Reduced_Size_Appendix_E_Remediation_System_OEMs_pps._1-1130.pdf

SD/PL-3/rg/DO-0004 Document Control Number PL3-005

9.14.15 Revision 0 – September 2015

AAppppeennddiixx EE RReemmeeddiiaattiioonn SSyysstteemm OOEEMMss

((OOrriiggiinnaall EEqquuiippmmeenntt MMaannuuffaaccttuurreerrss’’ MMaannuuaallss))

EE--11 TTaannkk 6633 RReeccoovveerryy SSyysstteemm ((SSeepptt.. 22001155)) EE--22 RReemmeeddiiaattiioonn CCoommppoouunndd TTrreeaattmmeenntt SSyysstteemm ((SSeepptt.. 22001155))

EE--33 PPrroodduucctt HHoollddiinngg aanndd TTrraannssffeerr SSyysstteemm ((SSeepptt.. 22001155)) EE--44 EEfffflluueenntt MMoonniittoorriinngg aanndd DDiisscchhaarrggee SSyysstteemm ((SSeepptt.. 22001155))

EE--55 EEmmiissssiioonnss aanndd OOffff--GGaass RReeccoovveerryy ((SSeepptt.. 22001155)) EE--66 RReemmeeddiiaattiioonn CCoommppoouunndd EEqquuiippmmeenntt ((SSeepptt.. 22001155))

EE--77 RReemmeeddiiaattiioonn CCoommppoouunndd EElleeccttrriiccaall && CCoonnttrroollss ((SSeepptt.. 22001155))

APPENDIX E

Tank 63 Recovery System

(Sept. 2015)

Grundfos-Redi-Flo-4-Manual

Franklin Electric 3-Phase Submersible

HW Pump Power Plug

Level Transducer - AST

Flow Meter and Totalizer - GPI

Level TROLL_500

BaroTROLL-100-200

Please leave these instructions with the pump for future reference.

Redi-Flo4 Stainless Steel Submersible Pumps for Environmental Applications

GRUNDFOS INSTRUCTIONS

US Installation and operating instructions

SAFETY WARNING

Grundfos Stainless Steel Submersible Pumps Your Grundfos Redi-Flo4 Environmental Pump is of the utmost quality. Combined with proper installation, your Grundfos pump will give you many years of reliable service.

To ensure the proper installation of the pump, carefully read the complete manual before attempting to install the pump.

Shipment Inspection

Examine the components carefully to make sure no damage has occurred to the pump-end, motor, cable or control box during shipment.

This Grundfos Redi-Flo4 Environmental Pump should remain in its shipping carton until it is ready to be installed. The carton is specially designed to protect it from damage. During unpacking and prior to installation, make sure that the pump is not contaminated, dropped or mishandled.

The motor is equipped with an electrical cable. Under no circumstance should the cable be used to support the weight of the pump.

You will find a loose data plate wired to the pump. It should be securely mounted at the well or attached to the control box.

PRE-INSTALLATION CHECKLIST

Before beginning installation, the following checks should be made. They are all critical for the proper installation of this submersible pump.

A. Condition of the Well

If the pump is to be installed in a new well, the well should be fully developed and bailed or blown free of cuttings and sand. Dispose of discharged materials in accordance with the specific job site requirements. The stainless steel construction of the Redi-Flo4 Environmental Pump makes it resistant to abrasion; however, no pump, made of any material, can forever withstand the destructive wear that occurs when constantly pumping sandy groundwater.

Determine the maximum depth of the well, and the drawdown level at the pump’s maximum capacity. Pump selection and setting depth should be based on this data.

The inside diameter of the well casing should be checked to ensure that it is not smaller than the size of the pump and motor.

B. Condition of the Water Redi-Flo4 pumps are designed for pumping cold groundwater that is free of air or gases.

Decreased pump performance and life expectancy can occur if the groundwater is not cold or contains air or gases.

C. Installation Depth Pumping sand or well sediment can occur when the pump motor is installed lower than the top of the well screen or within five feet of the well bottom. This can reduce the performance and life expectancy of the pump and should be avoided.

If the pump is to be installed in a lake, containment pond, tank or large diameter well, the water velocity passing over the motor must be sufficient to ensure proper motor cooling.

The minimum recommended water flow rates which ensure proper cooling are listed in Table A.

D. Electrical Supply The motor voltage, phase and frequency indicated on the motor nameplate should be checked against the actual electrical supply.

WIRE CABLE TYPE

The wire cable used between the pump and control box or panel should be approved for submersible pump applications. The conductor insulation should have a continuous Teflon® jacket with no splices and must be suitable for use with submersible pumps.

INSTALLATION

The riser pipe or hose should be properly sized and selected based on estimated flow rates and friction-loss factors.

A back-up wrench should be used when the riser pipe is attaching a riser pipe or metallic nipple to the pump. The pump should only be gripped by the flats on the top of the discharge chamber. The body of the pump, cable guard or motor should not be gripped under any circumstance.

If Steel Riser Pipe Is Used:

An approved pipe thread compound should be used on all joints. Make sure the joints are adequately tightened in order to resist the tendency of the motor to loosen the joints when stopping and starting.

When tightened, the first section of the riser pipe must not come in contact with the check valve retainer in the discharge chamber of the pump.

PRE-INSTALLATION CHECKLIST

After the first section of the riser pipe has been attached to the pump, the lifting cable or elevator should be clamped to the pipe. Do not clamp the pump. When raising the pump and riser section, be careful not to place bending stress on the pump by picking it up by the pump-end only.

Make sure that the electrical cables are not cut or damaged in any way when the pump is being lowered in the well.

The drop cable should be secured to the riser pipe at frequent intervals to prevent sagging, looping or possible cable damage.

If Plastic or Flexible Riser Pipe Is Used:

Use the correct compound recommended by the pipe manufacturer or specific job specifications. Besides making sure that joints are securely fastened, the use of a torque arrester is recommended when using these types of pipe.

Do not connect the first plastic or flexible riser section directly to the pump.

Always attach a metallic nipple or adapter into the discharge chamber of the pump. When tightened, the threaded end of the nipple or adapter must not come in contact with the check valve retainer in the discharge chamber of the pump.

The drop cable should be secured to the riser pipe at frequent intervals using an approved clip or tape to prevent sagging, looping and possible cable damage.

IMPORTANT - Plastic and flexible pipe tend to stretch under load. This stretching must be taken into account when securing the cable to the riser pipe.

