ON-SITE WASTEWATER PROD UCTS

Transcription

1 NOTICE TO INSTALLER: Instructions must remain with installation. FW Supesedes NEW Product information presented here re fl ects con di tions at time of publication. Consult factory regarding discrepancies or inconsistencies. 95 North Oak Street Kendallville, IN (8) visit our web site: ON-SITE WASTEWATER PROD UCTS OWNER S MANUAL Effluent Turbine Submersible Pumps Congratulations on the purchase of the Flint & Walling Effluent Turbine Submersible Pump. This Flint & Walling pump will provide years of trou ble-free service when installed according to the manufacturer recommendations. items con tained within, when fol lowed correctly, will not only ensure a long and problem-free life for the system, but also save time and money during in stal la tion. Should further as sis tance be nec es sary please call our Tech ni cal Service de part ment at This manual incorporates the installation, operation, maintenance, and service instructions into one doc u ment to aid in the own er ship of a Flint & Walling on-site wastewater product. Please read and review this manual be fore in stall ing the product. Many Table of Contents Safety Instructions... 1 Limited Warranty... 2 Preinstallation Information... 2 Pump Performance Data Electrical Data... 5 Major Components... 5 Pump Installation and Wiring Diagram... 6 System Wiring Instructions... 6 Splicing Underground Wires... 7 Start-up and Maintenance... 7 Troubleshooting & Service Checklist... 7 Typical Installations... 8 Safety Instructions TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MA JOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY IN- STRUCTIONS IN MANUAL AND ON PUMP. THIS MANUAL IS INTENDED TO ASSIST IN THE IN STAL LA TION AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH THE PUMP. This is a SAFETY ALERT SYMBOL. When you see this symbol on the pump or in the man u al, look for one of the following signal words and be alert to the potential for personal injury or property damage. Owner s Information Model Number: Date Code: Job Name: Dealer: Date of Purchase: Contractor: Date of Installation: System Readings During Operation: Voltage Amps 1 Warns of hazards that WILL cause serious personal injury, death or major property damage. Warns of hazards that CAN cause serious personal injury, death or major property damage. Warns of hazards that CAN cause personal injury or prop er ty damage. Indicates special instructions which are very important and must be followed. THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS PRIOR TO PERFORMING ANY WORK ON THIS PUMP. MAINTAIN ALL SAFETY DECALS

