RJSINGLE

1Ø Service Manual

• Submersible Pumps• Jet Pumps

RED JACKET®

Water Products

Table of ContentsThis manual covers single phase 4” submersiblepumps and jet pumps.

Submersibles: (Pages 1 – 48) PageTypical Systems ...................................................... 1-5Troubleshooting ................................................... 6-11

Amprobe Instructions ........................................ 12Ohmmeter Instructions ...................................... 13

A Capacitor Checkout .......................................... 14-15B Relay Checkout ................................................. 16-19C Overload Checkout ........................................... 20-21

Overload Kit ................................................... 21a-21bRed Jacket Control Box Tests ............................. 22-25

D Voltage Checkout ............................................. 26-27E Electrical Short Checkout .................................. 28-29F Motor Winding Resistance Checkout ................. 30-33G Cable Checkout ................................................ 34-35H Amperage Checkout ........................................ 36-40I Pressure Switch Adjustment .............................. 41-42J Pressure Tank Checkout ..................................... 43-44

Submersible Pump Disassembly ....................... 45-46Submersible Pump Reassembly ........................ 47-48

Jet Pumps: (Pages 49 – 81)Typical Systems .................................................... 49-53Troubleshooting .................................................. 54-611 Voltage Checkout ............................................. 62-632 Amperage Checks ............................................. 64-65

Ohmmeter Checks ........................................... 66-71Wiring Diagrams .............................................. 72-75

3 Checking Suction Lift ........................................ 76-774 Pressure Control Valves ..................................... 78-79

Jet Pump Disassembly ........................................ 80Jet Pump Reassembly ......................................... 81

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Red Jacket Water Products is a licensed trademark.

The ITT Engineered Blocks symbol are registered trademark andtradename of ITT Industries.

Three-wire system illustrated usinggalvanized tank.

Typical Submersible System . . .

NOTE:Piping below the frost line is commonin colder climate areas.In warm climates, the piping is oftenabove ground and tank placement isoften outside the house and/or insidea separate cover or housing.

1

Protected Power SupplyDisconnect Switch

Control Box PressureGauge To House

Piping

Shut-offValve

UnionDrain Tap

PressureRelief Valve

Air Escape Control

Pressure Switch

Line Check Valvewith Snifter

Union

Pitless Adapter

Drain and Y Fitting

RULE OF THUMB1. Use same size or larger pipe

as discharge on pump.2. Always use a check valve

for every 200 ft. of vertical pipe.

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Two-wire system illustrated; usingdiaphragm type tank.

Typical Submersible System . . .

CAUTIONAll electrical equipment must be connected tosupply ground. Follow applicable coderequirements.

2

Protected Power Supply

To House Piping

DisconnectSwitch

Shut-offValveUnion

PressureRelief Valve

DrainTap

Tank TeeCheck Valve ➁Frost Level

CheckValve ➀

PitlessAdapter ➀

PressureSwitch

RULE OF THUMB1. Use same size or larger

pipe as discharge on pump.2. Always use a check valve

for every 200 ft. of vertical pipe.

➀ On installations with a pitless adapterthe top check valve should be belowthe pitless, not at the tank, as thedischarge line should be pressurizedback to the pitless.

➁ On installations with well seals or wellpits it is allowable to locate the topcheck valve near the tank.

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3

ControlBox

CAUTIONAll electrical equipment must beconnected to supply ground. Followapplicable code requirements.

Three-wire Single Phase Wiring Diagram:

Breakeror Fuse

Pressure Switch

Ground

Ground

To Well

TYP

ICA

L SYSTEM

SFranklin Electric Control Box

L1 Black Red Yellow L2

L1 Black Red Yellow L2

Standard Red Jacket Control Box

Standard Control Box Deluxe Control Box withWatt-Knot Voltage Surge Protector

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Box with Magnetic Contactor

WHITEGROUND

LEAD

Watt-Knot

Relay

1 2

5

Ground

RunCapacitor

StartCapacitor

Line 1 Red Yel Blk

PressureSwitch

Level orPressureControl

Ground BoxAccording to

Local andNational Codes

Line 2Circuit Breaker

4

TYP

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S71⁄2 and 10 HP Red JacketControl Box

WhiteGround Lead

Relay1

65

Ground

StartCapacitor

StartCapacitor

Line 1 Red Yel Blk

Ground BoxAccording to

Local andNational Codes

Line 2Circuit Breaker

RunCapacitor

RunCapacitor

Watt-Knot

5

See the Franklin Electric AIM (Application,Installation, Maintenance) Manual for F.E.control box data and schematics.

TroubleshootingINDEX

An amprobe and ohmmeter are essential forproperly checking a system. Use of theamprobe is explained on page 12. Use of theohmmeter is explained on page 13.Find the basic problem . . . for which numeroussymptoms are listed and possible solutions aregiven for each:

Page■ Pump Will Not Start ............................... 7■ Pump Will Not Run ................................. 8■ Pump Runs, But Little or

No Water Delivered ................................ 9■ Insufficient Tank Pressure ...................... 10■ Pump Starts Too Frequently .................. 11

6

IMPORTANTThis manual is intended ONLY for use byprofessionals familiar with NEC (NationalElectric Codes) electrical codes and hydraulicand safety procedures of pump installations.

RULE OF THUMBRemember, there may be othersystem problems caused byauxiliary controls not covered inthis booklet.

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TroubleshootingPump Will Not Start . . .

If fuses and overload check okay . . .PROBLEM: ANSWER:1. No power or See D page 26.

incorrect voltage2. Defective pressure Inspect points and

switch replace switch ifnecessary.

3. Loose connection See E, F, Gin control box, pages 28-35.cable or motor.

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TroubleshootingPump Will Not Run . . .

If motor overload trips or fuses blow . . .PROBLEM: ANSWER:1. Improper size fuses Replace with correct.2. Wrong control box Replace with correct.3. Incorrect voltage See D page 26.4. Defective control box See A, B, C

pages 14-21.5. Loose connections See E page 28.

in control box, Condition causescable or motor improper resistance

readings.6. Cable insulation See G page 34.

damaged or splice Condition causesmay be open or improper resistanceshorted readings.

7. Defective pressure Inspect points and/switch or or replace switch ifplugged tubing necessary.

8. Control box in hot Temperature not toenvironment exceed 122°F (50°C).

9. Pump bound by Pull pump and clean.abrasives See H page 36.

Condition causeshigh amperage.

10. Motor shorted or See pages 30-33.grounded

8

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TroubleshootingPump Runs, But . . .

Little or no water delivered . . .PROBLEM: ANSWER:1. Line check valve stuck Replace if defective.

or installed backwards2. Connections loose See wiring diagram

or misconnected in in control box.control box

3. Incorrect voltage See D page 26.4. Pump not submerged Check water level

in well.5. Leak in piping system Replace if necessary.6. Worn pump Repair or replace

water-end.7. Worn motor Replace motor.8. Suction screen or Pull pump and clean.

impeller clogged9. Broken pump shaft Replace.

or coupling10. Motor running Three phase –

backwards reverse 2 leadsSingle phase – turnoff for 20 secondsand restart

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TroubleshootingInsufficient Tank Pressure . . .

PROBLEM: ANSWER:1. Improper pressure See I page 41.

switch setting2. Incorrect voltage See D page 26.

Repair or replace.3. Excessive pump wear Repair or replace.4. Leaks in piping system Repair or replace.5. Water level in well Drill a deeper well.

too low6. Pump too small for Install a larger

water depth horsepower pump.

10

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TroubleshootingPump Starts Too Frequently . . .

