Franklin Electric BT4 Series Horizontal Booster Pump Owner’s Manual

Franklin Electric BT4 Series Horizontal Booster Pump

The BT4 horizontal booster pump is a low- to medium- capacity, high-pressure, multi-stage unit. The BT4 can function as a multi-purpose high-pressure pump, aug- menting water pressure from either city mains or private water systems. It is also ideal for applications that require more pressure than flow. Size ranges from 5 gpm (18.9 lpm) to 45 gpm (170.3 lpm). The maximum operating pressure of this pump is 500 psi, and its maximum suction pressure is 75 psi. The water temperature is a maximum of 120°F.
This product is covered by a Limited Warranty for a period of 1 year from the date of original purchase by the consumer. For complete warranty information, refer to www.FranklinWater.com.

Specifications

Pump Construction| Suction in (cm)| Discharge in (cm)| HP Range| Motor Input| Flow Rates|
---|---|---|---|---|---|---
Cast Iron| ****

1

(2.54)

| ****

1

(2.54)

| 0.50 – 3| 1-phase| 5, 7, 10, 15,

20, 25

GPM

|
| 0.33 – 3|
0.50 – 3| 3-phase|
0.33 – 3| –|
Stainless Steel| | | |
| | 1 – 3| 1-phase| |
| 1.5| 1.5| 35 & 45|
1 – 3| 3-phase|
| (3.81)| (3.81)| GPM|
1 – 3| –|

SAFETY INSTRUCTIONS

• This equipment should be installed and serviced by technically qualified personnel who are familiar with the correct selection and use of appropriate tools, equipment, and procedures.
• Failure to comply with national and local electrical and plumbing codes and within Franklin Electric recommendations may result in electrical shock or fire hazard, unsatisfactory performance, or equipment failure.
• Know the product’s application, limitations, and potential hazards. Read and follow instructions carefully to avoid injury and property damage. Do not disassemble or repair unit unless described in this manual.
• Failure to follow installation or operation procedures and all applicable codes may result in the following hazards:

Risk of death, personal injury, or property damage due to explosion, fire, or electric shock.

• Do not use to pump flammable, combustible, or explosive fluids such as gasoline, fuel oil, kerosene, etc.
• Do not use in explosive atmospheres or hazardous locations as classified by the NEC, ANSI/NFPA70.
• Do not handle a pump or pump motor with wet hands or when standing on a wet or damp surface, or in water.
• When a pump is in its application, do not touch the motor, pipes, or water until the unit is unplugged or electrically disconnected.
• If the power disconnect is out of sight, lock it in the open position and tag it to prevent unexpected application of power.
• If the disconnect panel is not accessible, contact the electric company to stop service.

Risk of severe injury or death by electrical shock.

• To reduce risk of electrical shock, disconnect power before working on or around the system. More than one disconnect switch may be required to de-energize the equipment before servicing.
• Wire pump system for correct voltage.
• Be certain that this pump is connected to a circuit equipped with a ground fault circuit interrupter (GFCI) device if required by code.
• The pump includes a grounding connector. To reduce risk of electric shock, be certain that it is properly connected to ground.
• To avoid hazards when installing or servicing, install a double-pole disconnect near the pump installation.
• Use an appropriate discharge resistor to discharge the capacitor prior to working on the motor.
• Check local electrical and building codes before installation. The installation must be in accordance with their regulations as well as the most recent National Electrical Code (NEC) and the Occupational Safety and Health Act (OSHA), or Canadian Electrical Code (CEC).

Risk of bodily injury, electric shock, or equipment damage.

• This equipment must not be used by children or persons with reduced physical, sensory or mental abilities, or lacking in experi-ence and expertise, unless supervised or instructed. Children may not use the equipment, nor may they play with the unit or in the immediate vicinity.
• Do not run the pump dry. If run dry, the surface temperature of the pump will rise to a high temperature that could cause skin burns if touched and will cause serious damage to your pump.
• Equipment can start automatically. Lockout-Tagout before servicing equipment.
• The pump has been evaluated for use with water only. Pump should only be used with liquids compatible with pump component materials.
• An inoperative or malfunctioning pump could lead to flooding, resulting in personal injury or property damage.
• Pump may become hot during operation. Allow pump to cool before servicing.
• Operation of this equipment requires detailed installation and operation instructions provided in this manual. Read entire manual before starting installation and operation. End User should receive and retain manual for future use.
• Keep safety labels clean and in good condition.
• Keep work area clean, well-lit, and uncluttered.
• Wear safety glasses while installing or performing maintenance on the pump.

