Sta-Rite FLC-L Installation Manual

293 Wright Street, Delavan, WI 53115

Phone: 1-888-782-7483 Fax: 1-800-426-9446 Web Site: Sta-Rite.com

OWNER’S MANUAL

Convertible Deep Well Jet Pumps

NOTICE D’UTILISATION

Pompe à éjecteur transformables pour puits profonds

MANUAL DEL USUARIO

Bombas convertibles tipo “jet” para pozos profundos

Installation/Operation/Parts

For further operating, installation, or maintenance assistance:

Call 1-888-782-7483

English...........Pages 2-12

Installation/Fonctionnement/Pièces

Pour plus de renseignements concernant l’utilisation, l’installation ou l’entretien,

Composer le 1 (888) 782-7483

Français.........Pages 13-23

Instalación/Operación/Piezas

Para mayor información sobre el funcionamiento, instalación o mantenimiento de la bomba:

Llame al 1-888-782-7483

Español ....... Paginas 24-34

Safety 2

Important Safety Instructions

SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation, operation, and maintenance of the product. Save this manual for future reference.

This is the safety alert symbol. When you see this symbol on your pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury!

indicates a hazard which, if not avoided, will

result in death or serious injury.

indicates a hazard which, if not avoided,

could result in death or serious injury.

indicates a hazard which, if not avoided,

could result in minor or moderate injury. NOTICE addresses practices not related to

personalinjury.

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.

Electrical Safety

Risk of electrical shock. Capacitor voltage

may be hazardous. To discharge motor capacitor, hold insulated handle screwdriver BY THE HANDLE and short capacitor terminals together. Do not touch metal screwdriver blade or capacitor terminals. If in doubt, consult a qualifiedelectrician.

General Safety

Risk of burns. Do not touch an operating

motor. Motors are designed to operate at high temperatures. To avoid burns when servicing pump, allow it to cool for 20minutes after shut-down beforehandling.

Do not allow pump or any system component to freeze. To do so will void warranty.

Pump water only with this pump. Periodically inspect pump and system components. Wear safety glasses at all times when working on pumps. Keep work area clean, uncluttered and properly lighted;

store properly all unused tools and equipment. Keep visitors at a safe distance from the work areas.

Risk of explosion. Pump body may explode

if used as a booster pump unless relief valve capable of passing full pump flow at 75 psi is installed.

WARNING

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

Ground pump before connecting to power supply. Disconnect power before working on pump, motor or tank.

Wire motor for correct voltage. See “Electrical” section of this manual and motor nameplate.

Ground motor before connecting to power supply.

Meet National Electrical Code, Canadian Electrical Code, and local codes for all wiring.

Follow wiring instructions in this manual when connecting motor to power lines.

WARNING

Hazardous pressure! Install pressure relief valve in discharge pipe.

Release all pressure on system before working on any component.

Warranty 3

Limited Warranty

STA-RITE warrants to the original consumer purchaser (“Purchaser” or “You”) of the products listed below, that they will be free from defects in material and workmanship for the Warranty Period shown below.

Product Warranty Period

Water Systems Products — jet pumps, small centrifugal pumps, submersible pumps and related accessories

Pro-Source™ Composite Tanks 5 years from date of original installation Pro-Source™ Steel Pressure Tanks 5 years from date of original installation Pro-Source™ Epoxy-Lined Tanks 3 years from date of original installation

Sump/Sewage/Effluent Products

Our warranty will not apply to any product that, in our sole judgement, has been subject to negligence, misapplication, improper installation, or improper maintenance. Without limiting the foregoing, operating a three phase motor with single phase power through a phase converter will void the warranty. Note also that three phase motors must be protected by three-leg, ambient compensated, extra-quick trip overload relays of the recommended size or the warranty is void.

Your only remedy, and STA-RITE’s only duty, is that STA-RITE repair or replace defective products (at STA-RITE’s choice). You must pay all labor and shipping charges associated with this warranty and must request warranty service through the installing dealer as soon as a problem is discovered. No request for service will be accepted if received after the Warranty Period has expired. This warranty is not transferable.