2 Manufacturer warrants, to the purchaser and subsequent owner during the warranty period, every new product to be free from defects in material and workmanship under normal use and service, when properly used and maintained, for a period of one year from date of purchase by the end user, or 18 months from date of original manufacture of the product, whichever comes fi rst. Parts that fail within the warranty period, one year from date of purchase by the end user, or 18 months from the date of original manufacture of the product, whichever comes fi rst, that inspections determine to be defective in material or workmanship, will be repaired, replaced or remanufactured at Manufacturer's option, provided however, that by so doing we will not be obligated to replace an entire assembly, the entire mechanism or the complete unit. No allowance will be made for shipping charges, damages, labor or other charges that may occur due to product failure, repair or replacement. This warranty does not apply to and there shall be no warranty for any material or product that has been disassembled without prior approval of Manufacturer, subjected to misuse, misapplication, neglect, alteration, accident or act of God; that has not been installed, operated or maintained in accordance with Manufacturer's installation instructions; that has been exposed to outside substances including but not limited to the following: sand, gravel, cement, mud, tar, hydrocarbons, hydrocarbon derivatives (oil, gasoline, solvents, etc.), or other abrasive or corrosive substances, wash towels or feminine sanitary Limited Warranty products, etc. in all applications other than in raw sewage pumping applications. The warranty set out in the paragraph above is in lieu of all other warranties expressed or implied; and we do not authorize any representative or other person to assume for us any other liability in connection with our products. Contact Manufacturer at, 95 North Oak Street, Kendallville, IN 46755, Attention: Cus tom er Ser vice De part ment to obtain any need ed repair or re place ment of part(s) or additional in for ma tion pertaining to our warranty. MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR SPE- CIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES OR BREACH OF EX PRESSED OR IMPLIED WARRANTY; AND ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND OF MER CHANT ABIL I TY SHALL BE LIM IT ED TO THE DU RA TION OF THE EX PRESSED WAR RAN TY. Some states do not allow limitations on the duration of an implied warranty, so the above limitation may not apply to you. Some states do not allow the exclusion or limitation of incidental or con se quen tial dam ag es, so the above lim i ta tion or exclusion may not apply to you. This warranty gives you specifi c legal rights and you may also have other rights which vary from state to state. Preinstallation Information 1. Inspect your unit. Occasionally, products are damaged during ship ment. If the unit is damaged, contact your dealer be fore using. 2. Carefully read the literature provided to fa mil iar ize your self with spe cif ic details re gard ing in stal la tion and use. These ma te ri als should be retained for future ref er ence. 3. Risk of electrical shock Do not re move power supply cord and strain relief or connect conduit directly to the pump. In stal la tion and check ing of electrical circuits and hardware should be performed by a qualifi ed and li censed electrician. 4. Do not lift, carry, or hang pump by the elec tri cal ca bles. Dam age to the electrical cables can cause shock, burns or death. 5. For your protection, make cer tain the pump ground wire is properly connected to the ground wire with the incoming power line. Test for ground at the junction box using an Underwriters Laboratory listed circuit analyzer which will indicate if the power, neutral and ground wires are cor rect ly con nect ed. If in doubt, call a qual i fi ed li censed elec tri cian. 6. Make cer tain that the receptacle is with in the reach of the pump s power supply cord. DO NOT USE AN EXTENSION CORD. Extension cords that are too long or too light do not de liv er suffi cient voltage to the pump motor. But, more im por tant, they could present a safe ty haz ard if the in su la tion were to become damaged or the connection end were to get wet. 7. Make sure the pump elec tri cal sup ply cir cuit is equipped with fus es or cir cuit break ers of prop er capacity. A sep a rate branch circuit is rec om mend ed, and sized ac cord ing to the Na tion al Elec tri cal Code for the cur rent shown on the pump nameplate. 8. DO NOT run the pump dry. DO NOT run the pump with a completely closed discharge. DO NOT pump chem i cal or cor ro sive liquids. Failure to follow above warnings could result in damage to the pump, void ing the warranty and causing personal injury. 9. Check to be sure your pow er source is ca pa ble of handling the volt age re quire ments of the motor, as in di cat ed on the pump name plate. 1. The installation of pumps using auxiliary variable level fl oat switch es is the responsibility of the in stall ing party. Care should be taken such that the tethered fl oat switch will not hang up and are secured so that the pump will turn on and off properly. 11. Water ham mer creates momentary high pres sure surges. These surges can cause severe dam age to check valves and the piping system. Consideration for water ham mer must be included in the piping sys tem design. Reference ASPE Data Book, Chapter Some systems may re quire ex ter nal spring or lever weight ed check valves or other en gi neered solutions. 12. In cold climates the discharge pipe may be subject to freez ing. If the riser on the septic tank is above the frost line, it will be necessary to protect the system from freeze up. The discharge pipe can be insulated or the check valve can be removed. If the check valve is removed, the on-off cycle must be adjusted for any back-fl ow from the dis charge line. 13. According to the state of California (Prop 65), this product contains chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. 2

3 PUMP PERFORMANCE DATA GPM Models PUMP PERFORMANCE CURVE 1 GPM 1 1/4" NPT DISCHARGE 3/4 HP- 12 STAGE 1/2 HP- 8 STAGE 1/2 HP- 6 STAGE GALLONS LITERS FLOW PER MINUTE IL GALLONS LITERS 19 GPM Models PUMP PERFORMANCE CURVE 19 GPM 1¼" NPT DISCHARGE 3/4 HP 7 STAGE 1/2 HP 5 STAGE 1 HP - 9 STAGE FLOW PER MINUTE IL F53-5 1/ /8 F53-6 1/ /8 F53-7 1/ /4 F53-8 1/ /4 F53-9 3/ /16 F / /16 F / /16 F / /16 F /8 27 GPM Models PUMP PERFORMANCE CURVE 27 GPM /4 NPT DISCHARGE HP- 7 STAGE /4 HP 2 6 STAGE /2 HP- 4 STAGE GALLONS LITERS FLOW PER MINUTE IL GALLONS LITERS 35 GPM Models PUMP PERFORMANCE CURVE - 35 GPM 2 NPT DISCHARGE 3/4 HP - 3 STAGE 1/2 HP - 2 STAGE FLOW PER MINUTE IL54 F / /16 F / /16 F / /16 F /16 F / /8 F / /8 F / /4 3

