HP Pressure Booster Pumps 0306 User's Manual
Contents
1. This is a SAFETY ALERT SYMBOL When you see this symbol on the pump or in the manual look for one of the following signal words and be alert to the potential for per sonal injury or property damage MAMDANGER Warns of hazards that WILL cause serious personal injury death or major property damage if ignored A WARNING Warns of hazards that CAN cause serious i ersonal ITIO or death if ignored ACAUTION Warns of hazards that MAY cause minor personal injury product or property damage if ignored IMPORTANT Indicates factors concerned with operation installation assembly or maintenance which could result in damage to the machine or equipment if ignored NOTE Indicates special instructions which are important but are not related to hazards AWARNING A A WARNING A Wire motor for correct voltage See E Electrical section and Motor Data Charts S C amp D of this manual and motor nameplate Hazardous volt age Can shock burn or cause death Ground pump before con necting to power supply Ground motor before connecting to power supply Meet United States National Electrical Code and local codes for all wiring Do not handle a pump or pump motor with wet hands or when standing on a wet or damp surface or in water Follow wiring instructions in this manual when connect ing to power lines AWARNING Always disconnect power source before performing any work on or near the motor or its conn2. UIII Normally open n Y e a e To Nozzles To Drain NOTE Install solenoid valve on discharge side of pump IMPORTANT Clean all filters and strainers on a regular schedule Figure 7 i 6 FLINT amp WALLING INC 95 North Oak St Kendallville IN 46755 e www flintandwalling com a i i i l ion Installation C ontinue d Pump used to boost incoming pressure from a wall hydrant manual operation Hose Adapter A WARNING Wall Hydrant Ground motor Pressure Gauge before connecting to electrical power sup e Pressure ply Relief Valve U uol Service Tee y Hose Adapter Failure to ground motor can cause High Pressure Reinforced Hose severe or fatal electri cal shock hazard aa fo Hazardous voltage Can shock burn or A Outlet b cause death Do not ground to tie ae a gas supply line er ae l eTore connecting A to power supply High Pressure Reinforced Hose A Figure 8 CAUTION Proper rotation of pump impeller is critical on three phase motors See Motor Rotation under 115 Volts 230 Volts Operation section and Figure 12 y Single Phase gt Single Phase WIRING Line Line 1 Install ground wire and maintain this pump in accordance with your local electrical code and all other codes and ordinances that apply i m Y W Y W Consult your local building inspector El H E H for local code information L L 2 Ground the pump permanently using eI of Lo jT a a ap
3. pump motor of proper HP for each pump by referring to the following instructions 1 Follow steps as outlined under Rotary Seal Replacement and Pump Disassembly Figure 13 Remove Mechanical Seal Figure 14 Press In Seal 2 Remove cap screws that connect the motor to the mounting ring and pull motor away 3 Replace motor with standard Nema 56J jet pump motor by positioning motor against the mounting frame and assembling with four 4 cap screws IMPORTANT Because damage to the shaft seal can occur in disassembly a new seal will be necessary PUMP REASSEMBLY Before reassembling the pump carefully inspect the com ponent parts of the cartridge stage assembly looking for damage wear or heat distortion Pay careful attention to spacing direction of components and location of shims Refer to Figure 16 for proper facing and parts arrangement If damage to Stage components is evident a complete car tridge assembly or individual stage assemblies are available for replacement See Replacement Parts List 1 Reassembly should follow the reverse order of the disas sembly procedure with special care given to replacement of the rotary seal 2 Check top and bottom of o rings for damage It is recom mended that new o rings be used 3 Do not use pipe compound of Teflon tape on barrel threads The o rings will prevent pump from leaking 4 After pump is reassembled tighten the discharge head to a torque of 45 50
