Flint & Walling 4 (10 cm) Stainless Commander Plus S Series User Manual

Page 4

INSULATION AND CONTINUITY TEST

1. It is recommended that this test be done when the

splicing is complete and pump is being test run in

a tank of water. This test can be repeated after

installation in well but before the final electrical hook-

up is made to the control box or pressure switch (see

Figures 7 & 8).

IL0098

Figure 7

IL0099

Figure 8

Zero the ohmmeter by clipping the leads together and

adjusting the zero ohm knob until the needle indicates

zero. Zero the ohmmeter before each use or every time

selector switch is changed.

3. Clip one ohmmeter lead to bare cable end.

4. Clip the other lead to edge of steel tank in which

pump and cable are submerged. If pump is already

in the well, clip lead to discharge pipe metal well

casing or bare ground wire.

5. A reading of less that 1,000,000 ohms indicates that

cable or splice is grounded. Slowly raise cable from

the water at the ohmmeter end. When trouble spot

moves clear of the water, needle will move toward

infinity reading. In an old installation with the pump in

the well, a reading of 20,000 ohms or less indicates

a breakdown in the insulation; in this case pull the

pump.

PUMP INSTALLATION

1. The following pump installation instructions use

Schedule 80 PVC pipe or galvanized pipe. If either

of these two types are used, a foot clamp or vise will

be required to hold the PVC or galvanized pipe when

connecting the next pipe length.

2. Install the pump in a well which is sand-free, straight,

and has sufficient flow of water to supply the pump.

Clear well of sand and any other foreign matter with a

test pump before installing the submersible pump.

NOTE: Using the submersible pump to clean the well

will void the warranty. When drilling a new well in an

area where sand is a problem, a sand screen must be

installed to protect the pump and motor.

3. Chlorinate the well first. Drop 24 to 48 HTH (chlorine)

tablets into the well before lowering the pump into the

well. This will prevent contamination and the growth

of iron bacteria which could later plug the well and the

pump. The chlorinated water will be pumped out of

the system when testing the pump flow.

4. BE SURE the top edge of the well casing is perfectly

smooth; sharp or jagged edges can cut or scrape the

cable and cause a short.

5. Install a line check valve within 25 feet of the pump

and below the draw down level of the water supply.

The check valve should be the same size as the

discharge outlet of the pump or larger.

NOTE: Use of pipe smaller that the discharge tapping of

the pump will restrict the capacity of the pump and lower

its operating performance.

6. When connecting the first length of pipe and

placing the pump in the well casing, care should be

maintained to center the pump in the well. It is easier

to handle the pump if a short piece of pipe is installed

first, rather than a long piece. Install the check valve

at the end of the first piece of pipe prior to lowering

the pump into the well. Maintain alignment as the

pump is placed and lowered into the well, a torque

arrester is recommended. Position the torque arrestor

to within 6” of the pump discharge and clamp arrestor

to pipe. Wrap the pipe with enough tape at top and

bottom of torque arrestor to keep it from sliding up the

pipe while the pump is being lowered into the well.

7. If not already done, splice the electrical cable to the

motor leads. The cable and ground wire should be

taped to the discharge pipe. Tape the cable about 5

feet above the discharge and every 20 feet thereafter.

Install cable guards if required to eliminate rubbing

against the well casing. Do not let the cable drag

over the edge of the well casing. Never allow the

weight of the pump to hang on the cable alone.

17. Pitless Adapter — A pitless adapter provides below

grade discharge while maintaining above grade

access to the well. Placed below the frost line they

are frost proof and also prevent well contamination

by providing a water tight seal between the vertical

drop pipe and the horizontal service pipe connection

(Figure 1).

18. Well Seal — On well seal installations the piping in

the well projects above the well and is connected

above ground to the system piping by means of a

tee or elbow. Since the plumbing is above ground, it

must be protected from freezing (Figure 2).

19. Submersible Cable — Submersible power cable

must be UL listed for submersible pump application.

Selecting the proper cable size is important.

Undersized cable results in a too low voltage supply to

the pump motor and ultimate motor failure. Oversized

cable is costly and not necessary. Refer to cable

selection chart for proper cable selection. Cable is

selected for the maximum pump setting plus the offset

distance to the service entrance.

20. Ground Wire — The National Electric Code (NEC 250-

43) requires a separate ground wire be run down the

well to the submersible pump and to be connected to

all exposed metal parts of the pump and motor. Refer

to the most recent National Electric Code (NEC) for

additional grounding information. All wiring should be

done by a competent electrician.

INSTALLATION

SUBMERSIBLE CABLE INSTALLATION

1. Check power source. Check electrical supply for

correct fusing, correct wire size, and adequate

grounding and transformer size.

WARNING: Since most submersible pump problems are

electrical, it is very important that all electrical work be

done properly. Therefore, all electrical hook-up work

or electrical service work should be done ny a qualified

electrician or serviceman only!

2. Follow wiring directions in the control box and make

momentary tests to see that the motor runs.

Do not

run pump dry for more than three (3) seconds. If

test is satisfactory, proceed to Step 3 (cable splice).

3. First check cable size against the Submersible

Wire Size Chart. Use extreme care; this is a very

important step. If required length falls between

two wire sizes, use the larger of the two wire sizes

(smaller number).

IMPORTANT: Use of wire sizes smaller than those

specified in the charts will cause low starting voltage,

may cause early pump failure and will void the warranty.

Larger wire sizes may always be used for better operating

economy.

4. Splice motor leads to submersible cable with

commercially available potting, heat shrink splicing

kits or by careful tape splicing. Tape splicing should

use the following procedure.

a) Strip individual conductor of insulation only as far

as necessary to provide room for a stake type

connector. Tubular connectors of the staked type

are preferred. If connector O.D. is not as large as

cable insulation, build-up with rubber electrical tape.

b) Tape individual joints with rubber electrical tape,

using two layers; the first extending two inches

beyond each end of the conductor insulation end,

the second layer two inches beyond the ends of

the first layer. Wrap tightly, eliminating air spaces

as much as possible.

c) Tape over the rubber electrical tape with #33

Scotch electrical tape, (Minnesota Mining Co.)

or equivalent, using two layers as in step “B”

and making each layer overlap the end of the

preceding layer at least two inches.

5. In the case of a cable with three conductors encased

in a single outer sheath, tape individual conductors as

described, staggering joints. Total thickness of tape

should be less than the thickness of the conductor

insulation.

GROUND WIRE INSTALLATION

WARNING: Motor frame must be connected to power

supply ground or fatal electrical shock may result.

IL0097

Staked Connector

Rubber Tape

PVC Electrical Tape

2”

Figure 6

NOTE: All electrical wiring should be done by a

competent electrician.

1. Grounding the submersible pump is accomplished

by running a copper grounding wire from the pump

motor to the main electrical system ground.

2. The ground wire to be used must be of the same

size as the submersible power cable. It may be

insulated or bare. If insulated, it must be green, with

or without yellow stripe(s). The ground wire may be

part of, or separate from, the supply cable. It may be

continuous or spliced above the pump along with the

supply cable.

3. The motor lead wire assembly includes a green

insulated ground lead. Splice the ground wire to the

green insulated lead as shown in Figure 6.

4. The other end of the ground wire will be connected to

the power supply grounding terminal or to the control

panel ground bar if it is connected to the power

supply ground.

NOTE: See section entitled Grounding for detailed

grounding instructions.

This manual is related to the following products:

4 (10 cm) Cast Iron Captain Plus A Series 6 (15 cm) P Series 6 (15 cm) T Series 8 (20 cm) T Series