Flint & Walling Pressure Booster Pumps Instructions

Operating Instructions & Parts Manual

5.28

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

Pressure Booster Pumps

Description

Pressure booster pumps increase water pressure from city mains or private water systems. Applications include providing high water pressure for washing buildings, dairy walls or floors, hog parlors, poultry houses, rinsing or spray cooling equipment, lawn sprinkling and insecticide spraying.

Single-phase models are equipped with a capacitor start, thermal protected motor. Three-phase models require separate overload protection.

2 & 3HP

4.88

TEFC ONLY

3.88

1Ø TEFC ONLY

3.75

6.50

Figure 1

(MODELS WITH HANDLES)

7.15

9.00

1.44

"H" INLET

3.25 "C"

"F"

"J" DISCHARGE

Unpacking

When unpacking the unit, inspect carefully for any damage that may have occurred during transit.

NOTE: Use pump with clear water only.

9.75

1-1/2 & 2HP 1Ø TEFC

ALL 3HP 1Ø

IL0391B

Pump Dimensions 60 Hz Chart A

HP GPM Stage “C”

1/3 5 8 10.19 19.81 - - .75 .75

1/3* 5 8 10.19 20.06 22.04 - .75 .75

1/2 5 12 13.38 23.25 23.23 24.10 .75 .75

1/2* 5 14 14.97 25.34 26.82 25.69 .75 .75

3/4 5 16 16.54 26.91 28.77 27.51 .75 .75 3/4 7 12 13.38 23.75 25.61 24.35 .75 .75

3/4* 7 14 14.97 25.84 27.20 25.94 .75 .75

1 10 14 16.31 27.18 29.16 28.02 .75 .75

1-1/2 10 16 18.13 29.62 31.48 30.07 .75 .75

1* 10 20 21.69 33.18 34.54 33.40 .75 .75 1* 10 22 23.50 34.99 36.35 35.21 .75 .75 1* 10 23 24.38 35.87 37.73 36.09 .75 .75

2 19 14 17.89 29.88 32.12 30.87 .75 .75

1-1/2* 19 20 24.06 36.05 37.41 36.00 .75 .75

2* 19 22 26.13 38.12 40.36 39.11 .75 .75

2 27 11 15.38 27.37 29.61 28.36 1.00 1.00 3 27 14 18.50 30.49 33.85 33.35 1.00 1.00

2* 27 17 21.59 33.58 35.82 34.57 1.00 1.00

3 27 17 21.59 33.74 - - 1.00 1.00 2 35 6 13.94 25.93 28.17 26.92 1.00 1.00 3 35 8 17.13 29.12 32.48 31.98 1.00 1.00

1-1/2* 35 8 17.13 29.12 30.48 29.07 1.00 1.00

3* 35 14 26.86 38.85 42.21 41.71 1.00 1.00

F&W

1 Phase 3 Phase

TEFC

H J

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132934 C

PRESSURE ADDED - PSI 10 20 40 60 80 100 120 140 160 180 200 220

Stainless Steel

Fitted

PB0508S031 PB0508C031 PB0508A031‡ 1/3 8 10.2 9.6 8.3 6.5 4.3 96 PB0512S051 PB0512C051 PB0512A051‡ 1/2 12 10.0 9.5 8.3 7.1 6.0 4.0 2.3 132 PB0516S071 PB0516C071 PB0516A071 3/4 16 10.2 9.7 9.1 8.3 7.5 6.6 5.8 4.6 3.3 189 PB0712S071 PB0712C071 PB0712A071 3/4 12 14.0 13.4 12.2 10.9 9.5 8.9 7.0 4.6 158 PB1014S101 PB1014C101 PB1014A101 1 14 * * 14.5 13.4 12.3 11.2 9.8 8.0 6.0 2.3 183 PB1016S151 PB1016C151 PB1016A151 1-1/2 16 * * 15.0 14.1 13.1 12.1 11.0 9.8 8.2 5.2 2.0 212 PB1914S201 PB1914C201 PB1914A201 2 14 27.6 27.0 25.7 24.2 22.6 20.8 18.7 16.2 12.9 7.7 190 PB3506S201 PB3506C201 PB3506A201 2 6 48.0 47.0 42.5 35.2 24.0 85 PB2711S201 PB2711C201 PB2711A201 2 11 * * 31.5 29.5 27.1 24.2 20.3 13.0 147 PB3508S301 PB3508C301 PB3508A301 3 8 48.0 47.5 44.0 40.0 35.2 27.5 118 PB2714S301 PB2714C301 PB2714A301 3 14 * * 33.0 31.5 29.8 27.9 25.6 22.8 18.9 11.1 187