Typical Installation

Pump Installation Using Municipal Source

Pump Installation Vertical On Wall

Pump Installation Using Wall Hydrant or Faucet

Pump Installation Drawing Water from Below Pump

Pump Location

• Install the pump in a clean, dry, and ventilated location shielded from direct sun and precipitation.
• Provide adequate room for future servicing, protection from freezing temperatures, flooding, and equipment drainage.
• Bolt unit down evenly on a good foundation, preferably concrete, to prevent unnecessary stresses from pump movement.
• Install as close as possible to water source to minimize suction piping length.

Piping Instructions

• Properly support all suction and discharge piping to avoid strain on the pump.
• Piping should match the pump inlet and outlet connection sizes.
• For long runs, increase connections by one pipe size to avoid friction losses.
• The use of pipe thread sealant is recommended.
• Avoid the use of unions on the suction line if possible. All suction line connections must be airtight.
• Do not over-tighten piping connections.

Suction Line

Suction Lift Applications

NOTE : The total suction lift should not exceed 10 ft.

1. Install a new, clean pipe or hose, making sure piping rises vertically or is sloped continually upward from the water source to the pump inlet connection with no high spots that cannot be evacuated of air during the priming process.
2. A tee with a removable priming plug is recommended at the pump inlet when the pump is installed horizontally.
3. Install a foot valve to the end of the suction line to ensure system remains filled during off periods.

Booster/Flooded Suction Applications

• Install an isolation ball or gate valve between the water source and the suction inlet to facilitate future servicing.
  • When not servicing the pump, keep this valve wide open to allow flow to the pump.
• Install backflow prevention devices as required by code.

Discharge Line

1. Tighten the discharge pipe, using an opposing pipe wrench on the pump discharge.

2. Install a check valve to avoid the back-up of high pressure flow.

3. All discharge piping must have a pressure rating capable of withstanding the incoming inlet pressure plus the pump’s maximum shut-off head pressure.
   IMPORTANT : The pump should not be operated under a no-flow/shut-off head condition to avoid high pressure and pump damage.

4. Install a bypass line from the pump discharge back to the pump suction to provide a recirculation path for the brief periods between closing off the discharge and turning off the pump.

Electrical Connections

Risk of severe injury or death by electrical shock.

• To reduce risk of electrical shock, disconnect power before working on or around the system.

1. An electrician should be employed to do the wiring.

2. It is recommended that a separate circuit be provided from the distribution panel to the pump unit, properly protected with a fuse or circuit breaker.

3. Install a proper fused disconnect switch in the line, making sure the correct gauge of cable is used to carry the load.
   IMPORTANT : Undersized wire between the motor and the power source will adversely limit the starting and load carrying abilities of the motor.

4. Wire the motor according to the motor nameplate to achieve clockwise rotation when viewed from the motor end.

5. The power lines should be connected to the pressure switch terminals marked L1 and L2.

6. Very long leads will require a larger cable.

7. If needed, remove motor end compartment for viewing.

8. Make sure the insulated green or bare ground wire is securely connected to the green ground terminal screw on the motor terminal board.

9. For added safety, the pump and motor should be grounded to the well casing, if metal, or the ground in the distribution panel.

10. If using a pressure switch to control the pump on- and off- cycling, ensure that it has a low-pressure cutout feature to avoid damage to the pump.

11. For 3-phase motors, install a separate manual thermal overload switch or a magnetic starter with proper size heater elements.

12. Failure to provide proper overload protection to the motor will void any warranty.

13. Single phase motors up to 2HP typically include thermal overload protection and are reversible.

OPERATION

Risk of severe injury or death by electrical shock, high temperatures, or pressurized fluids.

