Installation Instructions for Model 100 Hand Pump
Contents:
Introduction
Electrical Installation: View a completed installation showing how
the electrical was reinstalled.
Section 1: Do It Your Self or Call a Pump Professional
?
Section 2: Inspecting Your Existing System.
Section 3: Replacing The Existing Well Cover.
Section 4: Pump Cylinder, Drop Pipe Installation.
Section 5: Pump Head Installation.
Section 6: Pumping Water, Finishing Touches.
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Introduction
Thank you for purchasing your Simple Pump. We are extremely proud
of the high quality products manufactured by Simple Pump. Simple
Pump performs installations on a regular basis in their testing
process. Pumps have been installed in a variety of well types and
sizes and the instructions are a result of experiences in those
installations. Please carefully read through these instructions.
Your time will be well spent. At any time, if you think you are
overwhelmed, please get the help of a qualified, professional pump
installer.
We will be referring to parts by their part number and name. Use
the Assembly Parts List list to identify parts as you read through
these instructions. See
the Parts Exploded View Picture.
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Assembly Parts
List:
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| P1 -Pumping Cylinder |
P7-Clevis |
D2-Sucker Rod |
| P2-Pump Head |
P8-Pivot Pin |
D3-Sucker Rod Guide |
| P3-Top Pump Rod |
P9-Cover |
D5-Top Drop Pipe |
| P4-Lever Bracket |
P10- Split Flange |
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| P5-Lever Link Arm |
P11-Safety Tool |
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| P6-Lever |
D1-Standard Drop Pipe |
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Section 1: Do It Yourself or Call a Pump
Professional?
Before considering whether to perform this installation yourself,
you need to first determine what type of cover is on your existing
well case. Replacing your existing well cover with the cover provided
with your new Simple pump is necessary to support the hand pump
head. Covers are made in a wide variety of shapes and form. We break
them down into two categories for determining who will perform the
installation:
PRESSURE PIPE THROUGH THE COVER
If your cover has pressure piping that passes through it and continues
to your house system, a pump installer can easily do the task of
replacing the cover. This type of cover generally supports the entire
string of pipe extending down to the electric pump. This string
of pipe can weigh hundreds of pounds. DO NOT ATTEMPT TO REMOVE THIS
TYPE OF COVER UNLESS YOU KNOW WHAT YOU ARE DOING! Your pump installer
has equipment to lift the string and the cover. Your installer can
lift the string a short distance, and using a special clamp, can
replace the old cover with the new cover and set it back onto the
case.
NO PRESSURE PIPE THROUGH THE COVER
If your cover does not have pressure piping passing through it,
you probably can perform the installation yourself if you are comfortable
with simple plumbing tasks. You will also need to disconnect your
existing well pump wiring under the cover and reconnect it through
the new cover. This may require installing electrical flexible conduit,
connecting electrical fittings and reconnecting the pump wiring.
It is important that you can safely eliminate the possibility of
power being applied to these lines while you are working on them.
These are usually 240 volts. ELECTRICITY CAN KILL! DO NOT ATTEMPT
TO PERFORM ELECTRICAL ALTERATIONS UNLESS YOU KNOW WHAT YOU ARE DOING.
If you have the skills described, the installation is really quite
simple. Most of the work is in changing over the well cover. Setting
the pump requires approximately three to five minutes per nine foot
section.
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Section 2: Inspecting Your Existing System.
In this section you will remove your existing cover and inspect
your well for any obstacles that might obstruct the installation
of your new hand pump.
a) Make certain that your electric well power source has been shut
off and locked off. You will probably be a considerable distance
from the power shutoff and the possibility of the power inadvertently
being turned on must be eliminated.
b) Remove your existing cover. There are so many styles; you will
have to figure this one out on your own.
c) Untangle any wiring under the cover and pull the wires from
the pump tight, with the excess out of the case.
d) Using a mirror reflecting the sun (don't laugh it's the best
way), shine down the casing. If you have a straight well, you can
see the water reflecting as deep as 200 feet. About 4 feet below
the ground level you will see the special fitting (called a "pitless
adapter") which takes your pressure piping to your house. The
piping to the hand pump will pass right beside this fitting. On
some installations, "torque arrestors" are installed
to keep the pipe and wiring at the center. Certain versions of these
might prevent the hand pump piping from passing to the water level,
in which case a pump installer can remove the unneeded ones. Torque
arrestors are only necessary at the electric pump. The Simple pump
will be installed 20 to 100 feet above the electric pump.