PROBLEM: ANSWER:1. Waterlogged tank

a. Galvanized Check tank for leaks.Check drain and “Y”fittings, snifter valvefor proper operation.

b. Captive air type See J page 43.2. Check valve Replace if necessary.

stuck open3. Improper pressure See I page 41.

switch setting4. Leaks in Repair or replace

piping system5. Pressure tank

improperly sized

11

RULE OFTHUMB

Must be sized toallow a minimumrun time per cycleas follows:

1⁄3 – 11⁄2 HP =1 minute run time2 HP & larger =2 minute run time

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Amprobe Instructions

The Amprobe is a multi-range, combinationammeter and voltmeter.Voltmeter Scales: 150 VOLTS 600 VOLTSAmmeter Scales: 5 AMPS 40 AMPS

15 AMPS 100 AMPS1. When used as an ammeter, the tongs are

placed around the wire being measured withthe rotary scale on the 100 amp range. Thenrotate the scale back to the smaller rangesuntil an exact reading is indicated.

2. When used as a voltmeter, the two leads areclipped into the bottom of the instrumentwith the rotary scale on the 600 volt range. Ifthe reading is less than 150 volts, rotate thescale to the 150 volt range to get a moreexact reading.

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Ohmmeter Instructions

The Ohmmeter is used for measuring theelectrical resistance of a wire circuit. The unit ofmeasurement is called an Ohm.1. The knob at the bottom of the Ohmmeter is

adjustable through six ranges:RX1 = R x 1RX10 = R x 10RX100 = R x 100RX1000 = R x 1,000RX10K = R x 10,000RX100K = R x 100,000

2. The round center knob is for the purpose ofadjusting the instrument to zero (0) afterclipping the two ohmmeter leads together.This must be done every time the rangeselection is changed.

If your ohmmeteris digital readouttype, refer to theinstructions that

came with it.

13

CAUTIONUse Ohmmeter only with power off.

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Capacitor with Ohmmeter

1. Disconnect leads to capacitor post.2. Setting: R x 1,0003. Connect ohmmeter leads to capacitor posts.4. Reading: Pointer should swing toward zero,

then back toward infinity.

14

CAUTIONDischarge the capacitor before makingthis check. (A screwdriver can be used tomake contact between capacitor’s posts.)

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A Capacitor Checkout

“Quick-Disconnect” Control Box

15

RULE OF THUMBTo recheck, reverse the OHMMETERLEADS.

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Relay with Ohmmeter

A. Blue Relay - Solid State1⁄3 – 1 HP QD Control BoxesUsed from 1994 until present time:

Step 1, Triac Test1. Meter setting:

R x 1,000.2. Connections: Cap

and B terminal.3. Correct meter

reading: Infinityfor all models.

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Checkout for 1⁄3 to 1 HP QD ControlBoxes

Step 2, Coil Test1. Meter setting:

R x 1.2. Connections:

L1 and B.3. Correct meter

reading: Zeroohms for all models.

17

Step 2, Coil Test1. Meter setting:

R x 1.2. Connections:

Y (Common)and L2.

3. Correct meterreading: Zeroohms for allmodels.

B. Black Solid State Switch1⁄3 – 1 HP QD Control Boxes

Used from 1985 until 1994Step 1, Triac Test1. Meter setting:

R x 1,000.2. Connections:

R (Start) terminaland orange leadon start switch.

3. Correct meterreading: Infinityfor all models.

C. Current (Amperage) Relay1⁄3 – 1 HP QD Control BoxesKlixon relays have 4 terminals, # startswith 155252, used until January, 1985Step 1, Coil Test1. Meter setting: R x 1.2. Connections: #1 & #3.3. Correct meter reading:

Less than 1 ohm for all models.Step 2, Contact Test1. Meter setting: R x 1,0002. Connections: #2 & #4.3. Correct meter reading:

Infinity for all models.

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D. Potential (Voltage) Relay11⁄2 – 15 HP, Integral HP Control BoxesGE relays have 3 terminals, # startswith 155031

Step 1, Coil Test1. Meter setting: R x 1,000.2. Connections: #2 & #5.3. Correct meter readings:

For 115 Volt Boxes:.7 – 1.8 (700 to 1,800 ohms).

For 230 Volt Boxes4.5 – 7.0 (4,500 to 7,000 ohms).

Step 2, Contact Test1. Meter setting: R x 1.2. Connections: #1 & #2.3. Correct meter reading:

Zero for all models.

Contactor CheckoutCheckout procedure for Integral HP andother ContactorsContactor Coil Test

(Disconnect lead from one side of coil)1. Meter setting: R x 1002. Connections: Coil terminals3. Correct meter reading: 180 to

1,400 ohmsContactor Contact Test

1. Meter Setting: R x 12. Connections: L1 & T1 or L2 & T23. Manually close contacts4. Correct meter reading: Zero ohms

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B F.E. Relay Checkout Continued

Additional information on troubleshootingand replacement parts for Franklin ElectricSingle Phase Control Boxes is available in theF.E. Application-Installation-MaintenanceManual (AIM Manual). It is available online atwww.franklin-electric.com or call the FranklinElectric Technical Hotline @ 800-348-2420.The AIM is also included in the TechnicalSection of our Water Products catalogs.

A new QD diagnostic tool: the QD service boxis available from Franklin Electric. It can beused to check voltage and current whilethe motor is running. Order it fromwww.franklin-electric.com using a credit card.

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20

Overload Protector with Ohmmeter1. Setting: R x 1.2. Connect leads to black wire and blue wire.3. Reading: 0.5 ohm maximum.

FRANKLIN MOTOR PROTECTIONBefore Jan.-July After July1985 1985 1985

Motor No overload Overload Overloadin Motor in Motor in Motor

Control Overload in Overload in No OverloadBox Control Box Control Box in Control

Box

See Overload Kit Instructions page 21a.

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Checkout . . .

OHMS

R x 1000R x 10KR x 100K

R x 100R x 10R x 1

ZEROOHMS

B V R L2 L1

Capacitor Relay

R x 1

1⁄3 to 1 HP“Quick-Disconnect”Control Box

21

For 11⁄2 HP (and Larger) Control Box . . .1. Set Ohmmeter at “R x 1”2. Connect the Ohmmeter leads to Terminal #1

and #3 on each Overload Protector.3. Reading should be not more than 0.5 Ohms

maximum on the scale.Integral HP Control Box

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C F.E. Overload Checkout . . .

21a

FRANKLIN ELECTRIC OVERLOAD KITINSTALLATION INSTRUCTIONSTo add an overload assembly to a Q-D box witha Blue Q-D relay produced in February, 1992(B92) or later. This will provide protection for asuper stainless motor produced in May, 1989(E89) and earlier.

OVERLOAD KITRATINGS AND PART NUMBERSRATING O.L. KIT #

1⁄3 – 115V 305 1009011⁄3 – 230V 305 1009021⁄2 – 115V 305 1009031⁄2 – 230V 305 1009043⁄4 – 230V 305 1009051 – 230V 305 100906

YELLOW

CAPACITOR

ORANGE

RED

BLACK

CONNECTIONLABEL

BLUE

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FRANKLIN ELECTRIC OVERLOAD KITINSTALLATION INSTRUCTIONS1. Disconnect power to the control box.2. Remove control box cover. Disconnect yellow and

orange leads and discard.3. Install new connection label supplied with overload kit

over the connection label.4. Loosen screw on QD relay, hold down bracket. Slide

overload bracket between QD relay and bracket.Tighten screw.

5. Connect overload assembly as follows;A) Yellow overload lead to L2 terminal;B) Yellow overload lead to Y (comm) terminal;C) Orange overload lead to empty capacitor terminal;D) Orange overload lead to cap terminal on QD relay.