PB2717S303** - - 3 17 * * * 34.1 32.3 30.5 28.3 25.8 23.1 20.0 16.6 11.4 225

- - PB5504A201 2 4 77.6 71.5 52.5 55

- - PB5506A301 3 6 77.8 74.4 65.0 51.1 31.9 83

- - PB8504A201 2 4 105.8 90.0 47.0 49

- - PB8505A301 3 5 108.8 98.8 60.0 25.0 60

‡ Equipped with carrying handle. 132079 handle available as an option for other models. † Example: If PB0508A031 pump is connected to supply 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.

** Only available in 3 phase

Motor voltage: Open Drip Proof Totally Enclosed Fan Cooled

Powder-

Coated Cast

Iron Fitted

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: PB0512A053

Cast Iron Fitted HP Stage Output - Gallons per Minute

60Hz Models

Single Phase: 1/2 thru 3 HP - 115/230V 60/50Hz Three Phase: 1/2 thru 3 HP - 208/230/460V 60/50Hz

Max.

Press.

PSI

Suction

Pipe

Tap

NPT

3/4” 3/4”

1” 1”

2” 2”

Disch.

Pipe

Tap

NPT

Single Phase Motor Data 60HZ Chart C

Single Phase† 60 Hz 3450 RPM Capacitor Start

1/3 1/2 3/4

1-1/2

2 3

Motor

Voltage

115/230 115/230 115/230 115/230 115/230 115/230

230

Factory

Connected

Motor

Voltage

115V 115V 115V 230V 230V 230V 230V

Service Factor Motor

Amps

Locked Rotor Motor

Amps

115V 230V 115V 230V

8.6

13.0

14.0

18.0

21.0

25.0

4.3

6.5

7.0

9.0

10.5

12.5

13.5

26.0

36.0

52.0

78.0

98.0

116.0

13.0

18.0

26.0

39.0

49.0

58.0

53.0

Code Letter

K K K

J H D

Single Phase Motor Data 50HZ

Single Phase† 50 Hz 2850 RPM Capacitor Start

1/2 3/4

1-1/2

†Thermal overload protector - automatic reset

115/230 115/230 115/230 115/230

230

115V 115V 230V 230V 230V

10.0

14.4

16.4

23.6

5.0

7.2

8.2

11.8

13.2

48.0

64.0

72.0

104.0

24.0

32.0

36.0

52.0

55.0

L K K H

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Three Phase Motor Data Chart D

Three Phase† 60/50 Hz 3450/2850 RPM Capacitor Start

3/4

1-1/2

3

Motor

Voltage

208-230/460 208-230/460 208-230/460 208-230/460 208-230/460

Factory

Connected

Motor

Voltage

230V 230V 230V 230V 230V

Service Factor Motor

Amps

Locked Rotor Motor

Amps

230V 460V 230V 460V

3.5

4.5

5.7

7.4

9.8

1.75

2.25

2.85

3.70

4.90

19.0

26.9

33.5

44.0

48.0

13.5

16.8

22.0

24.0

9.5

Code Letter

K K K K D

3 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 & inlet casting Cast iron 304 Stainless steel

O-Rings Buna-N Viton

Seal composition Carbon-silicon carbide, stainless steel spring

and Buna-N

*Models with powder coated inlet & discharge also available.

Carbon-silicon carbide, stainless steel spring and Viton

Minimum Wire Size Chart (Gauge) Chart F

Motor

1/3 115/230 1 14/14 14/14 14/14 12/14 12/14 15/15

1/2 115/230 1 12/14 12/14 12/14 12/14 10/14 15/15

3/4 115/230 1 12/14 12/14 10/14 10/12 8/12 15/15

1 115/230 1 10/14 10/14 10/12 8/12 6/10 20/15

11/2 115/230 1 10/12 8/12 6/12 */10 */10 30/15

2 115/230 1 10/12 8/12 6/12 */10 */10 30/15

3 230 1 10 10 10 10 8 20

3/4 230/460 3 14/14 14/14 14/14 14/14 14/14 15/15

1 230/460 3 14/14 14/14 14/14 14/14 12/14 15/15

11/2 230/460 3 14/14 14/14 14/14 12/14 12/14 15/15

2 230/460 3 14/14 14/14 14/14 12/14 10/12 15/15

3 230/460 3 14/14 14/14 14/14 12/14 10/12 15/15

1. (*) Not economical to run in 115V, use 230V.

