ELECTRICAL FACTS + FIGURES

Electrical facts and figures come into play in the installation of well systems. The process is different for jet pumps than fit is for submersible pumps. All electrical wiring is above ground for jet pumps. This is not the case with submersible pumps. When a submersible pump is installed, wiring goes right down into the well water. Obviously, the electrical connections must be properly protected from any form of water invasion.

Major electrical work is normally done by licensed electricians.

Pump installers and plumbers are allowed to do some electrical wiring, but they are limited in their ability to meet electrical needs for a well system.

In theory, the electrical work is pretty cut and dried. fit begins at a power panel or subpanel and makes fits way to the pump and pressure switch. The power source can be protected by simple circuit breakers.

A dedicated control box or disconnect box can be installed. This is more often the case with jet pumps. fit is best to leave this part of the job to a licensed electrician.

Before discussing the types of work that installers and plumbers normally do with electrical wiring, take note of Tables 7.1 and 7.2, which you can use for reference when performing this kind of work. The tables are self-explanatory.

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Tbl. 1 Electrical Data for Control Panel Enclosures

Enclosure Rating Explanation NEMA 1 Genera! Purpose To prevent accidental contact with enclosed apparatus. Suitable for application indoors where not exposed to unusual service conditions, NEMA 2 Drip tight To prevent accidental contact, and in addition, to exclude failing moisture or dirt.

NEMA 3 Weatherproof (Weatherproof Resistant) Protection against specified weather hazards. Suitable for use outdoors.

NEMA3 R Rain tight Protects against entrance of water from a beating rain. Suitable for general outdoor application not requiring sleetproof.

NEMA 4 Watertight Designed to exclude water applied in form of hose stream. To protect against stream of water during cleaning operations, etc.

NEMA 4X Watertight & Corrosion Resistant Designed to exclude water applied in form of hose stream. To protect against stream of water during cleaning operations, etc. Corrosion Resistant, NEMA 5 Dusttight Constructed so that dust won’t enter enclosed case. Being replaced in some Dust Tight equipment by NEMA 12.

NEMA 6 Watertight, Dusttight Intended to permit enclosed apparatus to be operated successfully when temporarily submerged in water.

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NEMA 7 Hazardous Locations Class I Designed to meet application requirements of National Electrical Code for Class 1, Hazardous Locations (explosive atmospheres). Circuit interruption occurs in air.

NEMA 8 Hazardous Locations A, B, C or D Class II - Oil Immersed Identical to NEMA 7 above, except the apparatus is immersed in oil.

NEMA 9 Class II - Hazardous Locations Designed to meet application requirements of National Electrical Code for Class II Hazardous Locations (combustible dusts, etc), E, F and G, NEMA 10 Bureau of Mines Permissible Meets requirements of U.S. Bureau of Mines. Suitable for use in coal mines.

NEMA 11 Dripproof Corrosion Resistant Provides oil immersion of apparatus such that fit is suitable for application where equipment is subject to acid or other corrosive fumes, MEMA12 Driptight, Dusttight For use in those industries where fit is desired to exclude dust, lint, fibers and flyings, or oil or industrial coolant seepage,

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Tbl. 2 Jet Pump Motor Data

HP Volts Phase Service Factor Max.

Load Amps Watts Circuit Breaker Switch

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Electricians handle all elements of wiring and electrical connection on some jobs, but there are also jobs for which they run a feed wire to either a jet pump or a wellhead and leave the rest to a plumber or pump installer. Who does what depends largely on code regulations in various local jurisdictions.

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CAPACITOR START INDUCTION RUN - SINGLE SPEED (NEW STYLE - AFTER APRIL, 1999)

Fig. 1 GRD Green (Ground)

Align black plug to 115 V or 230 V arrow.

½ HP wired 115 V, ¾ HP and up wired 230 V at factory.

LINE L1 L2 A 115V 230V A BLACK TRACER 1 2 3 BLACK TRACER BLACK TO WIRE FOR 230 V:

BLACK TRACER TO B BLACK TO A TO WIRE FOR 115 V:

BLACK TRACER TO A BLACK TO L1 230 V YELLOW YELLOW RED RED BLACK PHASE MAIN MAIN PURPLE WHITE B 115 V A L2 L1 L1 L2 L2 L1 B A CAPACITOR START INDUCTION RUN - SINGLE SPEED (OLD STYLE - UP TO APRIL, 1999)

"Black Tracer" is a black and white wire B Fgr. 1 Jet Pump Motor Wiring for A. O. Smith Motors

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115 VOLTAGE A - has 2 male connectors and 1 screw connector Motor is non-reversible CCW rotation shaft end.

