How to choose a cable for a well pump, what to look for

The cable is an important part of well pump setup that is frequently disregarded. Selecting the appropriate cable is crucial to guaranteeing the safe and effective operation of your well pump. A weak cable can cause problems with performance or even put the pump in danger because it connects the pump to the power source.

There are a number of things to take into account when choosing a cable for your well pump. Important things to consider are the cable’s length, gauge, kind of insulation, and the particular needs of your pump. Every one of these elements contributes to making sure that the electricity flowing to the pump is consistent and dependable.

Environmental factors should also play a role in your decision. It’s critical to select a cable that is waterproof and strong enough to endure rough conditions over time because it will be submerged in water. In order to avoid electrical problems and guarantee long-term safety, proper insulation is essential.

Making an informed choice will be made easier if you comprehend these components. You can safeguard your investment and make sure your well pump keeps working properly for many years to come by taking the time to select the appropriate cable. Let’s get into the specifics of what to consider when choosing a well pump cable.

Aspect	Details
Cable Type	Use a submersible pump cable, designed to be waterproof and durable.
Cable Size	Ensure the cable is thick enough to handle the pump"s power without overheating.
Wire Gauge	Check the pump manual for the recommended wire gauge to match the pump"s electrical requirements.
Cable Length	Measure the distance from the power source to the well and add some extra length for flexibility.
Insulation Quality	Look for cables with high-quality insulation to prevent damage from water and soil.
Temperature Rating	Choose a cable that can withstand the temperature changes in your area.

Cable Requirements

Every cable product needs to come with a certificate. It lists every feature that the product possesses. But all of its assertions must inevitably line up with reality. If not, the cable won’t be able to function effectively and dependably under the circumstances for which it was intended to be used. Consequently, even if an item’s price is extremely alluring, you should avoid purchasing it from questionable retail establishments.

The following are the primary cable specifications for submersible pumps:

• Possesses waterproof insulation.
• Ability to withstand high water pressure.
• Compliance with GOST R51777-2001.
• Compliance with SanPin standards for contact with drinking water.
• Possessing the required cross-section to operate at a given load.

Deep cables are also needed for submersible pump secondary requirements. They are equally significant, though. Take its length and flexibility, for instance. The first parameter is directly impacted by the separation between the power source and the connection point. The wire cross-section that is chosen is thicker the longer the distance.

If you need to build up the wires, the number of connections on the line also affects how well it operates. Furthermore, the electrical main’s dependability decreases with the number of such points. As a result, you must measure the future route precisely and buy the necessary quantity of cable in one piece.

In actuality, flexibility is secondary. Both the wire’s thickness and the sheath’s composition have an impact. It is important to consider that the cable should be able to easily pass into the well and not obstruct future maintenance when selecting its diameter. For instance, in the event that a pump needs to be quickly raised for maintenance or repair.

Consequences of making the wrong choice

Such a cable should not be used at all if the product certificate does not list a feature like water resistance. The operation of all equipment is seriously at risk if you accept the seller’s claims that the wires have excellent insulation.

PVS cables may only be used indoors; they have simple vinyl insulation covering their wires. The electric motor will unavoidably fail if they are used in a well. In addition, a burned-out motor might not even be salvageable.

Wires that have been improperly calculated or chosen with an inadequate cross-section will frequently overheat. The insulation melting process will start sooner the longer the machinery runs to pump water out of the well. Additionally, the cable will experience an unpredictable short circuit due to the loss of its fundamental defense. The worst-case scenario would be for the house’s entire electrical system to fail.

If the power phase is not considered, the cable may overheat and short circuit. Three-core wires will soon be unable to support the load when connected to a three-phase source. The effects will impact all of the building’s wiring in addition to the pump motor.

A wire gauge that is too small causes performance loss. The network will experience a rise in resistance. As a result, power declines. Additionally, the pump won’t be able to operate at its peak efficiency if you don’t receive as much as you require.

If the insulation on the cable is not up to sanitary codes and it is used as a drinking well, then everyone who uses the source in the house could be in danger. Every object that comes into contact with food needs to be marked with a stamp attesting to its total safety. Inevitably, most insulations release a variety of toxins. As a result, cable products are clearly divided into two categories: industrial and household.

