will probably not operate for long. A motor which has failed or with completely destroyed cable insulation. The pump must be pulled and the cable repaired or the motor replaced. Ohm Value 20,000,000 (or more) 10,000,000 (or more) 2,000,000 (or more) 500,000 2,000,000 20,000 500,000 10,000 20,000 Megohm Value 20.0 10.0 2.0

E. ELECTRICAL SHORT CHECKOUT

0.5 2.0 0.02 0.5

0.01 0.02

Less than 10,000

0 0.01

What It Means 1. If the ohm value is normal, the motor windings are not grounded and the cable insulation is not damaged. 2. If the ohm value is below normal, either the windings are grounded or the cable insulation is damaged. Check the cable at the well seal as the insulation is sometimes damaged by being pinched. Winding Resistance Measuring When measured as shown on page 30, motor resistance only should fall within the values in Table 3, page 31. When measured through the drop cable, the size and length of the cable must be known and the correct cable resistance from Table 2 subtracted from the ohmmeter reading to get the winding resistance for comparison with Table 3. 29

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Motor Winding Resistance Checkout . . .

Measuring Winding Resistance 1. Set the scale lever to R x 1 for values under 10 ohms. For values over 10 ohms, set the scale lever to R x 10. Zero balance the ohmmeter as described earlier on page 13. CAUTION
Open master breaker and disconnect all leads from control box to pressure switch (Q-D type control, remove lid) to avoid damage to meter or electric shock hazard.

2. Connect the ohmmeter leads as shown below. Table 2 Cable Resistance Copper
Size Cable 14 12 10 8 6 4 2 If aluminum cable is used the readings will be higher. Divide the ohm readings on this chart by 0.61 to determine the actual resistance of aluminum cable. DC Resistance of Cable per 100 Foot Length Ohms per Pair of Leads .544 .338 .214 .135 .082 .052 .032

Ground Wire

OHMS

R x 100 R x 10 Rx1

ZERO OHMS

R x 1000 R x 10K R x 100K

Motor Leads

Rx1 or R x 10

30

Table 3 Motor Resistance Franklin Electric Single Phase Motors Winding Resistance Motor Only (Ohms) Super Stainless
HP
1

F. MOTOR WINDING RESISTANCE CHECKOUT

3-Wire
Main Winding Start Winding Blk to Yellow Red to Yellow

2-Wire

Dia. 4" 4" 4" 4" 4" 4" 4" 4" 4" 4" 6" 6" 6" 6" 1 115 1 230 1 115 1 230 1 230 1 230 1 230 1 230 1 1 1 1 1 1

3 2 4

1.4-1.8 6.0-7.4 1.0-1.3 4.2-5.2 3.0-3.6 2.2-2.7 1.5-2.3 1.6-2.3 .9-1.5 .68-1.0 .55-.68 .36-.50 .27-.33 .17-.22

6.5-7.9 26.1-32 4.1-5.1 16.7-20.5 11.0-13.4 10.1-12.3 6.2-12.0 5.2-7.15 3.0-4.9 1.8-2.8 1.3-1.6 .92-1.2 .80-.99 .68-.93

1.4-1.8 6.0-7.4 1.0-1.3 4.2-5.2 3.0-3.6 2.2-2.7 1.5-1.9

1 112 2 3 5 5 712 10 15

High Thrust

RULE OF THUMB
Add resistance of drop cable when checking pump in well. See Table 2 page 30.

What it Means
1. If all ohm values are normal, the motor windings are neither shorted nor open, and the cable colors are correct. 2. If any one ohm value is less than normal, the motor is shorted. 3. If any one ohm value is greater than normal, the winding or the cable is open or there is a poor cable joint or connection. 4. If some ohm values are greater than normal and some less, the leads are mixed.

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SUBMERSIBLES

Motor Winding Resistance Checkout . . .

Measuring Winding Resistance CN Motors (RJ NEMA Motor made until Dec. 1999) Chart 1 Resistance of Motor Windings 4" and 6" Motors
HP 4 3 1 3 1 2 1 2 3 4 1 112 2 3 5 712 10
1 1