STA-RITE SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT DAMAGES WHATSOEVER. THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES,

INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE FOREGOING WARRANTIES SHALL NOT EXTEND BEYOND THE DURATION EXPRESSLY PROVIDED HEREIN.

Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on the duration of an implied warranty, so the above limitations or exclusions may not apply to You. This warranty gives You specific legal rights and You may also have other rights which vary from state to state.

This Limited Warranty is effective June 1, 2011 and replaces all undated warranties and warranties dated before June 1, 2011.

STA-RITE INDUSTRIES

293 Wright Street • Delavan, WI U.S.A. 53115

Phone: 1-888-782-7483 • Fax: 1-800-426-9446 • Web Site: Sta-Rite.com

whichever occurs first: 12 months from date of original installation, or 18 months from date of manufacture

12 months from date of original installation, or 18 months from date of manufacture

Typical Installations 4

Piping omitted for clarity

Drive over Suction

Figure 1: Drive and Suction Functions

Suction (Larger) Pipe

Figure 2: Reversed Connections

to Well

Discharge

Drive Pipe

sends water down the well to drive water up through the

Suction Pipe to Pump Suction

If well head and pump dont match, use a reversing adapter or twist reinforced flexible pipe to connect pump to well head.

Drive (Smaller) Pipe

328 0395

Well

Head

Tap clamp to seat it

Suction

over

Drive

819 0495

To Household Water System

Air Volume Control

Standard Tank

Air Volume

Priming Tee and Plug

Control Tube

Relief Valve

1835 0695

Suction Pipe From Well

Pressure Switch

Drive Pipe To Well

Figure 4: Typical Deep Well Installations

To Household Water System

Pressure Gauge and Priming Port

Relief Valve

Drive Point

"Double Pipe" (4" and Larger

Diameter Well)

Suction (Larger) Pipe from Well

Cased Well

"Single Pipe"

Diameter Well)

Drive

(Smaller) Pipe to Well

Well Head

Well Casing serves as Drive Pipe

Venturi

Ejector Nozzle

Foot Valve Strainer

Leather Cup Seals

1834 0695

Suction Pipe From Well

(2" and 3"

J 2P

ET NO

Open Water

Install venturi in larger port in front of pump.

Figure 3: Mount Ejector –

Shallow Well

820 0495

Built-in Check Valve

Pre-Charged

Priming Tee and Plug

Check Valve

Tank

Drive point below water level

Drive Coupling

Drive Point

Figure 5: Typical Shallow Well Installations

Foot Valve

Strainer

Priming Tee and Plug

Sanitary Well Seal

Well Casing

10'

Min.

5–10'

Screen

Foot Valve

1836 0695

Discharge Pipe and Pressure Tank Connections 5

Pressure Gauge and Priming Plug

Pressure Switch

Figure 6: Pre-charged Tank

Connections

To Household Water System

Air Volume Control

To Household Water System

Relief Valve

From Well

Pre-Charge Tank Connection (Figure 6)

If your system uses a pre-charged tank, it should be connected to the pump as shown in Figure 6. The relief valve must be capable of passing the entire pump capacity at 100 PSI pressure.

Check the pre-charge of air in the tank with an ordinary tire gauge. the precharge is measured when there is no water pressure in the tank. Disconnect power to the pump and drain the tank before checking the pre-charge. Your pump has a 30/50 PSI switch, so the tank pre-charge pressure should be 28PSI (that is, it should be 2 PSI lower than the cut-in pressure of the pressure switch.

No AVC is required for a pre-charged tank; the 1/8” NPT AVC port on the pump body should be plugged.

Standard Tank Connection (Figure 7)

If your system uses a standard tank, connect it to the pump as shown in Figure 7. The relief valve used with a standard tank must be capable of passing the entire pump capacity at 75 PSI pressure.