• To reduce risk of electrical shock, disconnect power before working on or around the system.
• Do not continuously run pump against closed discharge. Release all system pressure before working on any component.

Risk of damage to pump or other equipment.

• Do not let the unit run dry (without liquid). It is designed to be cooled by pumping fluid. The seal may be damaged and the motor may fail if the pump is allowed to run dry

1. Prime the pump.
2. Remove priming plug.
3. Pour water into the priming port.
4. Fill the pump and suction line with water.
5. Rotate motor shaft to let air in casing escape.
6. Refill at the priming port and replace priming plug.
7. If installing a 3-phase motor, check pump rotation by turning on power for a second.
8. If applicable, use the pump rotation warning labels or arrows on the pump to serve as a guide.
9. If direction is wrong, interchange any two of three wires either at the motor or starter.
10. Close all system outlets, then slightly open one system outlet, allowing excess air to bleed out of the system.
11. Start the pump.
12. Gradually open the discharge valve to the halfway point.
13. If the pump does not deliver water within seconds, stop the motor and prime pump again.
14. Several starting attempts may be necessary to expel all air from the pump and suction lines.
15. Once the pump is fully functioning, completely open the discharge valve and a system outlet

MAINTENANCE

Risk of severe injury or death by electrical shock.
To reduce risk of electrical shock, disconnect power before working on or around the

• Check the pump periodically for loose or rubbing parts.
• Service immediately if any unusual noise, leaks, or vibrations develop.
• Drain the pump should it be subjected to freezing temperatures.

Draining the Pump

All piping and water tanks exposed to freezing conditions must be drained.

For 5-25 GPM pumps:

1. Disconnect the suction line at a connection close to the pump casing and allow the water to drain.
2. Replace the suction line, carefully cleaning the threads and applying fresh thread compound.

For 35 & 45 GPM pumps:

1. Remove the drain plugs and drain the pump casing.
2. Carefully clean the threads and apply thread sealant.
3. Replace the drain plugs.

Disassembly Motor Removal

Risk of severe injury or death by electrical shock.
Dangerous voltages are present. Use an appropriate discharge resistor to discharge the capacitor prior to working on the motor.

1. Shut down system and lock out power.
2. Allow pump components to adequately cool.
3. Drain the pump. Refer to “Draining the Pump” on page 6.
4. Loosen the 2 set screws on the coupling.
5. Remove the 4 bolts, nuts, and lock washers.
6. Pull motor away from pump end.

Square Flange Motor Shaft Adapter Removal

Square flange motors have a motor shaft adapter which must be removed for use on a replacement motor:

1. Remove motor. Refer to “Motor Removal” on page 6.

2. Take off motor canopy

3. Discharge the motor capacitor by shorting its terminals with the blade of an insulated screwdriver.
   IMPORTANT : Hold the insulated screwdriver only by the handle. Do not touch the metal screwdriver blade or capacitor terminals.

4. Unscrew motor overload and move it aside without disconnecting its wires.

5. Secure the motor shaft with a 7/16-inch open-end wrench inserted onto the shaft flats.

6. For 3-phase motors only, use a 3/16-inch Allen wrench to turn the shaft screw clockwise and remove it from the center of the shaft adapter.

7. Unscrew motor shaft adapter from pump end of the motor shaft with a 5/8-inch open end wrench for use on new motor.
   NOTE: Some single-phase pumps do not have 5/8-inch flats and must be removed with a pair of vice grips.

Pump Disassembly

1. Separate motor from pump. Refer to steps 1-6 of “Motor Removal” on page 6.

2. Secure the pump shell and unscrew the discharge head by turning it clockwise with a pipe wrench and set aside.

3. Push the rubber bearing out from the pump discharge head.

4. Remove the pump shell from the bracket by turning it clockwise.

5. Lay aside the O-ring and discharge spacer.

6. While holding the coupling with a 1-1/8-inch open end wrench, remove the 1/2-inch nut and washer from the pump shaft.

7. Slide the following components up and off the pump shaft: two hub sleeves, shaft spacer (35 & 45 GPM only), stages (includes thrust washer and impeller assembly).