3 3 1 2 1 2 3 4 1 112
1 1

3-Wire Single Phase Ohmmeter Setting RX-1 Volts Main B-Y Start R-Y Both B-R 115 1.9-2.1 5.0-5.5 7.0-7.6 115 1.4-1.5 3.9-4.3 5.2-5.8 230 5.5-6.1 15.4-17.0 20.9-23.1 115 1.0-1.1 2.5-2.8 3.5-3.8 230 3.9-4.3 10.1-11.1 13.9-15.4 230 2.9-3.2 7.3-8.1 10.2-11.3 230 2.0-2.2 5.3-6.0 7.4-8.1 230 1.8-2.0 4.3-4.7 6.0-6.7 230 1.4-1.6 3.7-4.1 5.2-5.7 230 .9-1.1 3.3-3.7 4.2-5.0 230 .6-.8 2.0-2.3 2.6-3.1 230 .45-.50 1.3-1.5 1.8-2.0 230 .45-.50 .96-1.06 1.40-1.54 2-Wire Single Phase 115 1.9-2.1 9.7-10.7 11.6-12.8 230 7.9-8.7 16.7-18.7 24.8-27.5 115 1.4-1.5 10.7-11.8 12.0-13.3 230 5.5-6.1 11.1-12.2 16.5-18.3 230 3.9-4.3 10.0-11.1 13.9-15.4 230 2.8-3.1 7.3-8.1 10.1-11.2 230 2.0-2.2 3.8-4.2 5.8-6.4

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Chart 2 Resistance of Motor Windings 4" and 6" Motors Three Phase
Size HP Volts Red Jacket Motors 3.0-3.4 11.9-13.2 2.2-2.5 8.9-9.9 1.5-1.7 6.1-6.8 .8-.95 3.1-3.5 Franklin Motors 3.2-4.1 11.3-15.0 2.4-3.0 9.7-12.0 1.8-2.2 7.0-8.7 .9-1.2 3.6-4.4

F. MOTOR WINDING RESISTANCE CHECKOUT

4" 112 230 4" 112 460 4" 2 230 4" 2 460 4" 3 230 4" 3 460 4" 5 230 4" 5 460 Notes: 1. Resistance values are approximate for normal temperature (70F) and do not include cable. Readings will be higher (20%) for a hot motor or lower (10%) for a cold motor. Well cable will increase readings as much as 100% at maximum recommended lengths shown in the cable selection chart. 2. Three-phase motors have three main windings of equal resistance. 3. Resistance readings on two-wire pigtails will show the value of main windings only. Start windings may be checked by installing a three-wire pigtail and measuring as a three-wire stator. If ground is detected, check capacitor separate from motor.

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SUBMERSIBLES

Cable Checkout . . .

Checking Cable and Splice 1. Submerge cable and splice in steel barrel of water with both ends out of water. 2. Set ohmmeter selector on R x 100K and adjust needle to zero (0) by clipping ohmmeter leads together. 3. After adjusting ohmmeter, clip one ohmmeter lead to barrel and the other to each cable lead individually, as shown. 4. If the needle deflects to zero (0) on any of the cable leads, pull the splice up out of the water. If the needle falls back to () (no reading) the leak is in the splice. 5. If leak is not in the splice, pull the cable out of the water slowly until needle falls back to ( ) (no reading). When the needle falls back, the leak is at that point. 6. If the cable or splice is bad, it should be repaired or replaced.

34

G. CABLE CHECKOUT

Checking Cable and Splice Test

OHMS

Ohmmeter Set at R x 100K

R x 100 R x 10 Rx1 ZERO OHMS R x 1000 R x 10K R x 100K

Attach this lead to Metal Tank

35

SUBMERSIBLES

Amperage Checkout . . .

Table 4 Motor Current (1) Current Motor Running Under Load (Max. Amps) Franklin Electric Super Stainless Motors 3-Wire HP
1

2-Wire Red 0 0 0 0 0 0 1.3 2.6 Black 9.2 4.6 12.0 6.0 8.0 9.8 13.1

Dia. 4" 4" 4" 4" 4" 4" 4" 4"

Volts 115 230 115 230 230 230 230 230

Yellow 9.2 4.6 12.0 6.0 8.0 9.8 11.5 13.2

Black 9.2 4.6 12.0 6.0 8.0 9.8 11.0 11.9

3 2 4

1 112 2

High Thrust HP Dia. 3 5 5 712 10 15 4" 4" 6" 6" 6" 6"