Connect the Air Volume Control (AVC) tube to the 1/8” NPT AVC port on the pump body. Run the tubing from the pump’s AVC port to the AVC mounted on the tank. See the instructions provided with tank and AVC fordetails.

Sealing Pipe Joints

Use only PTFE pipe thread sealant tape or PTFE-based joint compounds for making all threaded connections to the pump itself. Do not use pipe joint compounds on plastic pumps: they can react with the plastic in pump components. Make sure that all pipe joints in the suction pipe are air tight as well as water tight. If the suction pipe can suck air, the pump

will not be able to pull water from the well.

Air Volume

Control Tube

276 0395

From Well

Priming Tee and Plug

Relief Valve

Pressure Switch

Figure 7: Standard Tank Connections

Electrical 6

Disconnect power before working on pump, motor, pressure switch, or wiring.

Motor Switch Settings

NOTICE: 1/3 and 1/2 HP motors are dual voltage and are factory set to 115V. 3/4 & 1 HP motors are also dual voltage, but are factory set to 230V. Motor terminal board (located under the motor end cover) should look like that shown below. Use the instructions to set your motor to match your power source.

Never connect a motor set to 115V to a 230V power source.

Plug Type Voltage Selector

Voltage is set to 230V. To change to 115V:

Power Connections

Voltage Change Plug

Ground Wire Connection

Figure 8: Voltage set to 230 V, Plug Type

1. Make sure power is off.

2. Pull the voltage change plug off of the tabs.

3. Move the voltage change plug to the 115 V position.

The plug will now cover 2 metal tabs and the arrow on the plug will line up with the 115V arrow on the label (see Figure 9).

Pressure Switch

Dial Type Voltage Selector

Voltage is set to 230V. To change to 115V:

Power Supply Connections

Voltage Change Dial

Pressure Switch

Ground Wire Connection

Figure 10: Voltage set to 230 V, Dial Type

1. Make sure power is off.

2. Turn the dial counter-clockwise until 115 shows in the dial window as shown in Figure 11.

Figure 9: Voltage set to 115 V, Plug Type

4. Attach the incoming power leads to the two outer screws on the pressure switch as shown in Figure 8.

5. Attach the ground wire to one of the grounding connections, shown in Figure 8.

6. If there are other wires, they should be capped.

Reinstall the motor end and pressure switch covers.

Figure 11: Voltage set to 115 V, Dial Type

3. Attach the incoming power leads to the two outer screws on the pressure switch as shown in Figure 10.

4. Attach the ground wire to the grounding connections as shown in Figure 10.

5. If there are other wires, they should be capped.

Reinstall the motor end and pressure switch covers.

Electrical 7

Hazardous voltage. Can shock, burn, or

kill. Connect ground wire before connecting power supply wires. Use the wire size (including the ground wire) specified in the wiring chart. If possible, connect the pump to a separate branch circuit with no other appliances on it.

Explosion hazard. Do not ground to a gas

supply line.

Wiring Connections

Fire hazard. Incorrect voltage can cause

a fire or seriously damage the motor and voids the warranty. The supply voltage must be within ±10% of the motor nameplate voltage.

NOTICE: Dual-voltage motors may be set for 115V or 230V. If necessary, reset the motor to the desired voltage, as shown. Do not alter the wiring in single voltagemotors.

Install, ground, wire, and maintain your pump in compliance with the National Electrical Code (NEC) or the Canadian Electrical Code (CEC), as applicable, and with all local codes and ordinances that apply. Consult your local building inspector for code information.

Connection Procedure:

1. Connect the ground wire first as shown in Figure 8. The ground wire must be a solid copper wire at least as large as the power supply wires.

2. There must be a solid metal connection between the pressure switch and the motor for motor grounding protection. If the pressure switch is not connected to the motor, connect the green ground screw in the switch to the green ground screw under the motor end cover. Use a solid copper wire at least as large as the power supply wires.