6. Replace cover on control box and reconnect power.

NOTES:

See overload checkout page 20.

QD control boxes produced after August 1985, (H85) donot contain an overload in the capacitor. On-windingthermal overloads were added to three-wire motors rated1⁄3 – 1 HP in April 1985, (D85). If a control box datedAugust 1985, (H85) or later is applied with a motor datedDecember 1984, (M84) or earlier, overload protection canbe provided by adding an overload kit to the control box.

Franklin Electric, ph. 800-348-2420, produced two QD stylecontrol boxes; a Black Solid State QD and a new BlueRelay Control Box which has a sealed blue relay inside.

The Solid State QD box uses a single overload protector.

The Blue Relay Box requires a new double overloadprotector.

The parts are identified in your Repair Part Price Bookunder the “Capacitor/Overload” or “QD Relay” heading.

The Solid State control box part no. ends with . . . 10.

The Relay box part no. ends with . . . 15.

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Box Tests

Single Phase Control Box 1⁄3, 1⁄2, 3⁄4, 1, 11⁄2, 2 HP

Test Component Terminals Meter ProperSetting Indication

A Relay Coil L2, Red R x 1000 2.5-4.5 (230V).5-1.5 (115V)Notes 1 and 2

Remove Metal Case Run Capacitor before proceeding if installedB Run Capacitor Individual R x 10K Needle swings

Terminals to right anddrifts back to left

Notes 3 and 5C Start Capacitor Red, Black R x 1000 Needle swings

Overload relay to right andContacts drifts back to left

Notes 4 and 5Reinstall all components before proceeding

D Ground Test Ground and R x 100K No indication (∞ )all other

terminals,one by one

If all the above tests have been OK, replace voltage relay (possiblewelded contacts or out of calibration).1. Control box terminals, except relay terminals, as indicated.2. Will not always indicate relay out of calibration or welded contacts.3. Indicates capacitor will take charge, but not always indicate aged

capacitor. Infinity (∞ ) reading with no needle swing indicates anopen capacitor or overload circuit breaker. Check individually withtests 4 and 1 at component terminals. Zero (0) reading indicatesshorted capacitor.

4. Check each capacitor individually by removing all wires from atleast one terminal.

5. Always reverse ohmmeter leads between each reading as capacitorwill take a charge, but not always indicate an aged capacitor.

22

Red Jacket 3, 5, 71⁄2 and 10 HPControl Box Check withOhmmeterStart Relay Reading Ohm Setting1. 3 & 5 HP 5.0-6.7 R x 1000

Terminals 2-5

2. 3 & 5 HP 0 R x 1Terminals 1-2

3. 71⁄2 & 10 HP 2.5-4.5 R x 1000Terminals 5-6

4. 71⁄2 & 10 HP 0 R x 1Terminals 1-6

Contactor1. 3 HP 8 R x 100

Coil Terminals

2. 5 HP 8 R x 100Coil Terminals

3. 71⁄2 HP 4 R x 100Coil Terminals

4. 10 HP 8.5 R x 10Coil Terminals

5. Contact Terminals ∞ R x 100k(both pair)

Circuit Breaker1. Check for continuity between the top and bottom terminals on

the R x 1 scale.Check with switch in both the ON and OFF position.(In ON position, meter will read zero ohms.)(In OFF position, meter will read infinity.)

CapacitorsMust be checked individually R x 10001. Meter must deflect then drift back slowly to infinity.

No deflection means capacitor is open. Steady low readingmeans capacitor is shorted.

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1⁄4 – 10 HP Red Jacket ControlBox Start Relay Chart

Control Part Pick- Voltage Drop Voltages CoilBox No. Up Max. -Out Max. Resistance VoltsNo. Min. Min.

S33NO 710691 139 153 15 47 8.8 RX 100 130S33N1 710701 259 288 35 94 3.9 RX 1K 253S50N0 710691 139 153 15 47 8.8 RX 100 130S50N1 710701 259 288 35 94 3.9 RX 1K 253S75N1 710701 259 288 35 94 3.9 RX 1K 253S100N1 710701 259 288 35 94 3.9 RX 1K 253S150N1 710701 259 288 35 94 3.9 RX 1K 253200T1 710701 259 288 35 94 3.9 RX 1K 253300T1 711421 261 290 50 100 5.8 RX 1K 332500T1 711421 261 290 50 100 5.8 RX 1K 332756R1 711181 259 288 35 94 3.9 RX 1K 253

1006R1 711171 259 288 35 94 3.9 RX 1K 253

Notes:1. Pick-up and drop-out voltage minimum and maximum are with

relay at cold condition.2. Coil resistance in ohms ± 10%.

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Control Box PartMFD Rating

VoltagePart No. No. ACS33N0 111761 161-139 125S33N1 111771 53-64 330S50N0 111781 189-227 125S50N1 111771 53-64 330S75N1 111791 64-77 330S100N1 112121 88-108 330S150N1 112121 88-108 330200T1 114021 108-130 330300T1 123001 165-198 330500T1 123001 165-198 330756R1 (2) 124871 243-292 3301006R1 (2) 123271 324-389 330U-CB0 111761 161-193 125U-CB1 12663-1 64-77 330

1⁄2 – 10 HP Red Jacket ControlBox Run Capacitor Chart

Control Box PartMFD Rating

VoltagePart No. No. ACS50N0 122511 10 370S50N1 122511 10 370S75N1 122511 10 370S100N1 122511 10 370S150N1 122511 10 370200T1 122531 15 370300T1 124891 35 370500T1 124901 60 370756R1 (2) 124811 35 440756R1 (2) 124751 50 370

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26

To Check Voltage with Franklin Electric“Q.D.” Type Control Box

1. Remove cover to break all motorconnections.

2. To check VOLTAGE: Use voltmeter on L1 andL2 as shown.

3. When checking voltage, all other majorelectrical appliances (that could be in use atthe same time) should be running.

4. If readings are not within the limits(see chart), call your power supplier.

Voltage LimitsMeasured Volts

Nameplate ▼ Min. Max.115V 1ø 105 125208V 1ø 188 228230V 1ø 210 250

CAUTIONL1 and L2 are still connected to power.

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D Voltage Checkout

Also see QD service box on page 19.

28

Measuring Insulation Resistance

1. Set the scale lever to R x 100K andadjust to 0.

2. Connect an ohmmeter lead to any one of themotor leads and the other to the metal droppipe. If the drop pipe is plastic, connect theohmmeter lead to the metal well casing orground wire.

CAUTIONOpen (turn off) master breaker anddisconnect all leads from control box orpressure switch (Q-D type control, removelid) to avoid damage to meter or electricshock hazard.

OHMS

R x 1000R x 10KR x 100K

R x 100R x 10R x 1

ZEROOHMS

R x 100K

DropCablewith

GroundWire

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29

Table 1 Normal Ohm and Megohm Values(Insulation Resistance) Between AllLeads and Ground

Insulation resistance does not vary with rating. All motors of all HP,voltage and phase rating have similar values of insulationresistance.

Condition of Motor and Leads Ohm MegohmValue Value

A new motor (without drop cable). 20,000,000 20.0(or more)

A used motor which can be 10,000,000 10.0reinstalled in the well. (or more)

Motor in Well. Ohm readings are 2,000,000 2.0for drop cable plus motor. (or more)A new motor in the well.

A motor in the well in reasonably 500,000 –good condition. 2,000,000 0.5 – 2.0

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

A motor which definitely has been 10,000 – 0.01 –damaged or with damaged cable. The 20,000 0.02pump should be pulled and repairs madeto the cable or the motor replaced. Themotor will not fail for this reason alone,but it will probably not operate for long.