8. Remove the bracket spacer and O-ring.

9. Slide the two shims and two shaft spacers up and off the pump shaft.
   NOTE : 45 GPM pumps have only one shaft spacer.

10. Use snap pliers to take the retaining ring off.

11. Slide the washer up and off the shaft.

12. Remove the mechanical seal rotating portion by gently tapping the coupling-shaft assembly from the pump side of the bracket.

13.  Gently tap the stationary portion of the mechanical seal from the bracket using a flat-blade screwdriver and rubber mallet.

Reassembly

NOTE : If only replacing a motor, without dis- or re-assembling any part of the pump from the coupling to the discharge, refer to “Motor Replacement” on page 9.

Square Flange Motor Shaft Adapter Reassembly

1. Secure the motor shaft with a 7/16-inch open-end wrench inserted onto the shaft flats.

2. Screw on the motor shaft adapter to the motor shaft, using a 5/8-inch open end wrench.
   NOTE : Some single-phase pumps do not have 5/8-inch flats and must be removed with a pair of vice grips.

3. For 3-phase motors only, use a 3/16-inch Allen wrench to turn the shaft screw counter-clockwise and tighten it in the center of the shaft adapter.

4. Reposition the motor overload and replace motor canopy.

Mechanical Seal Replacement

1. Insert a new stationary portion of the mechanical seal.

2. Lubricate seal with soapy water to ease installation.

3. Wear gloves to avoid contaminating the seal face.

4. Apply Loc-Tite 271 to the threaded end of the shaft and screw the shaft into the coupling.

5. Apply one drop of Loc-Tite 243 to each set screw and screw them just far enough into the ID of the coupling so as to allow for alignment with the motor shaft keyway.

6. Install the coupling-shaft assembly on the motor, lining up the shaft adapter keyway and ensuring that the coupling is fully seated on the motor shaft.
   NOTE : For square flange motors, the motor shaft must have the motor shaft adapter already installed on it. Refer to “Square Flange Motor Shaft Adapter Reassembly”

7. Place the bracket on top of the motor-coupling-shaft assembly, aligning the flange- and bracketholes.
   For 35 & 45 GPM pumps:

8. Slide the rubber protector on the curved end of the base.

9. Position the other end of the base on top of the bracket so that its holes align with the flangeand bracket- holes.

10. Bolt the bracket and motor (and, for 35 & 45 pumps, the base) together.

11. Square flange assemblies have bolts, lock washers, and nuts.

12. The bolts have a torque setting of 115 inch-lbs.

13. While continuing to hold the coupling in position with the screwdriver, tighten the set screws with a 5/32-inch Allen wrench.

14. The set screws have a torque setting of 75 inch-lbs.

15. Install the rotating part of the mechanical seal.

16. Insert the mechanical seal washer

Pump Shaft Assembly

1. Install the retaining ring securely in its groove using snap ring pliers.

2. Slide the two shaft spacers and two shims onto the pump shaft.
   NOTE : 45 GPM pumps have only one spacer.

3. Insert the O-ring.

4. Install bracket spacer with the correct side interlocking with the stage assembly.

5. Slide the following components onto the pump shaft: stages (includes thrust washer and impeller assembly), shaft spacer (for 35 & 45 GPM), two hub sleeves, and shaft washer.
   NOTE : Reinstall the thrusts with the brown-side facing the discharge.
   NOTE : The 35 & 45 GPM shaft spacer is narrower than the shaft spacer(s) on the bracket end of the pump shaft.

6. Hand tighten the nut onto the end of the pump shaft.

7. Install discharge spacer with the correct side interlocking with the stage assembly.

8. Insert the O-ring.

9. Apply anti-seize to the pump bracket threads and hand-tighten the pump shell back on, turning it counter-clockwise.

10. Insert the rubber bearing into the discharge head, aligning the anti-rotation tabs with the slots

11. Apply anti-sieze lubricant to the discharge head threads and hand-tighten the discharge head to the pump shell by twisting it counter-clockwise, then use a pipe wrench to secure it.

