NEMO SOLAR DC SUBMERSIBLE WELL PUMPS

SERVICE

NEMO SERVICE GUIDE
PREFACE: Previously, NemoPumps.com sold Nemo case-only kits for do-it-yourself assembly of a Nemo Case to a Flojet pump. This is an edited version of the original detailed assembly and dis-assembly instructions that were included with the kit. Although there have been various design upgrades over the years and this guide is not entirely representative of the current model of the Nemo Submersible Pump, it remains a practical overview and general guide to the construction and servicing of Nemo Submersible Well Pumps.
FLOJET PUMP OVERVIEW: Virtually any standard Flojet 2100 series pump can be fitted into a Nemo Submersible Case. However, within the 2100 series are numerous model numbers which signify a considerable range of different features. The most relevant pertain to voltage, motor load (amps), flow (GPM), and lift (head/pressure). Matching these factors to the specific conditions of the installation site can enhance the performance and longevity of the Nemo/Flojet pump unit. Since most sites dictate that voltage and head are somewhat static conditions, the main focus is therefore further narrowed to finding a balance between the directly proportionate factors of motor load and flow. The primary mechanism that links motor load and flow is the pump head cam. The size of the cam (designated by a number) determines the load/flow proportion at any given head and RPM. (Although motor RPM is a factor that does directly alter the equation, the degree of difference between most motor RPM ratings of 2100 series pumps is either marginal or nonexistent.) Ranging from minimum to maximum flow, there are 5 corresponding cam sizes used in Flojet 2100 series pump heads: #4 is minimum, #1 is low, #0 is medium, #2 is high, and #5 is maximum. In short, matching the pump to the site is primarily a matter of selecting a Flojet pump with a cam sized to lift an adequate flow of water to the required height without overloading the motor. In rule-of-thimb practice this normally translates into lower flow cams for high heads and higher flow cams for low heads.
EACH NEMO CASE IS COMPRISED OF THE FOLLOWING PARTS:
(1) ALUMINUM CASE
(2) MAIN GASKET
(3) RED + BLACK WIRE LEAD/PLUG ASSEMBLIES
(4) WIRE LEAD CRIMP CONNECTORS
(5) ALIGNMENT WIRES
(6) 1/2" OUTLET ADAPTER
(7) S.S. FILTER
(8) OUTLET PLUG
Other parts and tools required for the assembly/dis-assembly are as follows:
(A) FLOJET 2100 SERIES DUPLEX DIAPHRAGM PUMP
(B) ELECTRICAL TYPE CUT/CRIMP PLIERS
(C) MEDIUM PHILLIPS HEAD SCREWDRIVER
(D) ADJUSTABLE WRENCH OR PLIERS
(E) PVC ELECTRICAL TAPE
(F) MARINE GRADE SEALANT (3M 5200 FastCure)
(G) MEDIUM NEEDLE NOSE PLIERS
(H) DRILL AND BIT.
STEP 1: READ EVERY WORD and study every illustration of this entire document and identify each part, tool, tool use, and procedure required to perform each step in sequence. Notice that, where required, written step numbers correspond with illustrations designated by the same numbers.
STEP 2: STRIP FLOJET PUMP of extraneous exterior parts. Depending on Model #, the Flojet may have a base mounting plate, a pressure switch, and various outlet and inlet plugs and/or adaptors. Such parts are easily removed - mainly by simply unscrewing them from the basic motor/pump unit. The electrical wires should be cut at the point about 3" from where they emerge from the bottom of the pump motor. AC pumps have black and white, rather than black and red, motor wires and also have a removable, snap-off, green ground wire.
STEP 3: DRILL TWO WIRE ACCESS HOLES in lower section of pump head housing. Use a 3/16" drill bit. The lower section of the pump head housing is fastened to the pump motor by two deeply recessed screws. Each hole should be drilled (at a point 7/8" below the rim top of this lower section) through each side of the housing so as to emerge into each recess at a point just above the head of each screw.
STEP 4: INSTALL WIRE LEAD ASSEMBLIES. Feed the short end of the black wire lead assembly through the top of one of the two holes of the upper housing. Lightly lubricate the rubber plug with sealant and insert it into the hole. Using fingers and pliers, pull the wire and squeeze, press, and twist the plug into the hole until just 1/4"+/- of the plug remains protruding out of the top of the hole. Repeat the same procedure to install the red wire lead assembly into the other hole of the housing. The wires emerging from the bottom of the pump motor should be reduced to a length of about 3". Flatten and tape wrap the wire leads and the short spacer wires to the pump motor so that the 4 wires are equally spaced and aligned around the circumference of the motor; so that the wire leads can be connected to the motor wires and the spacer wires will function to center the pump in the case. Crimp connect the wire leads to the motor wires and neatly tape the connected wires to the bottom of the pump motor so that no wires pass over the bearing housing protrusion at the center bottom of the pump motor.
STEP 5: INSTALL PUMP IN PUMP CASE. Lightly coat the 1/4" wide top rim of the lower housing section with sealant and evenly place the top half of main gasket band so that it is evenly centered around said 1/4" wide top rim. Lightly coat the inside rim of the case with sealant. While keeping the band positioned, carefully commence to insert the pump into the case. Remove one of the 4 screws that hold the upper housing to the lower housing. (This is to let air escape from the case during the now imminent final compression fit.) Place the encased pump upright on a stable solid flat surface (such as a floor), and check that the band is evenly positioned in and around the top rim of the case. Place the gloved or similarly protected palms of your hands over the top of the pump head and, using your whole weight, press the pump the entire remaining distance (about 1/4" to 3/8") into the case. The gasketed rim of the lower housing section is thereby compressed into the case to a position slightly below the top of the case rim. At this point the pump will stop, as it cannot be pushed further into the case.
STEP 6: SECURE UPPER HOUSING. Into the screw hole, from which you removed one of the 4 screws to allow air to exit during compression (step 5), dab some sealant. Then heavily coat the screw shank with sealant and screw it into the hole until lightly snug. One at a time, remove each of the other 3 screws and repeat above procedure. Then evenly and firmly tighten down all 4 screws (minimum torque - 30 in/lb - but do not use excessive, thread-stripping, force).
STEP 7: INSTALL (a) OUTLET PLUG, (b) OUTLET ADAPTOR, AND (c) FILTER. (a) The side outlet of the pump head is marked with a molded arrow directly above the outlet. Lubricate the recessed hex headed threaded (black poly) plug and screw it firmly into the indicated (arrow) outlet with an Allen wrench. (Caution: over tightening and /or the use of a metal plug can cause the outlet wall to crack and render the head useless.) (b) Screw the 1/4" x 1/2" outlet adaptor, (coat the threads with sealant), into the threaded outlet on top of the pump, and snugly tighten with wrench. (c) Slightly compress the s.s. filter screen and insert it into the threaded inlet hole on the side of the pump head opposite the hole plugged in "b" above.
STEP 8: CAREFULLY REVIEW PREVIOUS STEPS to confirm that unit has been properly completed. Allow ample time for sealant to fully cure prior to installation of pump into well.
DISASSEMBLY: To access a Flojet pump for servicing or replacement, the pump can be removed from the Nemo Case in the following manner: In the side of the jaws of an appropriately sized pliers (medium needlenose recommended), firmly grip a part of the exposed top edge of the main gasket and stretch it upward. ( In some cases, the Flojet pump head may need to be removed and 2 pairs of pliers may be required to secure a good grip on the gasket.) Twist the pliers so that the gripped part of the gasket becomes increasingly stretch-wound around the head of the pliers. A repetition of this stretching process thins and thus incrementally loosens the gasket and thereby frees it, and thence the pump, from the case. After disassembly the original main gasket may be reusable but replacement gaskets are also available from NemoPumps at no charge. To disassemble and service a Flojet pump, first cut the wires at the connections near the bottom of the motor, remove tape and wire leads from sides of motor, pull out wire leads from pump head, then refer to Flojet documents included with pump.