Leave enough slack between clips or taped points to allow for this stretching. This tendency for plastic and flexible pipe to stretch will also affect the calculation of the pump setting depth. If the depth setting is critical, check with the manufacturer of the pipe to determine how to compensate for pipe stretch.

When these types of pipe are used, it is recommended that a safety cable be attached to the pump to lower and raise it. The discharge piece of Redi-Flo4 submersibles is designed to accommodate this cable (Figure 4).

Protect the Well from Contamination While installing the pump, proper care should be used not to introduce foreign objects or contaminants into the well. The well should be finished off above grade to protect against surface water from entering the well, causing contamination.

INSTALLATION

NOTE: Teflon® is a registered trademark of DuPont.

FIGURE 4

ELECTRICAL

WARNING: To reduce the risk of electrical shock during operation of this pump requires the provision of acceptable grounding. If the means of connection to the supply connected box is other than grounded metal conduit, ground the pump back to the service by connecting a copper conductor, at least the size of the circuit supplying the pump, to the grounding screw provided within the wiring compartment.

All electrical work should be performed by a qualified electrician in accordance with the latest edition of the National Electrical Code, local codes and regulations.

Verification of the electrical supply should be made to ensure the voltage, phase and frequency match that of the motor. Motor voltage, phase, frequency and full-load current information can be found on the nameplate attached to the motor. Motor electrical data can be found in Table C.

If voltage variations are larger than ± 10%, do not operate the pump.

Direct on-line starting is used due to the extremely fast run-up time of the motor (0.1 second maximum), and the low moment of inertia of the pump and motor. Direct on-line starting current (locked rotor amp) is between 4 and 6.5 times the full-load current.

Engine-Driven Generators If the Redi-Flo4 pump is going to be operated using an engine driven generator, we suggest the manufacturer of the generator be contracted to ensure the proper generator is selected and used. See Table B for generator sizing guide.

Control Box/Panel Wiring Single-phase motors must be connected as indicated in the motor control box. A typical single-phase wiring diagram using a Grundfos control box is shown (Figure 5-A).

High Voltage Surge Arresters A high voltage surge arrester should be used to protect the motor against lightning and switching surges. The correct voltage-rated surge arrester should be installed on the supply(line) side of the control box (Figure 5-B). The arrester must be grounded in accordance with the National Electric Code, local codes and regulations.

FIGURE 5-A

FIGURE 5-B

Single-Phase Wiring Diagram for GRUNDFOS Control Boxes

Single Phase Hookup

ELECTRICAL

Control Box and Surge Arrester Grounding The control box shall be permanently grounded in accordance with the National Electrical Code and local codes or regulations. The ground wire should be a bare copper conductor at least the same size as the drop cable wire size. The ground wire should be run as short a distance as possible and be securely fastened to a true grounding point.

True grounding points are considered to be: a grounding rod driven into the water strata, steel well casing submerged into the water lower than the pump setting level, and steel discharge pipes without insulating couplings. If plastic discharge pipe and well casing are used, a properly sized bare copper wire should be connected to a stud on the motor and run to the control panel. Do not ground to a gas supply line. Connect the grounding wire to the ground point first and then to the terminal in the control box or panel.

Wiring Checks Before making the final wiring connections of the drop cable to the control box terminal, it is a good practice to check the insulation resistance to ensure that the cable is good.

Measurements for a new installation must be at least 1,000,000 ohm. Do not start the pump if the measurement is less than this. If it is higher, finish wiring and verify that all electrical connections are made in accordance with the wiring diagram. Check to ensure the control box and high voltage surge arrester have been grounded.

START-UP

After the pump has been set into the well and the wiring connections have been made, the following procedures should be performed:

A. Attach a temporary horizontal length of pipe with installed gate valve to the riser pipe.

B. If required, make provisions to capture discharged fluids for disposal.

C. Adjust the gate valve one-third open.

D. Start the pump and let it operate until the water runs clear of sand and silt.

E. As the water clears, slowly open the gate valve in small increments until the desired flow rate of clear water is reached. The pump should not be operated beyond its maximum flow rating and should not be stopped until the groundwater runs clear.

F. If the groundwater is clean and clear when the pump is first started, the valve should still be opened until the desired flow rate is reached.

G. Disconnect the temporary piping arrangements and complete the final piping connections.

H. Under no circumstances should the pump be operated for any prolonged period of time with the discharge valve closed. This can result in motor damage due to overheating. A properly sized relief valve should be installed at the well head to prevent the pump from running against a closed valve.

I. Start the pump and test the system. Check and record the voltage and current draw on each motor lead.

OPERATION

A. The pump and system should be periodically checked for water quantity, pressure, drawdown, periods of cycling, and operation of controls. Under no circumstances should be the pump be operated for any prolonged periods of time with the discharge valve closed. This can result in motor and pump damage due to overheating. A properly sized relief valve should be installed at the well head to prevent the pump from running against a closed valve.

B. If the pump fails to operate, or there is a loss of performance, refer to Troubleshooting, Section 7.

TROUBLESHOOTING

The majority of problems that develop with submersible pumps are electrical, and most of these problems can be corrected without pulling the pump from the well. The following charts cover most of the submersible service work. As with any troubleshooting procedure, start with the simplest solution first; always make all the above-ground checks before pulling the pump from the well.

Usually only two instruments are needed – a combination voltmeter/ammeter, and an ohmmeter. These are relatively inexpensive and can be obtained from most water systems suppliers.

WHEN WORKING WITH ELECTRICAL CIRCUITS, USE CAUTION TO AVOID

ELECTRICAL SHOCK. It is recommended that rubber gloves and boots be worn and that care is taken to have metal control boxes and motors grounded to power supply ground or steel drop pipe or casing extending into the well. WARNING:

Submersible motors are intended for operation in a well. When not operated in a well, failure to connect motor frame to power supply ground may result in serious electrical shock.

TROUBLESHOOTING

Preliminary Tests

SUPPLY

VOLTAGE

How to Measure

By means of a voltmeter, which has been set to the proper scale, measure the voltage at the control box. On single-phase units, measure between line and neutral.

What it Means

When the motor is under load, the voltage should be within ± 10% of the nameplate voltage. Larger voltage variation may cause winding damage.

Large variations in the voltage indicate a poor electrical supply and the pump should not be operated until these variations have been corrected.

If the voltage constantly remains high or low, the motor should be changed to the correct supply voltage.

CURRENT

MEASUREMENT

How to Measure

By use of an ammeter, set on the proper scale, measure the current on each power lead at the control box. See the Electrical Data, Table C, for motor amp draw information.

Current should be measured when the pump is operating at a constant discharge pressure with the motor fully loaded.