To guarantee the longevity, effectiveness, and safety of your pump system, it is essential to select the appropriate cable for your well pump. The material, insulation, and gauge size of the cable should all be taken into account when choosing one. Choose a cable that is corrosion- and water-resistant; for optimal conductivity, it is usually composed of copper. Make sure the insulation is strong enough to endure electrical demands and subterranean conditions. Finally, in order to avoid overheating and guarantee optimal performance, the gauge size needs to correspond with the pump’s power requirements. You can make an informed choice that will maintain the smooth operation of your well pump by concentrating on these important factors.

Market offers

Let’s look at the well-known brands of submersible pump cables that a reputable manufacturer offers. The last statement’s veracity attests to the product’s warranty’s existence. Additionally, the wires’ quality improves with length.

For instance, top-notch pumping equipment is produced by the Pedrollo and Aquarius brands. However, they went above and beyond by starting to produce premium electrical cables that are ideal for their primary products in every way. Additionally, they add connecting components and steel cables to their pumps, which are additional little necessities.

Additionally, renowned Danish manufacturer Grundfos creates a unique underwater cable specifically for its deep-well pumps. Furthermore, it equips each of its pumps with electric motors that it manufactures itself. addresses their components as well.

runway cable

Excellent quality home products. includes centrifugal pumps of the ECV type. The name decoding reveals that the cable is submerged in water (B), that the core insulation is composed of high-density polyethylene (P), and that polyethylene (P) makes up the outer sheath.

Stranded copper core is used in the wires. When compared to products with solid wire, this results in a very flexible cable. You should consider the fact that this type of cable is single-core when making your selection. Consequently, when doing calculations, we must remember this feature. The core can be made of aluminum if desired. The name in this instance has a capital "A" added to it.

Ideal for networks using 50 Hz AC frequencies and voltages up to 1000 V in electrical terms. withstands 6.86*106 Pa of pressure. withstands temperatures between -40 and +80 °C well. has a second class of flexibility, but it requires fixed installation.

A 2.5-year warranty is offered by the manufacturers, and it is advised to get a new cable every 6 years. However, you must also consider the surrounding temperature. Only 32,000 hours will be left in the service life if the temperature reaches +50 °C. Additionally, it decreases twice more after the permitted maximum is attained.

From 1.2 to 70 mm2, the cross-sectional size range is extremely broad. The name needs to specify this parameter. For instance, the VPP-2.5 submersible pump cable features a core that measures 2.5 square millimeters in cross-section. 1000 MOhm is the insulation resistance at 380 V. additionally between 660 and 2500.

The outer sheath of the cable designated ERW is different from the one before it. It is vinyl (PVC) that he owns. It operates within a narrower temperature range of -15 to +65 °C. Furthermore, only stationary installation is necessary. VPPO cables must be used in locations where stray currents are present. Its copper wire winding between the cores and the shell sets it apart from other examples of its class. It eliminates electrical interference and serves as a shield.

KVV cable

The drinking wells are served by the series. According to the name’s decoding, this is a control cable with a PVC plastic outer sheath and core insulation. Additionally, there is a water-blocking winding between the wires and the outer insulation. If there is damage to the shell, she can assist. Water-submersible use is the primary function, but it can also be used for any kind of indoor or outdoor installation.

The number of cores in the cable varies, ranging from three to five. Copper is the only material used in their production. As a result, cables’ flexibility class rises to 4. However, the cable falls into the third flexibility category if the core cross-section is greater than 6 mm2. It is even utilized in artesian wells because of its resistance to extremely high pressure. Additionally, a dive site may only be as deep as half a kilometer.

Intended to function in a network with an alternating current frequency of up to 400 Hz and a voltage of no more than 660 V. Unlike the runway series, it is intended to last for 25 years of operation. Additionally, the temperature range for operation is -40 to +70 °C. It is possible to use movable or fixed installations. A design with a smaller diameter for the neutral wire is available for purchase.

Round cable shape, that is. However, there is a flat variant as well. KVV-P is the marking on it. Nothing else about the prototype is different. Additionally, there is a power model that is approved for use in drinking water and has a shell made of ethylene propylene rubber (EPR). Because of it, even at temperatures above normal, the conductors are able to maintain their throughput. Additionally, the flexibility class hits 5. KVR is marked.

KG cable

The product, or flexible cable, satisfies all requirements for drinking well use. is completely incapable of absorbing moisture and is unaffected by the organoleptic properties of water. In other words, it falls under the food category.

