SUBMERSIBLE PUMPS

4” - 6” - 8”
INSTALLATION, OPERATION & MAINTENANCE
INSTRUCTIONS

READ COMPLETE INSTRUCTIONS

CAREFULLY BEFORE
ATTEMPTING ANY WORK! 2. PRELIMINARY CHECKS!
2.1 Electrical power supply should match that
1. IMPORTANT PRECAUTIONS! shown on the motor nameplate in regards to voltage,
ampacity (current carrying capacity of circuit), phase
1.1 An improperly wired pump constitutes a and frequency in hertz (Hz). Electrical controls such
hazard to health and property. Electrical installation as pressure switches, starters, etc., must be checked
must be performed by qualified personnel. It must for proper sizing.
conform to the latest requirements of the National 2.2 Three-wire, single phase motors require a
Electrical Code (U.S.A.) and any codes in effect at matching control box. Electrical requirements on
the time of installation. Pay particular attention to control box nameplate must match the motor name-
the grounding requirements. plate information. Three-phase motors require a cor-
1.2 Piping must follow good plumbing prac- rect size ambient compensated starter with quick trip
tices and it must conform to current applicable local heaters on all legs. (Note: Heaters are not normally
and national codes. supplied with starters and must be purchased sepa-
1.3 It is recommended that any installation and rately.) Two wire motors do not require a control box
service be performed by a National Pump dealer. and are wired directly to automatic switching devices,
1.4 Use of submersible well pumps in open such as a pressure switch.
bodies of water such as lakes, swimming pools, etc. is 2.3 Inspect the pump and motor for any
not recommended due to possible shock hazards. damage incurred in transit.