What it Means

If the amp draw exceeds the listed service factor amps (SFA), check for the following:

1. Loose terminals in control box or possible cable defect. Check winding and insulation resistances.

3. Too high or low supply voltage.

4. Motor windings are shorted.

5. Pump is damaged causing a motor overload.

WINDING

RESISTANCE

How to Measure

Turn off power and disconnect the drop cable leads in the control box. Using an ohmmeter, set the scale selectors to Rx1 for values under 10 ohms and Rx10 for values over 10 ohms.

Zero-adjust the meter and measure the resistance between leads. Record the values.

Motor resistance values can be found in Electrical Data, Table C. Cable resistance values are in Table D.

What it Means

If all the ohm values are normal, and the cable colors correct, the windings are not damaged. If any one ohm value is less than normal, the motor may be shorted. If any one ohm value is greater than normal, there is a poor cable connection or joint. The windings or cable may also be open. If some of the ohm values are greater than normal and some less, the drop cable leads are mixed. To verify lead colors, see resistance values in Electrical Data, Table C.

INSULATION

RESISTANCE

How to Measure

Turn off power and disconnect the drop cable leads in the control box. Using an ohm or mega ohmmeter, set the scale selector to Rx 100K and zero-adjust the meter.

Measure the resistance between the lead and ground (discharge pipe or well casing, if steel).

What it Means

For ohm values, refer to table below.

Motors of all Hp, voltage, phase and cycle duties have the same value of insulation resistance.

TROUBLESHOOTING CHART

OHM VALUE MEGAOHM VALUE CONDITION OF MOTOR AND LEADS

Motor not yet installed:

2,000,000 (or more) 2.0 New Motor.

1,000,000 (or more) 1.0 Used motor which can be reinstalled in the well.

Motor in well (Ohm readings are for drop cable plus motor):

500,000 - 1,000,000 0.5 - 1.0 A motor in reasonably good condition.

20,000 - 500,000 0.02 - 0.5 A motor which may have been damaged by lightning or with damaged leads. Do not pull the pump for this reason.

10,000 - 20,000 0.01 - 0.02 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 still operate, but probably not for long.

less than 10,000 0 - 0.01 A motor which has failed or with completely destroyed cable insulation.

The pump must be pulled and the cable repaired or the motor replaced. The motor will not run in this condition.

A. Pump Does Not Run

POSSIBLE CAUSES HOW TO CHECK HOW TO CORRECT

1. No power at pump panel.

Check for voltage at panel. If no voltage at panel, check feeder panel for tripped circuits.

2. Fuses are blown or circuit breakers are tripped.

Remove fuses and check for continuity with ohmmeter.

Replace blown fuses or reset circuit breaker. If new fuses blow or circuit breaker trips, the electrical installation and motor must be checked.

3. Defective controls. Check all safety and pressure switches for operation. Inspect contacts in control devices.

Replace worn or defective parts.

4. Motor and/or cable are defective.

Turn off power. Disconnect motor leads from control box. Measure the lead to lead resistances with the ohmmeter (Rx1). Measure lead to ground values with ohmmeter (Rx100K). Record measured values.

If open motor winding or ground is found, remove pump and recheck values at the surface. Repair or replace motor or cable.

5. Defective capacitor. Turn off the power, then discharge capacitor. Disconnect leads and check with an ohmmeter (Rx100K).

When meter is connected, the needle should jump forward and slowly drift back.

If there is no needle movement, replace the capacitor.

POSSIBLE CAUSES HOW TO CHECK HOW TO CORRECT

Check drawdown during pump operation.

Lower pump if possible. If not, throttle discharge valve and install water level control.

2. Discharge piping or valve leaking.

Examine system for leaks. Repair leaks.

3. Pump strainer or check valve are clogged.

Remove pump and inspect. Clean, repair, rinse out pump and reinstall.

4. Pump worn. Same as B.2 above. If not close to pump curve, remove pump and inspect.

1. Draw-down is larger than anticipated.

C. Pump Runs But at Reduced Capacity

B. Pump Runs But Does Not Deliver Water

POSSIBLE CAUSES HOW TO CHECK HOW TO CORRECT

1. Groundwater level in well is too low or well is collapsed.

Check well draw-down. Lower pump if possible. If not, throttle discharge valve and install water level control.

2. Integral pump check valve is blocked.

Install pressure gauge, start pump, gradually close the discharge valve and read pressure at shut-off. After taking reading, open valve to its previous position. Convert PSI to feet.

(For water: PSI x 2.31 ft/PSI = ____ ft.), and add this to the total vertical distance from the pressure gauge to the water level in the well while the pump is running. Refer to the specific pump curve for the shut-off head for that pump model. If the measured head is close to the curve, pump is probably OK.

If not close to the pump curve, remove pump and inspect discharge section. Remove blockage, repair valve and valve seat if necessary.

Check for other damage. Rinse out pump and reinstall.

3. Inlet strainer is clogged.

Same as B.2 above. If not close to the pump curve, remove pump and inspect. Clean strainer, inspect integral check valve for blockage, rinse out pump and reinstall.

4. Pump is damaged. Same as B.2 above. If damaged, repair as necessary.

Rinse out pump and re-install.

D. Pump Cycles Too Much

POSSIBLE CAUSES HOW TO CHECK HOW TO CORRECT

1. Pressure switch is not properly adjusted or is defective.

Check pressure setting on switch and operation. Check voltage across closed contacts.

Re-adjust switch or replace if defective.

2. Level control is not properly set or is defective.

Check setting and operation. Re-adjust setting (refer to manufacturer data.) Replace if defective.

3. Plugged snifter valve or bleed orifice.

Examine valve and orifice for dirt or corrosion.

Clean and/or replace if defective.

E. Fuses Blow or Circuit Breakers Trip

POSSIBLE CAUSES HOW TO CHECK HOW TO CORRECT

1. High or low voltage. Check voltage at pump panel. If not within ± 10%, check wire size and length of run to pump panel.

If wire size is correct, contact power company. If not, correct and/or replace as necessary.

2. Control box wiring and components.

Check that control box parts match the parts list. Check to see that wiring matches wiring diagram. Check for loose or broken wires or terminals.

Correct as required.

3. Defective capacitor. Turn off power and discharge capacitor.

Check using an ohmmeter (Rx100K).

When the meter is connected, the needle should jump forward and slowly drift back.

If no meter movement, replace the capacitor.

4. Starting relay (Franklin single-phase motors only).

Check resistance of relay coil with an ohmmeter (Rx1000K). Check contacts for wear.