3. Connect the ground wire to a grounded lead in a service panel, to a metal underground water pipe, to a metal well casing at least ten feet (3m) long, or to a ground electrode provided by the power company or the hydro authority.

4. Connect the power supply wires to the pressure switch as shown in Figure 8.

Wiring Chart – Recommended Wire and Fuse Sizes

Model HP

115 Volts:

PLB 1/3 PLC FLC, FSLCH PLD FLD, FSLDH

PLF 1-1/2 19.2 25 10 (5.5) 4 (21)

230 Volts:

PLB 1/3 PLC FLC, FSLCH PLD FLD, FSLDH

PLF 1-1/2 9.6 12 (3) 10 (5.5)

Max Load

Amps

9.4 15 14 (2)

1/2

12.2

3/4

14.8

4.7

1/2

6.1

3/4

7.4

Branch Fuse

Rating Amps

20 12 (3)

15 14 (2)

0-100 (0-30) 101-200 (31-61) 201-300 (62-91) 301-400 (92-122) 401-500 (123-152)

Distance in Feet (Meters); Wire Size AWG (mm

10 (5.5)

8 (8.4)

8 (8.4) 6 (14) 4 (21)PLE 1

14 (2)

6 (14)

14 (2)

12 (3)

)

6 (14)

12(3)

10 (5.5)PLE 1

Preparing to Start the Pump - Deep Well 8

Figure 12: Fill Pump

556 0395

Figure 13: Prime Pump

A-Open Control Valve

Open control valve as far as possible and fill pump and piping through priming port or priming tee.

280 0395

Replace all fill plugs and close control valve completely.

Priming

Explosion hazard. Never run pump against closed discharge.

To do so can boil water inside pump, causing hazardous pressure in unit, risk of explosion and possibly scalding persons handling pump.

Risk of burns. Never run pump dry. Running pump without

water may cause pump to overheat, damaging seal and possibly causing burns to persons handling pump. Fill pump with water before starting.

1. Open the control valve as far as possible (see Figure 12). Then remove the priming plug from the pump and fill the pump, fill all piping between the pump and the well, and make sure that all piping in the well is full. If you have also installed a priming tee in the suction piping, remove the plug from the tee and fill the suction piping.

2. Replace all fill plugs and close the control valve completely (Figure 13).

3. Power on! Start the pump and watch the pressure gauge. The pressure should build rapidly to 50 PSI as the pump primes.

4. After 2 or 3 minutes, the gauge should show pressure. If not, stop the pump, remove the fill plugs, reopen the control valve, and refill the pump and piping. You may have to repeat this two or three times in order to get all the trapped air out of the piping. Don’t forget to close the control valve each time before you start the pump.

5. When pressure has built up and stabilized at about 50 PSI, slowly open the control valve (see Figure 14) and let the pressure drop until the pressure gauge needle starts to flutter. When the needle flutters, close the valve just enough to stop the flutter (see Figure 14). Your pump is now operating at its most efficient point.

6. After the pump has built up pressure in the system and shut off, check the pressure switch operation by opening a faucet or two and running enough water out to bleed off pressure until the pump starts. The pump should start when pressure drops to 30 PSI and stop when pressure reaches 50 PSI. Run the pump through one or two complete cycles to verify correct operation. This will also help clean the system of dirt and scale dislodged during installation.

7. (PL Series pumps only). Check for leaks around band clamp. If pump is leaking, tighten clamp nut 1-2 turns. Do not overtighten.

NOTICE: Due to normal irregularities in the cup seal leather and the inner walls of the casing, packer jets do not form a perfect seal. In a dormant system, pressure will leak off over time, causing pump to cycle periodically to maintain system pressure level.

B-Watch for Pressure Gauge to Flutter

C-Close Control Valve until Pressure

Stabilizes

Figure 14: Set Control Valve

281 0395

Preparing to Start the Pump – Shallow Well 9

Priming

Open control valve as far as possible and fill pump and piping through priming port or priming tee.