Volts 230 230 230 230 230 230

Yellow 17 27.5 27.5 42.1 51 75

Black 12.6 19.1 17.4 40.5 47.5 62.5

Red 6.0 10.8 10.5 5.4 8.9 16.9

36

Red Jacket NEMA Motor Data Chart 4 4" Motor Amperage Values (Center)
PH Idle* Name Max. Lock Fuse Code CL16 Plate Amps Rotor Size Heater Amps Amps Amps Elements (2) (3) (4) 1 4 115 1 6.2 8.8 10.1 26.0 10 N 1 3 115 1 7.2 10.5 12.1 33.5 12 N 1 3 230 1 3.6 5.3 6.1 19.5 6.5 P 1 2 115 1 8/5 14/5 16/4 42/5 17/5 M 1 2 230 1 3.3 6.8 7.2 23.0 10 L 3 4 230 1 4.4 8.0 9.2 29.5 10 L 1 230 1 6.1 10.0 10.9 41.0 12 L 112 230 1 6.2 12.0 14.1 46.0 15 J 112 230 3 3.8 6.5 8.4 37.0 10 K K42 112 460 3 2.0 3.3 4.0 18.0 5 M K32 2 230 1 8.8 16.5 18.4 57.0 20 H 2 230 3 4.5 9.0 11.3 41.0 12 J K50 2 460 3 2.3 4.5 5.8 22.0 6.5 K K34 3 230 1 15.5 21.0 27.0 96.0 25 H 3 230 3 8.0 11.8 14.7 65.0 15 K K55 3 460 3 3.6 5.9 7.2 32.0 8 L K41 5 230 1 16.5 30.5 35.0 135.0 35 G 5 230 3 11.5 19.0 21.9 95.0 25 J K62 5 460 3 6.4 9.5 10.9 56.0 12 J K52 2-Wire Motors 1 3 115 1 5.6 9.0 9.8 26.5 10 K 1 3 230 1 2.9 4.2 5.0 12.0 5 K 1 2 115 1 5.4 10.5 13.0 31.5 15 J 1 2 230 1 2.2 5.5 6.1 15.0 6.5 J 3 4 230 1 3.0 6.5 7.8 21.5 8 H 1 230 1 3.3 8.0 9.0 26.5 10 H 112 230 1 4.3 10.5 11.5 41.0 12 G * Idle amps are at rated voltage. Variations in voltage will change idle amps by 50%. 1. Maximum amps are designed values at service factor loads. Actual amps may be lower due to variations in pump load and voltage. 2. Overload protection for single phase motors are built into the motor up through 2 HP in the control box for 3 and 5 HP motors. Magnetic contactors are optional for , 3 & 5 HP single phase. All three phase magnetic starters have temperature compensated, quick-trip, three leg overload protection. 3. Use Fusetats, Fusestats or equivalent time delay fuses designed for motor starting. Separate branch circuit is recommended. 4. Normal thermal overloads used for standard motors will not trip fast enough to protect submersible motors and the quick-trip type heaters specified must be used (see Warranty). No substitutions may be made without factory approval. 37 HP Volts

H. AMPERAGE CHECKOUT

SUBMERSIBLES
Overload Heater 3&4 Trip NEMA Amps Starter (Approx.) Size Fuse Size (5) CL14 CL16

38
K70 K67 K56 K73 K72 K60 K77 K76 K67 K78 K78 K72 K87 K85 K74 K89 K86 K76 K70 K68 K56 K72 K72 K60 K75 K75 K67 K78 K77 K70 K87 K85 K73 K89 K86 K75 37.1 30.0 15.5 50.0 41.0 19.0 72.0 60.0 30.0 90.0 79.0 42.0 130.0 101.0 54.0 142.0 116.0 60.0 1 1 1 2 134 1 3 2 134 3 3 2 312 3 2 312 312 212 60 60 70 35 30 15 45 40 20 70 60 30 90 80 40 110 90 45 125 110 60 Mtr. Rtg. KVA Demand on Trans. (6) 12 12 15 11 10 10 15 13 13 22 20 20 29 27 28 38 34 34 43 40 40 Locked Rotor KVA/HP Code Letter H H G H H H K H H H G G G H H J K K G H H

Phase

Voltage

HP

Normal Amps (1)

Idle Amps (2)

Locked Amps

Chart 5 Red Jacket Motors

208 230 230 208 230 460 208 230 460 208 230 460 208 230 460 208 230 460 208 230 460

712 712 10 712 712 712 10 10 10 15 15 15 20 20 20 25 25 25 30 30 30

54.0 46.0 56.0 30.0 26.0 13.0 41.0 32.4 16.2 60.0 50.0 25.0 79.0 68.8 34.4 105.0 86.0 43.0 120.0 101.0 50.5

36.5 25.0 19.0 13 12 6 25 14 7 29 19 9.5 40 34 17 75 50 25 75 50 25

230 220 250 135 120 60 228 154 77 265 215 108 345 348 174 510 430 215 510 430 215

H. AMPERAGE CHECKOUT

NOTES: 1. Normal amps are designed values at service factor loads at rated voltages. Amps may be slightly higher or lower due to variations in pump load and voltage, but should never continuously exceed 115% of the given value. 2. Idle amps reading indicates pump uncoupled or broken shaft. Shutoff amps vary with pump (should be about 1.5 time idle amps). 3. Overload protection for single-phase motors are built into the motor up through 2 HP in the control box for 3 through 10 HP single, phase. Magnetic contactors are optional for 3, 5, 712 and 10 HP single-phase. All three-phase magnetic starters have temperature compensated, quick-trip, three leg overload protection. 4. Normal thermal overloads used for standard motors will not trip fast enough to protect submersible motors and the quick-trip type heaters specified must be used (see Warranty). No substitutions may be made without factory approval. 5. Use Fusetrons, Fusestats or equivalent time delay fuses designed for motor starting. Separate branch circuit is recommended. 6. Total transformer capacity must be equal to or greater than KVA shown. Add 15% to values if open Delta (three-phase with two transformers).