Replace defective relay.

TECHNICAL DATA

Table A Minimum Water Flow Requirements for Submersible Pump Motors

MOTOR CASING OR SLEEVE MIN. FLOW PAST

DIAMETER I.D. IN INCHES THE MOTOR (GPM)

4” 4 1.2 5 7 6 13 7 21 8 30

NOTES:

1. A flow inducer or sleeve must be used if the water enters the well above the motor or if there is insufficient water flow past the motor.

2. The minimum recommended water velocity over 4” motors is 0.25 feet per second.

Table B Guide for Engine-Driven Generators in Submersible Pump Applications

MINIMUM KILOWATT RATING OF

GENERATOR FOR THREE-WIRE

SUBMERSIBLE PUMP MOTORS

EXTERNALLY INTERNALLY

REGULATED REGULATED

MOTOR HP GENERATOR GENERATOR

0.33 HP 1.5 KW 1.2 KW

0.50 2.0 1.5

0.75 3.0 2.0

1.0 4.0 2.5

1.5 5.0 3.0

NOTES:

1. Table is based on typical 80°C rise continuous duty generators with 35% maximum voltage dip during start-up of single phase motors.

2. Contact the manufacturer of the generator to assure the unit has adequate capacity to run the submersible motor.

3. If the generator rating is in KVA instead of kilowatts, multiply the above ratings by 1.25 to obtain KVA.

CIRC. DUAL AMPERAGE FULL LOAD KVA MAX. GRUNDFOS

SER. BRK. OR ELEMENT FULL LOCK S.F. POWER CODE THRUST PART

HP PH VOLT FACT. STD. FUSE FUSE LOAD ROTOR AMPS EFF. FACTOR ** (LBS) NO.

TECHNICAL DATA

Table C Electrical Data – 60 Hz Submersible Pump Motors

GRUNDFOS MOTORS

4-Inch, Single Phase, 2-Wire Motors (control box not required)

4-Inch, Single Phase, 3-Wire Motors

1/3 1 230 1.75 15 5 3.4 25.7 4.6 59.0 77.0 6.8-8.2 S 770 79.952301 1/2 1 230 1.60 15 7 4.5 34.5 6.0 62.0 76.0 5.2-6.3 R 770 79.952302

3/4 1 230 1.50 20 9 6.9 40.5 8.4 62.0 75.0 3.2-3.8 N 770 79.952303

1 1 230 1.40 25 12 8.0 48.4 9.8 63.0 82.0 2.5-3.1 M 770 79.952304 1-1/2 1 230 1.30 35 15 10.0 62.0 13.1 64.0 85.0 1.9-2.3 L 770 79.952305

1/3 1 230 1.75 15 5 3.4 14.0 4.6 59.0 77.0 6.8-8.3 17.3-21.1 L 770 79.453301 1/2 1 230 1.60 15 7 4.5 21.5 6.0 62.0 76.0 4.7-5.7 15.8-19.6 L 770 79.453302

3/4 1 230 1.50 20 9 6.9 31.4 8.4 62.0 75.0 3.2-3.9 14-17.2 L 770 79.453303

1 1 230 1.40 25 12 8.0 38.0 9.8 63.0 82.0 2.6-3.1 10.3-12.5 K 770 79.453304 1-1/2 1 230 1.30 35 15 9.4 45.9 11.6 69.0 89.0 1.9-2.3 7.8-9.6 H 770 79.453305

LINE-TO-LINE

RESISTANCE

(OHMS)

Blk-Yel Red-Yel

Delta

FRANKLIN MOTORS

(refer to the Franklin Submersible Motors Application Maintenance Manual)

TECHNICAL DATA

Table D Total Resistance of Drop Cable (OHMS)

The values shown in this table are for copper conductors. Values are for the total resistance of drop cable from the control box to the motor and back.

To determine the resistance:

1. Disconnect the drop cable leads from the control box.

2. Record the size and length of drop cable.

3. Determine the cable resistance from the table.

4. Add drop cable resistance to motor resistance. Motor resistances can be found in the Electrical Data Chart, Table C.

5. Measure the resistance between each drop cable lead using an ohmmeter. Meter should be set on Rx1 and zero-balanced for this measurement.

6. The measured values should be approximately equal to the calculated values.

Wire Resistances

DISTANCE FROM 12 AWG WIRE 14 AWG WIRE

CONTROL BOX TO RESISTANCE RESISTANCE

PUMP MOTOR (FT.) (OHMS) (OHMS)

10 0.03 0.05 20 0.06 0.10 30 0.10 0.15 40 0.13 0.21 50 0.16 0.26 60 0.19 0.31 70 0.23 0.36 80 0.26 0.41 90 0.29 0.46

100 0.32 0.51 110 0.36 0.57 120 0.39 0.62 130 0.42 0.67 140 0.45 0.72 150 0.49 0.77 160 0.52 0.82 170 0.55 0.87 180 0.58 0.93 190 0.62 0.98 200 0.65 1.03

NOTES

NOTES

Redi-Flo4 Environmental Pumps manufactured by GRUNDFOS PUMPS CORPORATION (GRUNDFOS) are warranted to the original user only to be free of defects in material and workmanship for a period of 24 months from date of installation, but not more than 30 months from date of manufacture. GRUNDFOS' liability under this warranty shall be limited to repairing or replacing at GRUNDFOS' option, without charge, F.O.B. GRUNDFOS' factory or authorized service station, any product of GRUNDFOS' manufacture. GRUNDFOS will not be liable for any costs of removal, installation, transportation, or any other charges which may arise in connection with a warranty claim. Products which are sold but not manufactured by GRUNDFOS are subject to the warranty provided by the manufacturer of said products and not by GRUNDFOS' warranty. GRUNDFOS will not be liable for damage or wear to products caused by abnormal operating conditions, accident, abuse, misuse, unauthorized alteration or repair, or if the product was not installed in accordance with GRUNDFOS' printed installation and operating instructions.

To obtain service under this warranty, the defective product must be returned to the distributor or dealer of GRUNDFOS' products from which it was purchased together with proof of purchase and installation date, failure date, and supporting installation data. Unless otherwise provided, the distributor or dealer will contact GRUNDFOS or an authorized service station for instructions. Any defective product to be returned to GRUNDFOS or a service station must be sent freight prepaid; documentation supporting the warranty claim and/or a Return Material Authorization must be included if so instructed.

GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL

DAMAGES, LOSSES, OR EXPENSES ARISING FROM INSTALLATION, USE, OR ANY

OTHER CAUSES. THERE ARE NO EXPRESS OR IMPLIED WARRANTIES, INCLUDING

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, WHICH EXTEND

BEYOND THOSE WARRANTIES DESCRIBED OR REFERRED TO ABOVE.

Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages and some jurisdictions do not allow limitations on how long implied warranties may last. Therefore, 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 jurisdiction to jurisdiction.

LIMITED LIMITED LIMITED LIMITED LIMITED WAWAWAWAWARRANTYRRANTYRRANTYRRANTYRRANTY

L-RF-IO-001 Rev. 07/03

PRINTED IN USA

Grundfos Pumps Corporation 17100 W. 118th Terrace Olathe, Kansas 66061 Telephone: (913) 227-3400 Fax: (913) 227-3500

Grundfos Canada, Inc.

2941 Brighton Rd.

Oakville, Ontario L6H 6C9 Telephone: (905) 829-9533 Fax: (905) 829-9512

Bombas Grundfos de Mexico, S.A. de C.V.

Boulevard TLC #15, Parque Industrial Stiva Aeropuerto C.P. 66600 Apodaca, N.L. Mexico Telephone: 52-8-144-4000 Fax: 52-8-144-4010 www.grundfos.com

A

IM

M A

N U

A L

FR

A

N K

LI

N

E

LE

CT

R

IC

SUBMERSIBLE MOTORS

ATTENTION!

IMPORTANT INFORMATION FOR INSTALLERS OF THIS EQUIPMENT!

THIS EQUIPMENT IS INTENDED FOR INSTALLATION BY TECHNICALLY QUALIFIED PERSONNEL.

FAILURE TO INSTALL IT IN COMPLIANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES, AND

WITHIN FRANKLIN ELECTRIC RECOMMENDATIONS, MAY RESULT IN ELECTRICAL SHOCK OR FIRE

HAZARD, UNSATISFACTORY PERFORMANCE, AND EQUIPMENT FAILURE. FRANKLIN INSTALLATION

INFORMATION IS AVAILABLE FROM PUMP MANUFACTURERS AND DISTRIBUTORS, AND DIRECTLY

FROM FRANKLIN ELECTRIC. CALL FRANKLIN TOLL FREE 800-348-2420 FOR INFORMATION.

WARNING

SERIOUS OR FATAL ELECTRICAL SHOCK MAY RESULT FROM FAILURE TO CONNECT THE MOTOR,

CONTROL ENCLOSURES, METAL PLUMBING, AND ALL OTHER METAL NEAR THE MOTOR OR CABLE,

TO THE POWER SUPPLY GROUND TERMINAL USING WIRE NO SMALLER THAN MOTOR CABLE

WIRES. TO REDUCE RISK OF ELECTRICAL SHOCK, DISCONNECT POWER BEFORE WORKING ON OR

AROUND THE WATER SYSTEM. DO NOT USE MOTOR IN SWIMMING AREAS.

ATTENTION!

INFORMATIONS IMPORTANTES POUR L’INSTALLATEUR DE CET EQUIPEMENT.

CET EQUIPEMENT DOIT ETRE INTALLE PAR UN TECHNICIEN QUALIFIE. SI L’INSTALLATION N’EST

PAS CONFORME AUX LOIS NATIONALES OU LOCALES AINSI QU’AUX RECOMMANDATIONS DE

FRANKLIN ELECTRIC, UN CHOC ELECTRIQUE, LE FEU, UNE PERFORMANCE NON ACCEPTABLE,

VOIRE MEME LE NON-FONCTIONNEMENT PEUVENT SURVENIR. UN GUIDE D’INSTALLATION

DE FRANKLIN ELECTRIC EST DISPONIBLE CHEZ LES MANUFACTURIERS DE POMPES, LES

DISTRIBUTEURS, OU DIRECTEMENT CHEZ FRANKLIN. POUR DE PLUS AMPLES RENSEIGNEMENTS,

APPELEZ SANS FRAIS LE 800-348-2420.

AVERTISSEMENT

UN CHOC ELECTRIQUE SERIEUX OU MEME MORTEL EST POSSIBLE, SI L’ON NEGLIGE DE

CONNECTER LE MOTEUR, LA PLOMBERIE METALLIQUE, BOITES DE CONTROLE ET TOUT METAL

PROCHE DU MOTEUR A UN CABLE ALLANT VERS UNE ALIMENTATION D’ENERGIE AVEC BORNE

DE MISE A LA TERRE UTILISANT AU MOINS LE MEME CALIBRE QUE LES FILS DU MOTEUR. POUR

REDUIRE LE RISQUE DE CHOC ELECTRIQUE. COUPER LE COURANT AVANT DE TRAVAILLER PRES

OU SUR LE SYSTEM D’EAU. NE PAS UTILISER CE MOTEUR DANS UNE ZONE DE BAIGNADE.

ATENCION!

INFORMACION PARA EL INSTALADOR DE ESTE EQUIPO.

PARA LA INSTALACION DE ESTE EQUIPO, SE REQUIERE DE PERSONAL TECNICO CALIFICADO.

EL NO CUMPLIR CON LAS NORMAS ELECTRICAS NACIONALES Y LOCALES, ASI COMO CON LAS

RECOMENDACIONES DE FRANKLIN ELECTRIC DURANTE SU INSTALACION, PUEDE OCASIONAR,

UN CHOQUE ELECTRICO, PELIGRO DE UN INCENDIO, OPERACION DEFECTUOSA E INCLUSO LA

DESCOMPOSTURA DEL EQUIPO. LOS MANUALES DE INSTALACION Y PUESTA EN MARCHA DE

LOS EQUIPOS, ESTAN DISPONIBLES CON LOS DISTRIBUIDORES, FABRICANTES DE BOMBAS

O DIRECTAMENTE CON FRANKLIN ELECTRIC. PUEDE LLAMAR GRATUITAMENTE PARA MAYOR

INFORMACION AL TELEFONO 800-348-2420.

ADVERTENCIA

PUEDE OCURRIR UN CHOQUE ELECTRICO, SERIO O FATAL DEBIDO A UNA ERRONEA CONECCION

DEL MOTOR, DE LOS TABLEROS ELECTRICOS, DE LA TUBERIA, DE CUALQUIER OTRA PARTE

METALICA QUE ESTA CERCA DEL MOTOR O POR NO UTILIZAR UN CABLE PARA TIERRA DE CALIBRE

IGUAL O MAYOR AL DE LA ALIMENTACION. PARA REDUCIR EL RIESGO DE CHOQUE ELECTRIC,

DESCONECTAR LA ALIMENTACION ELECTRICA ANTES DE INICIAR A TRABAJAR EN EL SISTEMA

HIDRAULICO. NO UTILIZAR ESTE MOTOR EN ALBERCAS O AREAS EN DONDE SE PRACTIQUE

NATACION.