A motor which has failed or with Less than 0 – 0.01completely destroyed cable insulation. The 10,000pump must be pulled and the cablerepaired or the motor replaced.

What It Means1. If the ohm value is normal, the motor windings are not

grounded and the cable insulation is not damaged.

2. If the ohm value is below normal, either the windings aregrounded or the cable insulation is damaged. Check the cableat the well seal as the insulation is sometimes damaged bybeing pinched.

Winding Resistance MeasuringWhen measured as shown on page 30, motor resistance onlyshould fall within the values in Table 3, page 31. When measuredthrough the drop cable, the size and length of the cable must beknown and the correct cable resistance from Table 2 subtractedfrom the ohmmeter reading to get the winding resistance forcomparison with Table 3.

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Measuring Winding Resistance1. Set the scale lever to R x 1 for values under

10 ohms. For values over 10 ohms, set thescale lever to R x 10. Zero balance theohmmeter as described earlier on page 13.

2. Connect the ohmmeter leads as shownbelow.

Table 2 Cable Resistance – Copper

Size CableDC Resistance of Cable per 100 Foot

Length Ohms per Pair of Leads

14 .54412 .33810 .2148 .1356 .0824 .0522 .032

30

If aluminum cable isused the readingswill be higher. Dividethe ohm readings onthis chart by 0.61 todetermine the actualresistance ofaluminum cable.

CAUTIONOpen master breaker and disconnect allleads from control box to pressure switch(Q-D type control, remove lid) to avoiddamage to meter or electric shock hazard.

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Checkout . . .

OHMS

R x 1000R x 10KR x 100K

R x 100R x 10R x 1

ZEROOHMS

R x 1or

R x 10

MotorLeads

GroundWire

31

Table 3 Motor ResistanceFranklin Electric Single Phase MotorsWinding Resistance Motor Only (Ohms)

Super Stainless 3-Wire 2-Wire

HP Dia.Main Winding Start WindingBlk to Yellow Red to Yellow

1⁄34" 1ø 115 1.4-1.8 6.5-7.9 1.4-1.8

4" 1ø 230 6.0-7.4 26.1-32 6.0-7.4

1⁄24" 1ø 115 1.0-1.3 4.1-5.1 1.0-1.3

4" 1ø 230 4.2-5.2 16.7-20.5 4.2-5.23⁄4 4" 1ø 230 3.0-3.6 11.0-13.4 3.0-3.6

1 4" 1ø 230 2.2-2.7 10.1-12.3 2.2-2.7

11⁄2 4" 1ø 230 1.5-2.3 6.2-12.0 1.5-1.9

2 4" 1ø 230 1.6-2.3 5.2-7.15 –

High Thrust3 4" 1ø .9-1.5 3.0-4.9

5 4" 1ø .68-1.0 1.8-2.8

5 6" 1ø .55-.68 1.3-1.6

71⁄2 6" 1ø .36-.50 .92-1.2

10 6" 1ø .27-.33 .80-.99

15 6" 1ø .17-.22 .68-.93

RULE OF THUMBAdd resistance of drop cable when checkingpump in well. See Table 2 page 30.

What it Means1. If all ohm values are normal, the motor windings are neither

shorted nor open, and the cable colors are correct.

2. If any one ohm value is less than normal, the motor is shorted.

3. If any one ohm value is greater than normal, the winding or thecable is open or there is a poor cable joint or connection.

4. If some ohm values are greater than normal and someless, the leads are mixed.

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Measuring Winding Resistance

F Motor Winding ResistanceCheckout . . .

CN Motors (RJ NEMA Motor made until Dec. 1999)Chart 1 – Resistance of Motor Windings4" and 6" Motors

3-Wire – Single Phase

HP VoltsOhmmeter Setting RX-1

Main B-Y Start R-Y Both B-R1⁄4 115 1.9-2.1 5.0-5.5 7.0-7.61⁄3 115 1.4-1.5 3.9-4.3 5.2-5.81⁄3 230 5.5-6.1 15.4-17.0 20.9-23.11⁄2 115 1.0-1.1 2.5-2.8 3.5-3.81⁄2 230 3.9-4.3 10.1-11.1 13.9-15.43⁄4 230 2.9-3.2 7.3-8.1 10.2-11.31 230 2.0-2.2 5.3-6.0 7.4-8.1

11⁄2 230 1.8-2.0 4.3-4.7 6.0-6.72 230 1.4-1.6 3.7-4.1 5.2-5.73 230 .9-1.1 3.3-3.7 4.2-5.05 230 .6-.8 2.0-2.3 2.6-3.1

71⁄2 230 .45-.50 1.3-1.5 1.8-2.010 230 .45-.50 .96-1.06 1.40-1.54

2-Wire – Single Phase1⁄3 115 1.9-2.1 9.7-10.7 11.6-12.81⁄3 230 7.9-8.7 16.7-18.7 24.8-27.51⁄2 115 1.4-1.5 10.7-11.8 12.0-13.31⁄2 230 5.5-6.1 11.1-12.2 16.5-18.33⁄4 230 3.9-4.3 10.0-11.1 13.9-15.41 230 2.8-3.1 7.3-8.1 10.1-11.2

11⁄2 230 2.0-2.2 3.8-4.2 5.8-6.4

33

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Chart 2 – Resistance of Motor Windings4" and 6" Motors – Three Phase

Size HP VoltsRed Jacket Franklin

Motors Motors4" 11⁄2 230 3.0-3.4 3.2-4.14" 11⁄2 460 11.9-13.2 11.3-15.04" 2 230 2.2-2.5 2.4-3.04" 2 460 8.9-9.9 9.7-12.04" 3 230 1.5-1.7 1.8-2.24" 3 460 6.1-6.8 7.0-8.74" 5 230 .8-.95 .9-1.24" 5 460 3.1-3.5 3.6-4.4

Notes:1. Resistance values are approximate for normal temperature (70°F)

and do not include cable. Readings will be higher (20%) for a hotmotor or lower (10%) for a cold motor. Well cable will increasereadings as much as 100% at maximum recommended lengthsshown in the cable selection chart.

2. Three-phase motors have three main windings of equal resistance.3. Resistance readings on two-wire pigtails will show the value of

main windings only. Start windings may be checked by installing athree-wire pigtail and measuring as a three-wire stator. If ground isdetected, check capacitor separate from motor.

34

Checking Cable and Splice1. Submerge cable and splice in steel barrel of

water with both ends out of water.2. Set ohmmeter selector on R x 100K and

adjust needle to zero (0) by clippingohmmeter leads together.

3. After adjusting ohmmeter, clip oneohmmeter lead to barrel and the other toeach cable lead individually, as shown.

4. If the needle deflects to zero (0) on any ofthe cable leads, pull the splice up out of thewater. If the needle falls back to (∞ )(no reading) the leak is in the splice.

5. If leak is not in the splice, pull the cable outof the water slowly until needle falls backto (∞ ) (no reading). When the needle fallsback, the leak is at that point.

6. If the cable or splice is bad, it should berepaired or replaced.

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LES G Cable Checkout . . .

