Flint & Walling Commander Pro 300 User Manual
OWNERS GUIDE TO
INSTALLATION AND OPERATION OF
4” — 35-85 GPM and
6” — 50-250 GPM
8” — 325-400 GPM
SUBMERSIBLE PUMPS
WARNING
IMPORTANT SAFETY INSTRUCTIONS
RULES FOR SAFE INSTALLATION AND OPERATION
FW1184
0309
Supersedes
0408
1. Read these warnings and instructions carefully.
Failure to follow them could cause serious bodily
injury and/or property damage.
2. Follow all local electrical and safety codes as well
as the National Electrical Code (NEC) and the
Occupational Safety and Health Act (OSHA).
3. The power supply should be a separate circuit,
independent of all other circuits. Be sure it is
equipped with a fuse and disconnect box of
ample capacity.
4. For fire protection, the power supply should be
free of any building, preferably on a direct line
from the transformer. In the event of fire, the
wires will not be destroyed and the water supply
not cut-off.
5. Always disconnect power source before
performing any work on or near the motor or its
connected load. If the power disconnect point is
out-of-sight, lock it in the open position and tag
it to prevent unexpected application of power.
Failure to do so could result in fatal electrical
shock.
6. DO NOT handle pump with wet hands or when
standing in water as fatal electrical shock could
occur. Disconnect main power supply before
handling pump for any reason.
7. Shut off power source when voltage drops 10%
below the rated voltage of the motor.
8. Protect the power cable from coming in contact
with sharp objects, oil, grease, hot surfaces or
chemicals. DO NOT kink the power cable. If
damaged replace immediately.
9. NEVER leave the control box, fused disconnect
switch, or covers open (either partially or
completely) when not being worked on by a
competent electrician or repairman.
10. Always use caution when operating electrical
controls in damp areas. If possible, avoid
all contact with electrical equipment during
thunderstorms or extreme damp conditions.
11. Install all electrical equipment in protected area to
prevent mechanical damage which could produce
serious electrical shock and/or equipment failure.
12. Pump is designed to pump cold ground water
that is free of air or gases. Decreased pump
performance and life expectancy can occur if the
ground water is not cold (86F/30C) or contains air
or gases.
13. Pump and controls must be securely and
adequately grounded as specified in section 25043 item (A) of the U.S.A. National Electric Code
(NEC) and Section 26-954 Canadian Electrical
Code. Failure to do so could result in a fatal
injury.
14. DO NOT use this pump to pump flammable
liquids such as gasoline, fuel oil, kerosene, etc.
Failure to follow the above warning could result in
property damage and/or personal injury.
WARNING: The pump is intended for use in a well.
Motor frame must be connected to power supply
ground or fatal electrical shock may result. Do not use
this pump in swimming pools.
WARNING: This product contains chemicals known
to the State of California to cause cancer and birth
defects or other reproductive harm.
NOTE: Pumps with the “CSA” mark are tested to UL
standard UL778 and certified to CSA standard C22.2
No. 108.
130582
95 North Oak Street • Kendallville, IN 46755
1
IL0092
IL0093
Submersible
Cable
Riser
Pipe
Pitless
Adapter
Plastic or
Steel Pipe
Conduit
Typical Installation
Control Box
Fuse Disconnect
Box
Pre-Charged
Pressure Tank
Pressure
Relief Valve
Gate Valve
To Service
Torque
Arrestor
Fuse Disconnect
Check Valve
Submersible
Pump
Submersible
Motor
Box
Magnetic Starter
Figure 1 — Typical Installation with Pre-Charged Tank
Control Box
Submersible Power
Cable to Pump
Air Release and Pressure Gauge
Fused Switch
Box
Snifter
Check Valve
Check Valve
Tank
Pressure Switch
Pressure Switch Pressure Gauge Drain Valve
Three Phase Tank/Controls Installation
Outlet to
Service
Pressure Gauge
Single Phase Tank/Controls Installation
90º Elbow
Well Seal
Drain Valve
Pre-Charged
Pressure Tank
Pressure
Relief Valve
To Drain
Gate Valve
To Service
To Drain
Power Cable
Taped to
Pipe
Union
Bleeder Orifice
Check Valve
Check
Valve
Pressure
Switch
Relief
Valve
Figure 2 — Typical Installation with Standard Pneumatic Tank
95 North Oak Street • Kendallville, IN 46755
Pipe
Coupling
Pipe
Bleeder Valve
Rubber Orifice
Pipe
Pitless Unit
2
CABLE SELECTION
Single Phase, 2-Wire or 3-Wire Cable, 60 Hz (Service Entrance to Motor)
Motor Rating Copper Wire Size
Volts HP 14
115
230
1 foot = .3048 meters
1/3 130 210 340 540 840 1300 1610 1960 2390 2910 3540 4210 5060
1/2 100 160 250 390 620 960 1190 1460 1780 2160 2630 3140 3770
1/3 550 880 1390 2190 3400 5250 6520 7960 9690 11770
1/2 400 650 1020 1610 2510 3880 4810 5880 7170 8720
3/4 300 480 760 1200 1870 2890 3580 4370 5330 6470 7870
1 250 400 630 990 1540 2380 2960 3610 4410 5360 6520
1-1/2 190 310 480 770 1200 1870 2320 2850 3500 4280 5240
2 150 250 390 620 970 1530 1910 2360 2930 3620 4480
3 120* 190 300 470 750 1190 1490 1850 2320 2890 3610
5 0 0 180* 280 450 710 890 1110 1390 1740 2170 2680
7-1/2 0 0 0 200* 310 490 610 750 930 1140 1410 1720
10 0 0 0 0 250 390 490 600 750 930 1160 1430 1760
15 0 0 0 0 170* 270* 340 430 530 660 820 1020 1260
Three Phase, 3-Wire, 60 Hz, 200 and 230 Volts (Service Entrance to Motor)
Motor Rating Copper Wire Size
Volts HP 14 12 10 8 6 4 3 2 1 0 00 000 0000 250 300 350 400 500
200V
60Hz 3
Phase
3 Wire
230V
60Hz 3
Phase
3 Wire
460V
Phase
3 Wire
CAUTION: Use of wire size smaller than listed will void warranty.
(*) Meet the U.S. National Electrical Code ampacity only for individual conductor 60ºC cable. Only the lengths without * meet the code for jacketed 60ºC cable. Local code
Maximum lengths shown maintain motor voltage at 95% of service entrance voltage, running at maximum nameplate amperes. If service entrance voltage will be at least motor nameplate
voltage under normal load conditions, 50% additional length is permissible for all sizes.
This table is based on copper wire. If aluminum wire is used it must be two (2) sizes larger. Example: When the table calls for #12 copper wire you would use #10 aluminum wire.
Single phase control boxes may be connected at any point of the total cable length.
Cables #14 to #0000 are AWG sizes.
1/2 710 1140 1800 2840 4420
3/4 510 810 1280 2030 3160
1 430 690 1080 1710 2670 4140 5140
1-1/2 310 500 790 1260 1960 3050 3780
2 240 390 610 970 1520 2360 2940 3610 4430 5420
3 180 290 470 740 1160 1810 2250 2760 3390 4130
5 110* 170 280 440 690 1080 1350 1660 2040 2490 3050 3670 4440 5030
7-1/2 0 0 200 310 490 770 960 1180 1450 1770 2170 2600 3150 3560
10 0 0 0 230* 370 570 720 880 1090 1330 1640 1970 2390 2720 3100 3480 3800 4420
15 0 0 0 160* 250* 390 490 600 740 910 1110 1340 1630 1850 2100 2350 2570 2980
20 0 0 0 0 190* 300* 380 460 570 700 860 1050 1270 1440 1650 1850 2020 2360
25 0 0 0 0 0 240* 300* 370* 460 570 700 840 1030 1170 1330 1500 1640 1900
30 0 0 0 0 0 0 250* 310* 380* 470 580 700 850 970 1110 1250 1360 1590
1/2 930 1490 2350 3700 5760 8910
3/4 670 1080 1700 2580 4190 6490 8060 9860
1 560 910 1430 2260 3520 5460 6780 8290
1-1/2 420 670 1060 1670 2610 4050 5030 6160 7530 9170
2 320 510 810 1280 2010 3130 3890 4770 5860 7170 8780
3 240 390 620 990 1540 2400 2980 3660 4480 5470 6690 8020 9680
5 140* 230 370 590 920 1430 1790 2190 2690 3290 4030 4850 5870 6650 7560 8460 9220
7-1/2 0 160* 260 420 650 1020 1270 1560 1920 2340 2870 3440 4160 4710 5340 5970 6500 7510
10 0 0 190* 310 490 760 950 1170 1440 1760 2160 2610 3160 3590 4100 4600 5020 5840
15 0 0 0 210* 330 520 650 800 980 1200 1470 1780 2150 2440 2780 3110 3400 3940
20 0 0 0 0 250* 400 500 610 760 930 1140 1380 1680 1910 2180 2450 2680 3120
25 0 0 0 0 0 320* 400 500 610 750 920 1120 1360 1540 1760 1980 2160 2520
30 0 0 0 0 0 260* 330* 410* 510 620 760 930 1130 1280 1470 1650 1800 2110
1/2 3770 6020 9460
3/4 2730 4350 6850
1 2300 3670 5770 9070
1-1/2 1700 2710 4270 6730
2 1300 2070 3270 5150 8050
3 1000 1600 2520 3970 6200
5 590 950 1500 2360 3700 5750
7-1/2 420 680 1070 1690 2640 4100 5100 6260 7680
60
Hz 3
10 310 500 790 1250 1960 3050 3800 4680 5750 7050
15 0 340* 540 850 1340 2090 2600 3200 3930 4810 5900 7110
20 0 0 410* 650 1030 1610 2000 2470 3040 3730 4580 5530
25 0 0 0 530* 830 1300 1620 1990 2450 3010 3700 4470 5430
30 0 0 0 430* 680 1070 1330 1640 2030 2490 3060 3700 4500 5130 5860
40 0 0 0 0 500* 790 980 1210 1490 1830 2250 2710 3290 3730 4250
50 0 0 0 0 0 640* 800 980 1210 1480 1810 2190 2650 3010 3420 3830 4180 4850
60 0 0 0 0 0 540* 670* 830* 1020 1250 1540 1850 2240 2540 2890 3240 3540 4100
75 0 0 0 0 0 0 0 680* 840* 1030 1260 1520 1850 2100 2400 2700 2950 3440
100 0 0 0 0 0 0 0 0 620* 760* 940* 1130 1380 1560 1790 2010 2190 2550
requirements may vary.
12 10 8 6 4 3 2 1 0 00 000 0000
95 North Oak Street • Kendallville, IN 46755
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IL0094
READ THESE INSTRUCTIONS COMPLETELY BEFORE INSTALLATION
ASSEMBLY
CAUTION: Be sure pump size corresponds with
horsepower size of motor. If pump size exceeds
recommended motor, overloading of motor and
damage to the motor could result.
1. If not yet assembled, check that the pump and
motor mounting faces are free from dirt.
2. Assemble the pump liquid end and motor
together so that mounting faces are in contact.
Then tighten assembly bolts evenly.
NOTE: Apply non-toxic FDA approved waterproof
grease such as Mobile 102, Texaco CYGNUS2661 or
equivalent to the coupling before assembly of pump
coupling to motor shaft. This will prolong spline life
and prevent abrasives from entering the spline area.
3. Check for free rotation of the pump and motor. A
slight drag is permissible.
4. Assemble the pump lead guard over the motor
leads.
CAUTION: Do not cut or pinch lead wire during
assembly.
5. Assemble suction screen to pump mounting ring.
Lead Wire
Liquid End
Figure 3
Guard
Motor
PRE-INSTALLATION
To save possible added expense and extra trips,
observe and complete as many as possible of the
following precautions and pre-installation procedures
before going to the job site or beginning the
installation.
IMPORTANT PRECAUTIONS
1. Prior to installation, inspect the pump for damage.
Check for free pump and motor rotation. A slight
drag is permissible.
2. Check to make certain that the voltage of the
motor end and control agree with the available
phase and voltage. Check power source. Check
electrical supply for correct fusing, correct wire
size, and adequate grounding and transformer
size.
WARNING: Since most submersible pump problems
are electrical, it is very important that all electrical
work be done properly. Therefore, all electrical hook-
up work or electrical service work should be done by a
qualified electrician or service man only!
3. Throughout installation, take care not to damage
the insulation of the electrical cable or motor
leads. Never support the weight of the unit by
electrical cable or motor leads.
4. Before the pump is installed, the well should be
pumped free of sand and other foreign matter
with a test pump. The warranty is void if it is
used to clean the well.
5. Follow wiring directions in the control box and
make momentary tests to see that motor runs.
(It is normal to hear some noise from the pump
when you are momentarily testing it). Do not run
pump dry for more than three (3) seconds.
MAJOR WELL COMPONENTS (see Figures 1 & 2)
1. Submersible Pump — A submersible pump is a
multi-stage centrifugal. Each stage consists of an
impeller and diffuser. Water pressure increases in
equal amounts as it passes from stage to stage.
The more stages, the higher the pressure the
pump will develop.