Franklin Electric is committed to provide customers with defect free products through our program of continuous improvement. Quality shall, in every case, take precedence over quantity.

Commitment to Quality

Contents

The submersible motor is a reliable, efficient and trouble-free means of powering a pump. Its needs for a long operational life are simple. They are:

1. A suitable operating environment

2. An adequate supply of electricity

3. An adequate flow of cooling water over the motor

4. An appropriate pump load

All considerations of application, installation, and maintenance of submersible motors relating to these four areas are presented in this manual. Franklin Electric’s web page, www.franklin-electric.com, should be checked for the latest updates.

Application

Storage Frequency of Starts Mounting Position Transformer Capacity Effects of Torque Use of Engine Driven Generators Use of Check Valves Well Diameters, Casing, Top Feeding, Screens Water Temperature and Flow Flow Inducer Sleeve Head Loss Past Motor Hot Water Applications ..................................................... 7-8 Drawdown Seals Grounding Control Boxes and Panels Grounding Surge Arrestors Control Box and Panel Environment Equipment Grounding

3-Wire Control Boxes 2-Wire Motor Solid State Controls QD Relays (Solid State) Cable Selection 2-Wire or 3-Wire Two Different Cable Sizes Single-Phase Motor Specifications

Submersible Motors - Dimensions Tightening Lead Connector Jam Nut Pump to Motor Coupling

System Troubleshooting ................................................ 44-45 Preliminary Tests Insulation Resistance Resistance of Drop Cable

Identification of Cables Single-Phase Control Boxes Ohmmeter Tests QD Control Box Parts

Integral hp Control Box Parts ........................................ 51-52 Control Box Wiring Diagrams ........................................ 53-57

Pumptec-Plus Troubleshooting During Installation Pumptec-Plus Troubleshooting After Installation QD Pumptec and Pumptec Troubleshooting SubDrive/MonoDrive Troubleshooting ........................... 61-62 SubMonitor Troubleshooting Subtrol-Plus Troubleshooting ........................................ 64-65

Pump to Motor Assembly Shaft Height and Free End Play Submersible Leads and Cables

Single-Phase Motor Fuse Sizing Auxiliary Running Capacitors Buck-Boost Transformers

Cable Selection - 60 °C Three-Wire .............................. 16-17 Cable Selection - 60 °C Six-Wire Cable Selection - 75 °C Three-Wire .............................. 19-20 Cable Selection - 75 °C Six-Wire Three-Phase Motor Specifications ................................ 22-28 Overload Protection ...................................................... 29-31 Submersible Pump Installation Checklist (No. 3656) Submersible Motor Installation Record (No. 2207) Submersible Booster Installation Record (No. 3655) SubMonitor Power Factor Correction Three-Phase Starter Diagrams Three-Phase Power Unbalance Rotation and Current Unbalance Three-Phase Motor Lead Identification Phase Converters Reduced Voltage Starters Inline Booster Pump Systems ....................................... 36-39 Variable Speed Operation ............................................. 40-41

Franklin submersible motors are designed primarily for operation in the vertical, shaft-up position.

During acceleration, the pump thrust increases as its output head increases. In cases where the pump head stays below its normal operating range during startup and full speed condition, the pump may create upward thrust.

This creates upward thrust on the motor upthrust bearing.

This is an acceptable operation for short periods at each start, but running continuously with upthrust will cause excessive wear on the upthrust bearing.

With certain additional restrictions as listed in this section and the Inline Booster Pump Systems sections of this manual, motors are also suitable for operation in positions

Franklin Electric submersible motors are a water-lubricated design. The fill solution consists of a mixture of deionized water and Propylene Glycol (a non-toxic antifreeze). The solution will prevent damage from freezing in temperatures to -40 °F (-40 °C); motors should be stored in areas that do not go below this temperature.

The solution will partially freeze below 27 °F (-3 °C), but no damage occurs. Repeated freezing and thawing should be avoided to prevent possible loss of fill solution.

There may be an interchange of fill solution with well water during operation. Care must be taken with motors removed from wells during freezing conditions to prevent damage.

When the storage temperature does not exceed 100 °F (37 °C), storage time should be limited to two years. Where temperatures reach 100° to 130 °F, storage time should be limited to one year.

Loss of a few drops of liquid will not damage the motor as an excess amount is provided, and the filter check valve will allow lost liquid to be replaced by filtered well water upon installation. If there is reason to believe there has been a considerable amount of leakage, consult the factory for checking procedures.

The average number of starts per day over a period of months or years influences the life of a submersible pumping system. Excessive cycling affects the life of control components such as pressure switches, starters, relays and capacitors. Rapid cycling can also cause motor spline damage, bearing damage, and motor overheating. All these conditions can lead to reduced motor life.

The pump size, tank size and other controls should be selected to keep the starts per day as low as practical for longest life. The maximum number of starts per 24-hour period is shown in table 3.

Motors should run a minimum of one minute to dissipate heat build up from starting current. Six inch and larger motors should have a minimum of 15 minutes between starts or starting attempts.

from shaft-up to shaft-horizontal. As the mounting position becomes further from vertical and closer to horizontal, the probability of shortened thrust bearing life increases. For normal motor life expectancy with motor positions other than shaft-up, follow these recommendations:

1. Minimize the frequency of starts, preferably to fewer than 10 per 24-hour period. Six and eight inch motors should have a minimum of 20 minutes between starts or starting attempts

2. Do not use in systems which can run even for short periods at full speed without thrust toward the motor.

MOTOR RATING MAXIMUM STARTS PER 24 HR PERIOD

HP KW SINGLE-PHASE THREE-PHASE

Up to 0.75 Up to 0.55 300 300

1 thru 5.5 0.75 thru 4 100 300

7.5 thru 30 5.5 thru 22 50 100*

40 and over 30 and over - 100

Table 3 Number of Starts

* Keeping starts per day within the recommended numbers provides the best system life. However, when used with a properly configured Reduced Voltage Starter (RVS) or Variable Frequency Drive (VFD), 7.5 thru 30 hp three-phase motors can be started up to 200 times per 24 hour period.

Distribution transformers must be adequately sized to satisfy the kVA requirements of the submersible motor.

When transformers are too small to supply the load, there is a reduction in voltage to the motor.

