Flint & Walling Multi-Stage Effluent User Manual

NOTICE TO INSTALLER: Instructions must remain with installation.

Product information presented here re ﬂ ects con di tions at time of publication. Consult factory re gard ing dis crep an cies or in con sis ten cies.

&,).47!,,).').#

95 North Oak Street • Kendallville, IN 46755

(800) 345-9422

ON-SITE WASTEWATER PROD UCTS

OWNER’S MANUAL

Efﬂ uent Turbine Submersible Pumps

FW1104

0807

Supesedes

NEW

visit our web site:

www.ﬂ intandwalling.com

Congratulations on the purchase of the Flint & Walling Effluent Turbine Submersible Pump. This Flint & Walling pump will provide years of trou ble-free service when installed according to the manufacturer recommendations.

This manual in cor po rates the in stal la tion, operation, main te nance, and service instructions into one doc u ment to aid in the own er ship of a Flint & Walling on-site wastewater product. Please read and review this manual be fore in stall ing the product. Many

Table of Contents

Safety Instructions ..........................................................................1

Limited Warranty.............................................................................2

Preinstallation Information ..............................................................2

Pump Performance Data .............................................................3-4

Electrical Data ...............................................................................5

Major Components ........................................................................5

Pump Installation and Wiring Diagram ...........................................6

System Wiring Instructions .............................................................6

Splicing Underground Wires ...........................................................7

Start-up and Maintenance ..............................................................7

Troubleshooting & Service Checklist ..............................................7

Typical Installations .......................................................................8

items con tained within, when fol lowed correctly , will not only ensure a long and problem-free life for the system, but also save time and money during in stal la tion. Should further as sis tance be nec es sary please call our Tech ni cal Service de part ment at 1-800-742-5044.

Safety Instructions

TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MA JOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN MANUAL AND ON PUMP.

THIS MANUAL IS INTENDED TO ASSIST IN THE IN STAL LA TION AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH THE PUMP.

This is a SAFETY ALERT SYMBOL. When you see this symbol on the pump or in the man u al, look for one of the following signal words and be alert to the potential for personal injury or property damage.

Owner’s Information

Model Number: ______________________ Date Code: _________________

Job Name: ______________________________________________________

Dealer: _________________________________________________________

Date of Purchase: _______________________________________________

Contractor: _____________________________________________________

Date of Installation: _______________________________________________

System Readings During Operation: Voltage __________ Amps _________

Warns of hazards that WILL cause serious personal injury, death or major property damage.

Warns of hazards that CAN cause serious personal injury, death or major property damage.

Warns of hazards that CAN cause personal injury or prop er ty damage.

Indicates special instructions which are very important and must be followed.

THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS PRIOR TO PERFORMING ANY WORK ON THIS PUMP.

MAINTAIN ALL SAFETY DECALS.

022569

Limited Warranty

Manufacturer warrants, to the purchaser and subsequent owner during the warranty period, every new product to be free from defects in material and workmanship under normal use and service, when properly used and maintained, for a period of one year from date of purchase by the end user, or 18 months from date of original manufacture of the product, whichever comes ﬁ rst. Parts that fail within the warranty period, one year from date of purchase by the end user, or 18 months from the date of original manufacture of the product, whichever comes ﬁ rst, that inspections determine to be defective in material or workmanship, will be repaired, replaced or remanufactured at Manufacturer's option, provided however, that by so doing we will not be obligated to replace an entire assembly, the entire mechanism or the complete unit. No allowance will be made for shipping charges, damages, labor or other charges that may occur due to product failure, repair or replacement.

This warranty does not apply to and there shall be no warranty for any material or product that has been disassembled without prior approval of Manufacturer, subjected to misuse, misapplication, neglect, alteration, accident or act of God; that has not been installed, operated or maintained in accordance with Manufacturer's installation instructions; that has been exposed to outside substances including but not limited to the following: sand, gravel, cement, mud, tar, hydrocarbons, hydrocarbon derivatives (oil, gasoline, solvents, etc.), or other abrasive or corrosive substances, wash towels or feminine sanitary

products, etc. in all applications other than in raw sewage pumping applications. The warranty set out in the paragraph above is in lieu of all other warranties expressed or implied; and we do not authorize any representative or other person to assume for us any other liability in connection with our products.