39

SUBMERSIBLES

F.E. Control Box With Cover Attached

Control Box With Cover Attached

Ground To Power Supply

Amprobe Meter set on Ampere Scale

See Franklin Electric QD Service Box on Pg. 19. Red Jacket 1 Control Box - Check Amperage on Yellow Wire.
40

Pressure Switch Adjustment Checkout . . .

I. PRESSURE SWITCH ADJUSTMENT

Square D

Adjust in Proper Sequence: 1. CUT-IN: Turn range nut (big Spring) down for higher cut-in pressure, or up for lower cut-in. 2. CUT-OUT: Turn differential nut (small spring) down for high cut-out pressure, or up for lower cut-out. CAUTION (Square D)

To avoid damage, do not exceed maximum allowable system pressure. Check switch operation after resetting. Maximum pressure 65 PSI.

41

SUBMERSIBLES

FURNAS

1. MAIN SPRING ADJUSTMENT: Turn clockwise to increase both Cut-Out and Cut-In pressure. (2 PSI/turn). 2. DIFFERENTIAL ADJUSTMENT: Turn differential nut clockwise to increase Cut-Out pressure without affecting Cut-In (3 PSI/turn). CAUTION (FURNAS)

To avoid damage, do not exceed maximum allowable system pressure. Check switch operation after resetting. Maximum pressure 80 PSI.

42

Pressure Tank Checkout Procedure . . .

J. PRESSURE TANK CHECKOUT PROCEDURE

1. To check: Shut off power supply and drain system to 0 pressure. 2. Air pre-charge in tank should be 2 psi less than the cut-in pressure of the pressure switch. Example: If pressure switch setting is 30-50 psi, tank should be pre-charged with 28 lbs. air. 3. If water at valve, replace tank. RULE OF THUMB
Improper tank sizing may cause motor damage. 1 2 to 112 HP pumps Tank draw down should be equal to the pump capacity in GPM or greater. Example: 34 HP pump; capacity 12 GPM; pressure switch setting 30/50 PSI; correct tank V140. 2 HP and larger pumps tank drawdown should be double the pump capacity in GPM. Example: 3 HP pump; capacity 30 GPM; pressure switch setting 40/60 PSI; correct tank selection: 2 V350 tanks.

43

SUBMERSIBLES
Shown with base extension
44

Repair or Replace Some Considerations While our pumps are designed for ease of repair it is important to compare the cost of repair versus the cost of water end replacement. Replacing typical wear parts such as impellers and diffusers is a cost effective choice. However, if the outside metal parts such as the casing, motor adapter and discharge head all require replacement due to extremely harsh water it may be less expensive to simply purchase a complete new water end. A new casing or discharge head will require drilling and tapping for two new cable guard holes.

PUMP DISASSEMBLY

Pump Disassembly for Typical 4" Submersible Pumps...

1. Remove 4 cable guard screws and remove cable guard. 2. Reinstall top 2 screws so that discharge head and casing may be removed as one piece.

3. Using two pipe wrenches or a vice and pipe wrench, hold the motor adapter and turn the discharge head/ casing assembly clockwise (it has left-hand threads) to loosen the assembly. 45

4. Remove the casing assembly to expose the stages. 5. If required, remove the klip ring from the top of the shaft. This will allow you to remove the stages from the shaft. Note that on units which have operated in sandy water it may be hard to disassemble the stages. 6. Remove bearing spider and adapter ring. The complete stages should be removed one at a time, disassembled and inspected. Replace worn stage assemblies as needed. 7. On most models the shaft and coupling assembly is replaceable without removing the motor adapter. Lift the shaft off and inspect the coupling and motor splines for excessive wear. On some models the shaft assembly can be removed for inspection and/or replacement by removing the motor. Replace the entire shaft/coupling assembly if either shows wear. 8. If motor replacement is necessary, remove the 4 nuts from the motor studs and separate the motor and motor adapter. If motor is OK, leave assembly intact. 9. We use several check valve styles. Some are built-in and some push in from the top (outside) of the discharge head. Replace as necessary. You may replace any built-in check valve using a standard screw-in line type check valve.