Volts Phase

0-50 50-100 100-150 150-200 200-300

Distance In Feet From Motor To Service Panel

Breaker Size

(Amps)

Wire Size

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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.

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 personal injury or property damage.

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

Warns of hazards that CAN cause serious personal injury or death, if ignored.

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.

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 personal injury and/or property damage or puncture.

Do not touch an operating motor or engine. They are designed to operate at high temperatures.

This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Risk of Electric Shock. This pump has not been investigated for use in swimming pool areas.

NOTE: Pumps with the “CSA-CUS” mark are tested to UL standard 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

In any installation where property damage and/or personal injury might

result from an inoperative or leaking pump due to power outages, discharge line blockage, or any other reason, a backup system(s) should be used.

1. Locate pump as close to the fluid source as possible,

keeping 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.

Hazardous voltage. Can shock, burn or cause death. Ground

pump before connecting to power supply.

Wire motor for correct voltage. See “Electrical” section and Motor Data Charts C&D of this manual, and motor nameplate.

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.

3. Mount unit in a dry location that is easily accessible for

Follow wiring instructions in this manual when connecting

to power lines.

Always disconnect power source before performing any work on or near the motor

or its connected load. Do not use to pump flammable or explosive fluids such as gasoline, fuel oil, kerosene, etc. Do not use in flammable and/or explosive atmospheres.

inspection and maintenance. If a dry location is not available, 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.

Hazardous pressure! Install pressure relief valve in discharge pipe. Release all pressure on system before working on any component.

2. Pressure booster pumps are not recommended for suction lift applications.

PIPING

1. Use galvanized piping, rigid plastic or other suitable pipe

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.

5. Provide guarding around moving parts.

6. Keep visitors at a safe distance from the work area.

7. Periodically inspect pump and system components.

8. Protect electrical cord. Replace or repair damaged or worn cords immediately.

that will not collapse under suction or rupture due to pressure.

If hose is used, make sure it is the reinforced industrial type that is rated

higher than the shutoff pressure of the system. Ordinary garden hose will collapse 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.

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IL0418

IL0420

IL0421

IMPORTANT: The entire system must

be air and water tight for efficient/ proper operation.

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 typical installations.

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

permanent installation, bolt to a rigid foundation.

Use only components that

are rated for maximum pressure 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 that 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 discharge line.

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 sediment, 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 cleaning.

No Sags

Sags Allow Air Pockets

No Air Leaks In Inlet Pipe

Pipe Joint Compound Will Damage Plastic

If Air Flows Water Won’t

If Air Pockets Form, Water Won’t Flow

Figure 2 - No Air Pockets in Inlet Pipe

Mount pump in correct position or pump failure will result.

Correct

Figure 4A Figure 4B

IL1013

Figure 3 - Inlet Pipe Must Not Leak

Use Teflon Tape

Incorrect

SAND AND SEDIMENT TRAP FILTER

Standard Pressure Tank - 42 Gallon Or Larger

Outlet

Inlet

Sand Settles To The Bottom

Figure 5

Clean Out

IMPORTANT: Clean all filters and strainers on a regular schedule.

IL0419

IL1014

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Installation (Continued)

IL0423

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

nozzles for mist spraying, install a filter in the discharge plumbing to prevent the nozzles from becoming plugged. Multiple filters

should be plumbed in parallel.

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.

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 temperature around the motor should not exceed 104ºF (40ºC). 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 liquid.

Pump used to boost incoming city pressure (automatic operation).

Street Supply

Check Valve

Gate/Ball Valve (Normally open)

Figure 6

Union

Pressure Gauge

Check Valve

Service Tee

Inlet

Outlet

Gate/Ball Valve (Normally open)

To size tank properly - Match drawdown of tank to capacity of pump

Pressure Switch

Drain

Main Power Box

Fuse Box or Switch

Union

Pressure Gauge

IL0422

Pressure Relief Valve

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 operation).

Fuse Box or Switch

Pressure Gauge

Thermostat

Gate/Ball Valve

To avoid dangerous or fatal electrical shock, turn off power to motor before working on electrical connections.

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.

Line Filter Pressure Relief Valve

Figure 7

Solenoid Valve

To Drain

NOTE: Install solenoid valve on discharge side of pump. IMPORTANT: Clean all filters and strainers on a regular schedule.

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From Water Source

Gate/Ball Valve (Normally open)

To Nozzles

Installation (Continued)

IL0424

L2A B

IL0180

YELLOW

115 VOLT

SINGLE PHASE

LINE

230 VOLT

SINGLE PHASE

LINE

WHITE

GRAY

RED

TAN

YELLOW

WHITE

GRAY

RED

TAN

Ground motor before connecting to electrical power supply.

Failure to ground motor can

Hazardous voltage. Can shock, burn or cause death.

Ground pump before connecting to power supply.

phase motors. See Motor Rotation under Operation section and Figure 12.

WIRING

1. Install, ground, wire and maintain this pump in accordance with your local electrical code and all other codes and ordinances that apply. Consult your local building inspector for local code information.

2. Ground the pump permanently using a wire of size and type specified by local or United States National Electrical Code. Do not ground to a gas supply line.

3. Connect ground wire first. Connect to ground first, then to green grounding terminal provided on the motor frame, identified as GRD. Ground connection MUST be made to this terminal. 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 proper grounding information.

electrical specifications of the motor supplied. See Motor Data Charts.

cause severe or fatal electrical shock hazard.

Do not ground

to a gas supply line.

Proper rotation of pump impeller is critical on three

Make certain that the power supply conforms to the

Pump used to boost incoming pressure from a wall hydrant (manual operation).

Hose Adapter

Wall Hydrant

Pressure Gauge

Pressure Relief Valve

High Pressure Reinforced Hose

Service Tee

Inlet

Hose Adapter

Outlet

Spray Nozzle

Figure 8

High Pressure Reinforced Hose

NOTE: Dual voltage motors, change the red and gray wire to the voltage required.

Figure 9 - Wiring Diagram for Single Phase 1/3 - 2 HP Motors

230 Volts

Single Phase

LINE

L1 L2

A B

YELLOW

NOTE: Single voltage (230V) motor, and can not be connected to 115V.

Figure 10 - Wiring Diagram for Single Phase 3 HP Motors

GRAY

IL0181

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Installation (Continued)

IL1229

3 Phase

LINE LINE

3 Phase

HIGH VOLTAGELOW VOLTAGE

(WHEN REQ)

IL1231

LINE

HIGH VOLTAGELOW VOLTAGEGROUND T6

LINE

Figure 11 - Wiring Diagram for Baldor TEFC 3 Phase motors

3 Phase

HIGH VOLTAGELOW VOLTAGE

IL1230

Figure 12 - Wiring Diagram for Franklin Electric TEFC 1 Phase and 3 Phase motors

LINE

BROWN

VIOLET BLACK

YELLOW BLUE

BROWN VIOLET YELLOW

BLACK BLUE

1 Phase

HIGH VOLTAGE

(10)

(9) (2)

(3) (4)

LOW VOLTAGE

(10)

(9) (3)

(2) (4)

LINE

Figure 13 - Wiring Diagram for Marathon TEFC 3 Phase motors

LOW VOLTAGE 230V HIGH VOLTAGE 460 V

4 5 6

7 8 9

1 2 3

3-ø

4 5 6

7 8 9

1 2 3

L1 L3L2 L1 L3L2

IL0770

1 - Tan 4 - Yellow 7 - Purple

2 - Red 5 - Black 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 14 - Wiring Diagram for Three Phase Motors

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Installation (Continued)

5. Specific Wiring Procedure (Refer to Figures 9, 10, 11, 12, 13, 14 and Minimum Wire Size Chart).

a. Select the voltage you 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, 1 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, 11, 12, 13

& 14, 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.

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 confusing, 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 whenever 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 burnout 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.

Never 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 protection. 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 instructions 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 protection. 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).

/2, 2 and 3

Operation

Unit must be full of fluid before operating. 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 & 8).

1. Open valves or nozzle on inlet and discharge side of

pump.

2. To relieve trapped air, allow water supply to run a

minimum 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

reading of 2 psi minimum should show whenever the

pump is in operation (See Figures 6, 7 & 8). This reading insures that there is an ample supply of water into the pump inlet housing.

MOTOR/PUMP ROTATION

1. Single phase models are one (1) rotation only

(counterclockwise 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, interchange any two (2) incoming line (power)

leads.

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.

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Operation (Continued)

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.

IL1825

Figure 15 - Correct Motor/Pump Rotation (all units)

NOTE: See rotation arrow on inlet casting.

Maintenance

Disconnect power supply and depressurize system before servicing pump or removing any component.

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 discharge forward after removing discharge casting; or, the liquid 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 reassembling, reapply thread sealer.

PUMP DISASSEMBLY

To disassemble the pump, refer to the exploded parts view and Figures 16, 17 & 18 Tools Required:

• 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

1. To stabilize pump during disassembly, place block of wood underneath pump barrel.

2. Thread pipe into pump inlet port. This acts as a handle.

3. Using the pipe wrench, remove the discharge head, turning CCW (counter clockwise).

4. With the strap wrench, loosen the barrel, turning CCW (counter clockwise). DO NOT use pipe wrench on pump barrel.

5. 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 16).

The precision lapped faces of the mechanical seal are easily damaged.

Handle the replacement seal carefully. Short seal life will result if seal faces (ceramic & carbon) are nicked, scratched or dirty.

3. Clean the seal cavity 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). NOTE: Liquid soap solution - one drop of liquid soap combined 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 17).

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 18).

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Maintenance (Continued)

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 sufficient) 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 56J jet 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.

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 component 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 19 for proper facing and parts arrangement.

If damage to Stage components is evident, a complete cartridge assembly or individual stage assemblies are available for replacement (See Replacement Parts List).

1. Reassembly should follow the reverse order of the disassembly 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 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.

Figure 16 - Remove Mechanical Seal

Figure 17 - Press In Seal

3/4” Pipe Press Carefully

Cardboard Washer Protects Seal Face

Seal Cavity

IL0554

Figure 18 - If Necessary, Press With Cardboard And Pipe

Seal

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Troubleshooting Chart

Symptom Possible Cause(s) Corrective Action

Pump won’t start or run at full speed

Pump operates, but delivers little or no water

Excessive noise while pump in

Pump leaks 1. Worn mechanical seal (leaks at shaft) 1. Replace shaft (rotary) seal

1. Blown fuse or open circuit breaker 1. Replace fuse or close circuit breaker. See wire size chart for proper break/fuse size

2. Power supply in OFF position 2. Turn power on

3. Incorrect voltage at motor (check volt-

age with motor running)

3. Low voltage

a. Voltage must be within ± 10% of motor rated voltage.

Check incoming voltage. Contact power company

b. Make certain that voltage of motor matches voltage of

power supply. See motor name plate and motor wiring diagrams

c. Check wire size from main switch to pump. See wire

size chart for correct wire size

4. Loose, broken or incorrect wiring 4. Rewire any incorrect circuits. Tighten connections, replace defective wires

5. Defective motor 5. Replace motor

6. Pump hydraulic components clogged/

6. Replace worn parts or entire pump. Clean parts if required

worn/damaged

1. Manual or solenoid valves plumbed

into system restricting flow

1. a 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

b. Bleed trapped air in pump which keeps water from

reaching the pump. (Normally due to closed valve in discharge plumbing)

2. In-line filter restricting flow 2. Check all in-line filters to be sure they are not plugged or restricted

3. Low line voltage 3. See low line voltage corrective action (above)

4. Inadequate water supply to booster

pump

4. Check pressure on inlet side of booster to be sure positive pressure is maintained to the booster pump

5. Undersized piping 5. Replace undersized piping

6. Leak on inlet side of system 6. Make sure connections are tight. Repair leaks as necessary

7. Inadequate, defective or plugged foot

7. Clean, repair or replace as needed

valve and/or strainer

8. Worn or defective pump parts or

8. Replace worn parts or entire plugged impeller Clean parts if

pump.

9. Suction lift too great 9. Pump should be operated under flooded suction only

10. Pump not primed 10. Prime pump - Make certain inlet pipe is drawn up tight and pump and pipe are full of water

11. Incorrect rotation, motor running

backwards

11. Reverse motor rotation can occur on three phase units. To correct, interchange any two incoming power leads.

1. Pump not secured to firm foundation 1. Secure properly

2. Piping not supported 2. Make necessary adjustments

3. Restricted inlet line 3. Clean or correct

4. Cavitation (noise like marbles in pump) 4. a. Reduce speed on direct drive

b. Increase inlet pipe size

c. Too viscous (material being pumped too thick

5. Worn motor bearings 5. Replace bearings or motor

2. Worn o-ring seals 2. Replace o-ring seals, located inside both ends of the stainless steel shell

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Booster Pump Parts Drawing

IL0308

IL0127

10A

ITEM NO. DESCRIPTION

1 Motor 1A †Governor 1B †Switch Motor

2 Seal, Rotary

3 Barrel

4 Discharge Head 4A Discharge Bearing

5 O-ring (2) 6A Plate, Diffuser 6B Impeller 6C Diffuser 6D Diffuser Bearing 6E Shim as Required

7 Shaft and Coupling Assembly

8 Mounting Ring

9 Hex Head Bolts (4) 10 †MotorAccess Cover

10A †Screws, Access Cover (2)

*See note below parts included in cartridge assembly.

†ODP Motor Only

Figure 19

Internal Parts Detail

Figure 20 - Cartridge Assembly Includes Discharge Bearing, Shaft & 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.

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PRESSURE BOOSTER PUMP REPAIR PARTS

(For Pricing Refer To Repair Parts Price List)

Replacement Motors

IL0565

FORM NO. FW0045

SUPERSEDES 0208

0813

ITEM REPLACEMENT MOTORS QTY CAST IRON

ODP NEMA J 1/3 HP ODP NEMA J 1/2 HP 98J105 98J105 98S105 98J305 98J305 98S305 ODP NEMA J 3/4 HP 98J107 98J107 98S107 98J307 98J307 98S307

ODP NEMA J 1 HP 98J110 98J110 98S110 98J310 98J310 98S310 ODP NEMA J 1-1/2 HP 98J115 98J115 98S115 98J315 98J315 98S315 ODP NEMA J 2 HP 98J120 98J120 98S120 98J320 98J320 98S320 ODP NEMA J 3 HP 98J630 98J630 98S630 023251 023251 023251

10 Motor Cover w/Screws 1 136132R 136132R 136132R 136132R 136132R 136132R

* Screws, Motor Cover 2 136133 136133 136133 136133 136133 136133

ODP NEMA J 1/3 HP ODP NEMA J 1/2 HP 98J005 98J005 98S005 98J305 98J305 98S305 ODP NEMA J 3/4 HP 98J007 98J007 98S007 98J307 98J307 98S307

ODP NEMA J 1 HP 98J010 98J010 98S010 98J310 98J310 98S310 ODP NEMA J 1-1/2 HP 98J015 98J015 98S015 98J315 98J315 98S315 ODP NEMA J 2 HP 98J820 98J820 98S820 98J320 98J320 98S320

10 Motor Cover w/Screws 1 136132R 136132R 136132R 136132R 136132R 136132R

* Screws, Motor Cover 2 136133 136133 136133 136133 136133 136133

TEFC NEMA J 1/2 HP TEFC NEMA J 3/4 HP 021008 021008 021012 021012 TEFC NEMA J 1 HP 021009 021009 020688 020688

TEFC NEMA J 1-1/2 HP 020692 020692 020647 020647 TEFC NEMA J 2 HP 020693 020693 020689 020689 TEFC NEMA J 3 HP 021010 021010 020690 020690

* Not Shown

98J103 98J103 98S103

98J003 98J003 98S003

POWDER

COATED

SINGLE PHASE 60 HZ THREE PHASE 60 HZ

SINGLE PHASE 50 HZ THREE PHASE 60/50 HZ

SINGLE PHASE 60/50 HZ THREE PHASE 60/50 HZ

020691 020691 021011 021011

STAINLESS

STEEL

CAST IRON

POWDER

COATED

STAINLESS

STEEL

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FORM NO. FW0046 0312 SUPERSEDES 0509

PRESSURE BOOSTER PUMP REPAIR PARTS

(For Pricing Refer To Repair Parts Price List)

IL0565

ITEM DESCRIPTION QTY CAST IRON

5 - 7 - 10 - 19 GPM,

60 HZ & 50 HZ

27 - 35 GPM,

60 HZ & 50 HZ

55 - 85 GPM,

60 HZ & 50 HZ

ALL SERIES

60 HZ & 50 HZ

(†) Buna N - Carbon/Silicon Carbide (‡) Viton - Carbon/Silicon Carbide (■) Buna N (▲) Viton (*) Not Shown

(8) 132079 Handle available as an option

MATERIAL