35

Checking Cable and Splice Test

G. C

AB

LE CH

ECK

OU

T

Attach this leadto Metal Tank

OhmmeterSet at R x 100K

OHMS

R x 1000R x 10KR x 100K

R x 100R x 10R x 1

ZEROOHMS

36

Table 4 Motor Current(1) Current – Motor Running Under Load

(Max. Amps)Franklin Electric Super Stainless Motors

3-Wire 2-Wire

HP Dia. Volts Yellow Black Red Black

1⁄34" 115 9.2 9.2 0 9.2

4" 230 4.6 4.6 0 4.6

1⁄24" 115 12.0 12.0 0 12.0

4" 230 6.0 6.0 0 6.03⁄4 4" 230 8.0 8.0 0 8.0

1 4" 230 9.8 9.8 0 9.8

11⁄2 4" 230 11.5 11.0 1.3 13.1

2 4" 230 13.2 11.9 2.6 –

High ThrustHP Dia. Volts Yellow Black Red

3 4" 230 17 12.6 6.0

5 4" 230 27.5 19.1 10.8

5 6" 230 27.5 17.4 10.5

71⁄2 6" 230 42.1 40.5 5.4

10 6" 230 51 47.5 8.9

15 6" 230 75 62.5 16.9

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LES H Amperage Checkout . . .

37

Red Jacket NEMA Motor DataChart 4 – 4" Motor Amperage Values (Center)

HP Volts PH Idle* Name Max. Lock Fuse Code CL16Plate Amps Rotor Size HeaterAmps Amps Amps Elements

(2) (3) (4)1⁄4 115 1 6.2 8.8 10.1 26.0 10 N1⁄3 115 1 7.2 10.5 12.1 33.5 12 N1⁄3 230 1 3.6 5.3 6.1 19.5 6.5 P1⁄2 115 1 8/5 14/5 16/4 42/5 17/5 M1⁄2 230 1 3.3 6.8 7.2 23.0 10 L3⁄4 230 1 4.4 8.0 9.2 29.5 10 L1 230 1 6.1 10.0 10.9 41.0 12 L

11⁄2 230 1 6.2 12.0 14.1 46.0 15 J11⁄2 230 3 3.8 6.5 8.4 37.0 10 K K4211⁄2 460 3 2.0 3.3 4.0 18.0 5 M K322 230 1 8.8 16.5 18.4 57.0 20 H2 230 3 4.5 9.0 11.3 41.0 12 J K502 460 3 2.3 4.5 5.8 22.0 6.5 K K343 230 1 15.5 21.0 27.0 96.0 25 H3 230 3 8.0 11.8 14.7 65.0 15 K K553 460 3 3.6 5.9 7.2 32.0 8 L K415 230 1 16.5 30.5 35.0 135.0 35 G5 230 3 11.5 19.0 21.9 95.0 25 J K625 460 3 6.4 9.5 10.9 56.0 12 J K52

2-Wire Motors1⁄3 115 1 5.6 9.0 9.8 26.5 10 K1⁄3 230 1 2.9 4.2 5.0 12.0 5 K1⁄2 115 1 5.4 10.5 13.0 31.5 15 J1⁄2 230 1 2.2 5.5 6.1 15.0 6.5 J3⁄4 230 1 3.0 6.5 7.8 21.5 8 H1 230 1 3.3 8.0 9.0 26.5 10 H

11⁄2 230 1 4.3 10.5 11.5 41.0 12 G* Idle amps are at rated voltage. Variations in voltage will change idle amps by 50%.1. Maximum amps are designed values at service factor loads. Actual amps may be

lower due to variations in pump load and voltage.2. Overload protection for single phase motors are built into the motor up through

2 HP, in the control box for 3 and 5 HP motors. Magnetic contactors are optional for3 & 5 HP single phase. All three phase magnetic starters have temperaturecompensated, quick-trip, three leg overload protection.

3. Use “Fusetats”, “Fusestats” or equivalent time delay fuses designed for motorstarting. Separate branch circuit is recommended.

4. Normal thermal overloads used for standard motors will not trip fast enough toprotect submersible motors and the quick-trip type heaters specified must be used(see Warranty). No substitutions may be made without factory approval.

H. A

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38

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LES Chart 5 – Red Jacket Motors

Ove

rload

Mtr.

Rtg

.Lo

cked

Nor

mal

Idle

Lock

edHe

ater

Trip

NEM

AFu

seKV

ARo

tor

Phas

eVo

ltage

HPAm

psAm

psAm

ps3

& 4

Amps

Star

ter

Size

Dem

and

KVA/

HP(1

)(2

)(A

ppro

x.)

Size

(5)

on T

rans

.Co

deCL

14CL

16(6

)Le

tter

208

71 ⁄254

.036

.523

060

12H

1Ø23

071 ⁄2

46.0

25.0

220

6012

H23

010

56.0

19.0

250

7015

G20

871 ⁄2

30.0

1313

5K7

0K7

037

.11

3511

H23

071 ⁄2

26.0

1212

0K6

7K6

830

.01

3010

H46

071 ⁄2

13.0

660

K56

K56

15.5

115

10H

208

1041

.025

228

K73

K72

50.0

245

15K

230

1032

.414

154

K72

K72

41.0

13 ⁄440

13H

460

1016

.27

77K6

0K6

019

.01

2013

H20

815

60.0

2926

5K7

7K7

572

.03

7022

H3Ø

230

1550

.019

215

K76

K75

60.0

260

20G

460

1525

.09.

510

8K6

7K6

730

.013 ⁄4

3020

G20

820

79.0

4034

5K7

8K7

890

.03

9029

G23

020

68.8

3434

8K7

8K7

779

.03

8027

H46

020

34.4

1717

4K7

2K7

042

.02

4028

H20

825

105.

075

510

K87

K87

130.

031 ⁄ 2

110

38J

230

2586

.050

430

K85

K85

101.

03

9034

K46

025

43.0

2521

5K7

4K7

354

.02

4534

K20

830

120.

075

510

K89

K89

142.

031 ⁄ 2

125

43G

230

3010

1.0

5043

0K8

6K8

611

6.0

31 ⁄ 211

040

H46

030

50.5

2521

5K7

6K7

560

.021 ⁄2

6040

H

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NOTES:1. Normal amps are designed values at service factor loads at rated

voltages. Amps may be slightly higher or lower due to variations inpump load and voltage, but should never continuously exceed115% of the given value.

2. Idle amps reading indicates pump uncoupled or broken shaft. Shut-off amps vary with pump (should be about 1.5 time idle amps).

3. Overload protection for single-phase motors are built into the motorup through 2 HP, in the control box for 3 through 10 HP single-phase. Magnetic contactors are optional for 3, 5, 71⁄2 and 10 HPsingle-phase. All three-phase magnetic starters have temperaturecompensated, quick-trip, three leg overload protection.

4. Normal thermal overloads used for standard motors will not tripfast enough to protect submersible motors and the quick-trip typeheaters specified must be used (see Warranty). No substitutionsmay be made without factory approval.

5. Use “Fusetrons”, “Fusestats” or equivalent time delay fusesdesigned for motor starting. Separate branch circuit is recom-mended.

6. Total transformer capacity must be equal to or greater than KVAshown. Add 15% to values if open Delta (three-phase with twotransformers).

39

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40

F.E. Control Box With Cover Attached

Ground

To PowerSupply

AmprobeMeter set on

Ampere Scale

Control BoxWith Cover Attached

See Franklin Electric QD Service Box on Pg. 19.

Red Jacket 1Ø Control Box - Check Amperageon Yellow Wire.

41

Square D

Adjust in Proper Sequence:1. CUT-IN: Turn range nut (big Spring) down for

higher cut-in pressure, or up for lower cut-in.2. CUT-OUT: Turn differential nut (small spring)

down for high cut-out pressure, or up forlower cut-out.

CAUTION (Square D)To avoid damage, do not exceed maximumallowable system pressure. Check switchoperation after resetting. Maximum pressure65 PSI.