SUBMERSIBLES

46

PUMP REASSEMBLY

Pump Reassembly . . .
1. Clean all parts including the strainer. 2. Place shaft and coupling assembly onto motor spline. 3. Reattach the motor adapter to the motor. Tighten the nuts in an alternating pattern. 4. Install stage assemblies on shaft. 5. Longer units have intermediate bearing spiders and sleeve, which should be placed to divide the stages evenly. NOTE: Modified stage required directly below intermediate spider. 6. When all stages are in place, replace klip ring on shaft if required. NOTE: Models that require clip ring have a modified top stage. 7. Check upper bearing for wear and replace if loose on shaft. Place bearing spider on stack.

47

8. Replace casing/discharge head assembly, turning counterclockwise (left-hand threads). Turn it all the way down so that the casing bottoms against the flange on the motor adapter. 9. Using a pipe wrench on the motor adapter and one on the discharge head, tighten to approximately 85 lbs-ft. This will be approximately 18 to 14 turn from the hand tight position. 10. Remove the upper cable guard screws and replace the cable guard using all 4 screws. The cable guard should be straight up and down if the casing is properly tightened. 11. If you installed a new casing or discharge head they will have to be drilled and tapped to provide holes for the cable guard screws. Use a 964" drill and an 8-32 NC tap. 12. Replace the external wrap around strainer.

SUBMERSIBLES

48

Jet Pumps . . .
Since these are the basic types that have been used for many years, the vast majority of jet pump service work will be on these types . . .

JET PUMPS

RJA

RJDS

49

JET PUMPS

Typical Jet Pump System . . .

Shallow Well System illustrated is a Convertible jet pump with a pressure tank

RULES OF THUMB
All jet pumps should be located at the highest point in the suction side of the system. (Distance from well head to pump) If offset is greater than 20' . . . increase horizontal pipes by one size each. Never use pipes smaller than the pump suction tappings.

50

TYPICAL JET PUMP SYSTEMS

51

JET PUMPS

Typical Jet Pump System . . .

Deep Well Packer and twin pipe systems

52

TYPICAL JET PUMP SYSTEMS

Improper Installations Trap air Hard to prime

TRAPS AIR

Proper Installations Easy to prime

53

JET PUMPS

Troubleshooting
INDEX An amprobe, ohmmeter and vacuum pressure gauge are essential for properly checking a system. Use of the amprobe is explained on page 12. Use of the ohmmeter is explained on page 13. Use of the compound vacuum pressure gauge is explained on page 76. Find the basic problem . . . for which numerous symptoms are listed and possible solutions are given for each: Page Pump Will Not Run ............................... 55 Pump Runs, But Little or No Water Delivered ......................................... 56-57 Pump Starts and Stops Too Often .... 58-59 Insufficient Tank Pressure ...................... 60 Switch Does Not Cut Out ...................... 61 RULE OF THUMB
Remember there may be other system problems caused by auxiliary controls not covered in this booklet.

54

TROUBLESHOOTING

Troubleshooting
Pump Will Not Run . . . PROBLEM: 1. Blown fuse or power turned off 2. Broken or loose wiring connections. 3. Motor overload protection contacts open. a. Improper voltage. b. Pump bound mechanically will not turn freely. 4. Pressure switch faulty or out of adjustment. 5. Tubing or fittings on pressure switch plugged. 6. Faulty motor. ANSWER: Replace fuse close all switches. Examine all wiring and repair any bad connections. Overload contacts will close automatically in a short time. See 1 page 62 Remove motor end cap, turn motor shaft by hand. Unit should rotate freely. Adjust or replace switch. See I page 41. Remove switch tubing and/or all fittings and clean. See 2 page 64.

55

JET PUMPS

Troubleshooting
Pump Runs But . . . Little or no water delivered . . . PROBLEM: ANSWER: 1. Pump or pipes not Fill pump completely completely primed. with water through priming opening (reprime pump). a. Deep Well system Control valve must be set properly or system will not pump. See 4 pages 78 & 79. 2. Foot valve or end of a. Shallow Well suction pipe either not system Install submerged or buried. vacuum gauge See 3 page 76. b. Deep Well system Physically check well conditions. Foot valve in well or Replace foot valve if line check valve stuck necessary. (Very high closed. vacuum, 22 inches or more, see page 76). 3. Leaks on suction side Pressurize system of pump. and inspect. (Very common problem.)

56

TROUBLESHOOTING

Troubleshooting
Pump Runs But . . . PROBLEM: 4. Jet assembly plugged. ANSWER: A. Shallow Well system Clean if necessary. (Insert wire through 12" plug in shallow well adapter.) b. Deep Well system Pull jet assembly and clean. Disconnect the tubing and plug the connection in pump. If this corrects the trouble, the air control must be replaced. Check rating in product catalog.