4. turning CCW counter clockwise DO NOT use pipe wrench on pump barrel Holding the impeller stack in place position pump in upright position standing unit on the motor end cover 6 Use the 1 4 dowel rod to hold the stages down and in place on the pump shaft Remove pump barrel 7 Slide the stages off the pump shaft onto the 1 4 dowel rod Leave stages on rod and carefully set aside NOTE There may be some small 010 shim washers located next to the pump shaft coupling Keep these shims for re assembly 8 Through the side opening of the mounting frame hold the motor shaft with 9 16 wrench Remove the shaft and coupling from the motor using the 3 8 wrench on the hex shaped pump shaft NOTE If the hex shaft comes free leaving the coupling attached to the motor use vise grips to free the coupling MECHANICAL SEAL REPLACEMENT 1 Follow instructions under Pump Disassembly 2 Remove the mechanical seal assembly a The rotary portion of the seal assembly carbon ring Buna N gasket and spring will slide easily off the end of shaft b Using two 2 screwdrivers pry the ceramic seal and rub ber gasket from the recess of the mounting ring See Figure 14 ACAUTION The precision lapped faces of the mechan ical seal are easily damaged Handle the replacement seal carefully Short seal life will result if seal faces ceramic amp carbon are nicked scratched or dirty 3 Clean the seal ca
5. ft lbs If torque wrench is not available tighten firmly but avoid distortion or damage to plastic internal parts 5 After reassembly apply power momentarily to unit 15 to 30 seconds The pump and motor should rotate freely or with a light rubbing 3 4 Pipe Press ie N Cardboard Washer Protects Sea EA Seal Face po aa ra 3 Seal Cavity 110554 Figure 15 If Necessary Press With Cardboard And Pipe FLINT amp WALLING INC 95 North Oak St Kendallville IN 46755 e www flintandwalling com Troubleshooting Chart Symptom Pump won t start or run at full speed Pump oper ates but delivers little or no water Excessive noise while pump in Pump leaks Possible Cause s Blown fuse or open circuit breaker Power supply in OFF position Incorrect voltage at motor check volt age with motor running Loose broken or incorrect wiring Defective motor Pump hydraulic components clogged worn damaged Manual or solenoid valves plumbed into system restricting flow In line filter restricting flow Low line voltage Inadequate water supply to booster pump Undersized piping Leak on inlet side of system Inadequate defective or plugged foot valve and or strainer Worn or defective pump parts or pump Suction lift too great Pump not primed Incorrect rotation motor running backwards Pump not secured to firm foundation Piping not supported Restricted inlet line Cavitat
6. 05125051 PB0512C051 PBO512A051t 13 3 8 23 3 8 PB05165071 PB07125071 PB10145101 PB10165151 PB19145201 PB27115201 PB35065201 PB27145301 PB35085301 PBO508Y031 PBO514Y051 PBO 14Y071 PB1020Y101 PB1023Y101 PB2717Y201 PB1021Y101 PB1920Y151 PBO516C071 PB0712C071 PB1014C101 PB1016C151 PB1914C201 PB2711C201 PB3506C201 PB2714C301 PB3508C301 PBO516A071 PBO712A071 PB1014A101 PB1016A151 PB1914A201 PB2711A201 PB3506A201 PB2714A301 PB3508A301 PB5504A201 PB5506A301 PB8504A201 PB8505A301 PB0508X031 PB0514X051 PB0714X071 PB1020X101 PB1023X101 PB3508X151 16 1 2 13 3 8 16 5 16 17 5 8 18 1 8 15 3 8 13 15 16 18 1 2 17 1 8 13 3 4 18 1 16 16 1 2 19 5 16 10 3 16 14 7 16 14 15 16 21 11 16 24 3 8 21 5 16 16 13 16 22 1 2 24 1 16 26 1 8 27 23 7 8 27 1 4 29 3 16 29 11 16 27 1 2 25 7 8 30 9 16 29 3 16 25 15 16 30 3 16 28 5 8 31 1 2 20 3 16 25 7 16 25 15 16 33 5 16 36 33 7 16 29 11 16 34 3 16 34 3 8 37 3 16 NOTE Figure 1 holes in mounting base are open slotted 3 8 wide x 1 2 long dimension A amp B are centerline from these open slotted holes These holes are suitable for 1 4 to 3 8 bolts Dimensions also apply to three phase models t Equipped with carrying handle 132079 handle available as an option on other models Add 1 3 8 to G if handle is included 132934 1 FLINT WALLING INC 95 North Oak St e Kendallville IN 46755 e www flintandwalling
7. 5 208 230 460 5 7 208 230 460 7 4 208 230 460 9 8 tt3 HP 3 Phase motor operable on 60Hz only Material Construction Chart E Component Standard Models Stainless Steel Models Motor Rear access Nema 56J face Rear access Nema 56J face Bearings Ball ball permanently lubricated Ball ball permanently lubricated Impellers Noryl with 304 stainless steel bearing insert Noryl with 304 stainless steel bearing insert Diffuser Noryl Noryl Diffuser plates Delrin Delrin Pump shaft 416 Stainless steel 304 Stainless steel Pump shaft coupling 316 Stainless steel 316 Stainless steel Pump shell 304 Stainless steel 304 Stainless steel Discharge amp inlet casting Cast iron 304 Stainless steel O Rings Buna N Viton Seal composition Carbon silicon carbide stainless steel spring Carbon silicon carbide stainless steel spring and Buna N and Viton Models with powder coated inlet amp discharge also available Minimum Wire Size Chart Gauge Chart F Distance In Feet From Motor To Service Panel B ker Size Volts 050 50 100 100 150 150 200 200300 moo Amps 3s m 0 0 0 3s Not economical to run in 115V use 230V 3 FLINT WALLING INC 95 North Oak St e Kendallville IN 46755 e www flintandwalling com General Safety Information Carefully read and follow all safety instructions in this manual and on pump Keep safety labels in good condition Replace missing or damaged safety labels
8. 50 HZ MI E EI fr CI ee motors 55 85 GPM Discharge Head 2 NPT 021585 ITEMS 9 amp 10 60 HZ amp 50 HZ BS Mounting Ring 2 NPT o oa NET A ALL SERIES 3 Seal Rotary w Spring ly A uot 131100 136682 seoHzasoHz OR o o o 2 131925 131925 m 136607 A Hex Head Cap Screws 3 8 x 3 4 4 121106 121106 121106 t Buna N Carbon Silicon Carbide 4 Viton Carbon Silicon Carbide m BunaN A Viton Not Shown 8 132079 Handle available as an option MATERIAL S STAINLESSSTEEL SS___ s _ PBO508SXXX_ PB0512SXXX PBO516SXXX PB0712SXXX PB1014SXXX PB1016SXXX IN A CCC e taser A A ss osa tomo 30084 130685 136086 6 emana coumacomey SEPE ester ts teo tes os ets y C7 CASTIRON CI PB1914AXXX PB2711AXXX PB2714AXXX PB3506AXXX PB3508AXXX MATERIAL POWDERCOATED PC_ PB1914CXXX PB2711CXXX PB2714CXXX PB3506CXXX PB3508CXXX STAINLESS STEEL SS PB1914SXXX PB2711SXXX PB2714SXXX PB35065XXX PB3508SXXX 5 Cartridge assomby e A A _f_ ss 139162 139163 138946 139164 13965 Ci amp Pe 137221 136624 136628 136625 136631 e _ shats couping Assembly e ST aer ee ta 7 Barrel Shell TCL PCA amp SS 137223 135628 136630 136627 136633 MATERIAL CAST IRON PB5504XX PB5506XX PB8504XX PB8505XX ITEM DESCRIPTION MATERIAL PART NUMBER PA 60 HZ MODELS Cartridge Assembly 022293 022294 022295 0222908 6
9. Operating Instructions Parts Manual FWO154 0907 Please read and save these instructions Read carefully before attempting to assemble install operate or maintain the product Sup ersedes described Protect yourself and others by observing all safety information Failure to comply with instructions could result in per 0306 sonal injury and or property damage Retain instructions for future reference Description Unpacking Pressure booster pumps increase water pressure from city mains or private water sys When unpacking the unit inspect care tems Applications include providing high water pressure for washing buildings dairy fully for any damage that may have walls or floors hog parlors poultry houses rinsing or spray cooling equipment lawn occurred during transit sprinkling and insecticide spraying Stainless steel models can handle salt water and ead ee NOTE mp with clear r contaminated water in reverse osmosis filter and other aggressive water applications 9 a ii only Single phase models are equipped with a capacitor start thermal protected motor Three phase models require separate overload protection Inlet aes Discharge J l Figure 1 IL0391 60 Hz Motor Driven Pump Dimensions See Figure 1 Chart A Stainless Powder Coated Cast Iron Dimensions In Inches Steel Fitted Cast Iron Fitted Fitted a e jc Jo je F j6 H hp PB0508S031 PB0508C031 PBO508A031t 10 3 16 19 15 16 7 3 8 PB
10. Shaft amp Coupling Assembly 022289 022287 022288 022287 Barrel Shell Cl PC amp SS 022291 022292 138151 022290 STAINLESS STEEL SS PB0508YXXX PB0514YXXX PB0714YXXX PB1020YXXX PB1022YXXX PB1023YXXX 5 Cartridge Assomby HEPC 185103 o aa 807 et ss o 138682 021033 138683 020280 138684 Shaft amp Coupling Assembly ELEPO 13561 ads e o o a CAST IRON PB1920XXXX PB2717XXXX PB3508XXXX PB3514XXXXT MATERIAL aves CAST IRON PBO508XXXX PB0514XXXX PB0714XXXX PB1020XXXX PB1022XXXX PB1023XXXX MATERIAL POWDER COATED PB1920ZXXX PB2717ZXXX PB3508ZXXX PB3514ZXXXT PB1922ZXXX STAINLESS STEEL SS PB1920YXXX PB2717YXXX PB3508YXXX PB3514YXXXT ITEM DESCRIPTION MATERIAL PART NUMBER Cl 8 PC 020982 020980 136632 021017 139435 A les 0 138949 139165 021028 7 Cl 8 PC 020971 020916 136631 021015 139434 NOM OOPS AS es T 020098 138948 139158 021020 021425 7 Bare CIPC4ss 02009 138947 136633 021016 139436 i t Cartridge assembly includes impellers diffusers and shaft amp coupling assembly Components not available individually Sold as assembly only 50 HZ MODELS 14 FLINT amp WALLING INC 95 North Oak St Kendallville IN 46755 e www flintandwalling com
11. TS WIM ILO565 POWDER STAINLESS POWDER STAINLESS ea repiaceuserworors ary easrmon como even CISTON Coan e E Ses ADENA ee NEMA J 1 2 HP EE NEMA a NEMA J 3 4 HP eee NEMA J 1 HP AoE NEMA TZ HP NEMA J 1 1 2 HP ae NEMA J 2 HP ODPNEMAJ3HP 10 Motor Coverw Screws 1 136132R_ 136132R_ 136132R_ 136132R_ 136132R 136132R NI O IE O E a NEMA J 1 3 HP 96s003_ 96003 esoo3 soo NEMA AHP NEMA J 3 4 HP AEE NEMA HP ae NEMA J 1 HP oor NEMA eye NEMA J 1 1 2 HP ODPNEMAJ2HP 10 Motor Coverw Screws 1 136132R_ 136132R_ 136132R_ 136132R_ 136132R 136132R A A e e I TEFCNEMAJ1 2HP rr TA oT o 21008 021008 021012 021012 AP NEMA J 1 HP 021009 021009 020688 020688 JEEE NEMAS HHP NEMA J 1 1 2 HP 020692 020692 020647 020647 JEE NEMAS oe NEMA J 2 HP 02093 020693 020689 020689 TEFCNEMAJ3HP Pp zt 021010 020690 020690 Not Shown 13 FLINT amp WALLING INC 95 North Oak St Kendallville IN 46755 e www flintandwalling com FORM NO FW0046 PRESSURE BOOSTER PUMP REPAIR PARTS 0907 a i i SUPERSEDES 0206 For Pricing Refer To Repair Parts Price List PAGE 4 8A REPAIR PARTS 10 7 zM EZA IL0565 POWDER STAINLESS 5 7 10 19 GPM rr e 60 HZ amp 50 HZ 2 Mounting Ring 3 4 NPT 132002 136904 136639 27 35 GPM 1 Discharge Head 1 NPT 136635 137796 139166 See 60 HZ amp
