Xylem GOULDS IM096 User manual

4" Submersible Pumps
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
INSTRUCTION MANUAL
IM096

2
Table of Contents
SUBJECT PAGE
Safety Instructions ................... 3 & 4
Pump Protection Devices.................4
Installation Checklist .......................5
1.0 Typical Installations ...................6
2.0 Piping and Tank.........................7
3.0 Wire Sizing, Splicing and
Power Supply ...............................9
4.0 Wiring the Controls and
Switch .........................................9
5.0 Starting the Pump....................12
6.0 Paperwork and IOM ...............12
CentriPro 4" 1 Ph Motor Data ......13
Single Phase Wire Sizing Charts ....14
PumpSaver Schematics ..................14
Three Phase Motor Data...............15
Three Phase Motor
Electrical Data...........................16
Three Phase Motor
Wire Chart................................17
Resistance and Generator Data .....18
Wiring Diagrams ................. 19 & 20
Three Phase Starters ......................21
Troubleshooting.............................22
Limited Warranty ..........................66
Owner’s Information
Pump Model #:
Pump Serial #:
Motor Model #:
Motor Serial #:
Dealer:
Dealer Telephone:
Purchase Date:
Installation Date:
Volts:
Amps:
Owner’s Information Table of Contents

3
All electrical work must be performed by a qualified
technician. Always follow the National Electrical Code (NEC),
or the Canadian Electrical Code, as well as all local, state and provincial
codes. Code questions should be directed to your local electrical inspector.
Failure to follow electrical codes and OSHA safety standards may result
in personal injury or equipment damage. Failure to follow manufacturer’s
installation instructions may result in electrical shock, fire hazard, personal
injury or death, damaged equipment, provide unsatisfactory performance,
and may void manufacturer’s warranty.
Standard units are not designed for use in swimming pools,
open bodies of water, hazardous liquids, or where flammable
gases exist. Well must be vented per local codes. See specific pump catalog
bulletins or pump nameplate for all agency Listings.
Disconnect and lockout electrical power before installing or
servicing any electrical equipment. Many pumps are equipped
with automatic thermal overload protection which may allow an overheated
pump to restart unexpectedly.
Never over pressurize the tank, piping or system to a pressure
higher than the tank's maximum pressure rating. This will
damage the tank, voids the warranty and may create a serious hazard.
Protect tanks from excessive moisture and spray as it will cause
the tank to rust and may create a hazard. See tank warning
labels and IOM for more information.
WARNING
WARNING
WARNING
Important notice: Read safety instructions before proceeding with any wiring
SAFETY INSTRUCTIONS
TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR
PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN MANUAL AND ON PUMP.
THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION AND
OPERATION OF THIS UNIT AND MUST BE KEPT WITH THE PUMP.
This is a SAFETY ALERT SYMBOL. When you see this
symbol on the pump or in the manual, look for one of the
following signal words and be alert to the potential for
personal injury or property damage.
Warns of hazards that WILL cause serious personal injury,
death or major property damage.
Warns of hazards that CAN cause serious personal injury,
death or major property damage.
Warns of hazards that CAN cause personal injury or property
damage.
NOTICE:INDICATES SPECIAL INSTRUCTIONS WHICH ARE VERY
IMPORTANT AND MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS
PRIOR TO PERFORMING ANY WORK ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
DANGER
CAUTION
WARNING
WARNING
WARNING