5. Punctured diaphragm in air control. Galvanized tanks.

6. Original installation, incorrect nozzle or diffuser combination.

57

JET PUMPS

Troubleshooting
Pump Runs But . . . Pump starts and stops too often . . . POSSIBLE CAUSE: ANSWER: 1. Leaks in piping system. Pressurize piping system and inspect. Repair or replace. 2. Faulty pressure switch. Check contact points. Adjust or replace switch. See I page 41. 3. Waterlogged Pumps using Brady galvanized tank, control: Test by faulty air control. holding your ear on air control. If control is operating, air can be heard passing from control into tank when pump stops. If no air movement is heard, air control should be replaced. 4. Leaking tank or Use soapy water to air valve. find leaks. Repair or replace.

58

TROUBLESHOOTING

Troubleshooting
Pump Runs But . . . POSSIBLE CAUSE: 5. Not enough suction lift on shallow well system water flows into pump (flooded suction). 6. Insufficient vacuum or vacuum does not exist for long enough time to operate air control. 7. Improper air change in captive air tank. 8. Tank too small for pump. ANSWER: Throttle suction line with partially closed valve.

Pump requires minimum 3 vacuum for 15 seconds. See J page 43 in submersible section. Replace with proper size storage tank.

59

JET PUMPS

Troubleshooting
Pump Runs But . . . Pumps water, but does not develop 40 lbs. tank pressure. . . PROBLEM: ANSWER: 1. Leaks in well piping Pressurize piping or discharge pipe. system and inspect. 2. Jet or screen on foot Clean if necessary. valve partially plugged. 3. Improper pressure See 4 page 78. control valve setting (deep well only). 4. Suction lift too high Use vacuum gauge for shallow well on shallow well system. systems. Vacuum should not exceed 22 inches at sea level. a. Jet set too deep for On deep well system deep well system. check ratings tables in catalog for maximum jet depth. 5. Faulty air charger. Disconnect the tubing and plug the hole. If this corrects the trouble, the air control must be replaced. 6. Worn impeller hub Replace if necessary. and/or guide vane Clearance should not bore. exceed .012 on a side or .025 diametrically.

60

TROUBLESHOOTING

Troubleshooting
Pump Runs But . . . Pump develops 40 lbs. pressure, but switch does not cut out . . . PROBLEM: ANSWER: 1. Pressure switch See I page 41 in incorrectly set. submersible section. 2. Tubing or fittings Remove switch between switch and tubing and/or all pump plugged. fittings and clean. 3. Faulty switch or Replace if necessary. corroded contact points.

61

JET PUMPS

How to Use Volt-Ammeter For Voltage Check

CAUTION
Power is ON during voltage checking.

1. Attach leads to volt-ammeter and select proper voltage scale for voltage to be tested. 2. Place leads in A position to test for presence of incoming voltage. Voltage should be within + 10% of the design voltage specified on the motor nameplate in A, B and C test positions. 3. With disconnect switch in ON position, move leads to B position and test voltage flow through fuse(s). 4. The C position tests voltage at pressure switch terminals. The voltage should be within limits with the motor operating. Voltage Limits Measured Volts Nameplate Min. Max. 115V 1F 105 125 208V 1F 188 228 230V 1F 210 250

62

1. HOW TO USE VOLT AMMETER

63

JET PUMPS

How to Check Amperage

1. If attached, remove leads from volt-ammeter. Select lowest reading amperage scale according to motor nameplate rating. 2. With disconnect switch in OFF position, clamp instrument around one incoming lead at pressure switch. Turn switch ON and observe amperage as motor runs. With proper voltage, reading should not exceed the MAXIMUM LOAD AMPERAGE of motor. Excessive amps means an overloaded condition or incorrect voltage applied. Problem could also be in motor. Take readings with pump running at normal system pressure. At open discharge (zero pressure) the pump may exceed maximum amps due to no discharge head.

64

2. HOW TO CHECK AMPERAGE AT PRESSURE SWITCH

CAUTION
Power is ON during amperage testing.

65

JET PUMPS

Ohmmeter Checks . . .
CAUTION
Use ohmmeter only with POWER OFF.

Power supply OFF. Disconnect motor leads (L1 and L2). On dual-voltage motors, motor must be wired 230V for the checks listed below and illustrated on the page indicated for each check. Rewire for 230V if necessary.

CHECK: Page a. Ground ................................................. 67 b. Winding Continuity .......................... 68-69 c. Contact Points (Switch) ..................... 70-71 d. Overload Protector ........................... 72-73 e. Capacitor ......................................... 74-75
66

Ground Check . . .
CAUTION
Disconnect Power Source before checking.

