This document is an owner's manual for Sears Two and Three Wire Submersible Pumps, including associated control centers. It provides comprehensive information for safe installation, operation, troubleshooting, and repair.
Function Description:
The Sears submersible pumps are designed for well applications, drawing water from a well and delivering it to a residential water system, typically involving a pressure tank. The manual covers both 2-wire and 3-wire submersible pump models, with the 3-wire models requiring a separate control center for operation. The control center houses the electrical equipment necessary to start and run the 3-wire motor, including overload relays for protection against short circuits or voltage surges. The pumps are designed to maintain a consistent water pressure in the system, starting when pressure drops to a set point (e.g., 40 PSI) and stopping when it reaches a higher set point (e.g., 60 PSI).
Important Technical Specifications:
The manual lists several models with varying horsepower (HP), voltage, stages, and discharge pressure capabilities.
- 3-Wire Submersible Pump Model Nos.: 390.284020, 390.284030, 390.284040, 390.284050, 390.284060, 390.284070, 390.284080, 390.284090.
- Control Center Nos. (for 3-wire pumps): 390.284120, 390.284130, 390.284140, 390.284250, 390.284260, 390.284270.
- 2-Wire Submersible Pump Model Nos.: 390.285510, 390.285520, 390.285530.
The manual includes a performance chart (Table I) detailing GPM at various pumping depths and discharge pressures (P.S.I. - pounds per square inch).
- Residential Pumps with 1-1/4" Discharge (40 P.S.I.):
- 1/2 HP (115V/230V): 13.6 GPM at 20 ft, 8.6 GPM at 100 ft.
- 3/4 HP (230V): 13.5 GPM at 20 ft, 7.9 GPM at 175 ft.
- 1 HP (230V): 13.5 GPM at 125 ft, 7.4 GPM at 250 ft.
- 1-1/2 HP (230V): 13.5 GPM at 125 ft, 7.1 GPM at 400 ft.
- High Capacity Pumps with 1-1/4" Discharge (40 P.S.I.):
- 1 HP (230V): 26.4 GPM at 20 ft, 18.4 GPM at 100 ft.
- 1-1/2 HP (230V): 25.8 GPM at 40 ft, 15.4 GPM at 175 ft.
- 2 HP (230V): 26.4 GPM at 100 ft, 17.2 GPM at 250 ft.
- 3 HP (230V): 26.7 GPM at 125 ft, 16.8 GPM at 400 ft.
Electrical Specifications:
- Fusing, Wiring, and Cable Selection (Copper Conductors Only): Table II provides recommended AWG cable sizes and maximum cable lengths for various pump models, ensuring proper operation and preventing overheating. For example, a 1/2 HP 2-wire 230V pump requires a 15 Amp fuse and can use AWG 12 cable up to 650 feet or AWG 10 up to 1020 feet. A 3 HP 3-wire 230V pump requires a 45 Amp fuse and can use AWG 12 cable up to 190 feet, AWG 10 up to 300 feet, or AWG 8 up to 470 feet.
- Engine-Generator Minimum Watt Ratings:
- 1/2 HP: 2,000W (3-wire), 2,400W (2-wire)
- 3/4 HP: 3,000W (3-wire), 2,900W (2-wire)
- 1 HP: 4,000W (3-wire)
- 1-1/2 HP: 5,000W (3-wire)
- 2 HP: 7,500W (3-wire)
- 3 HP: 10,000W (3-wire)
- Overload Protector: Built into 2-wire motors and 1/2 through 1 HP 3-wire motors (automatic restart after cooling) or the control center for 1-1/2 through 3 HP 3-wire motors (manual reset).
- Surge Protection: Motors have built-in surge protectors, though they do not protect against direct or near direct lightning strikes.
Usage Features:
- Installation: Detailed instructions for both plastic and galvanized steel pipe installations. Emphasizes the importance of knowing well depth, depth to water, and drawdown water level. Recommends installing centering guides (Stock No. 2724) to keep the pump, pipe, and electrical cable centered in the well casing. A torque protector is recommended to prevent pipe twisting due to motor starting.