4 55 GPM Models PUMP PERFORMANCE DATA /2 HP-1 STAGE PUMP PERFORMANCE CURVE 55 GPM 2" NPT DISCHARGE GALLONS LITERS FLOW PER HOUR/MINUTE IL55 F / /4 F / /4 Model HP Motor Depth to Water Level in Feet - Capacities in Gallons per Minute Maximum 115V 23V Type Ft.. PSI F53-5 F53-6 1/2 2-wire F53-7 F53-8 1/2 2-wire F53-9 3/4 2-wire F531-5 F /2 2-wire F /4 2-wire F wire F532-5 F /2 2-wire F /4 2-wire F wire F533-5 F /2 2-wire F /4 2-wire F534-5 F /2 2-wire F /4 2-wire

5 Electrical Data for Flint & Walling Effluent Turbine Pumps HP Volts Phase Hz S.F. Fuse/Circuit Winding Maximum Locked KVA Breaker Amps Resistant Rotor Code Line to Amps Watts Amps Std. Delay Line 1/ R / R / N N Major Components 1. Submersible Effluent Turbine Pump - A submersible ef fl u ent tur bine pump is a multistage centrifugal design pump. Each stage con sists of an impeller and diffuser. Water pres sure in creas es in equal amounts as it passes from stage to stage. The more stag es, the higher the pressure the pump will de vel op. To correctly select a pump for a specifi c application, the fol low ing information must be known: The amount of discharge required in GPM or LPM The total dynamic head required in feet or meters Use this information along with the performance data found on the previous page to make your selection. 2. Control Panel - Submersible effl uent turbine pumps re quire the use of an above ground control panel or junction box with a pump control switch for proper op er a tion. Op er a tion of these pumps without a control pan el or junction box with a pump control switch can result in failure of the pump and void the war ran ty. 3. Float Switches - All submersible effl uent turbine pumps are nonautomatic. The use of fl oat switches are required for the proper operation of the pump. Operation of these pumps without fl oat switch es can result in failure of the pump and void the warranty. A minimum of two fl oat switches should be used in each ap pli - cation: A pump control fl oat switch A high water alarm fl oat switch 4. Piping - The submersible effl uent turbine pump can be in stalled with schedule PVC pipe. The pipe size should be 1¼ diameter for the 1 GPM to 27 GPM pump series and 2 diameter for the 35 GPM pump series. General piping from the pump to a splitter, distribution box, drain fi eld etc., should be the same diameter as stat ed above. For long pipe runs consult friction loss tables for correct pipe sizing. 5. Check Valve - A check valve is required in all duplex sys tems. It is also required when a large amount of effl uent can backfl ush into the system causing rapid cycling of the pump. A 1/8 weep hole must be drilled in the side of the discharge head when using a check valve (see drawing below for drill location). SK2222 5

6 Pump Installation and Wiring Diagram 1. Submersible ef flu ent turbine pumps may be installed in any ap pli ca tion where relatively clear effl uent, such as from a dos ing tank or high head STEP system etc., is being pumped. 2. Pumps should always be installed vertically. Pumps should never be installed horizontally. 3. Because of their low temperature rise, pumps under 2 HP do not require a fl ow inducer sleeve. 4. Mount the junction box in its permanent position. 5. Run prewired conduit, or equivalent submersible cable from the junc tion box to a fused disconnect or, if applicable, the control panel. 6. Feed the pump power cord and float switch cords into the junction box. 7. Make the connections in the junction box using the wiring di a grams below. If you are using a con trol panel or a fi ltered STEP system, follow the wiring di a grams and in struc tions included with them. 8. An alarm should be used with any system using a pump. Follow the wiring diagram with the alarm for installation and check your local codes. 9. Run the appropriate power to the control panel from a fused (cir cuit breaker) disconnect. The appropriate power supply in for - ma tion may be found on the pump nameplate. 1. To provide a suitable ground, a separate ground wire (green or bare) at least as large as the line conductors is required. It is connected from the electrical disconnect box to the con trol panel, to the junction box and to the green ground wire of the submersible motor lead. 11. Always disconnect all power when installing or ser vic ing the pump. 115 VOLT FUSED DISCONNECT (CIRCUIT BREAKER) 115 VOLT LINE GROUND 23 VOLT FUSED DISCONNECT (CIRCUIT BREAKER) 23 VOLT LINE GROUND JUNCTION BOX JUNCTION BOX GREEN GREEN GREEN GREEN 115V FLOAT SWITC 23V FLOAT SWIT 115 VOLT EFFLUENT TURBINE PUMP 1/2HP 23 VOLT EFFLUENT TURBINE PUMP 1/2HP - 1 1/2HP SK2221A SK2221B 6