2. OHMMETER CHECKS

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

67

JET PUMPS

OVERLOAD PROTECTOR GOVERNOR PRESSURE SWITCH

START CAPACITOR

Emerson Motor Shown

WIRING TERMINAL BOARD 115/230 VOLT VOLTAGE SELECTOR SWITCH

Ohmmeter Checks . . . b Winding Continuity AO Smith Motors

CAUTION
Disconnect Power Source before checking.

1. Terminal board connected for 230 V. 2. Set ohmmeter to R x 1, adjust to 0. 3. Slip a heavy piece of paper between motor switch points, discharge the capacitor and take the following ohm readings: a. Resistance between L1 and A must be the same as between A and yellow. b. Yellow to red (winding side of switch) must be the same as L1 to same red terminal. L1 = Blue wire L2 = White wire A = Purple wire
68

Ohmmeter tests on the new style terminal board with the quick-change voltage terminal plug, see picture on pg. 62 (Black plastic part with 2 wires in it) is simplified if your ohmmeter is equipped with the sharp, pointed probes rather than alligator clips. With the voltage change plug on the 230 volt terminal the Black wire in the plug is positioned on Terminal A. Simply touch one ohmmeter probe on the Black wire in the voltage change plug to get the A terminal reading. Another method is to remove the terminal board screws and place the alligator clip on the wire on the bottom side of Terminal A. Old Style (Brown) Terminal Board Wiring. A.O. SMITH MOTOR WIRING 115 VOLT 230 VOLT Black (from motor) Black (from motor) on L1 on A Black/White (Black tracer from overload) on A Black/White (Black tracer from overload) on B

2. OHMMETER CHECKS AO SMITH MOTORS

69

JET PUMPS

Ohmmeter Checks . . . b Winding Continuity Emerson Motors

CAUTION
Disconnect Power Source before checking.

1. Disconnect line leads. 2. Connect motor for 230 V operation NOTE: Do not connect power to the motor. 3. Set ohmmeter reading to R x 1K. 4. Put probes on terminals 1 and 4 on terminal board. Note resistance reading. Place probes on terminal 4 on terminal board and lead protector #3 on protector. Resistance should be the same between 1 and 4 as between 4 and Protector #3. 5. While still connected to terminal 4 and protector lead #3, depress actuator (governor). Resistance reading should go to max on ohmmeter.

70

Ohmmeter Checks . . . c Contact Points (switch) All Motors

CAUTION
Disconnect Power Source before checking.

2. OHMMETER CHECKS

1. Set ohmmeter to R x 1, adjust to 0. 2. Remove leads from switch. 3. Attach ohmmeter leads to each side of switch reading should be 0. 4. Flip governor weight to run position. Reading should be infinity.

Ohmmeter Checks . . . d Overload Protector . . .

All Motors CAUTION
Disconnect Power Source before checking.

1. Set ohmmeter to R x 1, adjust to 0. 2. Disconnect the overload leads. 3. Check resistance between terminals 1 and 2, then 2 and 3. If either reading is higher than 1, replace the overload. AO Smith Emerson 1 = Blue wire 1 = Purple wire 2 = Black/white wire 2 = Black/white wire 3 = Yellow wire 3 = Black wire
71

JET PUMPS

A.O. Smith Motor Terminal Board and Voltage Change Plug

STATOR LEADS BLACK WHITE PURPLE

BLACK TRACER YELLOW 2 3 1

115 230

BLUE

L2

PLUG

LINE LEADS

L1 YELLOW RED RED TRACER Black Tracer is a black and white wire

72

Emerson Motor Terminal Board and Voltage Change Switch

LINE 1

MOTOR WIRING

EMERSON AND AO SMITH MOTORS

LINE 2 4

115
73

JET PUMPS

Ohmmeter Checks . . . e Capacitor . . .

CAUTION
Disconnect Power Source before checking.

IMPORTANT
Discharge capacitor by touching the two terminals with the blade of an insulated handle screwdriver.

74

2. OHMMETER CHECKS
1. Set ohmmeter to R x 1,000, adjust to 0. 2. Disconnect leads on capacitor. 3. Attach ohmmeter leads to each terminal. Needle should swing to right and drift slowly to left. To double check, switch ohmmeter leads and repeat procedure. If the needle will not move or moves toward 0 and stays there, the capacitor is bad. 4. If a digital meter is used, readings should start low and rapidly increase to maximum value.

ALL MOTORS

75

JET PUMPS

Checking Suction Lift . . .

A vacuum gauge indicates total suction lift (vertical lift + friction loss = total lift) in inches of mercury. 1 on the gauge = 1.13 ft. of total suction lift (based on pump located at sea level). RULE OF THUMB
Practical suction lift at sea level is 25 ft. Deduct 1 ft. of suction lift for each 1,000 ft. of elevation above sea level.

