Grundfos Redi-Flo4 User manual

Please leave these instructions with the pump for future reference.

Redi-Flo4

Stainless Steel Submersible Pumps

for Environmental Applications

GRUNDFOS INSTRUCTIONS

US Installation and operating instructions

SAFETY WARNING

Grundfos Stainless Steel Submersible Pumps

Your Grundfos Redi-Flo4 Environmental Pump is of the utmost quality. Combined with

proper installation, your Grundfos pump will give you many years of reliable service.

To ensure the proper installation of the pump, carefully read the complete manual

before attempting to install the pump.

Shipment Inspection

Examine the components carefully to make sure no damage has occurred to the

pump-end, motor, cable or control box during shipment.

This Grundfos Redi-Flo4 Environmental Pump should remain in its shipping carton until it is

ready to be installed. The carton is specially designed to protect it from damage. During

unpacking and prior to installation, make sure that the pump is not contaminated,

dropped or mishandled.

The motor is equipped with an electrical cable. Under no circumstance should the cable

be used to support the weight of the pump.

You will find a loose data plate wired to the pump. It should be securely mounted at the well

or attached to the control box.

PRE-INSTALLATION CHECKLIST

Before beginning installation, the following checks should be made. They are all

critical for the proper installation of this submersible pump.

A. Condition of the Well

If the pump is to be installed in a new well, the well should be fully developed and bailed or

blown free of cuttings and sand. Dispose of discharged materials in accordance with the

specific job site requirements. The stainless steel construction of the Redi-Flo4

Environmental Pump makes it resistant to abrasion; however, no pump, made of any

material, can forever withstand the destructive wear that occurs when constantly pumping

sandy groundwater.

Determine the maximum depth of the well, and the drawdown level at the pump’s maximum

capacity. Pump selection and setting depth should be based on this data.

The inside diameter of the well casing should be checked to ensure that it is not smaller than

the size of the pump and motor.

B. Condition of the Water

Redi-Flo4 pumps are designed for pumping cold groundwater that is free of air or gases.

Decreased pump performance and life expectancy can occur if the groundwater is not cold

or contains air or gases.

C. Installation Depth

Pumping sand or well sediment can occur when the pump motor is installed lower than the

top of the well screen or within five feet of the well bottom. This can reduce the

performance and life expectancy of the pump and should be avoided.

If the pump is to be installed in a lake, containment pond, tank or large diameter well, the

water velocity passing over the motor must be sufficient to ensure proper motor cooling.

The minimum recommended water flow rates which ensure proper cooling are listed in

Table A.

D. Electrical Supply

The motor voltage, phase and frequency indicated on the motor nameplate should be

checked against the actual electrical supply.

WIRE CABLE TYPE

The wire cable used between the pump and control box or panel should be approved for

submersible pump applications. The conductor insulation should have a continuous Teflon®

jacket with no splices and must be suitable for use with submersible pumps.

INSTALLATION

The riser pipe or hose should be properly sized and selected based on estimated

flow rates and friction-loss factors.

A back-up wrench should be used when the riser pipe is attaching a riser pipe or metallic

nipple to the pump. The pump should only be gripped by the flats on the top of the

discharge chamber. The body of the pump, cable guard or motor should not be

gripped under any circumstance.

If Steel Riser Pipe Is sed:

An approved pipe thread compound should be used on all joints. Make sure the joints are

adequately tightened in order to resist the tendency of the motor to loosen the joints when

stopping and starting.

When tightened, the first section of the riser pipe must not come in contact with

the check valve retainer in the discharge chamber of the pump.

PRE-INSTALLATION CHECKLIST

After the first section of the riser pipe has been attached to the pump, the lifting cable or

elevator should be clamped to the pipe. Do not clamp the pump. When raising the pump

and riser section, be careful not to place bending stress on the pump by picking it up by the

pump-end only.

Make sure that the electrical cables are not cut or damaged in any way when the

pump is being lowered in the well.

The drop cable should be secured to the riser pipe at frequent intervals to prevent sagging,

looping or possible cable damage.

If Plastic or Flexible Riser Pipe Is sed:

Use the correct compound recommended by the pipe manufacturer or specific job

specifications. Besides making sure that joints are securely fastened, the use of a torque

arrester is recommended when using these types of pipe.

Do not connect the first plastic or flexible riser section directly to the pump.

Always attach a metallic nipple or adapter into the discharge chamber of the

pump. When tightened, the threaded end of the nipple or adapter must not come in

contact with the check valve retainer in the discharge chamber of the pump.