12. ance ACAUTION Disconnect power supply and depressur ize system before servicing pump or removing any compo nent ROUTINE Pump should be checked routinely for proper operation Replace or clean all filters and line strainers on a regular basis DRAINING This pump cannot be completely drained because of internal design Most of the liquid can be drained by tilting the dis charge forward after removing discharge casting or the liq uid can be drained through the inlet port Store in heated areas CLEANING If used for spraying insecticides pump should be thoroughly flushed with clean water after using LUBRICATION The motor has prelubricated bearings No lubrication is required SERVICING THREE PHASE UNITS Loctite thread sealer is used on the threads between the motor shaft and the pump shaft coupling When reassem bling reapply thread sealer PUMP DISASSEMBLY To disassemble the pump refer to the exploded parts view Figures 17 amp 18 Tools Required e Block of wood 2 x 4 x 12 Piece of 3 4 pipe 12 to 24 long Pipe wrench Strap wrench 1 4 Dowel rod about 24 long 9 16 Open end wrench 3 8 Open end wrench To stabilize pump during disassembly place block of wood underneath pump barrel Thread pipe into pump inlet port This acts as a handle 3 Using the pipe wrench remove the discharge head turn ing CCW counter clockwise 4 With the strap wrench loosen the barrel
13. ck 8 Gray 3 Orange 6 Blue 9 White CONNECTION FOR 3 PHASE 9 LEADS IF YOUR 3 PHASE LEADS ARE COLOR CODED MATCH NUMBER ABOVE TO THE CORRESPONDING COLOR NOTE To reverse rotation interchange any two incoming lines Power leads Figure 11 Wiring Diagram for Three Phase Motors Operation ACAUTION Unit must be full of fluid before operat ing Do not run dry or against a closed discharge Do not pump dirty water or abrasive liquids To do so will cause pump failure and will void the warranty VALVES The inlet valve should be in the full open position and the discharge valve should be partially open permitting some back pressure to be exerted against the pump when starting up Open valve after start up is completed PRIMING NOTE Before starting the pump it is absolutely necessary that both the pump and the inlet pipe be completely filled with water PRESSURE BOOST INSTALLATIONS Priming is automatic when pump is connected to a pressure source such as a hydrant or city main See Figures 6 7 amp 8 1 Open valves or nozzle on inlet and discharge side of pump 2 To relieve trapped air allow water supply to run a mini mum of 30 seconds before starting the pump IMPORTANT An adequate flow of water going into the pump is required so that the pumps impellers and shaft seal do not run dry and fail 3 If you installed a pressure gauge at the pump inlet a read ing of 2 psi minimum should show whenever the pump
14. com PERFORMANCE SPECIFICATIONS PRESSURE ADDED PSI 10 20 40 6o 80 100 120 140 160 180 200 Suction Powder Pipe Press Stainless Coated Cast Cast iron Output Gallons per Minute Tap Steel Fitted a Fitted PSI Iron Fitted NPT PPBososco31 PB0508A031e 18 8 95 87 73 58 35 a 7 PBO512S051 PBO512C051 PBOS12A051e 1 2 12 98 92 82 73 63 52 3 5 Peos16S071 FROR ICO PROT EROTA 3 8 16 991 95 871 80 73 65 58 PBO712S071 PBO712C071 PBO712A071e 3 4 12 14 0 134 122 10 9 95 79 6 0 Ppsiotasior Peroiacior Pstomaror 1 ia assais tirz os PB1016S151 PB1016C151 PB1016A151 1 1 2 16 147 138 129 119 108 PB1914S201 PB1914C201 PB1914A201 2 14 27 5 27 0 25 7 24 2 226 20 8 18 7 1 Pe35065201 Pa3506c201 Pessoeazor 2 6 arsar 40s 342233 PB2711S201 PB2711C201 PB2711A201 2 11 31 3 29 3 268 23 8 19 8 1 PB3508S301 PB3508C301 PB3508A301 3 8 41 5 41 1 40 9 40 0 34 2 26 4 10 0 tH PB2714S301 PB2714C301 PB2714A301 3 14 322 306 28 9 27 0 24 8 22 0 18 4 12 2 190 A ree a relists 1 E Tte gt po Bs506a301 3 6 778 744 65 0 511 319 ls gt oo PBe5o4a201 2 4 105 8 90 0 470 49 gt o PB8505Aa301 3 5 t088 e8s8 600 250 60 t Example If PB0508A031 pump is connected to s
15. e and starve the pump of water 2 The diameter of the inlet and discharge pipe should be no smaller than the corresponding ports of the pump See Figure 1 Smaller pipe will reduce the capacity of the pump Increase pipe size on long runs 3 Avoid air pockets in inlet piping or air will accumulate at high points making priming difficult 4 Use pipe compound on all joints and connections Use Teflon tape or plastic joint stik on plastic pipe Draw all pipe up tightly IMPORTANT The entire system must be air and water tight for efficient proper operation FLINT amp WALLING INC 95 North Oak St Kendallville IN 46755 e www flintandwalling com Installation PUMP INSTALLATION IMPORTANT Pump is built to handle clear water only it is not designed to handle water containing sand silt or other abrasives 1 Refer to Figures 6 7 and 8 for typi cal installations ACAUTION Support pump and piping when assembling and when installed Failure to do so may cause Piping to break pump to fail motor bearing failures etc 2 If the pump is used as part of a per manent installation bolt to a rigid foundation AWARNING Use only compo nents that are rated for maximum pres sure pump can produce when used in boosting system or any other system Do not exceed the total maximum pressure boost as listed per model in Performance Charts B PRESSURE BOOST SYSTEMS 1 On pressure boost systems locate the pump so t
16. ected load WZ__ Do not use to pump flammable or explosive fluids such as gasoline fuel oil kerosene etc Do not use in flam mable andlor explosive atmospheres t D pea Hazardous pressure Install pressure relief valve in discharge pipe Release all pressure on system before work ing on any component 1 Make workshop child proof use padlocks master switches remove starter keys 2 Wear safety glasses when working with pumps 3 Wear a face shield and proper apparel when pumping hazardous chemicals 4 Keep work area clean uncluttered and properly lighted replace all unused tools and equipment Provide guarding around moving parts Keep visitors at a safe distance from the work area Periodically inspect pump and system components Protect electrical cord Replace or repair damaged or worn cords immediately og a i 4 9 Do not insert finger or any object into pump or motor openings 10 Secure the discharge line before starting the pump An unsecured discharge line will whip possibly causing per sonal injury and or property damage or puncture ACAUTION Do not touch an operating motor or engine They are designed to operate at high temperatures A WARNING This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm A WARNING Risk of Electric Shock This pump has not been investigated for use in swimming pool areas NOTE P
17. er cord is plugged into power and will turn off whenever cord is disconnected from power MOTOR PROTECTION All single phase motors have built in thermal protection for all voltages The overload protects the motor against burn out from overload of low voltage high voltage and other causes The device is automatic and resets itself once the temperature has dropped to a safe point Frequent tripping of the device indicates trouble in the motor or power lines and immediate attention is needed A WARNING ever examine make wiring changes or touch the motor before disconnecting the main electrical supply switch The thermal device may have opened the electrical circuit Three phase motors do not have a built in thermal protec tion It is recommended that a properly sized magnetic or manual starter both with properly sized heaters be used with all three phase motors Install starters following instruc tions of the starter manufacturer See Motor Rotation under Operation Section for changing rotation on three phase motors All motors single and three phase should be equipped with a correctly fused disconnect switch to provide protec tion Consult local or United States National Electric Codes for proper fuse protection based on motor data chart See Charts C D and Wire chart F 8 Low Voltage 230V Om High Voltage 460V Q o lorena ooo oo Ly L2 Ls Lor82 bt L2 L3 1 Tan 4 Yellow 7 Purple 2 Red 5 Bla
18. hat there will always be a positive supply of water to the pump See Figures 6 7 and 8 2 For service convenience install a gate valve and union in the inlet and AUTION line ACAUTION Do not use a globe valve or other restricting type of valve that will seriously restrict the pumps discharge capacity 3 Install a check valve as shown in Figure 6 Be sure check valve flow arrows point in the direction of water flow 4 Whenever dirt sand or debris is present in the supply water install a strainer or filter on the inlet side of the pump See Figure 7 NOTE For heavy amounts of sedi ment install a trap filter on the inlet side of the pump See Figure 5 NOTE Pressure gauges installed before and after the filter will show pressure differential indicating the need for filter replacement or clean ing No Air Leaks In No Sags Sags Allow Air Pockets Pipe Joint Compound Inlet Pipe Will Damage Plastic If Air Flows Water Won t 1L0419 10418 If Air Pockets Form Water Won t Flow 10420 use Teflon Tape Figure 2 No Air Pockets in Inlet Pipe Figure 3 Inlet Pipe Must Not Leak AC AUTION Mount pump in correct position or pump failure will result Correct Incorrect MUU TL aed LLL IL0315 Figure 4A Figure 4B SAND AND SEDIMENT TRAP FILTER Standard Pressure Tank 42 Gallon Or Larger R Outlet Clean Out Sand Settles To The Bottom is Fig
19. ion noise like marbles in pump Worn motor bearings Worn mechanical seal leaks at shaft Worn o ring seals Corrective Action Replace fuse or close circuit breaker See wire size chart for proper break fuse size Turn power on Low voltage a Voltage must be within 10 of motor rated voltage Check incoming voltage Contact power company Make certain that voltage of motor matches voltage of power supply See motor name plate and motor wiring diagrams Check wire size from main switch to pump See wire size chart for correct wire size Rewire any incorrect circuits Tighten connections replace defective wires Replace motor Replace worn parts or entire pump Clean parts if required Check all valves on pump inlet and discharge sides of system to be sure they are opened properly to allow flow to and from the pump Bleed trapped air in pump which keeps water from reaching the pump Normally due to closed valve in discharge plumbing Check all in line filters to be sure they are not plugged or restricted See low line voltage corrective action above Check pressure on inlet side of booster to be sure positive pressure is maintained to the booster pump Replace undersized piping Make sure connections are tight Repair leaks as necessary Clean repair or replace as needed Replace worn parts or entire plugged impeller Clean parts if Pump should be operated under flooded suction only Prime pump Make certain i
20. is in operation See Figures 6 7 amp 8 This reading insures that there is an ample supply of water into the pump inlet housing FLINT WALLING INC 95 North Oak St Kendallville IN 46755 e www flintandwalling com Operation Continued MOTOR PUMP ROTATION 1 Single phase models are one 1 rotation only counter clockwise when facing the pump end and cannot be reversed 2 Proper rotation of pump impeller is critical for three phase pumps Pump motor should turn counterclockwise CCW when facing pump end Momentarily bump apply power for less than a second the motor to check for proper rotation To change rotation on three phase units ACAUTIC N two 2 incoming line power leads ACAUTION Do not go over recommended maximum operating pressure see Specifications while maintaining minimum flow of 1 5 GPM thru the pump Do not restrict the inlet line to the pump If driver electric motor is overloaded a valve can be installed in the discharge line to increase the back pressure and reduce driver loading START UP PROCEDURE Once the preceding instructions have been completed the pump can be started 1 During the first few hours of operation inspect the pump piping and any auxiliary equipment used in connection with the unit 2 Check for leaks excessive vibration or unusual noises Figure 12 Correct Motor Pump Rotation all units NOTE See rotation arrow on inlet casting Mainten
21. n O E O E IL0180 a wire of size and type specified W W by local or United States National Electrical Code Do not ground to a gas supply line NOTE Dual voltage motors change the red and 3 Connect ground wire first Connect gray wire to the voltage required Figure 9 Wiring Diagram for Single Phase 1 3 2 HP to ground first then to green ground Motors ing terminal provided on the motor frame identified as GRD Ground con nection MUST be made to this termi nal Do not connect motor to electrical power supply until unit is permanently grounded otherwise serious or fatal electrical shock hazard may be caused 4 Connect the other end of the ground wire to a properly grounded service panel or to a control panel ground bar if it is connected to the power supply ground IMPORTANT Check local and or United States National Electric Codes for AU i rounding information ACAUTION Make certain that the power supply conforms to the elec trical specifications of the motor sup plied See Motor Data Charts 230 Volts Single Phase Line IL0181 NOTE Single voltage 230V motor and can not be connected to 115V Figure 10 Wiring Diagram for Single Phase 3 HP Motors 7 FLINT amp WALLING INC 95 North Oak St Kendallville IN 46755 e www flintandwalling com Installation Continued 5 Specific Wiring Procedure Refer to Figures 9 10 amp 11 and Minimum Wire Size Chart a Select the voltage yo