Page 1
3. ACCESSORIES 10ft.-lbs of torque. Route the ground wire under the cable
guard and secure it to the discharge pipe along with the
3.1 National Pump offers various accessories that supply-power conductors. Terminate the other end with
would make a basic water system safer and more reliable. the proper size ring-tongue terminal and connect it to the
Examples are: surge protectors (lightning arrestors), low metal well casing using approved bonding technique.
flow cut-off controls, well seals, pressure relief valves, Continue ground wire and connect it to the supply
contactors, starters, pressure switches, etc. Installation ground. All above ground controls must be properly
instructions are normally supplied with the accessories bonded to the supply ground.
and some are explained elsewhere in this manual. Read
the accessories instructions carefully and integrate them 4.5 Perform all electrical connections from supply to
with the basic instructions contained in this manual. disconnect switch, to pressure switch and to the control
box or starter (when required). Do not connect pump
cable to the switch (2 wire installation) or control box (3
wire installation) at this point in the installation.
4. ELECTRICAL INSTALLATION
4.1 Select the proper size cable. Improper sizing will 4.6 Installations using packaged cable (AW28) on
result in excessive voltage drop and consequently im- 4” motors.
paired pump performance and efficiency. Refer to Section 4.6.1. Remove cable guard.
8, Tables 1 & 2 for selection chart. 4.6.2. Remove short “pigtail” on motor, if
equipped, by loosening the gland nut holding
Voltage at the pump should be within 10% of name- the connector to the motor completely and
plate rating. Example: 115 volt nameplate should have a pulling connector off.
minimum of 103.5 volts and a maximum of 126.5 volts.
4.6.3. Inspect the connector on package
cable (AW28) for damage and/or dirt in the
If calculations are used instead of the chart, or if the sockets. Plug connector to the motor making
chart does not show the size being used, start from the sure male and female parts match and the
service main entrance and continue on to the pump to polarizing slot and key are aligned. Push the
obtain total cable length. connector as far as it will go. Engage the gland
Voltage Drop = (Total length of cable in feet) nut and tighten until snug. Avoid cross-
x (Resistance in Ohms per foot) threading when starting the gland nut.
x (Maximum Amps)
4.6.4. Lay cable flat against pump and install
Voltage at Pump = (Service Main Voltage) cable guard. Check that the cable is not pinched
- (Voltage Drop)
anywhere along the guard. Proceed to Section
4.2 Provide a separate fused or circuit breaker- 4.8 for the remainder of the installation.
protected branch circuit. Refer to Section 8, Tables 3-6
for fusing (use Type D fuses only) or circuit breaker
4.7 Installations using bulk cable and short lead
sizing.
cable (pigtail) supplied with motor.
4.3 Install a main disconnect switch in full view and 4.7.1. Prepare the cable ends by stripping the
easily accessible from where the pressure switch and insulation to expose about 3/8” to 1/2” of the
pressure tank are located. Refer to Section 9 Wiring conductors.
Diagrams for typical electrical layouts. 4.7.2. If using the heat-shrink tubing method of
insulation, slip an appropriate length of tubing
4.4 Proper grounding is a prime requirement for a safe over each wire. Splice the wires to the motor
and reliable installation. Follow code requirements such as pigtail using the proper crimping tool and
the National Electrical Code (NEC) or Canadian Standards compression sleeves. Observe color coding. To
Association (CSA) Liquid Pump Standards. Use only insure a good connection and a strong splice,
copper wire for grounding. Proper grounding of solder may be applied to the joint after crimping.
submersible pumps may be accomplished in either of two Solder is mandatory above 5 hp. Use only rosin-
ways: a) use of a metal pipe from the pump discharge head core solder.
all the way to the pitless adapter (continuous metal path to
the well casing) or, b) if plastic pipe is used, a separate 4.7.3. Position shrink tubing (AW25-Series)
ground wire of the same size as the supply conductors over the joint making sure it is centered. Apply
should be installed. Terminate the wire with a 5/16” ring- heat on the shrink tubing with a flame or a
tongue terminal. On one of the motor mounting studs propane torch. If using a torch, keep the flame
closest to the motor electrical connector, install the ring- moving to prevent burning the tubing. Proper
tongue terminal, washer, and an additional nut. Tighten to shrink is reached when the tubing does not
show any further reduction in size and the waxy
Page 2 sealant has started to ooze at the ends.
 4.7.4. Check proper sealing of splice by immersing it 4.8 Complete the electrical connection to the pressure
in a container of water for ten (10) minutes and then switch, contactor, control box or starter. Refer to
taking a resistance reading between the water and each typical wiring diagrams. Section 9 to determine the
of the cable conductors. Connect one ohmmeter lead connections appropriate to the installation. Affix
to the conductor and the other lead to a piece of metal motor information sticker in an appropriate location
immersed in the same water. The resistance should be after filling out.
2 megohms (2 million ohms) or higher. A low
resistance indicates an insulation leak and must be 4.9 Surge Arrestors (Lightning Arrestors) - It is
corrected. highly recommended that surge arrestors be installed.
Surge arrestors will conduct high voltage surges to
ground before they can inflict damage to the motor.
OHMMETER
set at R x 100x Single-phase motors with integral surge protectors do
not require any additional protection.
Attach this lead to Motors without integral surge protection may be
metal tank or metal
plate in water protected by either the valve type (indoor-outdoor use)
or the expulsion type (outdoor only). Both are
available from your National Pump Dealer. Three-
phase motors will require three surge protectors.
Resistance Measurement
between cable and ground Connect as shown in the instructions accompanying
the protectors. In addition, use the following
Figure 1 procedure.
If a protector has already been installed at the lead-in
4.7.5. Measure the total resistance of the complete power lines to the user’s premises and is within 50
drop cable and motor circuit to insure that a good feet of the pump control box or pressure switch
installation, no additional protector(s) is required. On
splice was made. The total resistance should equal the
overhead supply line longer than 50 feet a protector at
length of the cable in feet, multiplied by the resistance
the control box is required. In any installation the
per foot plus the motor winding resistance (Tables 5- ground connection determines the effectiveness of the
8, Section 8). Use the low scale (Rx1) on the ohmme- system. Same size wire as supply cable to motor, or
ter for this test. A low reading, compared to what was larger, bare or stranded, should be used for grounding.
calculated, indicates a possible short in the cable or
motor winding; a high reading (more than double) 5. INSTALLATION IN THE WELL
indicates a high resistance joint, which must be
corrected by re-splicing. NOTE: On motors with 5.1 Before connecting any piping to the pump,
resistance of one (1) ohm or less, use a bridge-type REMOVE the check valve. Push the poppet on the
instrument to measure the resistance. A bridge-type check valve to insure proper functioning after the
instrument is designed for measuring low resistances. prolonged storage. If both checks are acceptable
Total Resistance = cable length in feet x resistance per reinstall the check valve. Use pipe sealant on the
foot + resistance of motor winding. On two wire threads.
motors connect the ohmmeter to the two leads to
measure the resistance. On three wire motors con- 5.2 On top-feeding wells and wells that have a much
nect the ohmmeter to the black and yellow to measure greater diameter than the pump, a sleeve should be
the resistance. used to obtain the necessary water flow around the
motor for cooling. Sleeves may be fabricated by the
installer. Refer to Section 10 for recommended design
OHMMETER
Set at R x 1
and suggested flow around the motor.