Contact Manufacturer at, 95 North Oak Street, Kendallville, IN 46755, Attention: Cus tom er Ser vice De part ment to obtain any need ed repair or re place ment of part(s) or additional in for ma tion pertaining to our warranty.

MANUFACTURER EXPRESSLY DIS CLAIMS LI A BIL I TY FOR SPE CIAL, CON SE QUEN TIAL OR IN CI DEN TAL DAM AG ES OR BREACH OF EX PRESSED OR IMPLIED WARRANTY; AND ANY IMPLIED WAR RAN TY OF FIT NESS FOR A PAR TIC U LAR PUR POSE AND OF MER CHANT ABIL I TY SHALL BE LIM IT ED TO THE DU RA TION OF THE EX PRESSED WAR RAN TY.

Some states do not allow limitations on the duration of an implied warranty, so the above limitation may not apply to you. Some states do not allow the exclusion or limitation of incidental or con se quen tial dam ag es, so the above lim i ta tion or exclusion may not apply to you.

This warranty gives you speciﬁ c legal rights and you may also have other rights which vary from state to state.

Preinstallation Information

1. Inspect your unit. Occasionally, products are damaged during ship ment. If the unit is damaged, contact your dealer be fore using.

2. Carefully read the literature provided to fa mil iar ize your self with spe cif ic details re gard ing in stal la tion and use. These ma te ri als should be retained for future ref er ence.

3. “Risk of electrical shock” Do not re move

power supply cord and strain relief or connect conduit directly

to the pump. In stal la tion and check ing of electrical circuits and hardware should be performed by a qualiﬁ ed and li censed electrician.

4. Do not lift, carry, or hang pump by the elec tri cal ca bles. Dam age to the electrical cables can cause shock, burns or death.

5. For your protection, make cer tain the pump ground wire is properly connected to the ground wire with the incoming power line. Test for ground at the

junc tion box using an Un der writ ers Lab o ra to ry list ed cir cuit an a lyz er which will indicate if the power, neutral and ground wires are cor rect ly con nect ed. If in doubt, call a qual i ﬁ ed li censed elec tri cian.

6. Make cer tain that the receptacle is with in the reach of the pump’s power supply cord. DO NOT USE AN EX TEN SION CORD. Extension cords that are too long

or too light do not de liv er sufﬁ cient voltage to the pump motor . But, more im por tant, they could present a safe ty haz ard if the in su la tion were to become damaged or the connection end were to get wet.

7. Make sure the pump elec tri cal sup ply cir cuit is equipped with fus es or cir cuit break ers of prop er ca pac i ty. A sep a rate branch circuit is rec om mend ed, and

sized ac cord ing to the “Na tion al Elec tri cal Code” for the cur rent shown on the pump nameplate.

8. DO NOT run the pump dry. DO NOT run the pump with a completely closed discharge. DO NOT pump chem i cal or cor ro sive liquids. Failure to follow above warnings could result in damage to the pump, void ing the warranty and causing personal injury.

9. Check to be sure your pow er source is ca pa ble of handling the volt age re quire ments of the motor, as in di cat ed on the pump name plate.

10. The installation of pumps using auxiliary variable level ﬂ oat switch es is the responsibility of the in stall ing party. Care should be taken such that the tethered ﬂ oat switch will not hang up and are secured so that the pump will turn on and off properly.

11. Water ham mer creates momentary high pres sure surges. These surges can cause severe dam age to check valves and the piping system. Consideration for water ham mer must be included in the piping sys tem design. Reference ASPE Data Book, Chapter 2.33. Some systems may re quire ex ter nal spring or lever weight ed check valves or other en gi neered solutions.