- Piping: Instructions for installing a pressure relief valve (Stock No. 27220) within 2 feet of the pressure tank, set to relieve pressure at 75 PSI. Also covers the installation of a pressure gauge (Stock No. 2768) and an automatic pressure switch (Stock No. 2782), typically set to start at 40 PSI and stop at 60 PSI.
- Tank Systems: Discusses two types of tanks: Captive Air® (no Air Volume Control needed) and Standard (requires an Air Volume Control to prevent waterlogging).
- Electrical Wiring: Provides diagrams and instructions for wiring control centers for different HP motors (1/2, 3/4, 1 HP Standard; 1-1/2, 2, 3 HP Energy Efficient). Emphasizes correct fusing, wiring, and grounding according to local and national electrical codes.
- Cable Splicing: Three methods are described: Soldering, Crimptype Connectors, and Heat-Shrink Splicing (for #8 wire cable only). Instructions include staggering lead ends, stripping insulation, and ensuring waterproof connections.
- Well Development and Pump Test: Crucial procedure before first use to clear solid materials from well water and determine well capacity. Involves pumping at a very low flow rate initially and gradually increasing it, visually checking water quality. This process can take 2-5 hours or more.
- Pump Setting: The pump should not be set closer than 5 feet from the bottom of the well and should be submerged 15 to 20 feet below the drawdown water level.
Maintenance Features:
- Warranty: Full one-year warranty on submersible pumps (materials or workmanship, including installation) and control centers (materials or workmanship). A limited warranty on submersible pumps (excluding controls) extends through three years for replacement pump only (installation paid by customer).
- Troubleshooting Guide: A comprehensive table of common troubles, their causes, and remedies.
- Little or no water delivered: Causes include low water level in well, plugged intake screen, stuck check valve(s), low voltage, worn impellers/diffusers. Remedies involve lowering the pump, cleaning the screen, checking/freeing check valves, verifying voltage, or returning pump for service.
- Air or milky water discharges from faucets: Caused by non-functioning air volume control (Standard tanks) or gaseous well water. Remedies include replacing AVC or checking with well professionals.
- Pump starts too frequently: Causes include leaks in pressure tank/plumbing, defective/misadjusted pressure switch, leaking check valve, waterlogged tank, or leaking drop pipe. Remedies involve checking for leaks, replacing switch, inspecting/replacing valves, recharging Captive Air® tanks, cleaning bleeder orifices (Standard tanks), or finding/repairing drop pipe leaks.
- Fuses blow or overload protector trips when motor starts: Causes include incorrect fuse/wire size, low/high voltage, stuck motor, grounded/shorted/open cable splices or motor windings, improper control center connections, or defective capacitors. Remedies include using correct fuse/wire size, verifying voltage, cleaning pump/well, consulting electrician, or checking/replacing capacitors.
- Motor will not start but does not blow fuses: Causes include no voltage to motor, grounded/shorted/open cable splices/motor windings, open circuit in control center, or faulty pressure switch. Remedies involve checking voltage at various points, consulting electrician, examining connections, or replacing pressure switch.
- Pressure switch fails to shut off pump: Causes include low voltage, faulty pressure switch, worn impellers/diffusers, leaking drop pipe, or low water level in well. Remedies involve verifying voltage, replacing switch, adjusting switch, cleaning well, or lowering pump.
- Fuses blow or overload protector trips when motor is running: Causes include low/high voltage, high ambient temperature (3-wire only), incorrect control center HP/voltage, incorrect wire size, or grounded/shorted/open cable splices/motor windings. Remedies involve verifying voltage, ensuring control center is not in direct sunlight, matching HP/voltage ratings, using correct wire size, or consulting electrician.
- Repair Parts List: Detailed lists and diagrams for control center and pump repair parts, including part numbers for different HP models. Contact information for Sears Product Service is provided for ordering parts and service.
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