Supply connections, use wires sized on the basis of 60ºC ampacity and rated minimum 90ºC.

WHT/BLK TRACER 2 - has 2 male connectors and 1 screw connector B - is a dummy terminal used to hold the Wht./Blk/

Tracer for 230V wiring 230 VOLTAGE CONNECTIONS EMERSON MOTOR WIRING 115/230 VOLTAGE CONNECTIONS 115 Voltage Black - A Wht./Blk. Tracer - 1 Line 1 - 2 Line 2 - A (Blue - 3) 2 3 1 B A LINE 1 LINE 2 BLACK BLACK 2 3 1 B A LINE 1 LINE 2 WHT/BLK TRACER 230 Voltage Black - 1 Wht./Blk. Tracer - B Line 1 - 2 Line 2 - A (Blue - 3) TO CHANGE MOTOR VOLTAGE:

Models without a Switch 115V to 230V Move Wht./Blk. tracer to B Move Blk. to 1 Models with Voltage Change Switch ___ 230V to 115V Move Blk. to A Move Wht./Blk. tracer to 1

Fgr. 2 Emerson Motor Wiring

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Plumbers and pump installers are normally allowed to work with existing electrical wiring when troubleshooting and repairing a well system. In some regions only licensed electricians are allowed to make new installations. Before you do any electrical work, make sure that your trade license and liability insurance covers you for the type of work to be done. And, of course, be certain that the wires you are working with on new installations are not energized with electrical power.

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Line L1 Range: adjust for cut-in point Grounding Provisions

#8-32 screws Differential: adjust for cut-out point

PRESSURE SWITCH ADJUSTMENT

Adjust in proper sequence:

1. CUT-IN: turn nut down for higher cut-in pressure, or up for lower cut-in.

2. CUT-OUT: Turn nut down for higher cut-out pressure, or up for lower cut-out.

CAUTION: TO AVOID DAMAGE, DO NOT EXCEED THE MAXIMUM ALLOWABLE SYSTEM PRESSURE. CHECK SWITCH OPERATION AFTER RESETTING.

Line L2 Load

Fgr. 3 Pressure Switch Adjustment

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LINE LOAD MOTOR L1 L2 LINE LOAD DIFFERENTIAL ADJUSTMENT

Turn clockwise to increase cut-out pressure without affecting cut-in. (3 PSI/turn) MAIN SPRING ADJUSTMENT Turn clockwise to increase both cut-out and cut-in pressure. (2 PSI/turn) HUBBELL (FURNAS) PRO CONTROL SWITCH

Fgr. 4 Pressure Switch Wiring for Hubbell Pro Control switch

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WIRING Diagrams AWA501/AWA502 FACTORY WIRED FOR 230 VAC.

FOR 115 VAC POWER SUPPLY, WIRE HOT LEG TO (L1) AND NEUTRAL TO (L2), JUMP (L2) TO (N).

230 VAC SINGLE PHASE 60 HZ S1-AUX S2-AUX TO CHEMICAL FEED PUMP PUMP NO. 1 LEAD PUMP ON/OFF GND R1 1T S1 3 HP MAX PUMP NO. 2 RUN RUN HAND OFF AUTO 1 2 2T 1 2 S2 L2 N 5 6 L1 1 2 R1 S2 S2 A LAG PUMP ON/OFF 3 4 R1 A A TD HAND OFF AUTO

Fgr. 5 Example of a Wiring Diagram

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TIP: Never trust an electrical switch. I made this mistake once with an electric water heater earlier in my career.

I pulled the main fuses in the house and started to remove the electrical wires.

After a surprising and shocking experience, I found that the water heater had a separate electrical source on the outside of the house.

Cut the power off based on the switch or circuit breaker. Then check the wire with an electrical meter to be sure that the wire is not carrying electricity.

Because of my early experience with electrical work, I now use two meters to check wires to ensure that one of them is not broken.

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POWER CONNECTION 230 VOLT L1 L2 1T PUMP NO. 1 INCOMING SINGLE PHASE POWER 230 VAC ONLY PUMP NO. 2 2T N 121 2 Fgr. 6 Example of a Wiring Diagram for a 230-Volt Pump

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MANUFACTURER'S RECOMMENDATIONS

Always follow the manufacturer's recommendations when installing a well system. Pay particular attention to this with the electrical wiring.

Confirm that the voltage coming to the pump wiring is the proper amount. Mixing up a 115-volt system with a 230-volt system is not going to work.

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Fgr. 7 Example of a Wiring Diagram for a 115-Volt Pump POWER CONNECTION 115 VOLT L1 L2 FACTORY WIRED FOR 230 VAC.

FOR 115 VAC POWER SUPPLY, WIRE HOT LEG TO (L1) AND NEUTRAL TO (L2), JUMP (L2) TO (N).