284 0395

Figure 15: Open Control Valve

To do so can boil water inside pump, causing hazardous pressure in unit, risk of explosion and possibly scalding persons handling pump.

water may cause pump to overheat, damaging seal and possibly causing burns to persons handling pump. Fill pump with water before starting.

1. Open the control valve as far as possible (see Figure 15). Then remove the priming plug from the pump and fill the pump, fill all piping between the pump and the well, and make sure that all piping in the well is full. If you have also installed a priming tee in the suction piping, remove the plug from the tee and fill the suction piping.

2. Replace all fill plugs. Leave the control valve open (in a shallow well installation, the control valve always stays open).

3. Power on! Start the pump. The pump should pump water in two or three minutes.

4. If you don’t have water after 2 or 3 minutes, stop the pump and remove the fill plugs. Refill the pump and piping. You may have to repeat this two or three times in order to get all the trapped air out of the piping. The control valve remains open throughout this procedure.

5. After the pump has built up pressure in the system and shut off, check the pressure switch operation by opening a faucet or two and running enough water out to bleed off pressure until the pump starts. The pump should start when pressure drops to 30 PSI and stop when pressure reaches 50 PSI. Run the pump through one or two complete cycles to verify correct operation. This will also help clean the system of dirt and scale dislodged during installation.

6. (PL Series pumps only). Check for leaks around band clamp. If pump is leaking, tighten clamp nut 1-2 turns. Do not overtighten.

Explosion hazard. Never run pump against closed discharge.

Risk of burns. Never run pump dry. Running pump without

Winterizing the Pump

To prepare the pump for freezing temperatures:

1. Shut off power to the pump.

2. Relieve system pressure. Open a faucet and let it drain until water stopsflowing.

3. Drain the pump. Your pump may have a separate drain plug. Remove this plug and let it drain.

Your pump may only have a plug or connection on the side of the

pump. Remove this and let the pump drain. Some water will remain in the pump. A small amount of water left in the pump will not harm it if it freezes.

Troubleshooting 10

Symptom Possible Cause(s) Corrective Action

Disconnect switch is off Be sure switch is on. Fuse is blown or circuit breaker tripped Replace fuse or reset circuit breaker. Starting switch is defective DISCONNECT POWER; Replace starting switch.

Refer to instructions on wiring (Page 9). DISCONNECT POWER; check and

Motor will not run

Motor runs hot and overload kicks off

Motor runs but no water is delivered*

* Stop pump; then check prime before looking for other causes. Unscrew priming plug and see if water is in priming hole.

Pump does not deliver water to full capacity (Also check point 3 immediately above)

Pump delivers water but does not shut off or pump cycles too frequently

Air spurts from faucets

Wires at motor are loose, disconnected, or wired incorrectly

Pressure switch contacts are dirty DISCONNECT POWER and file contacts with emery board or nail file. Motor is wired incorrectly Refer to instructions on wiring.

Voltage is too low

Pump cycles too frequently See section below on too frequent cycling. Pump in new installation did not pick up

prime through:

1. Improper priming

2. Air leaks

3. Leaking foot valve or check valve

Pump has lost prime through:

1. Air leaks

2. Water level below suction pipe inlet

Foot valve or strainer is plugged Clean foot valve or strainer. Ejector or impeller is plugged Clean ejector or impeller. Check valve or foot valve is stuck shut Replace check valve or foot valve. Pipes are frozen Thaw pipes. Bury pipes below frost line. Heat pit or pump house. Foot valve and/or strainer are buried in

sand or mud Water level is too low for shallow well

setup to deliver water Water level in well is lower than estimated A new nozzle and venturi combination may be needed. Steel piping (if used) is corroded or limed,

causing excess friction Piping is too small in size Use larger piping. Pressure switch is out of adjustment or

contacts are welded together Faucets have been left open Close faucets. Venturi, nozzle or impeller is clogged Clean venturi, nozzle or impeller. Standard pressure tank is waterlogged and

has no air cushion Pipes leak Check connections. Foot valve leaks Replace foot valve. Pressure switch is out of adjustment Adjust or replace pressure switch.