12. In cold climates the discharge pipe may be subject to freez ing. If the riser on the septic tank is above the frost line, it will be necessary to protect the system from freeze up. The discharge pipe can be insulated or the check valve can be removed. If the check valve is removed, the “on-off” cycle must be adjusted for any back-ﬂ ow from the dis charge line.

13. According to the state of California (Prop 65), this product contains chemicals known to the state of California to cause cancer and birth defects or other reproductive harm.

PUMP PERFORMANCE DATA

10 GPM Models

PUMP PERFORMANCE CURVE

FEET

METERS

400

120

112

104

TOTAL DYNAMIC HEAD

GALLONS LITERS

3/4 HP- 12 STAGE

360

320

280

1/2 HP- 8 STAGE

240

200

1/2 HP- 6 STAGE

160

120

2 4 6 8 10 12 14 16 18

0 8 16 24 32 40 48 56 64

Part Number HP Voltage Phase Amps Stages Height

F5030-0005‡ 1/2 115 1 12.0 6 22-3/8” F5030-0006‡ 1/2 230 1 6.0 6 22-3/8” F5030-0007‡ 1/2 115 1 12.0 8 25-1/4” F5030-0008‡ 1/2 230 1 6.0 8 25-1/4” F5030-0009‡ 3/4 230 1 8.0 12 29-15/16”

‡Includes 10 feet of #14-2G SJ0W-A power cord

10 GPM

1 1/4" NPT DISCHARGE

FLOW PER MINUTE

IL0501

19 GPM Models

PUMP PERFORMANCE CURVE

FEET

METERS

280

TOTAL DYNAMIC HEAD

GALLONS

3/4 HP

240

7 STAGE

200

160

1/2 HP

120

5 STAGE

LITERS

0 20 40 60 80 100

Part Number HP Voltage Phase Amps Stages Height F5031-0005‡ 1/2 115 1 12.0 5 21-15/16” F5031-0006‡ 1/2 230 1 6.0 5 21-15/16” F5031-0007‡ 3/4 230 1 8.0 7 25-1/16” F5031-0008‡ 1 230 1 9.8 9 28-1/8”

‡Includes 10 feet of #14-2G SJ0W-A power cord

19 GPM

1¼" NPT DISCHARGE

1 HP - 9 STAGE

5 10 15 20 25 30

FLOW PER MINUTE

IL0502

015414

27 GPM Models

PUMP PERFORMANCE

CURVE 27 GPM

FEET

METERS

1-1/4” NPT DISCHARGE

260 240

1 HP- 7 STAGE

220

3/4 HP

200

6 STAGE

180 160

140

1/2 HP- 4 STAGE

120

TOTAL DYNAMIC HEAD

100

GALLONS

LITERS

Part Number HP Voltage Phase Amps Stages Height F5032-0005‡ 1/2 115 1 12.0 4 21-3/16” F5032-0006‡ 1/2 230 1 6.0 4 21-3/16” F5032-0007‡ 3/4 230 1 8.0 6 24-3/16” F5032-0008‡ 1 230 1 9.8 7 26-7/16”

‡Includes 10 feet of #14-2G SJ0W-A power cord

5 10 15 20 25 30 35 40

0 20 40 60 80 100 120 140

FLOW PER MINUTE

IL0503

35 GPM Models

PUMP PERFORMANCE

FEET

METERS

120

100

TOTAL DYNAMIC HEAD

GALLONS LITERS

Part Number HP Voltage Phase Amps Stages Height F5033-0005‡ 1/2 115 1 12.0 2 18-7/8” F5033-0006‡ 1/2 230 1 6.0 2 18-7/8” F5033-0007‡ 3/4 230 1 8.0 3 20-1/4’