Acceptable for voltages up to 660 V in electrical networks. maintains all of its characteristics between -40 and +50 °C. features an outer sheath and conductive cores braided in rubber. It can be submerged up to 50 meters below the surface.

Additional letters that designate specific features may be present in the marking. "T" indicates that tropical climates are appropriate for using the cable. "HL" indicates that the item is intended for use in colder climates. The letter "N" designates flame-retardant insulation.

KPBC-90 cable

Its extremely potent parameters limit its use to the industrial sector. It can be utilized, for instance, in networks with voltages as high as 3300 V. It can function in harsh environments with up to +90 °C ambient temperatures.

Because armor consisting of galvanized steel tape protects it, it can bear heavy mechanical loads. The majority of uses are in oil wells. It is guaranteed by the manufacturer for a minimum of 18 months.

PVS cable

Decoding the abbreviation is as easy as pie. "P" indicates that a wire is present. "V" denotes the vinyl sheath enclosing the core. It is also intended for connection, according to "C." In the latter instance, it is acknowledged that the cable functions admirably as an extension cord for joining electrical appliances to the grid or to one another.

Possesses exceptional flexibility due to its copper cores and highly elastic insulation. The wire itself has a very wide cross-section range. actually for every situation. outstanding for networks that are either single-phase or three-phase. Range of operation: -25 to +40 °C. 6-year service life and a 2-year warranty are included.

Compared to all the above, PVS cable is far less expensive. for a single, straightforward reason. He’s not a big fan of moisture. Long-term storage in water renders its insulation useless. Thus, connecting it straight to a deep-well pump is strictly prohibited.

Many owners of plots with wells turn to cheap tricks because waterproof cables are costly, especially for drinking wells. Purchase wires that are precisely the well’s depth, with a water-repellent shell. Additionally, they already use regular PVS cable as an extension cable on the surface. to attach a power source to pumping apparatus.

Two things about the cables’ parameters that require extra attention. This portion of the insulation surrounding the conductive core. As a result, knowing how to compute the ideal wire diameter and comprehending the components used to make the shell are crucial.

Selection of section

It is crucial to consider the conductive core’s thickness. The effectiveness of productive equipment depends on its proper selection. The electrical circuit’s resistance will start to rise if there is not enough core section. This will result in a portion of the power being used for heat release (heating heating).

It will have an impact on the pump’s productivity. It won’t perform to its full potential if it gets less power. There will also be damage to the wires’ insulation. The protective properties will be diminished by a slow drying process. And there’s a risk of a short circuit here.

In order to compute the cross-section, the following parameters must be known:

• Power consumption of pumping equipment during operation.
• Pump current load.
• Distance from pump to power source.
• Nature of the electrical network (single-phase or three-phase).

Tabular data

With ready-made tabular data, determining the necessary wire cross-section for a well pump is the simplest method. Numerous references to them can be found in different books. Additionally, they fairly precisely list all the prerequisite parameters. The picture provided shows two of them.

Finding the necessary wire cross-section in the table is quite easy if you know how much power your pump uses and how far it is from the power source. For instance, you would need a cable with a core cross-section of 2.5 mm2 if you needed to connect a 1.1 kW electric motor to a 60-meter-distance single-phase electrical panel.

Then there are basic guidelines for electricians. A three-wire cable is used to connect to a single-phase network, and a four-wire cable is used to connect to a three-phase network. In the first scenario, the cross-section needs to grow by 0.5 mm2 for every 10 meters that the distance to the power source increases.

Additionally, you must bring a cable with a wire cross-section of 3 mm2 to the shield, which is 70 meters away, when using a pump of the aforementioned power. Additionally, a core with a cross section of 4 mm2 will be required if the line reaches a length of 100 meters. It is important to remember that the area of the net diameter of the core, devoid of insulation, constitutes the cross-section of the wire. Furthermore, it shouldn’t be mistaken for the cable’s actual thickness.

A core with a cross-section of just one square millimeter is required for a three-phase motor of the same power, but the cable needs to have four cores. In addition, the highway may be extended for a maximum of 200 meters. Additionally, use a 1.5 mm2 wire after this length.