5.3 Connect the piping to the pump and carefully

lower it in to the well. Caution should be exercised in
this operation so as to not injure the drop cable.
Fasten cable to the drop pipe at regular intervals, about
every 10 feet, with waterproof plastic electrical tape
or self-locking plastic bands. Use an approved well
Resistance Test of Entire
Cable Length and Motor cap to properly seal the top of the well and to provide a
suitable exit for the power cable and grounding
Figure 2 conductor, if required.

Page 3
 5.4 Final pump setting must be at least ten feet from TYPICAL INSTALLATIONS
the bottom of the well. It must also be at least ten feet 3-Wire Galvanized Tank Installation
below the maximum well drawdown (water level
depth).
To Circuit Breaker
If over-pumping a well is a possibility, safeguards or
Fuse Box
must be made through the use of accessories to Control Disconnect
prevent its occurrence. Box Switch

5.5 Use of a standard pneumatic tank requires the Shut Off

installation of an air charging system. Proceed to Valve

Section 5.5.1 if this is required. Tanks using a Air

Union
separate air chamber do not require an air charging Water
system Proceed to Section 5.6. Gauge
Pressure
5.5.1 Air Charger Operation and Installation. Switch
Pressure
Relief
Pressure storage tanks that are not equipped with a Union Valve

separating membrane between the air cushion and the Check

Valve
Drain

water will gradually lose the air charge if no provision

is made to replenish it. The air charging system for a
submersible pump consists of a drain and “Y” fitting
(AV11), a snifter valve (AV9), and an air escape
control (AA4).
Pitless
Adapter
The AV9 is installed on the discharge pipe at a
location not subject to freezing. An AV11 is installed Bleeder
Valve
between 7 and 20 feet below the AV9 on the same
Caution: All Electrical
discharge pipe. The AA4 is installed in the pressure Equipment must be
tank. In operation, as soon as the pump cuts out, the Torque
Arrestor connected to supply.
snifter valve will open to the atmosphere and the drain
and “Y” fitting will bleed the water in the pipe
between the AV9 and the AV11. On the next pump
turn-on, the slug of air in the pipe is forced into the
tank because the snifter valve and the “Y” fitting Figure 3
automatically close under pressure. If an excessive
amount of air is accumulated in the tank the AA4 will
automatically bleed it into the atmosphere.
The volume of air charged into the tank per complete
on-off cycle is determined by the distance between the
AV9 and the AV11. The larger the tank, the greater
the required distance, and thus the larger the volume Open Tank Installation
charged. Refer to the following chart to determine Float
approximate setting of drain fittings for different tank Switch
Disconnect To Fused or Circuit Breaker
sizes. Switch Protected Power Supply

Approximate Setting for Drain Fittings To Float Motor Control Box

Tank Size Gallons Depth from Surface To Switch or Starter

Install Drain Fittings

From Float
42 7 Switch
82 10 To Service
120 15
220 15
315 20
525 20

5.6 A safety-line of corrosion-resistant cable can be

attached to the discharge head eye on the pump and Figure 4
secured at the top of the well when using plastic drop
pipe. This is to safeguard against losing the pump
down the well if the pipe breaks.