‡Includes 10 feet of #14-2G SJ0W-A power cord

CURVE - 35 GPM

2” NPT DISCHARGE

3/4 HP - 3 STAGE

1/2 HP - 2 STAGE

10 20 30 40 50 60

0 40 80 120 160 200

FLOW PER MINUTE

IL0504

PUMP PERFORMANCE DATA

55 GPM Models

PUMP PERFORMANCE CURVE

55 GPM

FEET

METERS

15 10

TOTAL DYNAMIC HEAD

1/2 HP-1 STAGE

5 0

GALLONS LITERS

0 40 80 120 160 200 240 280 320 360

10 20 30 40 50 60 70 80 90 100

2" NPT DISCHARGE

FLOW PER HOUR/MINUTE

IL0505

Part Number HP Voltage Phase Amps Stages Height F5034-0005‡ 1/2‡ 115 1 12.0 1 17-3/4” F5034-0006‡ 1/2‡ 230 1 6.0 1 17-3/4” ‡Includes 10 feet of #14-2G SJ0W-A power cord

Model HP Motor

115V 230V 20’ 40’ 60’ 80’ 100’ 120’ 140’ 160’ 180’ 200’ 225’ 250’ 275’ 300’ 325’ 350’ Ft.. PSI

F5030-0005 F5030-0006 1/2 2-wire 14.3 13.2 12.0 10.8 9.4 7.6 6.5 177 77

F5030-0007 F5030-0008 1/2 2-wire 14.7 14.2 13.4 12.6 11.7 10.8 9.7 8.3 6.3 2.1 242 105

F5030-0009 3/4 2-wire 15.0 14.6 14.1 13.6 13.1 12.5 12.0 11.3 10.4 9.7 8.5 7.4 5.7 367 159

F5031-0005 F5031-0006 1/2 2-wire 24.6 22.7 20.5 17.9 15.0 10.4 159 69

F5031-0007 3/4 2-wire 24.6 23.3 21.7 20.0 18.2 16.0 13.3 9.6 219 95

F5031-0008 1 2-wire 25.5 24.4 23.2 22.1 20.7 19.4 17.8 16.2 13.7 10.7 5.0 277 120

F5032-0005 F5032-0006 1/2 2-wire 31.0 27.0 22.0 24.0 14.0 122 53

F5032-0007 3/4 2-wire 32.0 30.0 27.0 24.0 21.0 16.0 5.0 191 83

F5032-0008 1 2-wire 34.0 32.0 30.0 27.0 24.0 22.0 18.0 13.0 222 96

F5033-0005 F5033-0006 1/2 2-wire 48.0 39.0 26.0 67 29

F5033-0007 3/4 2-wire 43.0 40.0 31.0 20.0 100 43

F5034-0005 F5034-0006 1/2 2-wire 71.0 31 13

F5034-0007 3/4 2-wire 77.0 64.0 39.0 67 29

Type

Depth to Water Level in Feet - Capacities in Gallons per Minute Maximum

Electrical Data for Flint & Walling Efﬂ uent Turbine Pumps

Maximum Locked

Fuse/Circuit

HP Volts Phase Hz S.F.

Rotor

KVA

Breaker Amps

Code

Amps Watts Std. Delay

1/2 115 1 60 1.6 12 970 64.4 R 30 15 1.0 - 1.3 1/2 230 1 60 1.6 6 970 32.2 R 15 8 4.2 - 5.2 3/4 230 1 60 1.5 8 1325 40.7 N 20 10 3.0 - 3.6

1 230 1 60 1.4 9.8 1600 48.7 N 25 11 2.2 - 2.7

Amps

Major Components

1. Submersible Efﬂ uent Turbine Pump - A submersible ef ﬂ u ent tur bine pump is a multistage centrifugal design pump. Each stage con sists of an impeller and diffuser. Water pres sure in creas es in equal amounts as it passes from stage to stage. The more stag es, the higher the pressure the pump will de vel op.

switch es can result in failure of the pump and void the warranty.

A minimum of two ﬂ oat switches should be used in each ap pli -

ca tion:

• A pump control ﬂ oat switch

• A high water alarm ﬂ oat switch

Winding

Resistant

Line to

Line

To correctly select a pump for a speciﬁ c application, the fol low ing

information must be known:

• The amount of discharge required in GPM or LPM

• The total dynamic head required in feet or meters

Use this information along with the performance data found on the

previous page to make your selection.