I Pressure Switch AdjustmentCheckout . . .

I. PR

ESSU

RE SW

ITCH

AD

JUSTM

ENT

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42

FURNAS

1. MAIN SPRING ADJUSTMENT: Turn clockwiseto increase both Cut-Out and Cut-Inpressure. (2 PSI/turn).2. DIFFERENTIAL ADJUSTMENT: Turndifferential nut clockwise to increase Cut-Outpressure without affecting Cut-In (3 PSI/turn).

CAUTION (FURNAS)To avoid damage, do not exceed maximumallowable system pressure. Check switchoperation after resetting. Maximum pressure80 PSI.

43

1. To check: Shut off power supply and drainsystem to “0” pressure.

2. Air pre-charge in tank should be 2 psiless than the cut-in pressure of the pressureswitch.Example: If pressure switch setting is30-50 psi, tank should be pre-charged with28 lbs. air.

3. If water at valve, replace tank.

RULE OF THUMBImproper tank sizing may causemotor damage.1⁄2 to 11⁄2 HP pumps – Tank draw downshould be equal to the pump capacity inGPM or greater.Example: 3⁄4 HP pump; capacity 12 GPM;pressure switch setting 30/50 PSI; correcttank – V140.2 HP and larger pumps – tankdrawdown should be double thepump capacity in GPM.Example: 3 HP pump; capacity 30 GPM;pressure switch setting 40/60 PSI; correcttank selection: 2 – V350 tanks.

J Pressure Tank Checkout Procedure . . .

J. PR

ESSU

RE TA

NK

CH

ECK

OU

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OC

EDU

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44

Shown with base extension

45

Repair or Replace – Some Considerations –While our pumps are designed for ease of repair it isimportant to compare the cost of repair versus the costof water end replacement. Replacing typical wear partssuch as impellers and diffusers is a cost effectivechoice. However, if the outside metal parts such as thecasing, motor adapter and discharge head all requirereplacement due to extremely harsh water it may beless expensive to simply purchase a complete newwater end. A new casing or discharge head will requiredrilling and tapping for two new cable guard holes.

Pump Disassembly for Typical4" Submersible Pumps...1. Remove 4 cable guard screws and remove cable guard.2. Reinstall top 2 screws so that discharge head and

casing may be removed as one piece.

3. Using two pipe wrenches or a vice and pipe wrench,hold the motor adapter and turn the discharge head/casing assembly clockwise (it has left-hand threads) toloosen the assembly.

PU

MP

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46

4. Remove the casing assembly to expose the stages.5. If required, remove the klip ring from the top of the

shaft. This will allow you to remove the stages fromthe shaft. Note that on units which have operated insandy water it may be hard to disassemble the stages.

6. Remove bearing spider and adapter ring. The completestages should be removed one at a time, disassembledand inspected. Replace worn stage assembliesas needed.

7. On most models the shaft and coupling assembly isreplaceable without removing the motor adapter. Liftthe shaft off and inspect the coupling and motorsplines for excessive wear. On some models the shaftassembly can be removed for inspection and/orreplacement by removing the motor. Replace theentire shaft/coupling assembly if either shows wear.

8. If motor replacement is necessary, remove the 4 nutsfrom the motor studs and separate the motor andmotor adapter. If motor is OK, leave assembly intact.

9. We use several check valve styles. Some are built-inand some push in from the top (outside) of thedischarge head. Replace as necessary. You mayreplace any built-in check valve using a standardscrew-in line type check valve.

47

Pump Reassembly . . .1. Clean all parts including the strainer.2. Place shaft and coupling assembly onto motor spline.3. Reattach the motor adapter to the motor. Tighten the

nuts in an alternating pattern.4. Install stage assemblies on shaft.5. Longer units have intermediate bearing spiders and

sleeve, which should be placed to divide the stagesevenly. NOTE: Modified stage required directly belowintermediate spider.

6. When all stages are in place, replace klip ring on shaftif required. NOTE: Models that require clip ring have amodified top stage.

7. Check upper bearing for wear and replace if loose onshaft. Place bearing spider on stack.

PU

MP

REA

SSEM

BLY

48

8. Replace casing/discharge head assembly, turningcounterclockwise (left-hand threads). Turn it all theway down so that the casing bottoms against theflange on the motor adapter.

9. Using a pipe wrench on the motor adapter and one onthe discharge head, tighten to approximately 85 lbs-ft.This will be approximately 1⁄8 to 1⁄4 turn from the handtight position.

10. Remove the upper cable guard screws and replace thecable guard using all 4 screws. The cable guard shouldbe straight up and down if the casing is properlytightened.

11. If you installed a new casing or discharge head theywill have to be drilled and tapped to provide holes forthe cable guard screws. Use a 9⁄64" drill and an8-32 NC tap.

12. Replace the external wrap around strainer.

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RJDS

49

Jet Pumps . . .Since these are the basic types that have beenused for many years, the vast majority of jetpump service work will be on these types . . .

JET PU

MP

S

RJA

RULES OF THUMB• All jet pumps should be located at the

highest point in the suction side of thesystem.

• (Distance from well head to pump) Ifoffset is greater than 20' . . . increasehorizontal pipes by one size each.

• Never use pipes smaller than the pumpsuction tappings.

50

Typical Jet Pump System . . .JE

T P

UM

PS

Shallow WellSystem illustrated is a Convertible jet pumpwith a pressure tank

51

TYP

ICA

L JET PU

MP

SYSTEM

S

52

Typical Jet Pump System . . .Deep WellPacker and twin pipe systems

JET

PU

MP

S

53

TYP

ICA

L JET PU

MP

SYSTEM

S

TRAPS AIR

Improper Installations• Trap air• Hard to prime

Proper Installations• Easy to prime

TroubleshootingINDEX

RULE OF THUMBRemember there may be other systemproblems caused by auxiliary controls notcovered in this booklet.

54

An amprobe, ohmmeter and vacuum pressuregauge are essential for properly checking asystem. Use of the amprobe is explained onpage 12. Use of the ohmmeter is explained onpage 13. Use of the compound vacuumpressure gauge is explained on page 76.Find the basic problem . . . for which numeroussymptoms are listed and possible solutions aregiven for each:

Page■ Pump Will Not Run ............................... 55■ Pump Runs, But Little or No Water

Delivered ......................................... 56-57■ Pump Starts and Stops Too Often .... 58-59■ Insufficient Tank Pressure ...................... 60■ Switch Does Not Cut Out...................... 61

JET

PU

MP

S

TroubleshootingPump Will Not Run . . .

55

PROBLEM: ANSWER:1. Blown fuse or power Replace fuse – close

turned off all switches.2. Broken or loose Examine all wiring

wiring connections. and repair any badconnections.

3. Motor overload Overload contactsprotection contacts will closeopen. automatically in a

short time.a. Improper voltage. See 1 page 62b. Pump bound Remove motor endmechanically – will cap, turn motornot turn freely. shaft by hand. Unit

should rotate freely.4. Pressure switch faulty Adjust or replace

or out of adjustment. switch. See Ipage 41.

5. Tubing or fittings on Remove switchpressure switch tubing and/or allplugged. fittings and clean.

6. Faulty motor. See 2 page 64.

TRO

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TroubleshootingPump Runs But . . .

56

Little or no water delivered . . .PROBLEM: ANSWER:1. Pump or pipes not Fill pump completely

completely primed. with water throughpriming opening(reprime pump).a. Deep Wellsystem Controlvalve must be setproperly or systemwill not pump. See 4pages 78 & 79.