22. nlet pipe is drawn up tight and pump and pipe are full of water Reverse motor rotation can occur on three phase units To correct interchange any two incoming power leads Secure properly Make necessary adjustments Clean or correct a Reduce speed on direct drive b Increase inlet pipe size c Too viscous material being pumped too thick Replace bearings or motor Replace shaft rotary seal Replace o ring seals located inside both ends of the stainless steel shell FLINT WALLING INC 95 North Oak St e Kendallville IN 46755 www flintandwalling com Booster Pump Parts Drawing DESCRIPTION 4 DischargeHead _ 6B_ Impeller __ 6D DiffuserBearing 6E Shim as Required 8 MountimgRing_ Y HexHead Bolts 4 See note below parts included in cartridge assembly tODP Motor Only Internal Parts Detail Joa z 0 80 IL0308 IL0593 Figure 16 Cartridge Assembly Includes Discharge Bearing Shaft amp Coupling Assembly Diffuser Plate Impellers Diffuser Bearings Diffusers and O rings NOTE Illustration shows only two stages Pump has multiple stages Individual parts are not available separately 12 FLINT amp WALLING INC 95 North Oak St Kendallville IN 46755 e www flintandwalling com PRESSURE BOOSTER PUMP REPAIR PARTS FORM NO FW004s 0907 For Pricing Refer To Repair Parts Price List SUPERSEDES 0206 Replacement Motors PAGE 4 7A REPAIR PAR
23. shock turn off power to motor before working on electrical connec tions Supply voltage must be within 10 of nameplate voltage Incorrect voltage can cause fire or seriously damage motor and voids warranty If in doubt consult a licensed electrician Use wire size specified in wiring Chart F If possible connect pump to a separate branch circuit with no other appliances on it If motor wiring diagram differs from diagram shown below follow diagram on motor Pump used to boost incoming city pressure automatic operation Street Supply Main Power Box TT Check Valve Gate Ball Valve Normally open Gate Ball Valve m Y Normally To size tank open properly Match Fuse drawdown of TT Box Or Check oa Pressure aac Switch Valve gy a Union ee 4 Service Tee Inlet Outlet z Pressure Pressure LOSUN Switch Gauge ah IL0422 E ME Za AN Y HE Pressure Relief Drain Valve Figure 6 IMPORTANT A contained air pressure tank and pressure switch is required to keep the pump from rapid cycling and prevent the motor from over heating Install the tank and switch on the house side of system Pump used to boost water pressure in mist spray applications automatic opera tion Fuse Box or Switch Pressure Gauge Thermostat Gate Ball Valve _ Ol From Water Source A o 6 EA Line Filter Pressure Gate Ball Valve Relief Valve Solenoid
24. u are to use either 115V or 230V single phase 230V or 460V three phase b The 1 3 1 2 and 3 4 HP single phase pumps are factory connected for 115V at the motor The 1 112 2 and 3 HP pumps are factory connected for 230V at the motor Three phase models are factory connected for 230V at the motor c If the motor wiring must be changed to conform to your specific voltage requirements then the motor pressure switch or other controls should be rewired to conform to one of the wiring diagrams either 115V or 230V single phase 230V or 460V three phase Single phase 3 HP motors are 230V only and cannot be wired for 115V service d The motor wiring diagrams are Figures 9 10 amp 11 and also are located on the motor label of the pump 6 Remove the rear access cover of the motor 7 Make the wiring change and replace the rear access cover A WARNING Replace rear access cover before starting or operating pump Failure to do so can result in personal injury IMPORTANT Do not use an extension cord or splice wires Joints should be made in an approved junction box If the above information or the following wiring diagrams are con fusing consult a licensed electrician 8 All units are not supplied with pressure switches float devices on off switches or the like control devices Controls should be wired in at this time utilizing whatever instructions come with the controls All units supplied with cords will run whenev
25. umps with the CSA CUS mark are tested to UL stan dard UL778 and certified to CSA standard C22 2 No 108 Pre Installation HANDLING 1 Use handle supplied to lift pump 2 Avoid impact on pump or motor In particular avoid impact on discharge end of pump or rear motor access cover LOCATION A WARNING In any installation where property dam age andlor personal injury might result from an inoperative or leaking pump due to power outages discharge line block age or any other reason a backup system s should be used 1 Locate pump as close to the fluid source as possible keep ing the inlet pipe short as possible 2 Place unit where the pump and piping are protected from the weather and extremes of heat humidity and below freezing temperatures 3 Mount unit in a dry location that is easily accessible for inspection and maintenance If a dry location is not avail able mount it on a foundation well above the wet floor 4 Allow ample clearance around unit for free air circulation SUCTION LIMITATIONS 1 Units are non self priming 2 Pressure booster pumps are not recommended for suction lift applications PIPING 1 Use galvanized piping rigid plastic or other suitable pipe that will not collapse under suction or rupture due to pres sure ACAUTION If hose is used make sure it is the rein forced industrial type that is rated higher than the shutoff pressure of the system Ordinary garden hose will collaps