Using Formulas

The amount of voltage loss must be considered when selecting the proper cable for a well pump. This will mostly impact how the electric motor operates. The voltage drops in the network increase with its distance from the power source.

Losses should, in theory, not exceed 5% of the initial value. However, skilled electricians advise lowering this number to 3 in real life. in order for reserves to be available to counteract peak circumstances.

With specific formulas, tabular data can be examined. In order to accomplish this, we search for a parameter like current load in our pump’s technical data sheet. It will be 7.3 A for a motor with 1.1 kW. Additionally, you must ascertain copper’s resistivity. This constant is equivalent to 0.0172 Ohm×mm2/m.

Everything else is easy. We start by measuring the chosen wire’s resistance. In this instance, we must divide the result by the core’s cross-section (2.5 mm2) and multiply the resistivity of copper (0.0172) by the pump’s distance from the power source (60 meters). Consequently, we obtain the subsequent figure: 0.4128. Furthermore, the result needs to be multiplied by two because the current passes through one core and then returns through the other. This indicates that the chosen cable has an ohm resistance of 0.8256. For convenience, round up to 0.83.

After that, it is simple to calculate the voltage loss by multiplying the resistance of the entire cable (0.83) by the current load (7.3). The voltage loss will be shown by the resultant figure, 6.059. The next step is to determine if this value matches the allowable percentage. We divide it by 100% after multiplying it by the voltage in the home network (220). The outcome is 2.75. This indicates that the 2.5 mm2 wire cross-section that was chosen is perfect for our circumstances. However, the cross section needs to be increased if the result was greater than three.

Insulation

The material used for the deep-well pump’s cable sheath is:

• rubber;
• polyethylene;
• PVC;
• fluoroplastic.

The flexibility of the rubber-braided cable is excellent. Synthetic or natural raw materials, such as rubber, are both possible. But there’s a significant drawback to the rubber shell, no matter where it comes from. In comparison to other materials, it wears out quickly.

Because polyethylene insulation perfectly withstands exposure to a variety of harsh environments, it is thought to be very reliable. Elevated temperatures are perfectly tolerated by vulcanized polyethylene. It is not advised to use the common analog in extremely hot environments. because the material becomes unstable when heated.

Out of all the insulation types, PVC is the least expensive. During production, plasticizers are added to give it enough elasticity. Additionally, they somewhat lessen the material’s entire range of protective qualities. Nonetheless, they can completely shield current-carrying conductors from moisture.

Furthermore, the fluoroplastic shell is thought to be the best. The cores are coated with material during the manufacturing process and then heated. "Baking" produces insulation that is resistant to thermal, mechanical, and chemical influences. Furthermore, fluoroplastic is a great material for drinking wells and is entirely neutral.

All the materials can be formally categorized as food grade. However, this does not imply that using any kind of waterproof cable in a drinking well is acceptable. And regardless of what this product’s seller says, you have to request a special certificate to verify the words. Furthermore, in accordance with European norms.

Nations that provide these certificates of hygiene:

• Britain – WRAS.
• France – ACS.
• Italy – TIFQ.
• Germany – KTW.

Couplings

Use a heat-shrinkable version of the fill-type coupling or a waterproof one to connect the cable to the pump. The first approach is thought to be the best. However, the design has two flaws. The first one is minuscule. The idea is to give the compound a full day to solidify before lowering the pump into the well after the wires have been connected.

The second issue is that three couplings must be used simultaneously when utilizing a three-core wire. This might prohibit the diameter of the casing. Additionally, staggered connection placement will unavoidably result in skew in the pump. In the well, there will also be beats. Furthermore, this is not acceptable.

Using the 91-NBA series filler coupling solves problems. All three contacts can be reliably created in a single housing thanks to the design. Scotchfil compound is included in the coupling kit. It completely seals all joints after pouring and polymerization and further insulates the wire connection.

The heat shrink sleeve is an elastic vinyl sleeve with an internal adhesive layer that is waterproof. It is filled with one end of the wire. Subsequently, the sleeves are pushed onto the contact point and the cores are twisted. The vinyl tube then grips the wire connection firmly while being heated over an open flame.

The cost of this method is marginally less than that of a coupling. Experts caution against applying too much pressure to this connection, though. Additionally, the heat-shrink sleeve’s service life starts to rapidly decrease at depths greater than thirty meters.