2. Foot valve or end of a. Shallow Wellsuction pipe either not system Installsubmerged or buried. vacuum gauge See 3

page 76.b. Deep Wellsystem Physicallycheck wellconditions.

Foot valve in well or Replace foot valve ifline check valve stuck necessary. (Very highclosed. vacuum, 22 inches

or more, seepage 76).

3. Leaks on suction side Pressurize systemof pump. and inspect.(Very common problem.)

JET

PU

MP

S


57

PROBLEM: ANSWER:4. Jet assembly plugged. A. Shallow Well

system Clean ifnecessary. (Insertwire through 1⁄2"plug in shallow welladapter.)b. Deep Wellsystem Pull jetassembly and clean.

5. Punctured diaphragm Disconnect thein air control. tubing and plug theGalvanized tanks. connection in pump.

If this corrects thetrouble, the aircontrol must bereplaced.

6. Original installation, Check rating inincorrect nozzle or product catalog.diffuser combination.

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58

Pump starts and stops too often . . .POSSIBLE CAUSE: ANSWER:1. Leaks in piping system. Pressurize piping

system and inspect.Repair or replace.

2. Faulty pressure switch. Check contactpoints. Adjust orreplace switch.See I page 41.

3. Waterlogged Pumps using Bradygalvanized tank, control: Test byfaulty air control. holding your ear on

air control. If controlis operating, air canbe heard passingfrom control intotank when pumpstops. If no airmovement is heard,air control should bereplaced.

4. Leaking tank or Use soapy water toair valve. find leaks. Repair or

replace.

JET

PU

MP

S


59

POSSIBLE CAUSE: ANSWER:5. Not enough suction Throttle suction line

lift on shallow well with partially closedsystem – water flows valve.into pump (floodedsuction).

6. Insufficient vacuum or Pump requiresvacuum does not exist minimum 3” vacuumfor long enough time for 15 seconds.to operate air control.

7. Improper air change See J page 43 inin captive air tank. submersible section.

8. Tank too small Replace with properfor pump. size storage tank.

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60


Pumps water, but does not develop 40 lbs.tank pressure. . .PROBLEM: ANSWER:1. Leaks in well piping Pressurize piping

or discharge pipe. system and inspect.2. Jet or screen on foot Clean if necessary.

valve partially plugged.3. Improper pressure See 4 page 78.

control valve setting(deep well only).

4. Suction lift too high Use vacuum gaugefor shallow well on shallow wellsystem. systems. Vacuum

should not exceed22 inches at sea level.

a. Jet set too deep for On deep well systemdeep well system. check ratings tables

in catalog formaximum jet depth.

5. Faulty air charger. Disconnect the tubingand plug the hole. Ifthis corrects thetrouble, the aircontrol must bereplaced.

6. Worn impeller hub Replace if necessary.and/or guide vane Clearance should notbore. exceed .012 on a side

or .025 diametrically.

JET

PU

MP

S


61

Pump develops 40 lbs. pressure, but switchdoes not cut out . . .PROBLEM: ANSWER:1. Pressure switch See I page 41 in

incorrectly set. submersible section.2. Tubing or fittings Remove switch

between switch and tubing and/or allpump plugged. fittings and clean.

3. Faulty switch or Replace if necessary.corroded contactpoints.

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62

1. Attach leads to volt-ammeter and selectproper voltage scale for voltage to be tested.

2. Place leads in A position to test for presenceof incoming voltage.• Voltage should be within + 10% of the

design voltage specified on the motornameplate in A, B and C test positions.

3. With disconnect switch in ON position, moveleads to B position and test voltage flowthrough fuse(s).

4. The C position tests voltage at pressureswitch terminals. The voltage should bewithin limits with the motor operating.

Voltage Limits

Nameplate ▼Measured VoltsMin. Max.

115V 1F 105 125208V 1F 188 228230V 1F 210 250

CAUTIONPower is ON during voltage checking.JE

T P

UM

PS 1 How to Use Volt-Ammeter

For Voltage Check

63

1. H

OW

TO U

SE VO

LT AM

METER

64

1. If attached, remove leads from volt-ammeter.Select lowest reading amperage scaleaccording to motor nameplate rating.

2. With disconnect switch in OFF position,clamp instrument around one incoming leadat pressure switch.• Turn switch ON and observe amperage as

motor runs. With proper voltage, readingshould not exceed the MAXIMUM LOADAMPERAGE of motor.

• Excessive amps means an overloadedcondition or incorrect voltage applied.Problem could also be in motor.

• Take readings with pump running atnormal system pressure. At open discharge(zero pressure) the pump may exceedmaximum amps due to no discharge head.

JET

PU

MP

S 2 How to Check Amperage

65

CAUTIONPower is ON during amperage testing.

2. H

OW

TO C

HEC

K A

MP

ERA

GE A

T PR

ESSU

RE SW

ITCH

66

Power supply OFF. Disconnect motor leads(L1 and L2). On dual-voltage motors, motormust be wired 230V for the checks listedbelow and illustrated on the page indicated foreach check. Rewire for 230V if necessary.

CHECK: Pagea. Ground ................................................. 67b. Winding Continuity .......................... 68-69c. Contact Points (Switch) ..................... 70-71d. Overload Protector ........................... 72-73e. Capacitor ......................................... 74-75

CAUTIONUse ohmmeter only with POWER OFF.

JET

PU

MP

S 2 Ohmmeter Checks . . .

67

a. Set ohmmeter to R x 1,000.b. Attach one probe to ground screw and

touch other probe to all terminals onterminal board, switch, capacitor andprotector – any ohmmeter readingindicates ground.If digital meter is used, the reading shouldbe at least one megohm.

c. If grounded, check all external leads for cuts,breaks, frayed wires, etc. Replace damagedleads and recheck for grounds and properlead routings. Make sure replaced leads arenot pinched between canopy and end bell.If ground is in stator, replacement of motoris recommended.

CAUTIONDisconnect Power Source before checking.

2. O

HM

METER

CH

ECK

Sa Ground Check . . .

STARTCAPACITOR

WIRING TERMINAL BOARD

PRESSURE SWITCH

OVERLOAD PROTECTOR

GOVERNOR

115/230 VOLTVOLTAGE SELECTOR SWITCH

68

1. Terminal board connected for 230 V.2. Set ohmmeter to R x 1, adjust to 0.3. Slip a heavy piece of paper between motor

switch points, discharge the capacitor andtake the following ohm readings:

a. Resistance between L1 and A must be thesame as between A and yellow.

b. Yellow to red (winding side of switch) mustbe the same as L1 to same red terminal.


JET

PU

MP

S

2 Ohmmeter Checks . . .b Winding Continuity AO Smith Motors

L1 = Blue wireL2 = White wireA = Purple wire

Emerson MotorShown

69

2. O

HM

METER

CH

ECK

S – AO

SMITH

MO

TOR

SOhmmeter tests on the new style terminalboard with the quick-change voltage terminalplug, see picture on pg. 62 (Black plastic partwith 2 wires in it) is simplified if yourohmmeter is equipped with the sharp,pointed probes rather than alligator clips.With the voltage change plug on the 230 voltterminal the Black wire in the plug ispositioned on Terminal “A”. Simply touch oneohmmeter probe on the Black wire in thevoltage change plug to get the “A” terminalreading. Another method is to remove theterminal board screws and place the alligatorclip on the wire on the bottom side ofTerminal “A”.

Old Style (Brown) Terminal Board Wiring.