12. The pump discharge head has a torque setting of 75 inch-lbs.

13. Secure the coupling flats with a wrench and tighten the pump shaft nut.

14. The pump shaft nut has a torque setting of 30 inch-lbs.

Motor Replacement

The motor below is either a 56C or square flange model. If it is a square flange, ensure that the motor shaft adapter is already attached. Refer to “Square Flange Motor Shaft Adapter Reassembly” on page 7.

1. For 3-phase motors, check the motor rotation as described in “Operation” on page 5.
2. Apply one drop of Loc-Tite 243 to each set screw and screw them just far enough into the ID of the coupling so as to allow for alignment with the motor shaft keyway.
3. Slide the motor onto the pump bracket, lining up the shaft adapter keyway with the coupling set screws.
4. Fasten the motor to the pump bracket with the four provided bolts, lock washers, and nuts.
5. Square flange assemblies have bolts, lock washers, and nuts.
6. The end bolts have a torque setting of 115 inch-lbs.
7. Insert a flat-bladed screwdriver between the pump bracket and the coupling. Pry the coupling all the way toward the motor with the screwdriver.
8. While continuing to hold the coupling in position with the screwdriver, tighten the set screws with a 5/32-inch Allen wrench.
9. The set screws have a torque setting of 75 inch-lbs

Troubleshooting

Motor Fails to Start or Not Running

| Motor thermal protector tripped| Correct cause for high amperage, such as low voltage or excessive pumping.
Open circuit breaker or blown fuse| Check electric wiring and motor for short circuits and correct.
Impeller binding| Remove pump case and check for debris.
Motor improperly wired| Check complete suction line and all fittings for air leaks and verify foot valve has adequate submergence.
Defective motor| Take to an authorized motor shop for repair or replacement.

Little or no discharge

| Pump is not primed: air or gases in pumpage| Check suction line and foot valve for leaks. Make sure that water level has not dropped to uncover suction inlet. Prime pump.
Discharge or suction plugged or valve closed| Clear obstructions from suction and discharge lines.
Incorrect rotation (3 Phase only)| Interchange any two of three wires either at the motor or starter.
Low voltage or phase loss| Correct incoming power to match motor nameplate requirements.
Impeller worn or plugged| Clean or replace impeller.
System head too high| Reduce system head (back-pressure on pump) or resize pump.
Excessive suction lift or losses, or NPSHA too low for the pump| Locate pump closer to the water source, increase pipe size or resize pump.

Low pump capacity or pressure

| Valves in suction or discharge lines partially closed| Open valves to reduce possible restrictions.
Suction or discharge line par- tially plugged| Clear obstructions from discharge line.
Wrong pump rotation| Correct to proper rotation.

Excessive power con- sumption

| Impeller binding| Remove pump case and check for debris.
Discharge head too low creat- ing excessive flow rate| Close down discharge valve to increase pressure and throttle back flow rate.
Fluid viscosity: specific gravity too high| Modify fluid properties or resize pump.

Excessive noise and vibration

| Impeller binding| Remove pump case and check for debris.
Pump is not primed: air or gases in pumpage| Check complete suction line and all fittings for air leaks and verify foot valve has adequate submergence.
Discharge or suction plugged or valve closed| Clear obstructions from suction and discharge lines.
Impeller worn or plugged| Clean or replace impeller.
Excessive suction lift or losses. NPSHA too low for the pump| Locate pump closer to the water source, increase pipe size or resize pump.
Discharge head too low, creat- ing excessive flow rate| Close down discharge valve to increase pressure and throttle back flow rate.
Worn bearing| Check bearing for damage and replace if necessary.
Pump, motor, or piping loose| Verify all connections and mountings are secure and piping supported.
Water leakage at pump shaft| Defective seal assembly| Replace seal.

