FWPB Booster Pumps Instructions
FWPB Booster Pumps Instructions
FWPB Booster Pumps Instructions
0813
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product Supersedes
described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in per-
sonal injury and/or property damage! Retain instructions for future reference.
0113
5.28
2 & 3HP
9.00 1Ø TEFC ONLY
(MODELS WITH HANDLES) 4.88
1.44 TEFC ONLY
"J" DISCHARGE
"H" INLET
9.75
7.15 1-1/2 & 2HP 1Ø TEFC
3.88 ALL 3HP 1Ø
1
Copyright © 2012 FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • flintandwalling.com 132934
PRESSURE ADDED - PSI 10 20 40 60 80 100 120 140 160 180 200 220 Suction Disch.
Max.
Powder- Pipe Pipe
Stainless Steel Press.
Coated Cast Cast Iron Fitted HP Stage Output - Gallons per Minute Tap Tap
Fitted PSI
Iron Fitted NPT NPT
60Hz Models
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 3/4” 3/4”
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 1” 1”
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
2” 2”
- - PB8504A201 2 4 105.8 90.0 47.0 49
- - PB8505A301 3 5 108.8 98.8 60.0 25.0 60
‡ E quipped with carrying handle. 132079 handle available as an option for other models.
† E xample: 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
Single Phase 1/3 - 2 HP - 115/230; 3 HP - 230V 60 Hz.
Single Phase: 1/2 thru 3 HP - 115/230V 60/50Hz
Three Phase 1/2 - 2 HP - 208-230/460, 50/60Hz.
Three Phase: 1/2 thru 3 HP - 208/230/460V 60/50Hz
Three Phase 3 HP - 208-230/460, 60 HZ
For three phase models, use suffix “3” on the model no.
Example: PB0512A053
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Three Phase Motor Data Chart D
Three Phase† 60/50 Hz 3450/2850 RPM Capacitor Start
Factory Service Factor Motor Locked Rotor Motor
Motor Connected Amps Amps
HP Code Letter
Voltage Motor
Voltage 230V 460V 230V 460V
3
Copyright © 2012 FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • flintandwalling.com
General Safety Information 9. D o not insert finger or any object into pump or motor
Carefully read and follow all safety instructions in openings.
this manual and on pump. Keep safety labels in good 10. S ecure the discharge line before starting the pump. An
condition. Replace missing or damaged safety labels. unsecured discharge line will whip, possibly causing per-
sonal injury and/or property damage or puncture.
cal installations.
5
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Installation (Continued) Pump used to boost incoming city pressure (automatic operation).
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Copyright © 2012 FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • flintandwalling.com
Installation (Continued) Pump used to boost incoming pressure from a wall hydrant (manual operation).
! Hose Adapter
Ground motor Wall Hydrant
before connecting to Pressure Gauge
electrical power sup- Pressure
ply. Relief Valve
Failure to ground
Service Tee Hose Adapter
motor can cause High Pressure Reinforced Hose Inlet
severe or fatal electri-
Hazardous
cal shock hazard.
voltage. Can
shock, burn or Outlet
cause death. Do not ground to
Ground pump a gas supply line. Spray
before connecting
Nozzle IL0424
to power supply. High Pressure Reinforced Hose
Figure 8
Proper rotation of
pump impeller is critical on three phase
motors. See Motor Rotation under 115 VOLT 230 VOLT
Operation section and Figure 12. SINGLE PHASE SINGLE PHASE
LINE LINE
Wiring
1. Install, ground, wire and maintain L1 L1
this pump in accordance with your
local electrical code and all other A B L2 A B L2
codes and ordinances that apply.
Consult your local building inspector
YELLOW
WHITE
GRAY
RED
TAN
YELLOW
WHITE
GRAY
RED
TAN
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. NOTE: Dual voltage motors, change the red and
3.Connect ground wire first. Connect gray wire to the voltage required.
to ground first, then to green ground- Figure 9 - Wiring Diagram for Single Phase 1/3 - 2 HP
ing terminal provided on the motor Motors
frame, identified as GRD. Ground con-
nection MUST be made to this termi- 230 Volts
nal. Do not connect motor to electrical Single Phase
power supply until unit is permanently
Line
grounded; otherwise serious or fatal
electrical shock hazard may be caused. L1 L2
4. Connect the other end of the ground A B
wire to a properly grounded service
panel or to a control panel ground
bar if it is connected to the power
supply ground. Y G
IMPORTANT: Check local and/or E R
United States National Electric Codes L A
L Y
for proper grounding information. O
W
Make certain that IL0181
the power supply conforms to the elec-
trical specifications of the motor sup- NOTE: Single voltage (230V) motor, and can not
plied. See Motor Data Charts. be connected to 115V.