4
CAUTION
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
DANGER
WARNING
CAUTION
SAFETY INSTRUCTIONS (continued)
Do not lift, carry or hang pump by the electrical cables.
Damage to the electrical cables can cause shock,
burns or death.
Use only stranded copper wire to pump/motor and ground.
The ground wire must be at least as large as the power supply
wires. Wires should be color coded for ease of maintenance
and troubleshooting.
Install wire and ground according to the National Electrical
Code (NEC), or the Canadian Electrical Code, as well as all
local, state and provincial codes.
Install an all leg disconnect switch where required
by code.
The electrical supply voltage and phase must match all equip-
ment requirements. Incorrect voltage or phase can cause fire,
motor and control damage, and voids the warranty.
All splices must be waterproof. If using splice kits follow
manufacturer’s instructions.
Select the correct type and NEMA grade junction box for the
application and location. The junction box must insure dry,
safe wiring connections.
All motors require a minimum 5' submergence for proper refill
check valve operation.
Failure to permanently ground the pump, motor and controls
before connecting to power can cause shock, burns or death.
All three phase (3Ø) controls for submersible pumps must
provide Class 10, quick-trip, overload protection.
4" motors ≥2 HP require a minimum flow rate of .25 ft/sec.
or 7.62 cm/sec. past the motor for proper motor cooling.
The following are the minimum flows in GPM per well
diameter required for cooling: 1.2 GPM/4", 7 GPM/5",
13 GPM/6", 20 GPM/7", 30 GPM/8" or 50 GPM in a 10"
well.
Pumps ≥2 HP installed in large tanks should be installed in a
flow inducer sleeve to create the needed cooling flow or veloc-
ity past the motor.
This pump has been evaluated for use with Water Only.
CAUTION
CAUTION
PUMP PROTECTION
We recommend using SymCom’s PumpSaver to protect the system from low
water, rapid cycling, high/low voltage, dead heading/flow restriction and
overcurrent.

5
INSTALLATION CHECK LIST
• Enter the pump and motor information and other requested data on the front
of this manual.
• Inspect all components for shipping damage, report damage to the distributor
immediately.
• Verify that motor HP and pump HP match.
• Match power supply voltage and phase to motor and control specications.
• Select a dry, shaded location in which to mount the controls.
• Make all underwater and underground splices with waterproof splice
connections.
• Hold the pump at the discharge head when installing threaded pipe or an
adapter fitting as most pumps have left hand threads which will be loosened
if you hold the pump anyplace except the discharge head.
• Check all plumbing connections to insure they are tight and sealed with
Teflon tape.
• Verify that the pipe pressure rating is higher than pump shut-off pressure.
• Install a pressure relief valve on any system capable of creating over 75 PSI.
The system pressure cannot exceed the tank's maximum pressure rating.
• Locating the tank and controls in an area protected from rain, spray and
other environmental factors may prolong their useful life. Especially in areas
with acid rain and saline water.
• Locate the pressure switch within 4' of the pressure tank to prevent switch
chatter.
• Adjust tank pre-charge to 2 PSI below the system cut-in pressure setting, ex.
28 on a 30/50 system.
• Set the pump 10' above the well bottom to keep above sediment and debris.
• Insure that main power is disconnected, turned OFF, before wiring any com-
ponents.
• Wiring should be performed only by qualied technicians.
• Wiring and Grounding must be in compliance with national and local codes.
• Restrict the ow with a ball or globe valve, 1/3 open, before starting pump
for first time.
• Open a faucet or discharge valve on start-up to keep dirty water from enter-
ing the tank.
• Turn main breaker or disconnect ON.
• Run through several on/off cycles to verify proper switch operation.
• Check amps and enter the data on the front of this manual.
• Leave the manual with the owner or at the job site.