A.O. SMITH MOTOR WIRING115 VOLT 230 VOLTBlack (from motor) Black (from motor)on L1 on A

Black/White Black/White(Black tracer from (Black tracer fromoverload) on A overload) on B

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1. Disconnect line leads.2. Connect motor for 230 V operation

NOTE: Do not connect power to the motor.3. Set ohmmeter reading to R x 1K.4. Put probes on terminals 1 and 4 on terminal

board. Note resistance reading. Place probeson terminal 4 on terminal board and leadprotector #3 on protector. Resistance shouldbe the same between 1 and 4 as between4 and Protector #3.

5. While still connected to terminal 4 andprotector lead #3, depress actuator(governor). Resistance reading should go tomax on ohmmeter.


2 Ohmmeter Checks . . .b Winding Continuity Emerson Motors

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2. O

HM

METER

CH

ECK

S2 Ohmmeter Checks . . .

c Contact Points (switch) All Motors

1. Set ohmmeter to R x 1, adjust to 0.2. Remove leads from switch.3. Attach ohmmeter leads to each side of

switch – reading should be 0.4. Flip governor weight to run position.

Reading should be infinity.


2 Ohmmeter Checks . . .d Overload Protector . . .

All Motors

1. Set ohmmeter to R x 1, adjust to 0.2. Disconnect the overload leads.3. Check resistance between terminals 1 and 2,

then 2 and 3. If either reading is higherthan 1, replace the overload.AO Smith Emerson1 = Blue wire 1 = Purple wire2 = Black/white wire 2 = Black/white wire3 = Yellow wire 3 = Black wire


A.O. Smith Motor Terminal Boardand Voltage Change Plug

LINE LEADS

WHITE

PURPLE

BLUE

BLACK

STATOR LEADS

BLACK TRACERYELLOW

YELLOW

RED

RED TRACER

PLUG

1

2

3

L1

L2A

115

230

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“Black Tracer” is a black and white wire

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Emerson Motor Terminal Boardand Voltage Change Switch

MO

TOR

WIR

ING

EMER

SON

AN

D A

O SM

ITH M

OTO

RS

LINE 1

1

4

LINE 2

115

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IMPORTANTDischarge capacitor by touching the twoterminals with the blade of an insulatedhandle screwdriver.

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S 2 Ohmmeter Checks . . .e Capacitor . . .

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1. Set ohmmeter to R x 1,000, adjust to 0.2. Disconnect leads on capacitor.3. Attach ohmmeter leads to each terminal.

Needle should swing to right and drift slowlyto left. To double check, switch ohmmeterleads and repeat procedure.If the needle will not move or moves toward0 and stays there, the capacitor is bad.

4. If a digital meter is used, readings shouldstart low and rapidly increase tomaximum value.

2. O

HM

METER

CH

ECK

SA

LL MO

TOR

S

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RULE OF THUMBPractical suction lift at sea levelis 25 ft. Deduct 1 ft. of suctionlift for each 1,000 ft. ofelevation above sea level.

A vacuum gauge indicates total suction lift(vertical lift + friction loss = total lift) in inchesof mercury. 1” on the gauge = 1.13 ft. oftotal suction lift (based on pump located atsea level).

Shallow Well SystemInstall vacuum gauge in shallow well adapter.See opposite page. When pump is running, thegauge will show no vacuum if the end ofsuction pipe is not submerged or there is asuction leak. If the gauge shows a very highvacuum (22 inches or more), this indicates thatthe end of suction pipe is buried in mud, thefoot valve or check valve is stuck closed or thesuction lift exceeds capability of pump.

High Vacuum (22 inches or more)• Suction pipe end buried in mud• Foot valve or check valve stuck closed• Suction lift exceeds capability of the pump

Low Vacuum (or 0 vacuum)• Suction pipe not submerged• Suction leak

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Compound VacuumPressure GaugeThis gauge will showthe pressure or vacuumat any position in apump or system whereit is installed.

A reading of 20" on a vacuum gauge placedon the suction side of the pump would tellyou that you have a vacuum or suction liftof 22.6 ft.20" x 1.13' = 22.6 ft.

VacuumGauge

3. C

HEC

KIN

G SU

CTIO

N LIFT

22.6'Vertical LiftPlus Friction

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RULE OF THUMBIf pressure control valve is set too high,the air volume control will not function.If pressure control valve is set too low,the pump may not shut off.

When pump is first started or under maximumflow condition, pressure control should beimmediately adjusted to the pressurecorresponding to H.P. and jet assembly used.See rating tables in catalog for proper pressuresetting.1. Turn left to reduce pressure.2. Turn right to increase pressure.

To Adjust Pressure Control Valve:1. Close pressure control valve.2. Open faucet in house.3. Turn pump on.4. As pump picks up its prime, the pressure will

begin to rise on the gauge.5. Turn adjusting screw to set pressure control

valve to pressure recommended in catalog.

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S 4 Pressure Control Valves . . .

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Use with 1⁄2 and 3⁄4 HPpumps requiringcontrol valve settingsup to 35 PSI.

Use with pumpsrequiring 35 PSI orhigher control valvesetting: Typically allmulti-stage units andsingle-stage pumps1 HP and larger.

Use with deep wellmulti-stage and highpressure units.

4. P

RES

SUR

E CO

NTR

OL V

ALV

ES

AV15

AV21

Jet Pump Disassembly . . .

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Lubrication:A. The pump requires no lubrication.B. For the electric motor, refer to instructions

provided by the motor manufacturer.

SEAL REPLACEMENTSeal Removal:1. Disconnect electrical service to the pump.2. Relieve system pressure by opening a faucet or

drain valve until water stops flowing.3. Disconnect pressure switch tubing at the barbed

fitting on the pump case. If tubing does notslide off barbed fitting easily, cut it as close tothe fitting as possible.

4. Remove the four cap screws which hold thepump seal plate and motor to the pump case.Piping need not be disturbed.

5. Remove the pumping assembly, as one piece,(motor, seal plate, diffuser, and impeller) bycarefully prying them apart from the pump case.Exercise care so as not to damage the impeller.

6. Remove the diffuser from the seal plate exposingthe impeller.

7. Insert a regular slotted screwdriver into the slotin the motor shaft end at the impeller center.

8. While holding the motor shaft with thescrewdriver, unscrew the impeller by turningcounter-clockwise.

9. Slide rotating part of seal assembly from shaft(Figure 11). Separate seal plate from motor.

10. Remove stationary part of seal assembly(including rubber seal boot) from seal plate.

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New Seal Installation:1. Clean polished surface of stationary seal with

a clean cloth.2. Wet the outer edge of the rubber seal boot

with a soap solution.3. Insert rubber seal boot and ceramic seal

(polished side exposed) into seal plate. Makea cardboard washer to cover the ceramic sealsurface to be used while pressing seal intoposition. Cardboard washer is used to avoidscratching ceramic surface. Discard cardboardwasher after ceramic seal installation. (Figure 11).

4. Reposition seal plate onto motor and sliderotating seal assembly onto motor shaft withcarbon sealing face first until rubber end ringslides over shaft shoulder.

5. Screw impeller clockwise onto motor shaft usingscrewdriver in shaft end slot to hold the shaft.

6. Reattach diffuser to seal plate and carefullyreposition the pumping assembly to the pumpcase. Attach with the four cap screws.

7. Connect the pressure tubing by pressing onto barb fitting on pump case until tubingshoulders against stop edge of fitting. If tubingwas cut off, carefully remove excess tubing frombarb fitting with a knife, taking care not toscratch the fitting.

Motor Removal1. Follow Steps 1-10 of “Seal Removal.”Motor Replacement:1. Follow Steps 1-7 of “New Seal Installation.”

RULE OF THUMBDo not start motor until pump andsuction piping are filled with water.

NOTES

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OTES

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