FIELD-INSTALLED JUMPER INCOMING SINGLE PHASE POWER 115 VAC ONLY N

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CONNECTING THE PRESSURE SWITCH

Connecting the pressure switch to the wiring supply is not difficult. I have provided examples of how this is done. The advantage in installing jet pumps is that all the wiring is located at the pump.

When wiring must enter a hole for access to connection points, you need to install a stress-relief insert. This is simply a round device that has a threaded portion that fits through the hole. The device is held in place with a nut that screws on from the inside of the hole. Once the nut is threaded onto the stress-relief insert, you can feed the wiring cable though the insert.

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Fgr. 8 Optional Centripro Control Box and Pumpsaver: CONTROL BOX WITH PUMPSAVER

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Fgr. 9 Example of a Wiring Diagram for Field Connections

FIELD CONNECTIONS 1 LEAD PUMP START/STOP PRESSURE SWITCH CHEMICAL FEED PUMP (OPTIONAL) SEPARATE 115 VAC SUPPLY LAG PUMP START/STOP PRESSURE SWITCH (OPTIONAL) S1-AUX S2-AUX 23456

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A stress-relief clamp is located on the outside of the wiring hole. This is a metal strip below which the wiring cable is installed. Once enough cable is in the hole, tighten two screws on the bar, which provides pres sure on the electrical cable. This prevents wiring connections from being dislodged accidentally by pulling on the cable.

Wires must be stripped of their insulation to be installed under the nuts of a pressure switch. Once this is done, the copper wiring is installed under the connection point and then the securing nut is tightened. The tightening is done by turning the connection point clockwise. For this reason, you should bend a small crook in the wire and install fit with the crooked end positioned so that clockwise tension will tighten the wire. If you install the bent end of the wire in the other direction, the turning of the connection point creates a tendency for the wire to come off the connection stud.

There are two main wires and a ground wire to secure. The ground wire is installed under a green screw near the connection point. Confirm which wires are installed under which connection points on the switch.

This information is identified in the paperwork that comes with the type of switch you are working with. Normally the red wire is the hot wire and the black wire is the neutral wire, but don't make this assumption automatically. Check the manufacturer's recommendations to ensure that you are connecting the wires properly.

WIRING FOR SUBMERSIBLE PUMPS

Wiring for a submersible pump is buried in a trench and submerged in well water. fit is common for an electrician to install the wiring in a trench to the point where fit meets the wellhead. The wiring in the trench is turned up and placed inside conduit to protect fit. Submersible well caps are formed to allow the wiring to enter the well casing. An electrician may take the wiring to this point.

When the time comes to install a submersible pump, the work is done above ground before the pump is submerged. This is sometimes accomplished by stretching well pipe out on the ground and connecting the pump to fit. People who install pumps regularly use a pump well on the back of their trucks to hold the well pipe. This allows them to feed the piping out as they need to.

Once the pump is installed on the drop pipe, the wiring can be installed. Most submersible pumps use a three-wire system. Again, con firm voltage requirements and use the information provided by the pump manufacturer for the installation. You may be able to run your wiring the full length of the drop pipe without coupling fit, which is the preferred way to do fit.

Electrical wiring is taped to the drop pipe at close intervals to prevent the wiring from hanging loosely in the well. Electrical tape is normally used for this. fit is important to prevent the wiring from coming into con tact with the well casing. If fit does rub on the casing, the insulation can be chafed and create problems that will necessitate pulling the pump to replace the wiring.

When the pump, fits pipe, and fits wiring are lowered into the well, you need to keep the piping from sliding over the top edge of the well casing. This can damage both the piping and the wiring. Guide the pump assembly down the center of the well casing to prevent any scraping damage.

When the wiring reaches the wellhead from inside the well, fit has to be connected to the feed wires that come into the casing from the trench.

This is done with waterproof, heat-shrink connectors.

Heat-shrink connectors have a plastic sleeve and metal connection points. First, the insulation is stripped from the ends of the wiring. The wires are placed into the connector so that they are both fully under the connection points. Then the thin metal connectors are squeezed shut to secure the wiring.

Once the wires are under the connectors, you are ready to heat shrink the coupling. This is best done with a heat gun or a blow-dryer.

The plastic sleeves extend past the connectors and encircle the insulated wiring. When you apply heat, the plastic melts and fuses together. This makes the connection waterproof when fit is done properly.

We have covered the basics of wiring for new pump installations. We will go into more detail about electrical connections in Section 12,which deals with troubleshooting.

TIP: Never use wire nuts to connect wires that may come into contact with wet or damp conditions. Always use waterproof heat shrink connectors.