Shallow Well System Install vacuum gauge in shallow well adapter. See opposite page. When pump is running, the gauge will show no vacuum if the end of suction pipe is not submerged or there is a suction leak. If the gauge shows a very high vacuum (22 inches or more), this indicates that the end of suction pipe is buried in mud, the foot valve or check valve is stuck closed or the suction lift exceeds capability of pump.
High Vacuum (22 inches or more) Suction pipe end buried in mud Foot valve or check valve stuck closed Suction lift exceeds capability of the pump Low Vacuum (or 0 vacuum) Suction pipe not submerged Suction leak

76

3. CHECKING SUCTION LIFT

Compound Vacuum Pressure Gauge This gauge will show the pressure or vacuum at any position in a pump or system where it is installed.

A reading of 20" on a vacuum gauge placed on the suction side of the pump would tell you that you have a vacuum or suction lift of 22.6 ft. 20" x 1.13' = 22.6 ft. Vacuum Gauge

22.6' Vertical Lift Plus Friction

77

JET PUMPS

Pressure Control Valves . . .

When pump is first started or under maximum flow condition, pressure control should be immediately adjusted to the pressure corresponding to H.P. and jet assembly used. See rating tables in catalog for proper pressure setting. 1. Turn left to reduce pressure. 2. Turn right to increase pressure. RULE OF THUMB
If pressure control valve is set too high, the air volume control will not function. If pressure control valve is set too low, the pump may not shut off.

To Adjust Pressure Control Valve: 1. Close pressure control valve. 2. Open faucet in house. 3. Turn pump on. 4. As pump picks up its prime, the pressure will begin to rise on the gauge. 5. Turn adjusting screw to set pressure control valve to pressure recommended in catalog.

78

4. PRESSURE CONTROL VALVES

AV15

Use with 12 and 34 HP pumps requiring control valve settings up to 35 PSI.

Use with pumps requiring 35 PSI or higher control valve setting: Typically all multi-stage units and single-stage pumps 1 HP and larger. Use with deep well multi-stage and high pressure units.

AV21

79

JET PUMPS

Jet Pump Disassembly . . .

Lubrication: A. The pump requires no lubrication. B. For the electric motor, refer to instructions provided by the motor manufacturer. SEAL REPLACEMENT Seal Removal: 1. Disconnect electrical service to the pump. 2. Relieve system pressure by opening a faucet or drain valve until water stops flowing. 3. Disconnect pressure switch tubing at the barbed fitting on the pump case. If tubing does not slide off barbed fitting easily, cut it as close to the fitting as possible. 4. Remove the four cap screws which hold the pump seal plate and motor to the pump case. Piping need not be disturbed. 5. Remove the pumping assembly, as one piece, (motor, seal plate, diffuser, and impeller) by carefully prying them apart from the pump case. Exercise care so as not to damage the impeller. 6. Remove the diffuser from the seal plate exposing the impeller. 7. Insert a regular slotted screwdriver into the slot in the motor shaft end at the impeller center. 8. While holding the motor shaft with the screwdriver, unscrew the impeller by turning counter-clockwise. 9. Slide rotating part of seal assembly from shaft (Figure 11). Separate seal plate from motor. 10. Remove stationary part of seal assembly (including rubber seal boot) from seal plate.

80

New Seal Installation: 1. Clean polished surface of stationary seal with a clean cloth. 2. Wet the outer edge of the rubber seal boot with a soap solution. 3. Insert rubber seal boot and ceramic seal (polished side exposed) into seal plate. Make a cardboard washer to cover the ceramic seal surface to be used while pressing seal into position. Cardboard washer is used to avoid scratching ceramic surface. Discard cardboard washer after ceramic seal installation. (Figure 11). 4. Reposition seal plate onto motor and slide rotating seal assembly onto motor shaft with carbon sealing face first until rubber end ring slides over shaft shoulder. 5. Screw impeller clockwise onto motor shaft using screwdriver in shaft end slot to hold the shaft. 6. Reattach diffuser to seal plate and carefully reposition the pumping assembly to the pump case. Attach with the four cap screws. 7. Connect the pressure tubing by pressing on to barb fitting on pump case until tubing shoulders against stop edge of fitting. If tubing was cut off, carefully remove excess tubing from barb fitting with a knife, taking care not to scratch the fitting. Motor Removal 1. Follow Steps 1-10 of Seal Removal. Motor Replacement: 1. Follow Steps 1-7 of New Seal Installation.

JET PUMP DISASSEMBLY

RULE OF THUMB
Do not start motor until pump and suction piping are filled with water. 81

NOTES

NOTES

82

NOTES

NOTES
83

REDJACKET
Water Products

2004 Red Jacket Water Products www.redjacketwaterproducts.com PRINTED IN USA RJSINGLE