2. Submersible Motor — Submersible pumps can
be powered by either single phase or three phase
motors. Make certain that the motor corresponds
with the horsepower required by the pump.
Failure to do so, could result in overloading of the
motor and motor damage.
3. Control Box — Single phase submersible motors
require the use of an above ground control box
for starting. Operation of these motors without
control boxes or with incorrect boxes can result in
failure of motors which will void the warranty.
4. Magnetic Starters and Overload Protection
— Three phase submersible motors require the
use of an above ground magnetic starter and
overload protection. Operation of these motors
without or incorrect starters and protectors will
result in the failure of motor which will void
the warranty. See Magnetic Starter Chart for
the correct selection of magnetic starters and
ambient compensated quick trip protectors.
5. The Well — The well should be sand free and
have a sufficient flow of water to supply the
pump. Clear well of sand and any other foreign
matter with a test pump before installing the new
submersible pump.
CAUTION: Using the submersible pump to clean the
well will void the warranty.
6. When drilling a new well in an area where sand is
a problem, a sand screen should be installed to
protect the pump and motor.
7. The well should be straight so damage during
installation does not occur to the pump or motor
by becoming lodged in a crooked well casing.
95 North Oak Street • Kendallville, IN 46755
4
8. The complete pump and motor should be
IL0077
IL0096
submerged at least ten feet below the draw
down level of the well, and the motor should be
a minimum of ten feet off the bottom of the well
(Figure 4).
9. The Piping — Install the pump with pipe of the
same diameter as the discharge port of the pump
or larger.
10 ft.
Drawn Down Water
Level
10 ft.
10 ft. Min.
Figure 4
Top of Well Screen
Bottom of Well
NOTE: Use of pipe smaller that the discharge port
of the pump will restrict the capacity of the pump and
lower its operating performance.
10. Check Valve — A check valve is required on all
submersible installations. This valve maintains
water within the pipe when the pump is running. A
line check should be installed within 25 feet of the
pump and below the draw down level of the water
supply.
a. For well depths exceeding 200 feet, it is
suggested that an additional check valve be
installed every 125 feet.
b. An additional check valve should be installed in
the horizontal line between the well top and the
pressure tank (See Figures 1 & 2).
CAUTION: Make certain that the check valve is
pointing in the right direction, arrow pointing towards
the tank.
11. Torque Arrester — To center the pump as it is
being lowered into the well, a torque arrester is
recommended. This will also minimize the pump
whipping due to the starting torque of the motor
(See Figure 2).
NOTE: On plastic pipe installations a torque
arrester must be installed. Cable guards should also
be installed.
12. Pressure Tank — The purpose of the pressure
tank is to allow an amount of water to be drawn
before the pressure drops enough to cause the
pump to start. Without a pressure tank, the pump
would start and stop continuously when water is
drawn. There are two types of pressure tanks,
the standard tank that requires an air volume
control and the pre-charged tank.
a. On a standard pneumatic tank system, air
is introduced to compensate for that which
is absorbed by the water. Each time the
pump cycles air is added to the tank through
a bleeder and snifter valve. The excess air
is released by a float assembly (air volume
control) in the upper side tapping of the tank
(See Figure 2).
b. In a pre-charged tank, a flexible diaphragm
or bladder separates the air and water areas
of the tank. The air chamber is pre-charged
by means of a tire valve with pressure 2 PSI
less than the cut-on pressure of the pump.
Because the air is not in contact with the
water, it cannot be absorbed by the water.
Therefore, the original charge of air is never
lost.
13. In pre-charged tank systems, none of the
fittings for air introduction or air level control are
required (Figure 1). The piping in the well is also
different for the two systems. The pre-charged
tank system does not require a bleeder orifice
assembly, which simplifies the installation.
Pump On. Water Enters
The Reservoir
Figure 5
System Filled.
Pump Off
14. The tank size should be selected to keep
the pump starts per day as low as practical
for maximum life. Excessive motor cycling
accelerates motor bearing and spline wear, pump
wear and contact erosion. Use as a guide, 100
starts per day (24 hours) on single phase motors
and 300 starts per day on three phase units.
15. Pressure Switch — The pressure switch provides
for automatic operation. The pump starts when
the pressure drops to the switch cut-in setting
and stops when the pressure reaches the switch
cut-out setting. The pressure switch must be
installed as close to the tank as possible (Figures
1 & 2).
16. Pressure Relief Valve — A properly sized
pressure relief valve must be installed on any
95 North Oak Street • Kendallville, IN 46755
5
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