Wiktor Wise
Testing an electric submersible well pump is critical for sustaining your water supply system. Before conducting any tests, it is important to prioritise safety by disconnecting the pump's power supply and wearing protective gear, such as gloves and glasses. The first step is to evaluate the pump's performance by measuring water output using a flow meter and comparing it to the pump's specifications. Next, check the pressure at the discharge line using a pressure gauge, as abnormal readings may indicate a blockage or pump failure. The type of test performed depends on the pump's configuration, which can be two-wire, three-wire, or four-wire. For two-wire pumps, verifying the voltage is essential, while ohm tests are crucial for all configurations to determine the integrity of the motor windings. Additionally, checking the check valve on the pump and pressure tank is important, as a faulty valve can cause the pump to work harder and drain your lines. Troubleshooting the motor itself is often a good starting point for diagnosis, and this can be done by testing the winding resistance and insulation resistance with an ohmmeter and megohmmeter, respectively.
| Characteristics | Values |
|---|---|
| Safety | Disconnect the pump's power supply to avoid electrical shock. Wear safety equipment, such as gloves and glasses. |
| Performance | Measure water output using a flow meter and compare it to the pump's specifications. Check for leaks and strange noises. |
| Voltage | For a two-wire pump, verify the voltage provided. Use a multimeter to confirm it matches the desired value. |
| Resistance | Measure resistance across each motor terminal using a multimeter or ohmmeter. Compare to the published values from the pump manufacturer. |
| Check Valve | With the pressure tank fully pressurized, shut off the water after the tank. If the pressure remains constant, there may be an issue with the motor causing it to short cycle. If the pressure drops, the check valve is bad. |
| Amperage | Amp the start wire; it should bump the needle and then go to 0. If it stays drawing amps, there may be an issue with the start winding or capacitor. |
| Control Box | Check the control box for issues. |
| Wiring | Ensure correct wiring configuration for the pump. Two-wire motors are 1.5 HP and below and do not require a control box. Three-wire motors require an external control box or starter. |
| Motor | Test the motor using a megohmmeter (megger) or ohmmeter to determine if there is an electrical short or open circuit. |
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What You'll Learn
Check the voltage
To test the voltage of a submersible well pump, it is important to first disconnect the pump's power supply to avoid electrical shock. Always wear safety equipment, such as gloves and glasses, for protection.
For a two-wire pump, take the cover off your pressure switch and check the voltage between the two screws for each leg. Ensure that each side matches the desired value, which is usually 115v. If the voltage is lower, the problem may be in the electrical wiring to the pump, possibly due to a blown fuse.
If you have a three-wire pump, you can use an ohm meter to check the incoming three wires from the pump to determine if it is functioning correctly. You can also test the current draw on each of the conductors with a clamp-on ammeter, referring to a diagnostic table supplied by the pump and motor manufacturer to determine whether the readings are good or bad.
Additionally, you can perform an ohm test to determine the integrity of the motor windings. Disconnect the electricity and use a multimeter to measure the resistance across each motor terminal. This test is critical for understanding the performance of the motor and identifying any potential issues.
By following these steps and regularly checking the voltage and electrical components of your submersible well pump, you can ensure its optimal performance and prevent future repairs.
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Measure water output
To measure the water output of your electric submersible well pump, you will need to use a flow meter to determine how many gallons per minute (GPM) the pump delivers. This reading should then be compared to the pump's specifications. A substantial decline in performance could indicate a problem with the pump.
Before conducting any tests, it is important to prioritise safety. Disconnect the pump's power supply to avoid electrical shock, and always wear protective equipment, such as gloves and safety glasses.
In addition to measuring water output, you can also test the pressure at the discharge line using a pressure gauge. Abnormal readings may suggest a blockage or pump failure.
If you are using a two-wire pump, simply verify the voltage provided to it. Utilise a multimeter to confirm that the voltage matches the desired value.
It is also possible to test the current draw on each of the conductors. You can refer to a diagnostic table, supplied by the pump and motor manufacturer, outlining how much current on each wire is considered good or bad. With a clamp-on ammeter, you can easily perform this test yourself.
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Check the check valve
Check valves are an essential component of well pump plumbing systems. They stop water from flowing back into the well when the pump turns off, protecting the system from various problems. When a submersible pump’s built-in check valve goes bad, it must be replaced.
To test whether the check valve is functioning correctly, first, turn off the connection between the pressure tank and what it services (e.g. household plumbing). After waiting about an hour, if the tank is still losing pressure, it means something on the downwell side of the system is the cause. In many instances, the check valve is responsible for this pressure loss and must be repaired or replaced.
If you have a multimeter, you can use it to ohm out every wire to every other wire and every wire to metal (ground). If your electrical readings are all correct, you may be able to put a check valve between the pump and the pipe.
To check the check valve on your pump, first, fully pressurize your pressure tank. Then, shut the water off after the tank. Now, only your tank and pump are connected. If the pressure remains constant for 10 minutes or more, something is happening with your motor to cause it to short cycle. If the pressure drops, you have a bad check valve, which is causing your pump to work extra hard and draining your lines, which causes your pump to run.
To check the check valve, you must pull the submersible well pump. If the check valve is bad, it won't close, allowing water to drain through the impeller. This causes the impeller to spin in reverse while the pump is off, so the motor has to work extra hard to get the water moving in the correct direction. A bad check valve can also prevent water from moving out of the pump, causing excessive loads on the motor.
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Test the motor
Testing the motor of an electric submersible well pump is an important step in diagnosing any issues with the pump's functioning. Here are some detailed steps and procedures to test the motor effectively:
- Check the Voltage: Ensure that the voltage supplied to the pump is correct. Standard voltages for submersible well pumps are 115V, 120V, 230V, or 240V. Check the pump's label or manufacturer's specifications to determine the required voltage.
- Measure Amperage: With the pump running, measure the amperage using an ammeter. Compare the reading to the expected amperage specified on the pump's label or in the manufacturer's documentation.
- Winding Resistance and Insulation Resistance: Test the winding resistance and insulation resistance of the motor using an ohmmeter and a megohmmeter (megger), respectively. These tests will help determine if there are any electrical shorts or open circuits in the motor windings, which can affect the pump's performance. Compare the measured values with the manufacturer's published values.
- Check the Check Valve: A faulty check valve can cause the motor to work harder than usual. With the pressure tank fully pressurized, shut off the water after the tank. If the pressure remains constant for 10 minutes or more, there may be an issue with the motor causing it to short cycle.
- Diagnose Electrical Readings: If you suspect a problem with the motor, check the electrical readings between the wires. Disconnect the pump from the pressure switch and take resistance readings. If the meter reads OL, it indicates a broken wire. If the resistance is lower than expected, it suggests a short circuit inside the motor.
- Visual Inspection: If possible, visually inspect the motor and its components for any signs of damage, corrosion, or wear. This may involve removing the pump from the well or accessing the motor through a maintenance panel.
- Contact a Professional: If you are unsure about any aspects of testing the motor, it is advisable to contact a qualified electrician or well pump technician for assistance. They can provide expert guidance and ensure safe handling of electrical equipment.
Remember to follow appropriate safety precautions when working with electrical equipment and always disconnect the power supply before performing any tests or inspections.
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Measure resistance
Measuring the resistance of an electric submersible well pump is a critical step in determining the integrity of the motor windings and ensuring the pump is functioning properly. Here are the steps you can take to measure the resistance:
Disconnect the Power Supply: Before conducting any tests or measurements, it is crucial to prioritize safety. Disconnect the pump's power supply to avoid any risk of electrical shock. This step ensures that you can work on the pump without the possibility of it turning on unexpectedly.
Use Appropriate Safety Equipment: Wear protective gloves and glasses to safeguard yourself from any potential hazards during the testing procedure.
Select the Right Tool: You can use a multimeter or an ohmmeter (recommended) to measure the resistance. These tools allow you to accurately gauge the resistance across each motor terminal.
Turn Off Electricity: Ensure that the electricity is turned off before taking any measurements. This step is essential for safety and to prevent any interference during the testing process.
Interpret the Results: Compare your measured resistance values with the published values provided by the pump manufacturer for their motor selections. If your readings fall outside the specified range, it may indicate an issue with the motor windings or a broken wire.
Advanced Testing: For more comprehensive testing, you can employ a megohmmeter (megger) to check for electrical shorts or open circuits in the motor windings, which can significantly impact the performance of the motor.
By regularly measuring the resistance of your electric submersible well pump and following the steps outlined above, you can ensure the optimal functioning of your pump and promptly identify and address any potential issues.
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