Consequently, the surface is the ideal location for its application. Additionally, you can relyably connect a waterproof cable to a standard PVA wire with its assistance. The waterproof cable will be installed from the pump’s power source. You can save a ton of money on materials this way.

Video description

The following video will demonstrate how to use heat-shrinkable sleeves to extend the cable of a borehole pump:

Without a coupling

A unique terminal block is present in certain wellhead designs. It enables you to connect a cable to a pump without the need for couplings. You must prepare the wire ends as normal before using it. In other words, remove the insulation about 10 mm from the edge.

After that, the cables are put into the block using the "friend opposite friend" principle. Reliable contact is ensured by a clamping bolt. However, if the fastening is too tight, the wire may flatten into tiny wires, which will impede communication.

Additionally, sparking happens in the terminal block when the bolt is not tightened enough. Here, the oxidation processes start. Additionally, the block itself may melt with time. For this reason, master plumbers would rather not use a modernized head. However, they employ one of the coupling-based techniques.

Pump components

Apart from selecting the appropriate cable for pumping equipment, there are a few other considerations that must be made. They’re all connected to convenience, security, and productivity. Let us examine them, beginning with the electrical component.

The pump motor could be negatively impacted by small voltage spikes in the home network. Engine speed is increased by even slight voltage increases. Additionally, adjusting to abrupt changes in operating conditions speeds up wear. As a result, it is advised to install an inverter (frequency converter) on the apparatus.

This addition will never again cause hydraulic shocks and will dependablely protect the engine. Additionally, it eliminates all of the well’s dynamic vibrations. A temperature sensor is a must for the inverter, and the only way to connect it is via a thermal relay.

A gasoline generator is a handy tool to have on the farm. It will be useful when there are power outages. Furthermore, it will be absolutely required in any area where a power line has not yet been installed. However, the above-mentioned frequency converter must be included in the kit in order for the equipment to function.

Apart from electrical engineering, you also have to consider how convenient it is to perform repairs or preventive maintenance. We are referring to the capability of rapidly and simply extracting the pump from the well. Certain owners don’t think twice about pulling the pump by the power cable or the water supply hose.

But the risks are very high. First, there could be a break in the wires as well as the hose. Second, this will unavoidably cause the pump to skew and increase the chance that it will become stuck in the casing pipe. It is also very difficult to prevent such an accident.

As a result, the pump has a safety rope attached to it. Furthermore, the pump has a unique ring. In order to prevent distortions during lifting, it is also clearly centered. The end of the cable ought to have a clamp on it. In order to prevent it from sagging but without becoming tense, the other end of the safety rope is fastened near the well head.

The weight of the pumping apparatus is taken into consideration when choosing the cable’s diameter. Furthermore, consideration is given not only to the pump but also to the hose, power cable, and safety rope’s own weight. Additionally, we can’t overlook the reserve. As a result, the approximate weight calculation is increased by two to three times, just in case. And they already select a trustworthy cable based on these criteria.

Video description

The following criteria are demonstrated in the video when choosing a wire for submersible pumps:

Selecting the appropriate cable for your well pump is essential to guaranteeing its effectiveness and durability. The type, size, material, and insulation of the cable are important considerations. By making sure these parts match your well pump’s specifications, you can help prevent problems like voltage drops and overheating.

Gaining an understanding of the operating environment of the cable is crucial. Well pumps are frequently submerged in water or placed in humid environments, so the cable needs to be corrosion-resistant and waterproof. This lessens the need for regular maintenance or replacements by ensuring safe and dependable operation over time.

Furthermore, the cable’s length is a major factor in your choice. Larger gauge cables are needed over longer distances in order to maintain proper voltage and avoid power loss. Always refer to the manufacturer’s instructions and, if necessary, professional assistance to ascertain the appropriate cable size for your particular configuration.

In summary, you can help ensure your well pump runs effectively and safely by carefully choosing a cable based on its type, size, material, insulation, and environmental suitability. You can safeguard your investment and steer clear of typical problems brought on by making the wrong cable selection by paying attention to these details.

Video on the topic

How to EXTEND a CABLE for a well PUMP to extend a water submersible wire

Connecting a well pump cable with HEISSKRAFT heat shrinks

Selection of cable core cross-section – Water supply for a private house

How to connect submersible cable for submersible pumps

Well pump cable connection

Selecting a cable for a submersible pump