The drop cable should be secured to the riser pipe at frequent intervals using an approved

clip or tape to prevent sagging, looping and possible cable damage.

IMPORTANT - Plastic and flexible pipe tend to stretch under load. This stretching must be

taken into account when securing the cable to the riser pipe.

Leave enough slack between clips or taped points to allow for

this stretching. This tendency for plastic and flexible pipe to stretch

will also affect the calculation of the pump setting depth. If the depth

setting is critical, check with the manufacturer of the pipe to

determine how to compensate for pipe stretch.

When these types of pipe are used, it is recommended that a safety

cable be attached to the pump to lower and raise it. The discharge

piece of Redi-Flo4 submersibles is designed to accommodate this

cable (Figure 4).

Protect the Well from Contamination

While installing the pump, proper care should be used not to

introduce foreign objects or contaminants into the well. The well

should be finished off above grade to protect against surface water

from entering the well, causing contamination.

INSTALLATION

NOTE: Teflon®is a registered trademark of DuPont.

FIGURE 4

ELECTRICAL

WARNING: To reduce the risk of electrical shock during operation of this pump

requires the provision of acceptable grounding. If the means of connection to

the supply connected box is other than grounded metal conduit, ground the

pump back to the service by connecting a copper conductor, at least the size of

the circuit supplying the pump, to the grounding screw provided within the

wiring compartment.

All electrical work should be performed by a qualified electrician in accordance

with the latest edition of the National Electrical Code, local codes and regulations.

Verification of the electrical supply should be made to ensure the voltage, phase and

frequency match that of the motor. Motor voltage, phase, frequency and full-load current

information can be found on the nameplate attached to the motor. Motor electrical data can

be found in Table C.

If voltage variations are larger than ±

10%, do not operate the pump.

Direct on-line starting is used due to the

extremely fast run-up time of the motor (0.1

second maximum), and the low moment of

inertia of the pump and motor. Direct on-line

starting current (locked rotor amp) is

between 4 and 6.5 times the full-load

current.

Engine-Driven Generators

If the Redi-Flo4 pump is going to be

operated using an engine driven generator,

we suggest the manufacturer of the

generator be contracted to ensure the

proper generator is selected and used. See

Table B for generator sizing guide.

Control Box/Panel Wiring

Single-phase motors must be connected as

indicated in the motor control box. A typical

single-phase wiring diagram using a

Grundfos control box is shown (Figure 5-A).

High Voltage Surge

Arresters

A high voltage surge arrester should be

used to protect the motor against lightning

and switching surges. The correct voltage-

rated surge arrester should be installed on

the supply(line) side of the control box

(Figure 5-B). The arrester must be

grounded in accordance with the

National Electric Code, local codes and regulations.

FIGURE 5-A

FIGURE 5-B

Single-Phase Wiring Diagram for

GRUNDFOS Control Boxes

Single Phase Hookup

ELECTRICAL

Control Box and Surge Arrester Grounding

The control box shall be permanently grounded in accordance with the National Electrical

Code and local codes or regulations. The ground wire should be a bare copper conductor

at least the same size as the drop cable wire size. The ground wire should be run as short

a distance as possible and be securely fastened to a true grounding point.

True grounding points are considered to be: a grounding rod driven into the water strata,

steel well casing submerged into the water lower than the pump setting level, and steel

discharge pipes without insulating couplings. If plastic discharge pipe and well casing are

used, a properly sized bare copper wire should be connected to a stud on the motor and

run to the control panel. Do not ground to a gas supply line. Connect the grounding wire to

the ground point first and then to the terminal in the control box or panel.

Wiring Checks

Before making the final wiring connections of the drop cable to the control box terminal, it is

a good practice to check the insulation resistance to ensure that the cable is good.

Measurements for a new installation must be at least 1,000,000 ohm. Do not start the pump

if the measurement is less than this. If it is higher, finish wiring and verify that all electrical

connections are made in accordance with the wiring diagram. Check to ensure the control

box and high voltage surge arrester have been grounded.

START-UP

After the pump has been set into the well and the wiring connections have been

made, the following procedures should be performed:

A. Attach a temporary horizontal length of pipe with installed gate valve to the riser pipe.

B. If required, make provisions to capture discharged fluids for disposal.

C. Adjust the gate valve one-third open.

D. Start the pump and let it operate until the water runs clear of sand and silt.

E. As the water clears, slowly open the gate valve in small increments until the desired

flow rate of clear water is reached. The pump should not be operated beyond its

maximum flow rating and should not be stopped until the groundwater runs clear.