Figure 10 - Wiring Diagram for Single Phase
3 HP Motors
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Installation (Continued)
3 Phase
3 Phase
LOW VOLTAGE HIGH VOLTAGE
GROUND LOW VOLTAGE HIGH VOLTAGE
6 5 4 6 5 4 T6 T5 T4 T6 T5 T4
(WHEN REQ)
9 8 7 T9 T8 T7
T7 T1
T8 T9 T8 T7
9 8 7 T5
T6 T3 T2 T1 T3 T2 T1
3 2 1 T3 T2
3 2 1
LINE LINE
LINE LINE
IL1231
IL1229
Figure 11 - Wiring Diagram for Baldor TEFC 3 Phase Figure 13 - Wiring Diagram for Marathon TEFC 3 Phase
motors motors
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Installation (Continued) Operation
5.Specific Wiring Procedure (Refer to Figures 9, 10, 11, 12, Unit must be full of fluid before operat-
13, 14 and Minimum Wire Size Chart). ing. Do not run dry, or against a closed discharge. Do not
a. Select the voltage you are to use, either 115V or 230V pump dirty water or abrasive liquids. To do so will cause
single phase, 230V or 460V three phase. pump failure and will void the warranty.
b. The 1/3, 1/2 and 3/4 HP single phase pumps are factory Valves
connected for 115V at the motor. The 1, 11/2, 2 and 3 The inlet valve should be in the full open position and the
HP pumps are factory connected for 230V at the motor. discharge valve should be partially open, permitting some
Three phase models are factory connected for 230V at back pressure to be exerted against the pump when starting
the motor. up. Open valve after start up is completed.
c. If the motor wiring must be changed to conform to your Priming
specific voltage requirements then the motor, pressure NOTE: Before starting the pump it is absolutely necessary
switch or other controls should be rewired to conform that both the pump and the inlet pipe be completely
to one of the wiring diagrams (either 115V or 230V, filled with water.
single phase; 230V or 460V, three phase). Single phase 3
HP motors are 230V only and cannot be wired for 115V Pressure Boost Installations
service. Priming is automatic when pump is connected to a pressure
d. The motor wiring diagrams are Figures 9, 10, 11, 12, 13 source such as a hydrant or city main (See Figures 6, 7 & 8).
& 14, and also are located on the motor label of the 1. Open valves or nozzle on inlet and discharge side of pump.
pump. 2. To relieve trapped air, allow water supply to run a mini-
6. Remove the rear access cover of the motor. mum of 30 seconds before starting the pump.
7. Make the wiring change and replace the rear access cover. IMPORTANT: An adequate flow of water going into the
! pump is required so that the pumps impellers and shaft seal
Replace rear access cover before starting do not run dry and fail.
or operating pump. Failure to do so can result in personal
3. If you installed a pressure gauge at the pump inlet, a read-
injury.
ing of 2 psi minimum should show whenever the pump is
IMPORTANT: Do not use an extension cord or splice wires.
in operation (See Figures 6, 7 & 8).
Joints should be made in an approved junction box. If the
This reading insures that there is an ample supply of water
above information or the following wiring diagrams are con-
into the pump inlet housing.
fusing, consult a licensed electrician.
8. All units are not supplied with pressure switches, float
devices, on/off switches, or the like (control devices). Motor/PUMP Rotation
Controls should be wired in at this time, utilizing whatever 1. Single phase models are one (1) rotation only (counter-
instructions come with the controls. All units supplied clockwise when facing the pump end) and cannot be
with cords, will run whenever cord is plugged into power reversed.
and will turn off whenever cord is disconnected from 2. Proper rotation of pump impeller is critical for three phase
power. pumps. Pump motor should turn counterclockwise (CCW)
when facing pump end. Momentarily “bump” (apply
Motor Protection
power for less than a second) the motor to check for
All single phase motors have built in thermal protection for
proper rotation. To change rotation on three phase units,
all voltages. The overload protects the motor against burn-
interchange any two (2) incoming line (power) leads.
out from overload of low voltage, high voltage and other
causes. The device is automatic and resets itself once the Do not go over recommended maximum
temperature has dropped to a safe point. Frequent tripping operating pressure (see Specifications), while maintaining
of the device indicates trouble in the motor or power lines minimum flow of 1.5 GPM thru the pump. Do not restrict the
and immediate attention is needed. 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
Never examine, make wiring changes or
touch the motor before disconnecting the main electrical and reduce driver loading.
supply switch. The thermal device may have opened the
electrical circuit.