6
Figure 1
Figure 2
Protected Power Supply
Disconnect Switch
Control Box Pressure
Gauge To House
Piping
Shut-off Valve
Union
Drain Tap
Pressure Relief Valve
Air Escape Control
Pressure Switch
Line Check Valve with Snifter
Union
Pitless Adapter
Drain and Y Fitting
Approximate Drain Fitting Setting
Distance Drain and “Y”
Tank Capacity Fitting Below the Line Check
42 gallon (159 L) 7 feet (2.1m)
82 gallon (310 L) 10 feet (3m)
120 gallon (454 L) 15 feet (4.6m)
220 gallon (833 L) 15 feet (4.6m)
315 gallon (1192 L) 20 feet (6.1m)
525 gallon (1981 L) 20 feet (6.1m)
Protected Power Supply To House Piping
Disconnect Switch
Shut-off Valve
Union
Pressure Relief Valve
Drain Tap
Tank Tee
Check Valve ②
Frost Level
GALVANIZED TANK INSTALLATION
1.0 TYPICAL INSTALLATIONS
1.0 TYPICAL INSTALLATIONS
Check Valve ①
Pitless Adapter ①
Pressure Switch
①On installations with a pitless adapter the top check
valve should be below the pitless, not at the tank, as the
discharge line should be pressurized back to the pitless.
②On installations with well seals or well pits it is allowable
to locate the top check valve near the tank.
CAPTIVE AIR TANK INSTALLATION
NOTICE: TANK PRE-CHARGE PRESSURE CHANGES MUST BE
MADE USING THE AIR VALVE ON TOP OF THE TANK.

7
2.0 PIPING
Notice: Most 4" submersibles have
left-hand discharge head threads,
hold the pump only at the
“discharge head” when installing
fittings or threaded pipe.
2.1 General
The pump discharge
piping should be sized for
efficient pump operation.
Use the Friction Loss
Tables to calculate total
dynamic head using different pipe
sizes. As a rule of thumb, use 1" for
up to 10 gpm, 1¼" for up to 30 gpm,
1½" for up to 45 gpm, and 2" for up
to 80 gpm. In the case of long pipe
runs it is best to increase pipe size.
Some pumps are capable of very high
discharge pressures, please select pipe
accordingly. Consult with your pipe
supplier to determine the best type of
pipe for each installation.
2.2 Pressure Tank,
Pressure Switch
and Pressure
Relief Valve
Select a dry location in
which the ambient temper-
ature is always above 34º
F (1º C) in which to install
the tank, pressure switch,
and pressure relief valve. The tank
should be located in an area where a
leak will not damage property.
The pressure switch should be
located at the tank cross tee and
never more than 4' from the tank.
Locating the switch more than
4' from the tank will cause
switch chatter.
Do not install valves, filters, or high
loss fittings between the switch and
the tank(s) as switch chatter may
result. As an example, a 1¼" spring
check valve has friction loss equal to
12' of pipe, placing the valve between
the pressure switch and the pressure
tank is the same as moving the pres-
sure switch 12' away from the tank. It
will create switch chatter.
On multiple tank installations the
switch should be as close to the cen-
ter of the tanks as possible. Multiple
tank installations should have a mani-
fold pipe at least 1½ times the size of
the supply pipe from the pump. This
will reduce the Friction Head in the
manifold and reduce the possibility
of switch chatter.
Pressure relief valves are required on
any system that is capable of
producing 100 psi or 230' TDH. If
blow-off may damage property,
connect a drain line to the pressure
relief valve and run it to a suitable
drain.
2.3 Adjusting Tank
Pre-Charge
Insure that the tank is empty of
water. Use a high quality pressure
gauge to check the tank pre-charge
pressure. The pressure should be 2 psi
below the pump cut-in pressure. As
an example, a 30-50 psi system would
use a tank pre-charge of 28 psi.
2.4 Discharge Pipe
Note: Most discharge heads are
threaded into the casing with left-
hand threads. Hold the pump only
at the discharge head when installing
fittings. Failure to hold the discharge
head will loosen it and pump damage
will result on start-up.
If your pipe requires an adapter we
strongly recommend using stain-
less steel. Galvanized fittings or pipe
should never be connected directly to
a stainless steel discharge head as
galvanic corrosion may occur. Plastic
or brass pumps can use any
material for this connection. Barb
type connectors should always be
double clamped.
Hazardous pressure can
cause personal injury or
property damage.
CAUTION
2.0 PIPING
Do not install tank where
it will be subjected to
spray from irrigation
systems. Exposure to such
spray could result in
corrosion of the tank,
eventually leading to an
explosion which can cause
property damage, serious
personal injury or death.
DANGER