Table 4 references the motor horsepower rating, single-phase and three-phase, total effective kVA required, and

NOTE: Standard kVA ratings are shown. If power company experience and practice allows transformer loading higher than standard, higher loading values may be used to meet total effective kVA required, provided correct voltage and balance is maintained.

the smallest transformer required for open or closed three-phase systems. Open systems require larger transformers since only two transformers are used.

Other loads would add directly to the kVA sizing requirements of the transformer bank.

During starting of a submersible pump, the torque developed by the motor must be supported through the pump, delivery pipe or other supports. Most pumps rotate in the direction which causes unscrewing torque on right-handed threaded pipe or pump stages. All threaded joints, pumps and other parts of the pump support system must be capable of withstanding the maximum torque repeatedly without loosening or breaking. Unscrewing joints will break electrical cable and may cause loss of the pump-motor unit.

To safely withstand maximum unscrewing torques with a minimum safety factor of 1.5, tightening all threaded joints to at least 10 lb-ft per motor horsepower is recommended (table 4A). It may be necessary to tack or strap weld pipe joints on high horsepower pumps, especially at shallower settings.

Table 4A Torque Required (Examples)

MOTOR RATING TOTAL

EFFECTIVE

KVA

REQUIRED

SMALLEST KVA RATING-EACH TRANSFORMER

OPEN WYE

OR DELTA

2- TRANSFORMERS

CLOSED

WYE OR DELTA

3- TRANSFORMERS

HP KW

1.5 1.1 3 2 1

2 1.5 4 2 1.5

3 2.2 5 3 2

5 3.7 7.5 5 3

7.5 5.5 10 7.5 5

10 7.5 15 10 5

15 11 20 15 7.5

20 15 25 15 10

25 18.5 30 20 10

30 22 40 25 15

40 30 50 30 20

50 37 60 35 20

60 45 75 40 25

75 55 90 50 30

100 75 120 65 40

125 93 150 85 50

150 110 175 100 60

175 130 200 115 70

200 150 230 130 75

Table 4 Transformer Capacity

MOTOR RATING MINIMUM SAFE

TORQUE-LOAD HP KW

1 hp & Less 0.75 kW & Less 10 lb-ft

20 hp 15 kW 200 lb-ft

75 hp 55 kW 750 lb-ft

200 hp 150 kW 2000 lb-ft

WARNING: To prevent accidental electrocution, automatic or manual transfer switches must be used any time a generator is used as standby or back up on power lines. Contact power company for use and approval.

Table 5 lists minimum generator sizes based on typical 80 °C rise continuous duty generators, with 35% maximum voltage dip during starting, for Franklin’s three-wire motors, single- or three-phase.

This is a general chart. The generator manufacturer should be consulted whenever possible, especially on larger sizes.

There are two types of generators available: externally and internally regulated. Most are externally regulated.

They use an external voltage regulator that senses the output voltage. As the voltage dips at motor start-up, the regulator increases the output voltage of the generator.

Internally regulated (self-excited) generators have an extra winding in the generator stator. The extra winding senses the output current to automatically adjust the output voltage.

Generators must be sized to deliver at least 65% of the rated voltage during starting to ensure adequate starting torque. Besides sizing, generator frequency is important as the motor speed varies with the frequency (Hz). Due to pump affinity laws, a pump running at 1 to 2 Hz below motor nameplate frequency design will not meet its performance curve. Conversely, a pump running at 1 to 2 Hz above may trip overloads.

Generator Operation

Always start the generator before the motor is started and always stop the motor before the generator is shut down. The motor thrust bearing may be damaged if the generator is allowed to coast down with the motor running. This same condition occurs when the generator is allowed to run out of fuel.

Follow generator manufacturer’s recommendations for de-rating at higher elevations or using natural gas.

It is recommended that one or more check valves always be used in submersible pump installations. If the pump does not have a built-in check valve, a line check valve should be installed in the discharge line within 25 feet of the pump and below the draw down level of the water supply. For deeper settings, check valves should be installed per the manufacturer’s recommendations. More than one check valve may be required, but more than the recommended number of check valves should not be used.

Swing type check valves are not acceptable and should never be used with submersible motors/pumps. Swing type check valves have a slower reaction time which can cause water hammer (see next page). Internal pump check valves or spring loaded check valves close quickly and help eliminate water hammer.

Check valves are used to hold pressure in the system when the pump stops. They also prevent backspin, water hammer and upthrust. Any of these can lead to early pump or motor failure.

NOTE: Only positive sealing check valves should be used in submersible installations. Although drilling the check valves or using drain-back check valves may prevent back spinning, they create upthrust and water hammer problems.

A. Backspin - With no check valve or a failed check valve, the water in the drop pipe and the water in the system can flow down the discharge pipe when the motor stops. This can cause the pump to rotate in a reverse direction. If the motor is started while it is backspinning, an excessive force is placed across the pump-motor assembly that can cause impeller damage, motor or pump shaft breakage, excessive bearing wear, etc.

B. Upthrust - With no check valve, a leaking check valve, or drilled check valve, the unit starts under

Table 5 Engine Driven Generators

MOTOR RATING MINIMUM RATING OF GENERATOR

HP KW

EXTERNALLY REGULATED INTERNALLY REGULATED

KW KVA KW KVA

1/3 0.25 1.5 1.9 1.2 1.5

1/2 0.37 2 2.5 1.5 1.9

3/4 0.55 3 3.8 2 2.5

1 0.75 4 5.0 2.5 3.13

1.5 1.1 5 6.25 3 3.8

2 1.5 7.5 9.4 4 5

3 2.2 10 12.5 5 6.25

5 3.7 15 18.75 7.5 9.4

7.5 5.5 20 25.0 10 12.5

10 7.5 30 37.5 15 18.75

15 11 40 50 20 25

20 15 60 75 25 31

25 18.5 75 94 30 37.50

30 22 100 125 40 50

40 30 100 125 50 62.5

50 37 150 188 60 75

60 45 175 220 75 94

75 55 250 313 100 125

100 75 300 375 150 188

125 93 375 469 175 219

150 110 450 563 200 250

175 130 525 656 250 313

200 150 600 750 275 344

NOTE: This chart applies to 3-wire or 3-phase motors. For best starting of 2-wire motors, the minimum generator rating is 50% higher than shown.

Franklin Electric submersible motors are designed to operate with a cooling flow of water over and around the full length of the motor.

If the pump installation does not provide the minimum flow shown in table 6, a flow inducer sleeve (flow sleeve) must be used. The conditions requiring a flow sleeve are:

flow requirements.