Replacement Parts

5-25 GPM

305374959
2| Fastener kit| 305421901

3*

| Coupling kit, stainless steel| 305421902
Coupling kit, bronze| 305421903
Coupling kit, stainless steel for 56C pump end mounting| ****

305421001

4

| Pump/motor bracket, stainless steel| 305421904
Pump/motor bracket, cast iron| 305421905
Pump/motor bracket, stainless steel for 56C pump end mounting| ****

305421002

5

| Mechanical seal, viton| 305421906
Mechanical seal, buna| 305421907
Mechanical seal, viton for 56C pump end mounting| 305421003
7| O-ring set| 305421908
8| Stage assembly| Refer to “Stage Assembly” on page 13
9| Top bearing| 305421909
10| Discharge head| 305421910
6, 11,

12

| Suction/discharge spac- ers, pump shaft (& hard- ware), pump shell| ****

Only Available in “Hydraulic Overhaul Kit” on page 13

NOTE: ships with mechanical seal
NOTE: Items 1-5 are for square flange pump mounting unless otherwise specified

35 & 45 GPM

Items

| ****

Descriptions

| Order Number By Motor Size
---|---|---
1.0 HP| 1.5 HP| 2.0 HP| 3.0 HP

1

| Single-phase motor, ODP| 305374963| 305374964| 305374965| 305374966
Single-phase motor, TEFC| 305374971| 305374972| 305374973| 305374974
3-phase motor, ODP| 305374967| 305374968| 305374969| 305374970
3-phase motor, TEFC| 305374975| 305374976| 305374977| 305374978
2| Fastener kit| 305421971
3*| Coupling kit| 305421001
4| Pump/motor bracket| 305421972
5| Mechanical seal| 305421003
7| O-ring set| 305421908
8| Stage Assembly, 35 gpm| 305404928
Stage Assembly, 45 gpm| 305404929
9| Top bearing, 35 gpm| 305421973
Top bearing, 45 gpm| 305421974
10| Discharge head| 305421975
6, 11,

12

| Suction/discharge spacers, pump shaft (and shaft hardware), pump shell|

Only Available in “Hydraulic Overhaul Kit” on page 13.

13

| Base, single-phase motor, ODP| 305421976| 305421977
Base, single-phase motor, TEFC| 305421977
Base, 3-phase motor, ODP| 305421976| 305421977
Base, 3-phase motor, TEFC| 305421977

NOTE: ships with mechanical seal

Stage Assembly

Hydraulic Overhaul Kit

Includes suction/discharge spacers, o-ring set, stage assembly, top bearing, pump shaft and hardware, and the pump shell

GPM

| Order Number by Motor Size (Stage Count Reference)
---|---
1/3 HP| 1/2 HP| 3/4 HP| 1.0 HP| 1.5 HP| 2.0 HP| 3.0 HP
5| 305422901

(7)

| 305422902

(9)

| 305422903

(12)

| 305422904

(15)

| –| –| –
7| 305422001

(6)

| 305422905

(8)

| 305422906

(10)

| 305422907

(14)

| 305422908

(19)

| –| –
10| 305422002

(5)

| 305422909

(7)

| 305422910

(8)

| 305422911

(11)

| 305422912

(15)

| 305422913

(18)

| –
15| –| 305422003

(5)

| 305422914

(6)

| 305422915

(8)

| 305422916

(12)

| 305422917

(15)

| –
20| –| 30422004

(4)

| 305422918

(5)

| 305422919

(7)

| 305422920

(10)

| 305422921

(12)

| 305422922

(15)

25| –| –| 305422005

(4)

| 305422923

(6)

| 305422924

(8)

| 305422925

(10)

| 305422926

(13)

35| –| –| –| 305422927

(3)

| 305422928

(5)

| 305422929

(7)

| 305422930

(9)

45

|

–

|

–

|

–

| 305422931

(2)

305422932

(3)

|

305422933

(4)

| 305422934

(5)

305422935

(6)

|

305422936

(7)

For technical assistance, parts, or repair, please contact:
106524101 Rev. 010 10/22
Copyright © 2022, Franklin Electric, Co., Inc. All rights reserved.
800.348.2420
franklinwater.com

References

• Home | Franklin Electric
• Franklin Electric - Latin America - Inicio
• Water Pumps & Systems | Franklin Water
• Franklin Electric - Latin America - Inicio
• Water Pumps & Systems | Franklin Water

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