8
The pump discharge head has a loop
for attaching a safety cable. The use
of a safety cable is recommended
when using poly pipe as the pipe
stretches when under pressure and
filled with water.
2.5 Installing Pump in Well
If using a torque arrestor, install it
per the manufacturer’s installation
instructions. Consult the seller for
information on torque arrestors and
for installation instructions.
Connect the discharge pipe to the
discharge head or adapter. Barb
style connectors should be double
clamped. Install the pump into the
well using a pitless adapter or similar
device at the wellhead. Consult the
fitting manufacturer or pitless
supplier for specific installation
instructions.
Using waterproof electrical tape,
fasten the wires to the drop pipe at
10' intervals. Pump suppliers also sell
clip-on style wire connectors that
attach to the drop pipe.
2.6 Special Piping For
Galvanized Tank
Systems
When using a galvanized tank install
an AV11 Drain & Y fitting in the well
and a check valve with snifter valve
at the tank. This will add air to the
tank and prevent water logging the
tank. Use an AA4 Air Escape on the
tank to allow excess air to escape.
The distance between the AV11
and check valve with snifter valve
determines the amount of air intro-
duced on each cycle. See the table for
recommended settings. See Figure 2
in Sec 1.0.
Gaseous wells should use galvanized
or glass lined steel tanks with AA4
air escapes to vent off excess air and
prevent “spurting” at the faucets.
Methane and other explosive or
dangerous gases require special water
treatment for safe removal. Consult a
water treatment specialist to address
these issues.
Installations with top feeding wells
should use flow sleeves on the pump.
2.7 Check Valves
Our pumps use four different styles of
check valves. We recommend check
valves as they prevent back-spinning
the pump and motor which will
cause premature bearing wear. Check
valves also prevent water hammer and
upthrust damage. Check valves should
be installed every 200' in the vertical
discharge pipe. See notes 1 & 2 on
Figure 1 for other check valve place-
ment recommendations.
If you wish to disable a check valve
for a drain back system, you should
use other means to prevent water
hammer and upthrust damage:
• Built-in stainless steel valves have a
flat which is easily drilled through
using an electric drill and a ¼" or
3⁄8" drill bit to disable the valve.
• Poppet style check valves which
are threaded in from the top of
the discharge head can be easily
removed using a ½" nut driver or
deep socket. The hex hub is visible
and accessible from the top.
• Internal Flomatic™ design plastic
poppet style valves must be
removed from inside which
requires pump disassembly.
• Built-in plastic poppet style valves
with a stem through the top may
be removed from discharge head
by pulling on the stem with pliers.

9
3.0 WIRE
SIZING,
SPLICING and
POWER SUPPLY
Always follow the National Electric
Code (N.E.C.), Canadian Electrical
Code, and any state, provincial, or
local codes.
We suggest using only copper wire.
Size wire from the charts found in
the Technical Data section of this
manual, MAID manual, or an
N.E.C. (National Electric Code)
code book. If discrepancies exist the
N.E.C. book takes precedence over a
manufacturer’s recommendations.
3.1 Splicing Wire to
Motor Leads
When the drop cable must be spliced
or connected to the motor lead, it is
necessary that the splice be water-
tight. The splice can be done with
heat shrink kits or waterproof tape.
A. Heat Shrink Splice Instructions
To use a typical heat shrink kit: strip
½" from the motor wires and drop
cable wires; it is best to stagger the
splices. Place the heat shrink tubes
on the wires. Place the crimps on the
wires and crimp the ends. Slide the
heat shrink tubes over the crimps and
heat from the center outward. The
sealant and adhesive will ooze out
the ends when the tube shrinks. The
tube, crimps, sealant, and adhesive
create a very strong, watertight seal.
B. Taped Splice Instructions
A) Strip individual conductor of
insulation only as far as
necessary to provide room for a
stake type connector. Tubular
connectors of the staked type are
preferred. If connector O.D. is
not as large as cable insulation,
build-up with rubber electrical
tape.
B) Tape individual joints with
rubber electrical tape, using two
layers; the first extending two
inches beyond each end of the
conductor insulation end, the
second layer two inches beyond
the ends of the first layer. Wrap
tightly, eliminating air spaces as
much as possible.
C) Tape over the rubber electrical
tape with #33 Scotch electrical
tape, or equivalent, using two
layers as in step "B" and making
each layer overlap the end of the
preceding layer by at least two
inches.
In the case of a cable with three
conductors encased in a single outer
sheath, tape individual conductors as
described, staggering joints.
Total thickness of tape should be no
less than the thickness of the conduc-
tor insulation.
4.0 WIRING
THE
CONTROLS and
SWITCH
4.1 Mounting the Motor
Control Box
Single phase 3-wire control boxes
meet U.L. requirements for Type
3R enclosures. They are suitable for
vertical mounting in indoor and out-
door locations. They will operate at
temperatures between 14ºF (-10ºC)
and 122ºF (50ºC). Select a shaded,
dry place to mount the box. Insure
that there is enough clearance for the
cover to be removed.
WARNING
Hazardous voltage
can shock, burn or
cause death.
4.0 WIRING
THE
CONTROLS and
SWITCH
WARNING
Hazardous voltage
can shock, burn or
cause death.
3.0 WIRE
SIZING,
SPLICING and
POWER SUPPLY