F. If the groundwater is clean and clear when the pump is first started, the valve should

still be opened until the desired flow rate is reached.

G. Disconnect the temporary piping arrangements and complete the final piping

connections.

H. Under no circumstances should the pump be operated for any prolonged

period of time with the discharge valve closed. This can result in motor damage

due to overheating. A properly sized relief valve should be installed at the well head to

prevent the pump from running against a closed valve.

I. Start the pump and test the system. Check and record the voltage and current draw

on each motor lead.

OPERATION

A. The pump and system should be periodically checked for water quantity, pressure,

drawdown, periods of cycling, and operation of controls. Under no circumstances

should be the pump be operated for any prolonged periods of time with the

discharge valve closed. This can result in motor and pump damage due to

overheating. A properly sized relief valve should be installed at the well head to prevent

the pump from running against a closed valve.

B. If the pump fails to operate, or there is a loss of performance, refer to Troubleshooting,

Section 7.

TROUBLESHOOTING

The majority of problems that develop with submersible pumps are electrical, and most of

these problems can be corrected without pulling the pump from the well. The following

charts cover most of the submersible service work. As with any troubleshooting

procedure, start with the simplest solution first; always make all the above-ground checks

before pulling the pump from the well.

Usually only two instruments are needed – a combination voltmeter/ammeter, and an

ohmmeter. These are relatively inexpensive and can be obtained from most water systems

suppliers.

WHEN WORKING WITH ELECTRICAL CIRCUITS, USE CAUTION TO AVOID

ELECTRICAL SHOCK. It is recommended that rubber gloves and boots be worn

and that care is taken to have metal control boxes and motors grounded to power

supply ground or steel drop pipe or casing extending into the well. WARNING:

Submersible motors are intended for operation in a well. When not operated in a

well, failure to connect motor frame to power supply ground may result in serious

electrical shock.

TROUBLESHOOTING

Preliminary Tests

SUPPLY

VOLTAGE

How to Measure

By means of a voltmeter, which has

been set to the proper scale, measure

thevoltageatthe controlbox.Onsingle-

phaseunits, measure between lineand

neutral.

What it Means

When the motor is under load, the

voltage should be within ± 10% of the

nameplate voltage. Larger voltage

variation may cause winding damage.

Large variations in the voltage indicate

a poor electrical supply and the pump

should not be operated until these

variations have been corrected.

If the voltage constantly remains high

or low, the motor should be changed to

the correct supply voltage.

CURRENT

MEASUREMENT

How to Measure

Byuse of anammeter, set onthe proper

scale, measure the current on each

power lead at the control box. See the

Electrical Data, Table C, for motor amp

drawinformation.

Current should be measured when the

pump is operating at a constant

discharge pressure with the motor fully

loaded.

What it Means

If the amp draw exceeds the listed

service factor amps (SFA), check for

the following:

1. Loose terminals in control box or

possiblecabledefect.Checkwinding

and insulation resistances.

3. Too high or low supply voltage.

4. Motor windings are shorted.

5. Pump is damaged causing a motor

overload.

WINDING

RESISTANCE

How to Measure

Turn off power and disconnect the drop

cable leads in the control box. Using an

ohmmeter, set the scale selectors to

Rx1for valuesunder 10ohms andRx10

for values over 10 ohms.

Zero-adjust the meter and measure the

resistance between leads. Record the

values.

Motor resistance values can be found

in Electrical Data, Table C. Cable

resistance values are in Table D.

What it Means

Ifall the ohmvalues are normal, andthe

cable colors correct, the windings are

not damaged. If any one ohm value is

less than normal, the motor may be

shorted.If any one ohm value is greater

than normal, there is a poor cable

connection or joint. The windings or

cable may also be open. If some of the

ohmvalues aregreater thannormal and

some less, the drop cable leads are

mixed. To verify lead colors, see

resistance values in Electrical Data,

TableC.

INSULATION

RESISTANCE

How to Measure

Turn off power and disconnect the drop

cable leads in the control box. Using an

ohm or mega ohmmeter, set the scale

selectorto Rx 100Kand zero-adjust the

meter.

Measure the resistance between the

leadand ground (discharge pipe orwell

casing, if steel).

What it Means

For ohm values, refer to table below.

Motors of all Hp, voltage, phase and

cycle duties have the same value of

insulation resistance.