Three phase motors do not have a built in thermal protec-
tion. 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 instruc-
tions 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 protec-
tion. 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).
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Operation (Continued) barrel.
Start - Up Procedure 5. Holding the impeller stack in place, position pump in
Once the preceding instructions have been completed, the upright position, standing unit on the motor end cover.
pump can be started. 6. Use the 1/4” dowel rod to hold the stages down and in
1. During the first few hours of operation, inspect the pump, place on the pump shaft. Remove pump barrel.
piping and any auxiliary equipment used in connection 7. Slide the stages off the pump shaft onto the 1/4” dowel
with the unit. rod. Leave stages on rod and carefully set aside.
2. Check for leaks, excessive vibration or unusual noises. 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
IL0539 1. Follow instructions under “Pump Disassembly”.
Figure 15 - Correct Motor/Pump Rotation (all units) 2. Remove the mechanical seal assembly.
a. The rotary portion of the seal assembly (carbon ring,
NOTE: See rotation arrow on inlet casting. Buna-N gasket and spring will slide easily off the end of
shaft).
Maintenance b. Using two (2) screwdrivers, pry the ceramic seal and rub-
ber gasket from the recess of the mounting ring (See
Disconnect power supply and depressur- Figure 16).
ize system before servicing pump or removing any compo-
nent. The precision lapped faces of the mechan-
ical seal are easily damaged. Handle the replacement seal
Routine
carefully. Short seal life will result if seal faces (ceramic &
Pump should be checked routinely for proper operation. carbon) are nicked, scratched or dirty.
Replace or clean all filters and line strainers on a regular 3. Clean the seal cavity of the mounting ring and the motor
basis. thoroughly.
Draining 4. Wet outer edge of rubber cup on ceramic seat with liquid
This pump cannot be completely drained because of internal soap solution. Use sparingly (one drop only).
design. Most of the liquid can be drained by tilting the dis-
NOTE: Liquid soap solution - one drop of liquid soap com-
charge forward after removing discharge casting; or, the liq-
bined with one teaspoonful of water.
uid can be drained through the inlet port. Store in heated
areas. 5. W
ith thumb pressure, press ceramic seal half firmly and
Cleaning squarely into seal cavity. Polished face of ceramic seat
If used for spraying insecticides, pump should be thoroughly is up. If seal will not seat correctly, remove, placing seal
flushed with clean water after using. face up on bench. Reclean cavity. Seal should now seat
Lubrication correctly (See Figure 17).
The motor has prelubricated bearings. No lubrication is 6. If seal does not seat correctly after recleaning cavity,
required. place a cardboard washer over polished seal face and
Servicing Three-Phase Units carefully press into place using a piece of standard clean
Loctite (thread sealer) is used on the threads between the
3/4” pipe as a press (See Figure 18).
motor shaft and the pump shaft coupling. When reassem-
bling, 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, turn-
ing CCW (counter clockwise).
4. With the strap wrench, loosen the barrel, turning CCW
(counter clockwise). DO NOT use pipe wrench on pump
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Maintenance (Continued) If damage to Stage components is evident, a complete car-
IMPORTANT: Do not scratch seal face. tridge assembly or individual stage assemblies are available
7. D ispose of cardboard washer and recheck seal face to for replacement (See Replacement Parts List).
1. Reassembly should follow the reverse order of the disas-
be sure it is free of dirt, foreign particles, scratches and
sembly procedure with special care given to replacement
grease.
of the rotary seal.