Air charge too low in pre-charged tank

Pump is picking up prime When pump has picked up prime, it should pump solid water with no air. Leak in suction side of pump Suction pipe is sucking air. Check joints for leaks with soapy water. Well is gaseous Consult factory about installing a sleeve in the well. Intermittent over-pumping of well. (Water

drawn down below foot valve.)

tighten all wiring.

Hazardous voltage. Capacitor voltage may be hazardous. To

discharge capacitor, hold insulated handle screwdriver BY THE HANDLE and short capacitor terminals together. Do not touch metal screwdriver blade or capacitor terminals. If in doubt, consult a qualified electrician.

Check with power company. Install heavier wiring if wire size is too small (See Electrical / Wiring Chart).

In new installation:

1. Re-prime according to instructions.

2. Check all connections on suction line, AVC, and ejector with soapy water or shaving cream.

3. Replace foot valve or check valve. In installation already in use:

1. Check all connections on suction line and shaft seal.

2. Lower suction line into water and re-prime. If receding water level in well exceeds 25’ (7.6M), a deep well pump is needed.

Raise foot valve and/or strainer above bottom of water source. Clean foot valve and strainer.

A deep well jet will be needed if your well is more than 25’ (7.6M) depth to water.

Replace with plastic pipe where possible, otherwise with new steel pipe.

DISCONNECT POWER; adjust or replace pressure switch.

Drain tank to air volume control port. Check AVC for defects. Check all connections for air leaks.

DISCONNECT POWER and open faucets until all pressure is relieved. Using tire pressure gauge, check air pressure in tank at valve stem located on the tank. If less than pressure switch cut-in setting (30-50 PSI), pump air into tank from outside source until air pressure is 2 PSI less than cut-in setting of switch. Check air valve for leaks (use soapy solution) and replace core if necessary.

Lower foot valve if possible, otherwise restrict pump discharge.

Repair Parts 11

Diffuser (AL Series)

Service Kits:

Seal and Gasket Kit PP1500 Overhaul Kit: 1/3 and 1/2 HP PP1560 Overhaul Kit: 3/4HP PP1565

Diffuser (FSL/FL Series)

Pressure Gauge Kit PP2102 Pressure Switch Kit PP2151

FSL/FL Series

Repair Parts – Cast Iron Jet Pumps

Ref. Part Description Qty. FSLCH-L, FLC-L 1/2 HP FSLDH-L, FLD-L 3/4 HP

1 Motor 1 J218-582A-115-PKG A100DLL 2 Water Slinger 1 17351-0009 17351-0009 3 Seal Plate 1 N3-1043P N3-1043P 4 Seal Plate Gasket 1 N20-35 N20-35 5 Shaft Seal 1 U109-6A U109-6A 6 Impeller 1 J105-40P J105-86P 7 Diffuser 1 L1-25P L1-48P 8 Diffuser, Screws 3 – –

9 Diffuser Ring 1 L21-1 L21-1 10 Barbed Fitting – Straight 1 U111-211T U111-211T 11 Pipe Plug, 1/8” Sq. Hd 1 U78-56ZPS U78-56ZPS 12 Control Valve Assembly 1 01322 01322 13 Control Valve Gasket 1 L20-39 L20-39 14 Drain Plug U78-941ZPV U78-941ZPV 15 Priming Plug 1 U78-959T U78-959T 16 Pump Body 1 L76-44 L76-44 17 Switch Tube 1 U37-672P U37-672P

• Barbed Fitting – Elbow 1 – – 18 Pressure Switch 1 U217-1202 U217-1202 19 Lock Nut 1 U36-112ZP U36-112ZP 20 Connector 1 L43-5C L43-5C 21 3/8-16x1-1/2” Capscrews 4 U30-75ZP U30-75ZP 22 Pressure Gauge – – 23 Pipe Plug, 1/2” Sq. Hd. 1 _ _

• Not illustrated.

Series

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