Page 4
 TYPICAL INSTALLATIONS (CONT.) 6.2 For single phase pumps:
Leave open one faucet in the house. Start pump.
2-Wire Captive Air Tank Installation
Observe pressure buildup and allow water to flow
for about a minute. Close the faucet. Pump
To Circuit Breaker or
Fuse Box should stop when pressure reaches the cut-out
Disconnect
Switch
setting.

6.3 Pressure switch cut-in and cut-out points are

Shut
Off
adjustable. Refer to instruction card in the
Valve
pressure switch for procedures. On precharged
tanks, the precharge pressure as measured at the
Union
Schraeder valve when no water is in the tank,
Gauge
should measure about 2 psig below the cut-in
pressure of the switch. Adjust precharge as
Pressure
Relief required.
Valve
Check Drain
Valve
Union 6.4 For three-phase pumps.
Modify the discharge piping so that a full free-
discharge flow may be observed. Start the pump
Pitless
Adapter
and observe rate of flow. Turn power off and
reverse any two leads. Start pump and compare
flow from the previous one. Combination of con-
nections resulting in the highest flow rate is the
one giving the correct rotation. Check also the
Torque Caution: All Electrical current unbalance between the three legs. Unbal-
Arrestor Equipment must be
connected to supply. anced current could result in the above normal
operating temperatures. Maximum unbalance
allowable is 5% of the average of the three legs.
If an excessive unbalance is experienced it must
be determined if it is caused by the motor or the
power supply. “Roll” the leads to the motor by a
sequence as follows. This procedure will not
Figure 5
change the established rotation (see illustration
below).
5.7 Piping to the Tank.
5.7.1. A pressure relief valve must be installed as Ampere readings must be taken at each roll.
close to the pressure tank as possible if the pump Three sets of readings will result.
is capable of developing 75 psig or higher
If the abnormal reading stays with the same
discharge pressure. The relief valve should be
supply line, for example L1, then the supply is
sized to handle the flow that the pump can
defective and the power company should be
produce at 75 psig discharge pressure.
notified. If the abnormal reading stays with the
same motor lead, for example “yellow”, then the
5.8 Make final electrical connections to switch or
motor and/or its lead lines, including splices, is at
control box.
fault and must be investigated and corrected.
6. START-UP AND FINAL CHECKS Secure the connections.
6.1 Double-check entire installation paying
particular attention to these items:
a.) Pressure switch connection to control check
valve and check valve direction, if they are used.
b.) Interconnection of pressure switch to other
electrical components of the systems. Refer to
Section 9 for wiring diagrams.
c.) Grounding
d.) Shut-off valve locations in the house piping.
e.) Pressure relief valve installation.

Page 5
 7. TROUBLE SHOOTING CHART
In case of difficulties, refer to the chart to locate basic problems with the system. Once the
problem is located, refer to specific sections in this manual for details.

CONDITION PROBABLE CAUSE REMEDY

PUMP WILL 1. Motor overload protector trip 1. Overload will automatically reset.
NOT RUN a. Incorrect control box Investigate cause of overload.
b. Incorrect connections a. Check nameplate for HP and voltage.
c. Faulty overload protector b. Check with wiring diagram (see motor
d. Low voltage control box wiring instruction).
e. Ambient temperature of control box c. Replace protector if 3-wire motor.
or starter too high Replace motor if 2-wire motor.
f. Pump bound by foreign matter d. Check voltage at control box.
e. Pull pump and examine.
2. Blown fuse, broken or loose electric 2. Check fuses, relays or heater elements for correct
connections. size capacitor and all electrical connections.
3. Motor control box or starter not in proper 3. Make sure box is in upright position.
position.
4. Cable insulation damaged. 4. Locate and repair as per instructions.
5. Splice may be open or grounded 5. Check resistance between cable leads
with ohmmeter. If open or grounded,
pull pump.
6. Faulty pressure switch. 6. Repair or replace.
7. Faulty liquid level control. 7. Check relay, wires and electrodes.

PUMP RUNS 1. Line check valve backward 1. Reverse check valve

BUT NO WATER 2. Pump is air-bound. 2. Successively start and stop pump until water
DELIVERED flows normally.
3. Lift too high for pump. 3. Check with rating table.
4. Intake strainer or impeller plugged, or pump in 4. Pull pump and clean, check well depth. Raise
mud or sand. setting if necessary.
5. Pump not submerged 5. Lower pump if permissible
Check recovery of well.
6. Well may contain excessive amounts of air or 6. Start and stop pump several times. If this does
gas. not remedy conditions, pump may not be able to
cooperate because of too much gas.
7. Three-phase unit running backwards. 7. Reverse rotation.

REDUCED 1. Lift too high for pump. 1. Check rating

CAPACITY OR 2. Strainer or impellers partly plugged. 2. Pull pump and clean.
INSUFFICIENT 3. Scaled or corroded discharge pipe or leaks 3. Replace pipe and repair leaks.
TANK PRESSURE anywhere in system.
4. Well may contain excessive amounts of air or gas. 4. Start and stop pump several times. If this does
not remedy conditions, pump may not be able to
cooperate because of too much gas.
5. Excess wear due to abrasives. 5. Replace worn parts.
6. Three phase pump running backward. 6. Reverse rotation.

PRESSURE 1. Incorrectly set. 1. Change settings.

SWITCH DOES 2. Switch opening plugged. 2. Clean openings or install new switch.
NOT CUT OUT 3. Leaks anywhere in system. 3. Repair leaks.
4. Three-phase unit running backward. 4. Reverse rotation.

PUMP STARTS 1. Water-logged tank. 1. a. Check tank for leaks. (Plug at top of tank
TOO FREQUENTLY may be leaking air.)
b. Be sure drain and “Y” fittings are functioning
properly. Check operation of snifter valve.
2. Check valve leaking. 2. Replace check valve.
3. Pressure switch out of adjustment. 3. Readjust to correct setting or replace.
4. Leaks in service line. 4. Locate and correct.

Page 6
SECTION 8 TECHNICAL DATA
Cable Selection
TABLE 1 Single Phase Motor Maximum Cable Length (Motor to Service Entrance)
Motor Rating Copper
Cooper Wire
Wire Size
Siz e
Volts H.P. 14 12 10 8 6 4 2 0 00
1/3 134 212 333 522 610 1240 1890 2550
115
1/2 100 159 249 390 608 930 1410 1910
1/3 533 850 1350 2110 3290 5025 7650
1/2 404 641 1003 1575 2450 3750 5710
3/4 293 473 740 1161 1810 2760 4210 5680
1 248 392 617 968 1507 2300 3510 4730 5920
1 1/2 205 326 510 801 1248 1920 2930 3950 4940
230
2 180 286 449 703 1096 1675 2550 3440 4300
3 229 359 563 877 1339 2041 2750 3440
5 216 315 490 750 1142 1540 1925
7 1/2 270 362 553 842 1136 1420
10 250 425 650 875 1100

TABLE 2 Three Phase Motor Maximum Cable Length (Motor to Service Entrance)
Motor Rating Copper
C Wire
o o p er W Size
ire S iz e
Volts H.P. 14 12 10 8 6 4 2 0 00 000 0000
1 1/2 320 510 800 1260
2 250 390 610 960 1500
3 180 290 450 710 1110 1690
200 V 5 300 470 730 1110 1690
60 H Z 7 1/2 340 530 810 1230 1660
or 10 250 390 600 920 1240 1540
50 H Z 15 270 410 630 850 1060 1270
20 320 480 650 810 970 1150
25 390 530 660 790 930
30 430 540 640 750
1 1/2 430 680 1070 1680
2 320 510 790 1250 1940
3 240 380 600 940 1470 2240
230 V 5 250 390 620 960 1470 2230
60 H Z 7 1/2 290 450 700 1070 1630 2200
AND
10 340 520 800 1220 1640 2050
220V
15 360 550 830 1130 1410 1680
50 H Z
20 420 640 860 1070 1280 1510
25 340 520 700 870 1040 1230
30 420 570 710 850 1000
1 1/2 1720
2 1280 2030
3 960 1530 2400
460 V 5 630 1000 1570 2470
60 H Z 7 1/2 460 730 1150 1800 2610
AND 10 550 850 1340 2090 3190
360 V 15 590 920 1430 2190 3340
50 H Z 20 700 1100 1670 2550 3440
(Divide
lengths 25 570 890 1360 2070 2600 3500
by 1.4 30 730 1110 1690 2280 2650 3400
for
40 850 1300 1750 2190 2610 3070
360V
60 HZ) 50 680 1040 1400 1750 2090 2450
60 870 1180 1470 1760 2070
75 950 1190 1420 1670
100 890 1060 1240