10
4.2 Verify Voltage and Turn
Supply Power Off
Insure that your motor voltage and
power supply voltage are the same.
Place the circuit breaker or discon-
nect switch in the OFF position to
prevent accidentally starting the
pump before you are ready.
Three-phase starter coils are very
voltage sensitive; always verify actual
supply voltage with a voltmeter.
High or low voltage, greater than
±10%, will damage motors and
controls and is not covered under
warranty.
4.3 Connecting Motor Leads
to Motor Control Box,
Pressure Switch or
Starter
Caution Do not power the
unit or run the pump until
all electrical and plumbing
connections are completed.
Verify that the disconnect
or breaker is OFF before
connecting the pressure switch line
leads to the power supply. Follow
all local and national codes. Use a
disconnect where required by code.
A. Three-Wire Single Phase Motor
Connect the color coded motor leads
to the motor control box terminals
- Y (yellow), R (red), and B (black);
and the Green or bare wire to the
green ground screw.
Connect wires between the Load
terminals on the pressure switch
and control box terminals L1 and
L2. Run a ground wire between the
switch ground and the control box
ground. See Figure 4 or 5.
B. Two-Wire Single Phase Motor
Connect the black motor leads to the
Load terminals on the pressure switch
and the green or bare ground wire
to the green ground screw. CentriPro
2-wire motors will not work with
Franklin Electric PumpTec. Use a
PumpSaver. See Figure 3.
C. Three phase motors
Connect the motor leads to T1, T2,
and T3 on the 3 phase starter. Con-
nect the ground wire to the ground
screw in the starter box. Follow
starter manufacturers instructions
for connecting pressure switch or
see Figure 6.
4.4 Connect To
Power Supply
Complete the wiring by
making the connection
from the single phase pres-
sure switch Line terminals
to the circuit breaker panel
or disconnect where used.
Three phase - make the connections
between L1, L2, L3, and ground on
the starter to the disconnect switch
and then to the circuit breaker panel.
Three phase installations must be
checked for motor rotation and
phase unbalance. To reverse motor
rotation, switch (reverse) any two
leads. See the instructions for check-
ing three phase unbalance in section
4.6. Failure to check phase unbalance
can cause premature motor failure
and nuisance overload tripping. If
using a generator, see Technical Data
for generators.
4.5 Three Phase Overload
Protection
Use only Class 10, quick-trip over-
load protection on three-phase
submersible motors. See Definite
Purpose Starters in this manual.
Call the pump manufacturer’s
Customer Service group for selection
assistance.
WARNING
Hazardous voltage
can shock, burn or
cause death.
WARNING
Hazardous voltage
can shock, burn or
cause death.