Warning, Caution – Star Water Systems Star 4in Sub Instr2&3-wire User Manual

Page 2

WARNING

ELECTRICAL SHOCk ALERT
Follow all local electrical and safety codes, as well

as the National Electrical Code (NEC) and the

Occupational Safety and Health Act (OSHA).
ELECTRICAL SHOCk ALERT
All electrical wiring or service should be done by a

qualified electrician.

EXPLOSION ALERT
Do not use to pump flammable or explosive fluids

such as gasoline, fuel oil, kerosene, etc. Do not use in

flammable and/or explosive atmospheres.
HAZARDOUS PRESSURE ALERT
Install pressure relief valve in discharge pipe. Release

all pressure on system before working on any

component.

CAUTION

ELECTRICAL SHOCk MAY OCCUR
Wire motor for correct voltage. See Electrical section

and motor nameplate.
ELECTRICAL SHOCk MAY OCCUR
Ground motor and controls before connecting to

power supply.
ELECTRICAL SHOCk MAY OCCUR
Follow wiring instructions in this manual when

connecting to power lines.
ELECTRICAL SHOCk MAY OCCUR
Protect power cable from nicks or cuts from sharp

objects or scraping on well casing when lowering

pump into well. Do not allow it to come into contact

with oil, grease, hot surfaces or chemicals.
ELECTRICAL SHOCk MAY OCCUR
The motor voltage and phase indicated on the motor

nameplate should be checked against the actual

electrical supply. Check your power source. Check

electrical supply for correct fusing, wire size, and

adequate grounding and transformer size.

PRODUCT DAMAGE MAY OCCUR
The power supply for a submersible pump should be

a separate circuit, independent of all other circuits. It

must be equipped with a fuse box of ample capacity.
PRODUCT DAMAGE MAY OCCUR
Shut off power source when voltage drops 10%

below rated voltage of motor.
FIRE SAFETY
For fire protection, power supply should be free

of any building, preferably on a direct line from

transformer. In event of fire, wires will not be

destroyed and water supply not cut-off.

NOTE: Install all electrical equipment in protected area to provide adequate ventilation for pressure switch

and controls to prevent moisture damage to components.
NOTE: Install pump, pressure tank, pitless adaptor or well seal in accordance with state and local plumbing

codes.

SAFETY INFORMATION

PREPARATION

Before beginning installation of product, make

sure all parts are present. Compare parts with

package contents drawing. If any part is missing or

damaged, do not attempt to assemble the product.

Contact customer service for replacement parts.

Estimated Installation Time: 2 hours.

Tools Required for Installation: Hacksaw,

screwdriver, pliers, pipe vise, pipe wrenches (2),

wire cutters, wire strippers/crimpers, adjustable

wrench (medium-large), Ohmmeter, propane torch,

knife or round file, small weight.
Materials Required for Installation: Control

box for 3-wire plus ground models (see chart on

page 6) Submersible pump cable, power cable,

pressure tank, shrink tube & butt connectors, 1-1/4

in. check valve, torque arrestor, hose clamps, pipe

fittings, pitless adaptor or well seal, pressure switch,

pressure gauge, pressure relief valve, tank cross,

1/4 in. minimum safety rope, electrical tape,. You

will also need either enough 1-1/4 in. Schedule 80

PVC pipe to reach 20 ft. below the static level or 20

ft. below the drawdown level of your well, or coiled

poly pipe rated for 160 PSI. Poly pipe cannot be used

for installations any deeper than 200 ft.
Optional Materials: 1-1/4 in. male barbed

adaptor for use with poly pipe, cable guards to

protect wire inside the well, thread tape and thread

paste.

SUBMERSIBLE PUMP CABLE AND POWER

CABLE SELECTION
Check cable size against Submersible Wire Size Chart

A . For 3-wire plus ground models, motor and control

box voltage must match. Submersible power cable

must be UL listed for submersible pump applications.

For Canadian installations, type RWU, TWU, SGOW or

SWOW power supply cable is recommended. Cable

is selected for the maximum pump setting plus the

offset distance to the service entrance.
IMPORTANT: Use of wire sizes smaller than those

specified in the chart will cause low starting voltage,

may cause early pump failure and will void the

warranty. Larger wire sizes may always be used for

better economy of operation. Be sure voltage at

pressure switch or fuse is between the following

limits:
115V Rated - Between 104 & 127 volts
230V Rated - Between 210 & 250 volts
NOTE: A small AWG number, i.e. 10 Ga., is larger in

diameter than a large AWG number, i.e. 14 Ga.
The National Electric Code (NEC 250-43) requires a

separate ground wire be run down the well to the

submersible pump and connected to all exposed

metal parts of the pump and motor. Refer to the

most recent National Electric Code (NEC) Article 250

(grounding) for additional information.
NOTE: All wiring should be done by a qualified

electrician.

Volt

Maximum Cable Length In Feet Using AWG Cable*

#14

#12

#10

1/2

110/115

100

160

250

1/2

230

400

650

1020

3/4

230

300

480

760

230

250

400

630

1-1/2

230

190

310

480

230

150

250

390

230

120

190

300

NOTE: Wire length is the total distance from power source to pump depth.

Wire Size Chart A

WARNING: 3-WIRE SUBMERSIBLES ONLY: This submersible pump must be wired

directly to a control box of the same horsepower and voltage rating in order to work

properly. IT MUST BE USED WITH WITH A CONTROL BOX.