2. Control Panel - Submersible efﬂ uent turbine pumps re quire the use of an above ground control panel or junction box with a pump control switch for proper op er a tion. Op er a tion of these pumps without a control pan el or junction box with a pump control switch can result in failure of the pump and void the war ran ty.

3. Float Switches - All submersible efﬂ uent turbine pumps are non- au to mat ic. The use of ﬂ oat switches are required for the proper operation of the pump. Operation of these pumps without ﬂ oat

4. Piping - The submersible efﬂ uent turbine pump can be in stalled with schedule 40 PVC pipe. The pipe size should be 1¼” diameter for the 10 GPM to 27 GPM pump series and 2” diameter for the 35 GPM pump series.

General piping from the pump to a splitter, distribution box, drain

ﬁ eld etc., should be the same diameter as stat ed above. For long pipe runs consult friction loss tables for correct pipe sizing.

5. Check Valve - A check valve is required in all duplex sys tems. It is also required when a large amount of efﬂ uent can backﬂ ush into the system causing rapid cycling of the pump.

A 1/8” weep hole must be drilled in the side of the discharge

head when using a check valve (see drawing below for drill location).

SK2222

Pump Installation and Wiring Diagram

1. Submersible ef flu ent turbine pumps may be installed in any ap pli ca tion where relatively clear efﬂ uent, such as from a dos ing tank or high head STEP system etc., is being pumped.

2. Pumps should always be installed vertically. Pumps should never be installed horizontally.

3. Because of their low temperature rise, pumps under 2 HP do not require a ﬂ ow inducer sleeve.

4. Mount the junction box in its permanent position.

5. Run prewired conduit, or equivalent submersible cable from the junc tion box to a fused disconnect or, if applicable, the control panel.

6. Feed the pump power cord and float switch cords into the junc tion box.

7. Make the connections in the junction box using the wiring di a grams below. If you are using a con trol panel or a ﬁ ltered STEP

system, follow the wiring di a grams and in struc tions included with them.

8. An alarm should be used with any system using a pump. Follow the wiring diagram with the alarm for installation and check your local codes.

9. Run the appropriate power to the control panel from a fused (cir cuit breaker) disconnect. The appropriate power supply in for ma tion may be found on the pump nameplate.

10. To provide a suitable ground, a separate ground wire (green or bare) at least as large as the line conductors is required. It is connected from the electrical disconnect box to the con trol panel, to the junction box and to the green ground wire of the submersible motor lead.

11. Always disconnect all power when installing or ser vic ing the pump.

115 VOLT

FUSED DISCONNECT

(CIRCUIT BREAKER)

115 VOLT LINE

WHITE

BLACK

WHITE

GROUND

WHITE

GREEN

WHITE

BLACK

GREEN

JUNCTION BOX

BLACK

WHITE

BLACK

115V

FLOAT SWITC

230 VOLT

FUSED DISCONNECT

(CIRCUIT BREAKER)

230 VOLT LINE

WHITE

BLACK

WHITE

GROUND

WHITE

GREEN

WHITE

BLACK

GREEN

JUNCTION BOX

BLACK

WHITE

BLACK

230V

FLOAT SWI

115 VOLT

EFFLUENT TURBINE PUMP

1/2HP

SK2221A

230 VOLT

EFFLUENT TURBINE PUMP

1/2HP - 1 1/2HP

SK2221B

Splicing Underground Wires

Splicing of wires to be buried must be done according to the National Electrical Code. Wire connectors or splicing means installed on conductors for direct burial shall be listed for such use.

Start-up and Maintenance

Before placing the equipment into operation the following must be checked:

• Septic tank and/or pump chamber should be pumped and cleaned prior to in stal la tion in existing system.

• Septic tank and/or pump chamber must be watertight.

• Installation needs to be according to instructions.

• Installation should include an easy access riser and tamper resistant lid.