TROUBLESHOOTING CHART

OHM VALUE MEGAOHMVALUE CONDITION OF MOTOR AND LEADS

Motor not yet installed:

2,000,000 (or more) 2.0 New Motor.

1,000,000 (or more) 1.0 Used motor which can be reinstalled in the well.

Motor in well (Ohm readings are for drop cable plus motor):

500,000 - 1,000,000 0.5 - 1.0 A motor in reasonably good condition.

20,000 - 500,000 0.02 - 0.5 A motor which may have been damaged by lightning or with damaged

leads. Do not pull the pump for this reason.

10,000 - 20,000 0.01 - 0.02 A motor which definitely has been damaged or with damaged cable.

The pump should be pulled and repairs made to the cable or the

motor replaced. The motor will still operate, but probably not for long.

less than 10,000 0 - 0.01 A motor which has failed or with completely destroyed cable insulation.

The pump must be pulled and the cable repaired or the motor

replaced. The motor will not run in this condition.

A. Pump Does Not Run

POSSIBLE CAUSES HOW TO CHECK HOW TO CORRECT

1. No power at pump

panel. Check for voltage at panel. If no voltage at panel, check feeder

panel for tripped circuits.

2. Fuses are blown or

circuit breakers are

tripped.

Remove fuses and check for continuity

with ohmmeter. Replace blown fuses or reset circuit

breaker. If new fuses blow or circuit

breaker trips, the electrical installation

and motor must be checked.

3. Defective controls. Check all safety and pressure switches

for operation. Inspect contacts in

control devices.

Replace worn or defective parts.

4. Motor and/or cable are

defective. Turn off power. Disconnect motor leads

from control box. Measure the lead

to lead resistances with the

ohmmeter (Rx1). Measure lead to

ground values with ohmmeter

(Rx100K). Record measured values.

If open motor winding or ground is

found, remove pump and recheck

values at the surface. Repair or replace

motor or cable.

5. Defective capacitor. Turn off the power, then discharge

capacitor. Disconnect leads and

check with an ohmmeter (Rx100K).

When meter is connected, the

needle should jump forward and

slowly drift back.

If there is no needle movement,

replace the capacitor.

TROUBLESHOOTING CHART

POSSIBLE CAUSES HOW TO CHECK HOW TO CORRECT

Check drawdown during pump

operation. Lower pump if possible. If not, throttle

discharge valve and install water level

control.

2. Discharge piping or

valve leaking. Examine system for leaks. Repair leaks.

3. Pump strainer or check

valve are clogged. Remove pump and inspect. Clean, repair, rinse out pump and

reinstall.

4. Pump worn. Same as B.2 above. If not close to pump curve, remove

pump and inspect.

1. Draw-down is larger

than anticipated.

C. Pump Runs But at Reduced Capacity

B. Pump Runs But Does Not Deliver Water

POSSIBLECAUSES HOW TOCHECK HOWTOCORRECT

1. Groundwater level in

well is too low or well is

collapsed.

Check well draw-down. Lower pump if possible. If not,

throttle discharge valve and install

water level control.

2. Integral pump check

valve is blocked. Install pressure gauge, start pump,

gradually close the discharge valve and

read pressure at shut-off. After taking

reading, open valve to its previous

position. Convert PSI to feet.

(For water: PSI x 2.31 ft/PSI = ____ ft.),

and add this to the total vertical distance

from the pressure gauge to the water

level in the well while the pump is

running. Refer to the specific pump

curve for the shut-off head for that pump

model. If the measured head is close to

the curve, pump is probably OK.

If not close to the pump curve,

remove pump and inspect discharge

section. Remove blockage, repair

valve and valve seat if necessary.

Check for other damage. Rinse out

pump and reinstall.

3. Inlet strainer is

clogged. Same as B.2 above. If not close to the pump curve,

remove pump and inspect. Clean

strainer, inspect integral check

valve for blockage, rinse out pump

and reinstall.

4. Pump is damaged. Same as B.2 above. If damaged, repair as necessary.

Rinse out pump and re-install.

D. Pump Cycles Too Much

POSSIBLECAUSES HOW TOCHECK HOWTOCORRECT

1. Pressure switch is not

properly adjusted or is

defective.

Check pressure setting on switch

and operation. Check voltage across

closed contacts.

Re-adjust switch or replace if

defective.

2. Level control is not

properly set or is

defective.

Check setting and operation. Re-adjust setting (refer to

manufacturer data.) Replace if

defective.

3. Plugged snifter valve

or bleed orifice. Examine valve and orifice for dirt or

corrosion. Clean and/or replace if defective.

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