7 Splicing Underground Wires Splicing of wires to be buried must be done according to the National Electrical Code. Wire connectors or splicing means installed on conductors for direct burial shall be listed for such use. Before placing the equipment into operation the following must be checked: Septic tank and/or pump chamber should be pumped and cleaned prior to in stal la tion in existing system. Septic tank and/or pump chamber must be watertight. Installation needs to be according to instructions. Installation should include an easy access riser and tamper resistant lid. Filter assembly needs to be in place and secure. Float tree needs to be in place, secure and adjusted for proper cycling. Make sure fl oat switches are free to move within the basin. Be sure electrical connections are watertight and conform to the Uniform Building Code and the National Electrical Code (NEC). Fill the septic tank and/or pump chamber with water and check the system for operation. After installing the pump into the containment area with ad e quate submer gence, open the discharge valve fully. Start the unit using manual controls. If fl ow is appreciably less than rated per for mance, pump may Start-up and Maintenance be air locked. To expel trapped air, jog the unit several times, using the manual con trols. Have a qualifi ed electrician take voltage and current mea sure ments on the black wire of single phase. Record these read ings in the space provided in the Owner s Information section on the front this manual for future ref er ence. Be sure to complete all items such as installing the lid on the riser, securely closing the control panel, and checking the sys tem op er a tion have been com plet ed before placing the system into ser vice. Routine maintenance should include: Service fi lter in STEP system and/or septic tank. Clean pump screen. Make sure the check valve is functioning properly. Check wire connections. Make sure the weep hole is clear. Make sure the fl oat switches are free to move within the basin. Make sure there are no leaks in the plumbing. Make sure there is no excessive noise while the pump is running. Troubleshooting and Service Checklist ELECTRICAL PRECAUTIONS- Before servicing a pump, always shut off the main power breaker and then unplug the pump - making sure you are not standing in water and wearing insulated protective sole shoes. Under fl ooded conditions, contact your local electric company or a qualifi ed licensed electrician for disconnecting electrical service prior to pump removal. CONDITION A. Pump will not start or run. B. Motor overheats and trips over load or blows fuse. C. Pump starts and stops too often. D. Pump will not shut off. E. Pump operates but delivers little or no water. COMMON CAUSES Check fuse, low voltage, over load open, open or incorrect wiring, open switch, impeller or seal bound mechanically, defective capacitor or relay when used, motor or wiring shorted. Float assembly held down. Switch defective, dam aged, or out of adjustment. Incorrect voltage, negative head (discharge open lower than normal), impeller or seal bound mechanically, or relay, motor shorted. Check valve stuck or none installed in long distance line, over load open, level switch(es) defective, sump pit too small, leak in the system. Debris under fl oat assembly bound by pit sides or other, switch de fec tive, damaged or out of adjustment, leak in the system. Check strainer housing, dis charge pipe, or if check valve is used vent hole must be clear. Discharge head exceeds pump ca pac ity. Low or incorrect voltage. Incorrect motor ro ta tion. Capacitor de fec tive. In com ing water con tain ing air or causing air to enter pump ing chamber. F. Drop in head and/or capacity after a period of use. Increased pipe friction, clogged line or check valve. Abrasive material and ad verse chem i cals could possibly deteriorate impeller and pump housing. Check line. Remove unit and inspect. If the above checklist does not uncover the problem, consult the factory - Do not attempt to service or otherwise disassemble pump. Service must be by Flint & Walling Authorized Service Stations. 7

8 P/N ZOELLER WARNING! P/N REV. A O Z ELLER PUMP CO. LOUISVILLE, KY! WARNING ELECTRICAL SHOCK HAZARD Typical Installations ALL INSTALLATIONS REQUIRE A FILTER BEFORE THE PUMP. Z EFFLUENT TURBINE PUMP NOTE: Flow must be directed around the motor for cooling on 2 HP and higher units. SEPTIC TANK SK222 C Z EFFLUENT TURBINE PUMP SEPTIC TANK SK North Oak Street Kendallville, IN (8) FAX (26) Quality Products Since 1866!