Now that you have determined that you have a relatively unobstructed
path to the water, you can proceed.
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Section 3: Replacing The Existing Well
Cover.
Tools: Wire cutters, strippers, Allen wrench set.
a) When you untangled the pump wiring, you should have found connections.
Typically these are wire nuts under electrical tape. They may be
crimped connectors, in which case you will need to cut the wires
close to the connectors. You will usually have three wires and sometimes
four. Note the colors and disconnect them. As an additional safety
precaution, take the bare wire ends coming from the house and touch
them to the well case one at a time as you disconnect them. If for
some reason there were power, they would arc against the case and
not you. The wires must reconnect in the same order. You may need
to tie some twine onto the pump wires to keep them from falling
down the well. The wires should however be taped to the piping a
few feet down.
b) Inspect the outer rim of the well case. Your new cover (P9)
is made to fit either a standard 4", 5" , 6" or 8"
pipe. The case should measure either 4 5/8, 5 5/8, 6 5/8" or
8 5/8" on the outside diameter. Three holes are in the cover(P9);
one where the split flange (P10) is located, one 1" threaded
hole for the electrical, and a 1 _" hole for a pressure pipe
for an existing submersible pump if it is routed through the cap
(see previous section heading "PRESSURE PIPE THROUGH THE COVER").
Any unused holes should be plugged when the installation is complete
with the plugs provided with the cover (P9). Your new cover(P9)
has 1/16" clearance Well drillers often leave torch slag on
the case. This needs to be removed if it protrudes beyond the outside
diameter. A sharp flat file will remove it. A electric hand grinder
will also work very quickly.
c) Taking the wiring from inside the case, pass the wires through
the 1" threaded port in the new cover(P9). Now slide the cover
(P9) over the case, level if necessary and tighten the four outer
set- screws.
d) You will need to carefully evaluate your wiring to determine
the best method to enclose the wiring. Sometimes flexible conduit
is the easiest method. However you finish off the electrical conduit,
make certain that the wiring is reconnected in the same order as
the original. Also make certain that the wiring inside the case
does not obstruct the path for the hand pump piping as you look
down through the split flange (P10). Once your existing wiring is
reconnected, you can energize your electric pump and make sure that
it is working normally before you proceed.
The hardest part is done.
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Section 4: Pump Cylinder, Drop Pipe Installation.
In this section we will review the installation of the entire string
of new drop pipe with the pump cylinder at the bottom. Being extremely
cautious during this sequence is critical. Dropping the entire pipe
string down the well is easy. They are almost impossible to retrieve.
Follow these directions! Tools, supplies: Two pairs of channel locks,
safety tool (P11), Teflon plumber's tape, bleach/water 1part bleach
24 parts water. Before starting, let's identify and organize the
parts that we will need. The drop pipes are all identical except
the one that will be used on the top (D5). This one has male threads
on both ends. The top end has 1 1/4" pipe threads on a fitting.
a) Lay out all of your pipes with the capped ends away from you.
Now take the fiberglass sucker rod (D2) and slide one into each
pipe (male end out) until it bumps the plastic cap, including the
top drop pipe (D5).
b) Take the pump cylinder (P1) over to one of the standard drop
pipes (D1) and remove the end cap (on the male end of the drop pipe)
and screw together the fiberglass sucker rod with steel pump rod
protruding out of the pump cylinder. Tighten with two pairs channel
locks until snug, being careful to only grip the metal portions
of both rods and not the fiberglass. DO NOT CRUSH EITHER THE STAINLESS
STEEL FITTING ON THE FIBERGLASS SUCKER ROD OR THE FIBERGLASS ITSELF!
c) Apply the Teflon tape to the threads on the male end of the
drop pipe (D1) and thread the drop pipe into the pump cylinder.
Be careful not to cross thread. Tighten with two pairs of channel
locks.
d) Pour the bleach solution over the pump cylinder. (Watch your
clothes.)
e) (Two persons) Now stand the assembly on end with the pump cylinder
at the bottom and, insert the assembly into the new well cover through
the split flange (P10). When the pump passes through the port, slide
the safety tool over the pipe and let it lay on the split flange.
As the pipe is lowered, the safety tool will stop the drop pipe
at the coupling. You can now let loose. (Attaching a 3/8" Polypropylene
rope to the cylinder/pipe will keep you from loosing it down the
well. At end of install, tie the rope to an eye bolt installed in
the well casing about 6" down by you.)
f) You should be looking at a coupling with a rod protruding about
4" out. (The rod should be pushed to the bottom if it is not
already there.) Now take a sucker rod guide (D3) and slide it over
the protruding rod and into the coupling. You are ready for the
next section of drop pipe.
g) Take another section of standard drop pipe (D1) with the sucker
rod inserted and stand on end with the plastic cap down. With one
person holding the pipe upright over the coupling in the cover,
the other can remove the plastic cap and align the sucker rods.