8. Inspect shaft to be sure it is free of nicks and scratches. 2. Check top and bottom of o-rings for damage. It is recom-
9. A pply liquid soap solution sparingly (one drop is suffi- mended that new o-rings be used.
cient) to inside diameter of rubber rotating member. 3. Do not use pipe compound of Teflon tape on barrel
10. S lide rotating seal member (carbon face down toward threads. The o-rings will prevent pump from leaking.
ceramic face) and spring over the shaft. 4. After pump is reassembled, tighten the discharge head to
IMPORTANT: Do not nick or scratch carbon face of seal a torque of 45-50 ft/lbs. If torque wrench is not available,
when handling. tighten firmly but avoid distortion or damage to plastic
Motor Replacement internal parts.
The motor can be replaced with any standard Nema 56J jet 5. After reassembly, apply power momentarily to unit (15 to
pump motor (of proper HP for each pump) by referring to 30 seconds). The pump and motor should rotate freely or
the following instructions. with a light rubbing.
1. F ollow steps as outlined under Rotary Seal Replacement
and Pump Disassembly.
2. R emove cap screws that connect the motor to the
mounting ring and pull motor away.
3. R eplace 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 com-
ponent 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.
3/4” Pipe
Press Carefully
Cardboard
Washer
Protects Seal Seal
Face
Seal Cavity
IL0554
Figure 16 - Remove Mechanical Seal Figure 17 - Press In Seal Figure 18 - If Necessary, Press With
Cardboard And Pipe
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Troubleshooting Chart
Symptom Possible Cause(s) Corrective Action
Pump won’t 1. Blown fuse or open circuit breaker 1. R
eplace fuse or close circuit breaker. See wire size chart for
start or run proper break/fuse size
at full speed 2. Power supply in OFF position 2. Turn power on
3. Incorrect voltage at motor (check volt- 3. Low voltage
age with motor running) a. oltage must be within ± 10% of motor rated voltage.
V
Check incoming voltage. Contact power company
b. ake certain that voltage of motor matches voltage of
M
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. R
ewire 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
Pump oper- 1. Manual or solenoid valves plumbed 1. a Check all valves on pump inlet and discharge sides of
ates, but into system restricting flow system to be sure they are opened properly to allow
delivers little flow to and from the pump
or no water 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 4. Check pressure on inlet side of booster to be sure positive
pump 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 11. Reverse motor rotation can occur on three phase units. To
backwards correct, interchange any two incoming power leads.
Excessive 1. Pump not secured to firm foundation 1. Secure properly
noise while 2. Piping not supported 2. Make necessary adjustments
pump in
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
Pump leaks 1. Worn mechanical seal (leaks at shaft) 1. Replace shaft (rotary) seal
2. Worn o-ring seals 2. Replace o-ring seals, located inside both ends of the stainless
steel shell
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Copyright © 2012 FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • flintandwalling.com
Booster Pump Parts Drawing
10A
10
1B
1A
1
9
2
5
7
6A
6E
6C
ITEM NO. DESCRIPTION 6A
1 Motor 3
1A †Governor
1B †Switch Motor
2 Seal, Rotary 5
3 Barrel 4A
6B 4
4 Discharge Head 6D
4A Discharge Bearing
5 O-ring (2)
4
6A Plate, Diffuser
6B Impeller
6C Diffuser
6D Diffuser Bearing
6E Shim as Required
IL0127
7 Shaft and Coupling Assembly
8 Mounting Ring
9 Hex Head Bolts (4)
10 †MotorAccess Cover
Figure 19
10A †Screws, Access Cover (2)
*See note below parts included in cartridge assembly.
†ODP Motor Only
IL0308
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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Copyright © 2012 FLINT & WALLING, INC. • 95 North Oak St. • Kendallville, IN 46755 • flintandwalling.com
PRESSURE BOOSTER PUMP REPAIR PARTS FORM NO. FW0045
0813
(For Pricing Refer To Repair Parts Price List) SUPERSEDES 0208
Replacement Motors
9
10
IL0565
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FORM NO. FW0046
0312
PRESSURE BOOSTER PUMP REPAIR PARTS
SUPERSEDES 0509 (For Pricing Refer To Repair Parts Price List)
10 7
8 3 1
6
9
4
4
2 IL0565
POWDER STAINLESS
ITEM DESCRIPTION QTY CAST IRON
COATED STEEL
5 - 7 - 10 - 19 GPM, 1 Discharge Head 3/4” NPT 1 132000 136905 136640
60 HZ & 50 HZ 2 Mounting Ring 3/4” NPT 1 132002 136904 136639
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