26. upply line of sufficient capacity carrying water at 40 PSI and the output of the pump is held to 7 3 GPM by a gate valve the pump will add 40 PSI to line pressure for a total output pressure of 80 PSI Operation of pump in this range may result in reduced pump life and or motor damage To keep pump and seal lubricated a minimum flow of 1 5 GPM must always be maintained through the pump Motor voltage Single Phase 1 3 2 HP 115 230 3 HP 230V 60 Hz Three Phase 1 2 2 HP 208 230 460 50 60Hz Three Phase 3 HP 208 230 460 60 HZ For three phase models use suffix 3 on the model no Example PBO512A053 e Handle included with these models only so E 3 5 6 3 63 r of Single Phase Motor Data 60HZ Chart C Single Phaset 60 Hz 3450 RPM Capacitor Start Factory Service Factor Motor Locked Rotor Motor Motor Connected Amps Amps Voltage Motor CORE ECELER Voltage 115 230 115 230 115 230 115 230 115 230 115 230 230 Single Phase Motor Data 50HZ Single Phaset 50 Hz 2850 RPM Capacitor Start 115 230 115 230 115 230 115 230 230 tThermal overload protector automatic reset 2 FLINT amp WALLING INC 95 North Oak St Kendallville IN 46755 e www flintandwalling com Three Phase Motor Data Chart D Three Phaset 60 50 Hz 3450 2850 RPM Capacitor Start Factory Service Factor Motor Locked Rotor Motor Motor Connected Amps Amps Code Letter Voltage Motor 208 230 460 3 5 208 230 460 4
27. ure 5 l IMPORTANT Clean all filters and strainers on a regular schedule 5 FLINT amp WALLING INC 95 North Oak St Kendallville IN 46755 e www flintandwalling com Installation Continued 5 A pressure gauge installed in the inlet pipe close to the inlet port See Figure 6 will show if enough water is being supplied to the pump See Operation Section Priming Pressure Boost Installations 6 On installations that are using noz zles for mist spraying install a filter in the discharge plumbing to prevent the nozzles from becoming plugged Multiple filters should be plumbed in parallel AWARNING Install a pressure relief valve on any installation where pump pressure can exceed the pressure tank s maximum working pressure or on systems where the discharge line can be shut off or obstructed Extreme over pressure can result in personal injury or property damage ACAUTION This unit is not waterproof and is not intended to be used in showers saunas or other potentially wet locations The motor is designed to be used in a clean dry location with access to an adequate supply of cooling air Ambient tem perature around the motor should not exceed 104 F 40 C For outdoor installations motor must be protected by a cover that does not block airflow to and around the motor This unit is not weatherproof nor is it able to be submersed in water or any other liq uid To avoid dangerous or fatal elec trical
28. vity of the mounting ring and the motor thoroughly 4 Wet outer edge of rubber cup on ceramic seat with liquid soap solution Use sparingly one drop only 0 0 0 90 N UI FLINT amp WALLING INC 95 North Oak St Kendallville IN 46755 e www flintandwalling com Maintenance Continued NOTE Liquid soap solution one drop of liquid soap com bined with one teaspoonful of water 5 With thumb pressure press ceramic seal half firmly and squarely into seal cavity Polished face of ceramic seat is up If seal will not seat correctly remove placing seal face up on bench Reclean cavity Seal should now seat correctly See Figure 14 6 If seal does not seat correctly after recleaning cavity place a cardboard washer over polished seal face and carefully press into place using a piece of standard clean 3 4 pipe as a press See Figure 15 IMPORTANT Do not scratch seal face 7 Dispose of cardboard washer and recheck seal face to be sure it is free of dirt foreign particles scratches and grease 8 Inspect shaft to be sure it is free of nicks and scratches 9 Apply liquid soap solution sparingly one drop is suffi cient to inside diameter of rubber rotating member 10 Slide rotating seal member carbon face down toward ceramic face and spring over the shaft IMPORTANT Do not nick or scratch carbon face of seal when handling MOTOR REPLACEMENT The motor can be replaced with any standard Nema 56 jet
Download Pdf Manuals
Related Search