Franklin Electric’s standard submersible motors, except Hi-Temp designs (see note below), are designed to operate up to maximum service factor horsepower in water up to 86 °F (30 °C). A flow of 0.25 ft/s for 4" motors rated 3 hp and higher, and 0.5 ft/s for 6" and 8" motors is required for proper cooling. Table 6 shows minimum flow rates, in gpm, for various well diameters and motor sizes.

If a standard motor is operated in water over 86 °F (30 °C), water flow past the motor must be increased to maintain safe motor operating temperatures. See HOT WATER APPLICATIONS on page 7.

NOTE: Franklin Electric offers a line of Hi-Temp motors designed to operate in water at higher temperatures or lower flow conditions. Consult factory for details.

0.25 ft/s = 7.62 cm/sec 0.50 ft/s = 15.24 cm/sec 1 inch = 2.54 cm

If the flow rate is less than specified, then a flow inducer sleeve must be used. A flow sleeve is always required in an open body of water. FIG. 1 shows a typical flow inducer sleeve construction.

EXAMPLE: A 6" motor and pump that delivers 60 gpm will be installed in a 10" well.

From table 6, 90 gpm would be required to maintain proper cooling. In this case adding an 8" or smaller flow sleeve provides the required cooling.

FIG. 1

WORM GEAR

CLAMPS

INTAKE

FLOW INDUCER

SLEEVE

SUBMERSIBLE

MOTOR

CENTERING BOLT

LOCK NUTS

INSIDE SLEEVE

CENTERING

BOLT HOLE

(3 REQUIRED)

BOTTOM END VIEW

NOTCH OUT

FOR CABLE

GUARD

SAW CUTS

CENTERING BOLTS

MUST BE LOCATED

ON MOTOR CASTING.

DO NOT LOCATE ON

STATOR SHELL.

Table 6 Required Cooling Flow a zero head condition. This causes an uplifting or upthrust on the impeller-shaft assembly in the pump.

This upward movement carries across the pump-motor coupling and creates an upthrust condition in the motor. Repeated upthrust can cause premature failure of both the pump and the motor.

C. Water Hammer - If the lowest check valve is more than 30 feet above the standing (lowest static) water level, or a lower check valve leaks and the check valve above holds, a vacuum is created in the discharge piping. On the next pump start, water moving at very high velocity fills the void and strikes the closed check valve and the stationary water in the pipe above it, causing a hydraulic shock. This shock can split pipes, break joints and damage the pump and/or motor. Water hammer can often be heard or felt. When discovered, the system should be shut down and the pump installer contacted to correct the problem.

MINIMUM GPM REQUIRED FOR MOTOR COOLING IN WATER UP TO 86 °F (30 °C).

CASING OR

SLEEVE ID

INCHES (MM)

4" MOTOR (3-10 HP)

0.25 FT/S

GPM (L/M)

6" MOTOR

0.50 FT/S

GPM (L/M)

8" MOTOR

0.50 FT/S

GPM (L/M)

4 (102) 1.2 (4.5) - -

5 (127) 7 (26.5) - -

6 (152) 13 (49) 9 (34) -

7 (178) 20 (76) 25 (95) -

8 (203) 30 (114) 45 (170) 10 (40)

10 (254) 50 (189) 90 (340) 55 (210)

12 (305) 80 (303) 140 (530) 110 (420)

14 (356) 110 (416) 200 (760) 170 (645)

16 (406) 150 (568) 280 (1060) 245 (930)

Table 7 lists the approximate head loss due to flow between an average length motor and smooth casing or flow inducer sleeve.

Franklin Electric offers a line of Hi-Temp motors which are designed to operate in water with various temperatures up to 194 °F (90 °C) without increased flow. When a standard pump-motor operates in water hotter than 86 °F (30 °C), a flow rate of at least 3 ft/s is required. When selecting the motor to drive a pump in over 86 °F (30 °C) water, the motor horsepower must be de-rated per the following procedure.

1. Using table 7A, determine pump gpm required for different well or sleeve diameters. If necessary, add a flow sleeve to obtain at least 3 ft/s flow rate.

MOTOR DIAMETER 4" 4" 4" 6" 6" 6" 8" 8"

CASING ID IN INCHES (MM) 4 (102) 5 (127) 6 (152) 6 (152) 7 (178) 8 (203) 8.1 (206) 10 (254)

Fl ow

R at e in g pm

(l /m

25 (95) 0.3 (.09)

50 (189) 1.2 (.37)

100 (378) 4.7 (1.4) 0.3 (.09) 1.7 (.52)

150 (568) 10.2 (3.1) 0.6 (.18) 0.2 (.06) 3.7 (1.1)

200 (757) 1.1 (.34) 0.4 (.12) 6.3 (1.9) 0.5 (.15) 6.8 (2.1)

250 (946) 1.8 (.55) 0.7 (.21) 9.6 (2.9) 0.8 (.24) 10.4 (3.2)

300 (1136) 2.5 (.75) 1.0 (.30) 13.6 (4.1) 1.2 (.37) 0.2 (.06) 14.6 (4.5)

400 (1514) 23.7 (7.2) 2.0 (.61) 0.4 (.12) 24.6 (7.5)

500 (1893) 3.1 (.94) 0.7 (.21) 37.3 (11.4) 0.6 (0.2)

600 (2271) 4.4 (1.3) 1.0 (.30) 52.2 (15.9) 0.8 (0.3)

800 (3028) 1.5 (0.5)

1000 (3785) 2.4 (0.7)

Table 7 Head Loss in Feet (Meters) at Various Flow Rates

CASING OR

SLEEVE ID

4" HIGH

THRUST MOTOR

6" MOTOR 8" MOTOR

INCHES (MM) GPM (L/M) GPM (L/M) GPM (L/M)

4 (102) 15 (57)

5 (127) 80 (303)

6 (152) 160 (606) 52 (197)

7 (178) 150 (568)

8 (203) 260 (984) 60 (227)

10 (254) 520 (1970) 330 (1250)

12 (305) 650 (2460)

14 (356) 1020 (3860)

16 (406) 1460 (5530)

Table 7A Minimum gpm (l/m) Required for 3 ft/s (.91 m/sec) Flow Rate

7 Continued on next page

EXAMPLE: A 6" pump end requiring 39 hp input will pump 124 °F water in an 8" well at a delivery rate of 140 gpm. From table 7A, a 6" flow sleeve will be required to increase the flow rate to at least 3 ft/s.

Using table 8, the 1.62 heat factor…