Page 7
SECTION 8 Technical Data Cont... TABLE 5
Single-phase 6” - 3 wire 60 HZ Submersible Motors
Motor Model No. Prefix 226
TABLE 3
Single-phase 4” - 2 wire 60 HZ Submersible Motors
Maximum Circuit Breaker or Winding Res.
Motor Model No. Prefix 244 H.P. Volts
Amps Fuse Siz e* - Amps Ohms
5 230 29.5 80 .55-.68
Maximum Circuit Breaker or Winding Res. 7 1/2 230 40.0 100 .40-.50
H.P. Volts
Amps Fuse Siz e* - Amps Ohms
10 230 52.0 150 .27-.33

1/3 115 8.9 25 1.5-1.9 * Use Type D fuses only.

1/3 230 4.4 15 6.0-7.4

1/2 115 11.9 30 1.0-1.3 TABLE 6

Three-phase 4” - 3 wire 60 HZ Submersible Motors
1/2 230 5.9 15 4.2-5.2 Motor Model No. Prefix 234
3/4 230 8.0 20 2.7-3.4
Maximum Circuit Breaker or Winding Res.
H.P. Volts
1 230 9.6 25 2.2-2.8 Amps Fuse Siz e* - Amps Ohms

1 1/2 230 13.1 35 1.5-1.9 1 1/2 200 7.3 20 2.4-3.4

1 1/2 230 6.3 20 3.2-4.1
* Use Type D fuses only.
1 1/2 460 3.1 15 11.3-15.0
1 1/2 575 2.5 15 15.1-26.0
2 200 9.4 25 1.9-2.4
TABLE 4 2 230 8.2 20 2.4-3.0
Single-phase 4” - 3 wire 60 HZ Submersible Motors
2 460 4.1 15 9.7-12.0
Motor Model No. Prefix 214 & 224
2 575 3.3 15 13.6-18.9
3 200 13.1 35 1.3-1.7
Maximum Circuit Breaker or Winding Res.
H.P. Volts
Amps Fuse siz e* - Amps Ohms 3 230 11.4 30 1.8-2.2
3 460 5.7 15 7.0-8.7
1/3 115 8.9 25 1.5-1.9
3 575 4.6 15 11.0-13.6
1/3 230 4.4 15 6.0-7.4
5 200 20.0 50 .70-.94
1/2 115 11.9 30 1.0-1.3 5 230 17.4 45 .93-1.2
1/2 230 5.9 15 4.2-5.2 5 460 8.7 25 3.6-4.4

3/4 230 8.0 20 2.7-3.4 5 575 7.0 20 5.6-6.9

7 1/2 200 30.8 80 .55-.68
1 230 9.6 25 2.2-2.8
7 1/2 230 26.8 70 .76-.93
1 1/2 230 11.5 30 1.5-1.9
7 1/2 460 13.4 35 2.4-3.4
2 230 13.2 35 1.6-2.3 7 1/2 575 10.7 30 3.5-5.1
3 230 16.5 45 .9-1.5 10 460 17.6 45 1.8-2.3

5 230 27.5 80 .68-1.0 10 575 14.1 40 2.8-3.5

* Use Type D fuses only. * Use Type D fuses only.

Page 8
SECTION 9 WIRING DIAGRAMS

Page 9
SECTION 10 FLOW SLEEVE

Electrical
Wires
Discharge
Pipe

Well Seal

Seal prevents leakage

around discharge pipe
and flow sleeve

FLOW SLEEVE
Pump
Figure 6

Water Water
Flow Flow

Motor
Spacers bolted
to flow sleeve
for centering
motor

Page 10
NOTES

Page 11
Page 12 IOM/Sub468 07/16