Thread both together making sure they are not cross-threaded and
tighten with two pairs of channel locks, being careful not to grip
the fiberglass portion of the sucker rod and not crushing the stainless
steel fittings on the ends. Apply Teflon tape to the male threads
and thread the pipe into the coupling and tighten with two pairs
of channel locks. Do not let the coupling spin on the safety tool,
as it can work its way out. Lift the pipe string while the other
person removes the safety tool. As soon as the coupling passes through
the port, reinsert the safety tool and hold it until the next coupling
approaches. As the next coupling nears the safety tool, the other
person can grab the sucker rod and pull upward helping to support
the load and to keep the other person from pinching his fingers
as the coupling comes into contact with the safety tool.
This process is repeated for each section of standard drop pipe.
When you suspect that you might be near your water level, pull up
on the sucker rod at any time. If you are not in the water yet,
the rod will fall very quickly. When you are in water, the rod will
fall more slowly. Sometimes, as the pipe is lowered, a gurgling
sound can be heard when the pump is in water. You can also stroke
the rod repeatedly and water will be pumped up the string. If you
are in water, it will become harder to stroke after ten strokes
or so. The pipe string is also much heavier with water in it.
h) When you are ready for the top drop pipe, install it just like
the others. Lower this one down to the safety tool like the others.
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Section 5: Pump Head Installation.
In this section we will review the installation and assembly of
the pump head. Tools, supplies: Two pair of channel locks.
a) Find the 3/4" diameter top pump rod (P3) and thread it
onto the sucker rod (D2) at the well cover. With a pair of channel
locks, grip the 3/4" steel rod only near its end, being careful
not to mar the finish of the steel rod. Tighten with two pairs of
channel locks until snug.
b) Attach the lever bracket (P4) to the pump head with the 1/4"
Allen screw provided. The straight side of the bracket should be
at the top.
c) Apply Teflon tape to the male thread at the top of the drop
pipe string. Slide the pump head over the 3/4" shaft and align
and thread onto the top drop pipe (D5). Make sure the pump head
is perfectly vertical. This part is easy to cross thread. While
holding the D5 coupling with a pair of channel locks, the other
person can tighten by turning the top of the pump head.
d) Now with a 1/4" Allen wrench, find the clamping screw inside
the split flange. Lift and remove the safety tool and lower the
pump head into the split flange. This is a snug fit. Rotate the
assembly clockwise and the pump will work its way through the split
flange. Continue lowering the pump head body (P2) through the well
cap split flange (P10) until pump head is at a convenient height.
Tighten the split flange clamping screw.
e) Attach the clevis (P7) to the top pump rod (P3) and tighten
while gripping the shaft only near the end, next to the clevis.
f) Slide the link arm (P5) over the lever bracket (P4) aligning
the holes. Insert the pivot pin (P8). These go in a little hard.
A little Vaseline on the tip helps.
g) Assemble the lever (P6) to the lever link arm (P5) and clevis
(P7) using the remaining pivot pins.
You are ready to pump water!
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Section 6: Pumping Water. Finishing Touches.
It will require about one stroke for each foot of water depth to
get the water up to the pump head. 100 feet will require about 100
to 120 strokes. There is a very small bleeder hole (1/32 of a inch)
about 8 feet below your pump head, in the top drop pipe. This takes
about 15 minutes to drain and protects the pump against freezing.
Each time you go out to pump after a period of time, it will require
about six to 10 strokes to get the water back to the pump head.
The check valves in the pump cylinder allow a very small amount
of leakage over time. Over several days or weeks, you may need to
pump a few extra strokes to get the water back to the top.
Pressure Piping: The outlet nipple has hose threads on one side
and 3/4" pipe threads on the other. This allows for a variety
of possible piping configurations from the outlet. If you intend
to pressurize your house pressure tank from the hand pump, we recommend
that a check valve be installed so that the freeze protection drain
will not drain off your house pressure. Also make sure that a relief
valve is installed somewhere in the system to prevent over-pressuring.
The Simple pump can deliver well over 100 PSI, which may damage
your house plumbing if protection is not provided. In climates where
freezing occurs, protection will need to be provided to prevent
the Simple pump from freezing if piped from the outlet.
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