• Filter assembly needs to be in place and secure.

• Float tree needs to be in place, secure and adjusted for proper cycling.

• Make sure ﬂ oat switches are free to move within the basin.

• Be sure electrical connections are watertight and conform to the Uniform Building Code and the National Electrical Code (NEC).

• Fill the septic tank and/or pump chamber with water and check the system for operation.

After installing the pump into the containment area with ad e quate sub mer gence, open the discharge valve fully. Start the unit using manual controls. If ﬂ ow is appreciably less than rated per for mance, pump may

Troubleshooting and Service Checklist

be air locked. To expel trapped air, jog the unit several times, using the manual con trols. Have a qualiﬁ ed electrician take voltage and current mea sure ments on the black wire of single phase. Record these read ings in the space provided in the “Owner’s Information” section on the front this manual for future ref er ence.

Be sure to complete all items such as installing the lid on the riser, securely closing the control panel, and checking the sys tem op er a tion have been com plet ed before placing the system into ser vice.

Routine maintenance should include:

• Service ﬁ lter in STEP system and/or septic tank.

• Clean pump screen.

• Make sure the check valve is functioning properly.

• Check wire connections.

• Make sure the weep hole is clear.

• Make sure the ﬂ oat switches are free to move within the basin.

• Make sure there are no leaks in the plumbing.

• Make sure there is no excessive noise while the pump is running.

ELECTRICAL PRECAUTIONS- Before servicing a pump, always shut off the main power breaker and then unplug

the pump - making sure you are not standing in water and wearing insulated protective sole shoes. Under ﬂ ooded conditions, contact your local electric company or a qualiﬁ ed licensed electrician for disconnecting electrical service prior to pump removal.

CONDITION A. Pump will not start or run.

B. Motor overheats and trips over load or

blows fuse.

C. Pump starts and stops too often.

D. Pump will not shut off.

E. Pump operates but delivers little or no

water.

F. Drop in head and/or capacity after a period of use.

COMMON CAUSES

Check fuse, low voltage, over load open, open or incorrect wiring, open switch, impeller or seal bound mechanically, defective capacitor or relay when used, motor or wiring shorted. Float assembly held down. Switch defective, dam aged, or out of adjustment.

Incorrect voltage, negative head (discharge open lower than normal), impeller or seal bound mechanically, or relay, motor shorted.

Check valve stuck or none installed in long distance line, over load open, level switch(es) defective, sump pit too small, leak in the system.

Debris under ﬂ oat assembly bound by pit sides or other, switch de fec tive, damaged or out of adjustment, leak in the system.

Check strainer housing, dis charge pipe, or if check valve is used vent hole must be clear. Discharge head exceeds pump ca pac ity. Low or incorrect voltage. Incorrect motor ro ta tion. Capacitor de fec tive. In com ing water con tain ing air or causing air to enter pump ing chamber.

Increased pipe friction, clogged line or check valve. Abrasive material and ad verse chem i cals could possibly deteriorate impeller and pump housing. Check line. Remove unit and inspect.

If the above checklist does not uncover the problem, consult the factory - Do not attempt to service or otherwise disassemble pump. Service must be by Flint & Walling Authorized Service Stations.

ALL INSTALLATIONS REQUIRE A FILTER BEFORE THE PUMP.

WARNING!

P/N

ZOELLER

NOTE: Flow must be directed around the motor for cooling on 2 HP and higher units.

Typical Installations

EFFLUENT

TURBINE PUMP

SEPTIC TANK

WARNING

ELECTRICAL SHOCK HAZARD

P/N 10-1193 REV. A

0ELLER

PUMP CO.

LOUISVILLE, KY

SK2220

EFFLUENT TURBINE PUMP

&,).47!,,).').#

95 North Oak Street

Kendallville, IN 46755

(800) 345-9422

FAX (260) 347-0909

www.ﬁ ntandwalling.com

SEPTIC TANK

Quality Products

Since 1866!

SK2219

Flint & Walling Multi-Stage Effluent User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual