Flint & Walling Stainless Commander User Manual

OWNERS GUIDE TO

INSTALLATION AND OPERATION

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

0314

Supersedes

0611

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 250-43 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.

NOTE: Pumps with the “CSA” mark are tested to UL standard UL778 and certified to CSA standard C22.2 No.

108.

130582

Typical Installation

Submersible Cable

Riser Pipe

Pitless Adapter

Plastic or Steel Pipe

Torque Arrestor

Check Valve

Submersible Pump

Submersible Motor

Figure 1 — Typical Installation with Pre-Charged Tank

Submersible Power Cable to Pump

Bleeder Orifice

Power Cable Taped to Pipe

Check Valve

Figure 2 — Typical Installation with Standard Pneumatic Tank

Conduit

IL0092

Union

Control Box

Check Valve

Magnetic Starter

Fused Switch Box

Snifter

Pressure Switch

Pitless Unit

Control Box

Pressure Switch

Check Valve

Single Phase Tank/Controls Installation

Check Valve

Three Phase Tank/Controls Installation

Air Release and Pressure Gauge

Tank

Relief Valve

Fuse Disconnect Box

Pressure Gauge

Fuse Disconnect Box

Pressure Gauge

Outlet to Service

Drain Valve

Pre-Charged Pressure Tank

Pressure Relief Valve

Gate Valve

To Drain

Pre-Charged Pressure Tank

Pressure Relief Valve

Gate Valve

To Drain

90º Elbow

Well Seal

Pipe

Coupling

Pipe

Bleeder Valve Rubber Orifice

Pipe

To Service

IL0093A

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* 390 490 600 740 910 111 0 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* 470 580 700 850 970 111 0 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

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

ell Screen

IL0096

Pump on.

Water enters

the reservoir

System Filled.

Pump Off

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

IL0094B

Figure 3

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.

Guard

Motor

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 multistage 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.

8. The complete pump and motor should be submerged at least twenty 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).

Drawdown Water Level

20 Ft.

Top of W

10 Ft. Min.

Figure 4

Bottom of Well

9. The Piping — Install the pump with pipe of the same diameter as the discharge port of the pump or larger.

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 100 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 cuton 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.

Figure 5

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 installation where the pump pressure can exceed the pressure tank’s maximum working pressure or on systems where the discharge line can be shut off or obstructed. The relief valve drain port should be piped to a drain (Figures 1 & 2).

WARNING: Not providing a relief valve can cause extreme over pressure, which could result in personal and/or property damage.

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Flint & Walling Stainless Commander User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual