Flint and Walling 132934 Pressure Booster Pump Owner’s Manual

Flint and Walling 132934 Pressure Booster Pump

Specifications :

• Pressure Booster Pumps
• Materials: Stainless Steel, Powder-Coated Cast Iron, Cast Iron
• Motor: Capacitor start, thermal protected motor for single-phase models
• Phase: Single-phase and three-phase models available
• Usage: Increase water pressure from city mains or private water systems

Product Usage Instructions

Unpacking:
When unpacking the unit, inspect carefully for any damage that may have occurred during transit.
NOTE: Use pump with clear water only.

Installation:

1. Choose a suitable location for the pump near the water source.
2. Ensure the pump is securely placed on a level surface.
3. Connect the suction and discharge pipes according to the specified NPT sizes.
4. Check all connections for tightness to prevent leaks.

Operation:

1. Start by ensuring the power supply is connected and stable.
2. Prime the pump by filling the suction pipe with water to remove air pockets.
3. Turn on the pump and adjust pressure settings as needed.
4. Monitor the pump during operation for any unusual noises or vibrations.

Maintenance:

1. Regularly check and clean the pump intake to prevent clogs.
2. Inspect motor components for wear and tear, replacing any damaged parts promptly.
3. Keep the pump housing clean and free from debris.

FAQ:

1. Q: Can this pump be used with hot water?
   A: No, this pump is designed for use with clear water only. Using hot water may damage the pump components.

2. Q: What should I do if the pump is making unusual noises?
   A: If you hear unusual noises coming from the pump, immediately turn it off and inspect for any obstructions or mechanical issues. Contact a qualified technician if needed.

3. Q: How often should I replace the pump’s filters?
   A: Filters should be checked regularly and replaced if they appear clogged or dirty. The frequency of replacement may vary depending on usage and water quality.

Operating Instructions & Parts Manual
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

Pressure Booster Pumps

Description

• Pressure booster pumps increase water pressure from city mains or private water systems. Applications include providing high water pressure for washing buildings, dairy walls or floors, hog parlors, poultry houses, rinsing or spray cooling equipment, lawn sprinkling and insecticide spraying.
• Single-phase models are equipped with a capacitor start, thermal protected motor. Three-phase models require separate overload protection.
• Unpacking
  When unpacking the unit, inspect carefully for any damage that may have occurred during transit.
  NOTE: Use pump with clear water only.

Pump Dimensions    60 Hz Chart A

HP| GPM| Stage| “C”| F| H| J
F &W| TEFC

1 Phase           3 Phase

|
1/3| 5| 8| 10.19| 19.81| –| –| .75| .75
1/3| 5| 8| 10.19| 20.06| 22.04| –| .75| .75
1/2| 5| 12| 13.38| 23.25| 23.23| 24.10| .75| .75
1/2| 5| 14| 14.97| 25.34| 26.82| 25.69| .75| .75
3/4| 5| 16| 16.54| 26.91| 28.77| 27.51| .75| .75
3/4| 7| 12| 13.38| 23.75| 25.61| 24.35| .75| .75
3/4| 7| 14| 14.97| 25.84| 27.20| 25.94| .75| .75
1| 10| 14| 16.31| 27.18| 29.16| 28.02| .75| .75
1-1/2| 10| 16| 18.13| 29.62| 31.48| 30.07| .75| .75
1| 10| 20| 21.69| 33.18| 34.54| 33.40| .75| .75
1| 10| 22| 23.50| 34.99| 36.35| 35.21| .75| .75
1| 10| 23| 24.38| 35.87| 37.73| 36.09| .75| .75
2| 19| 14| 17.89| 29.88| 32.12| 30.87| .75| .75
1-1/2| 19| 20| 24.06| 36.05| 37.41| 36.00| .75| .75
2| 19| 22| 26.13| 38.12| 40.36| 39.11| .75| .75
2| 27| 11| 15.38| 27.37| 29.61| 28.36| 1.00| 1.00
3| 27| 14| 18.50| 30.49| 33.85| 33.35| 1.00| 1.00
2| 27| 17| 21.59| 33.58| 35.82| 34.57| 1.00| 1.00
3| 27| 17| 21.59| 33.74| –| –| 1.00| 1.00
2| 35| 6| 13.94| 25.93| 28.17| 26.92| 1.00| 1.00
3| 35| 8| 17.13| 29.12| 32.48| 31.98| 1.00| 1.00
1-1/2| 35| 8| 17.13| 29.12| 30.48| 29.07| 1.00| 1.00
3| 35| 14| 26.86| 38.85| 42.21| 41.71| 1.00| 1.00
50Hz

PERFORMANCE SPECIFICATIONS

PRESSURE ADDED – PSI ‡| 10| 20| 40| 60| 80| 100| 120| 140| 160| 180| 200| 220| Max. Press. PSI| Suction Pipe Tap NPT| Disch. Pipe Tap NPT
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---
Stainless Steel Fitted| Powder- Coated Cast Iron Fitted| Cast Iron Fitted| HP| Stage| Output – Gallons per Minute
PB0508S031 D| PB0508C031| PB0508A031| 1/3| 8| 10.2| 9.6| 8.3| 6.5| 4.3| | | | | | | | 96| ****

3/4”

| ****

3/4”

---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---
PB0512S051 D| 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
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| ****

1”

| ****

1”

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
PB2714S301 ‡‡| PB2714C301 ‡‡| PB2714A301| 3| 14| | | 33.0| 31.5| 29.8| 27.9| 25.6| 22.8| 18.9| 11.1| | | 187
PB2717S303A| –| –| 3| 17| | | *| 34.1| 32.3| 30.5| 28.3| 25.8| 23.1| 20.0| 16.6| 11.4| 225
PB2717S303T*| –| –| 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| **

2”

| ****

2”

–| –| PB5506A301| 3| 6| 77.8| 74.4| 65.0| 51.1| 31.9| | | | | | | | 83
–| –| PB8504A201| 2| 4| 105.8| 90.0| 47.0| | | | | | | | | | 49
–| –| PB8505A301| 3| 5| 108.8| 98.8| 60.0| 25.0| | | | | | | | | 60

• † Example: 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
• ‡‡ Models marked are also available in 575V, 3 Phase Only.
• Motor voltage:
  • Open Drip Proof
  • Single Phase 1/3 – 2 HP – 115/230; 3 HP – 230V 60 Hz. Three Phase 1/2 – 2 HP – 208-230/460, 50/60Hz. Three Phase 3 HP – 208-230/460, 60 HZ
  • Three Phase 2 – 3 HP – 575V, 60Hz
  • For three phase models, use suffix “3” on the model no.
  •   Example: PB0512A053
  • Totally Enclosed Fan Cooled
  • Single Phase: 1/2 thru 3 HP – 115/230V 60/50Hz
  • Three Phase: 1/2 thru 3 HP – 208/230/460V 60/50Hz
  • ∆ Less than 50% US content

Single Phase Motor Data 60HZ Chart C

Single Phase† 60 Hz 3450 RPM Capacitor Start

HP

| Motor Voltage| Factory Connected Motor Voltage| Service Factor Motor Amps| Locked Rotor Motor Amps|

Code Letter

115V| 230V| 115V| 230V
1/3| 115/230| 115V| 8.6| 4.3| 26.0| 13.0| K
1/2| 115/230| 230V| 13.0| 6.5| 36.0| 18.0| K
3/4| 115/230| 230V| 14.0| 7.0| 52.0| 26.0| K
1| 115/230| 230V| 18.0| 9.0| 78.0| 39.0| L
1-1/2| 115/230| 230V| 21.0| 10.5| 98.0| 49.0| J
2| 115/230| 230V| 25.0| 12.5| 116.0| 58.0| H
3| 230| 230V| –| 13.5| –| 53.0| D
Single Phase Motor Data 50HZ
Single Phase† 50 Hz 2850 RPM Capacitor Start
1/2| 115/230| 115V| 10.0| 5.0| 48.0| 24.0| M
3/4| 115/230| 115V| 14.4| 7.2| 64.0| 32.0| L
1| 115/230| 230V| 16.4| 8.2| 72.0| 36.0| K
1-1/2| 115/230| 230V| 23.6| 11.8| 104.0| 52.0| K
2| 230| 230V| –| 13.2| –| 55.0| H

†Thermal overload protector – automatic reset

Three Phase† 60/50 Hz 3450/2850 RPM Capacitor Start

HP

| Motor Voltage| Factory Connected Motor Voltage| Service Factor Motor Amps| Locked Rotor Motor Amps|

Code Letter

230V| 460V| 230V| 460V
3/4| 208-230/460| 230V| 3.5| 1.75| 19.0| 9.5| K
1| 208-230/460| 230V| 4.5| 2.25| 26.9| 13.5| K
1-1/2| 208-230/460| 230V| 5.7| 2.85| 33.5| 16.8| K
2| 208-230/460| 230V| 7.4| 3.70| 44.0| 22.0| K
3 ††| 208-230/460| 230V| 9.8| 4.90| 48.0| 24.0| D

(*) Not economical to run in 115V, use 230V.

General Safety Information

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.

• This is a SAFETY ALERT SYMBOL. When you see this symbol on the pump or in the manual, look for one of the following signal words and be alert to the potential for personal injury or property damage.

• WARNING

  • Warns of hazards that WILL cause serious personal injury, death or major property damage if ignored.

• WARNING

  • Warns of hazards that CAN cause serious personal injury or death, if ignored.

• CAUTION

  • Warns of hazards that MAY cause minor personal injury, product or property damage if ignored.

• IMPORTANT: Indicates factors concerned with operation, installation, assembly or maintenance which could result in damage to the machine or equipment if ignored.

• NOTE: Indicates special instructions which are important but are not related to hazards.

• WARNING

  • Hazardous voltage.  Can shock, burn or cause death. Ground pump before connecting to power supply.
  • Wire motor for correct voltage. See
  • “Electrical” section and Motor Data Charts C&D of this manual, and motor nameplate.
  • Ground motor before connecting to power supply.
  • Meet United States National Electrical Code and local codes for all wiring.
  • Do not handle a pump or pump motor with wet hands or when standing on a wet or damp surface or in water.
    Follow wiring instructions in this manual when connecting to power lines.

• WARNING

  •   Always disconnect power source before performing any work on or near the motor or its connected load.
  • Do not use to pump flammable or explosive fluids such as gasoline, fuel oil, kerosene, etc. Do not use in flammable and/or explosive atmospheres.
  • Hazardous pressure! Install pressure relief valve in discharge pipe. Release all pressure on system before working on any component.

1.  Make workshop child proof – use padlocks, master switches; remove starter keys.
2.  Wear safety glasses when working with pumps.
3. Wear a face shield and proper apparel when pumping hazardous chemicals.
4. Keep work area clean, uncluttered and properly lighted; replace all unused tools and equipment.
5. Provide guarding around moving parts.
6. Keep visitors at a safe distance from the work area.
7. Periodically inspect pump and system components.
8. Protect electrical cord. Replace or repair damaged or worn cords immediately.
9. Do not insert finger or any object into pump or motor openings.
10. Secure the discharge line before starting the pump. An unsecured discharge line will whip, possibly causing personal injury and/or property damage or puncture.
    • CAUTION
    • Do not touch an operating motor or engine. They are designed to operate at high temperatures.
    • WARNING
    • This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
    • WARNING
    • Risk of Electric Shock. This pump has not been investigated for use in swimming pool areas.

NOTE: Pumps with the “CSA-CUS” mark are tested to UL standard UL778 and certified to CSA standard C22.2 No. 108.
Pre-Installation
HANDLING
Avoid impact on pump or motor. In particular, avoid impact on discharge end of pump or rear motor access cover.

LOCATION

WARNING
In any installation where property damage and/or personal injury might result from an inoperative or leaking pump due to power outages, discharge line blockage, or any other reason, a backup system(s) should be used.

1. Locate pump as close to the fluid source as possible, keeping the inlet pipe short as possible.
2. Place unit where the pump and piping are protected from the weather and extremes of heat, humidity and below freezing temperatures.
3. Mount unit in a dry location that is easily accessible for inspection and maintenance. If a dry location is not available, mount it on a foundation well above the wet floor.
4.  Allow ample clearance around unit for free air circulation.

SUCTION LIMITATIONS

1. Units are non self-priming.
2.  Pressure booster pumps are not recommended for suction lift applications.

PIPING

1. Use galvanized piping, rigid plastic or other suitable pipe that will not collapse under suction or rupture due to pressure.

CAUTION

1. If hose is used, make sure it is the reinforced industrial type that is rated higher than the shutoff pressure of the system. Ordinary garden hose will collapse and starve the pump of water.
2. The diameter of the inlet and discharge pipe should be no smaller than the corresponding ports of the pump (See Figure 1). Smaller pipe will reduce the capacity of the pump. Increase pipe size on long runs.
3. Avoid air pockets in inlet piping or air will accumulate at high points, making priming difficult.
4. Use pipe compound on all joints and connections. Use Teflon tape or plastic joint stich, on plastic pipe. Draw all pipe up tightly.

IMPORTANT: The entire system must be air and water tight for efficient/proper operation.

Installation

PUMP INSTALLATION IMPORTANT: Pump is built to handle clear water only; it is not designed to handle water containing sand, silt or other abrasives.

1.  Refer to Figures 6, 7, and 8 for typical installations.
   CAUTION
   Support pump and piping when assembling and when installed. Failure to do so may cause piping to break, pump to fail, motor bearing failures, etc.

2. If the pump is used as part of a permanent installation, bolt to a rigid foundation.
   WARNING
   Use only components that are rated for maximum pressure pump can produce when used in boosting system or any other system. Do not exceed the total maximum pressure boost as listed per model in Performance Charts B.

PRESSURE BOOST SYSTEMS

1. On pressure boost systems, locate the pump so that there will always be a positive supply of water to the pump (See Figures 6, 7 and 8).

2. For service convenience, install a gate valve and union in the inlet and discharge line.
   CAUTION
   Do not use a globe valve or other restricting type of valve that will seriously restrict the pumps discharge capacity.

3. Install a check valve as shown in Figure 6. Be sure check valve flow arrows point in the direction of water flow.

4. Whenever dirt, sand or debris is present in the supply water, install a strainer or filter on the inlet side of the pump (See Figure 7).
   NOTE: For heavy amounts of sediment, install a trap filter on the inlet side of the pump (See Figure 5).
   NOTE: Pressure gauges installed before and after the filter will show pressure differential indicating the need for filter replacement or cleaning.
   CAUTION
   Mount pump in correct position or pump failure will result.
   SAND AND SEDIMENT TRAP FILTER

5. A pressure gauge installed in the inlet pipe close to the inlet port, (See Figure 6) will show if enough water is being supplied to the pump. See Operation Section – Priming, Pressure Boost Installations.

6. On installations that are using nozzles for mist spraying, install a filter in the discharge plumbing to prevent the nozzles from becoming plugged. Multiple filters should be plumbed in parallel.

   • WARNING
   • Install a pressure relief valve on any installation where pump pressure can exceed the pressure tank’s maximum working pressure or on systems where the discharge line can be shut off or obstructed. Extreme over pressure can result in personal injury or property damage.
   • CAUTION
   • This unit is not waterproof and is not intended to be used in showers, saunas or other potentially wet locations. The motor is designed to be used in a clean dry location with access to an adequate supply of cooling air. Ambient temperature around the motor should not exceed 104ºF (40ºC). For outdoor installations, motor must be protected by a cover that does not block airflow to and around the motor. This unit is not weatherproof nor is it able to be submersed in water or any other liquid.
   • To avoid dangerous or fatal electrical  shock, turn off power to motor before working on electrical connections.
   • Supply voltage must be within ± 10% of nameplate voltage. Incorrect voltage can cause fire or seriously damage motor and voids warranty. If in doubt, consult a licensed electrician.
   • Use wire size specified in wiring
   • Chart F. If possible, connect pump to a separate branch circuit with no other appliances on it. If motor wiring diagram differs from diagram shown below, follow diagram on motor.

Pump used to boost incoming city pressure (automatic operation).
IMPORTANT: A contained air pressure tank and pressure switch is required to keep the pump from rapid cycling and prevent the motor from over heating. Install the tank and switch on the house side of system.
Pump used to boost water pressure in mist spray applications (automatic operation).
NOTE: Install solenoid valve on discharge side of pump.
IMPORTANT: Clean all filters and strainers on a regular schedule.

WARNING
Hazardous voltage. Can shock, burn or cause death. Ground pump before connecting to power supply.

• Ground motor before connecting to electrical power supply.
• Failure to ground motor can cause severe or fatal electrical shock hazard.
• Do not ground to a gas supply line.
• CAUTION
• Proper rotation of pump impeller is critical on three phase motors. See Motor Rotation under Operation section and Figure 16.

WIRING

1. Install, ground, wire and maintain this pump in accordance with your local electrical code and all other codes and ordinances that apply. Consult your local building inspector 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.
3. Connect ground wire first. Connect to ground first, then to green grounding terminal provided on the motor frame, identified as GRD. Ground connection MUST be made to this terminal. Do not connect motor to electrical power supply until unit is permanently grounded; otherwise serious or fatal electrical shock hazard may be caused.
4.  Connect the other end of the ground wire to a properly grounded service panel or to a control panel ground bar if it is connected to the power supply ground.
   IMPORTANT: Check local and/or United States National Electric Codes for proper grounding information.
   CAUTION
   Make certain that the power supply conforms to the electrical specifications of the motor supplied. See Motor Data Charts.

Pump used to boost incoming pressure from a wall hydrant (manual operation).

• **NOTE: Dual voltage motors, change the red and gray wire to the voltage required.
  Figure 9 – Wiring Diagram for Single Phase 1/3 – 2 HP Motors
  NOTE:** Single voltage (230V) motor, and can not be connected to 115V.
  Figure 10 – Wiring Diagram for Single Phase 3 HP Motors
  Figure 11 – Wiring Diagram for Baldor TEFC 3 Phase motors
  CONNECTION FOR 3 PHASE, 9 LEADS. IF YOUR 3 PHASE LEADS ARE COLOR CODED, MATCH NUMBER ABOVE TO THE CORRESPONDING COLOR.

• NOTE: To reverse rotation, interchange any two incoming lines (Power) leads.
  Figure 15 – Wiring Diagram for WEG Three Phase Motors

Figure 13 – Wiring Diagram for Marathon TEFC 3 Phase motors

Figure 12 – Wiring Diagram for Franklin Electric TEFC 1 Phase and 3 Phase motors
CONNECTION FOR 3 PHASE, 9 LEADS. IF YOUR 3 PHASE LEADS ARE COLOR CODED, MATCH NUMBER ABOVE TO THE CORRESPONDING COLOR.
NOTE: To reverse rotation, interchange any two incoming lines (Power) leads.
Figure 14 – Wiring Diagram for Three Phase Motors

1. Specific Wiring Procedure (Refer to Figures 9, 10, 11, 12, 13, 14, 15 and Minimum Wire Size Chart).

2. Select the voltage you are to use, either 115V or 230V single phase, 230V or 460V three phase.

3.  Please refer to the pump’s motor nameplate as product may ship from the factory in either 115V or 230V. Please verify power supply and prewired connections before connecting or starting the pump. Three phase models are factory connected for 230V at the motor.

4. c. If the motor wiring must be changed to conform to your spe-cific voltage requirements then the motor, pressure switch or other controls should be rewired to conform to one of the wiring diagrams (either 115V or 230V, single phase; 230V or 460V, three phase). Single phase 3 HP motors are 230V only and cannot be wired for 115V service.

5. The motor wiring diagrams are Figures 9, 10, 11, 12, 13, 14 & 15 and also are located on the motor label of the pump.

6. Remove the rear access cover of the motor.

7. Make the wiring change and replace the rear access cover.
   WARNING
   Replace rear access cover before starting or operating pump. Failure to do so can result  in personal injury.
   IMPORTANT: Do not use an extension cord or splice wires. Joints should be made in an approved junction box. If the above information or the following wiring diagrams are confusing, consult a licensed electrician.

8. 8. All units are not supplied with pressure switches, float devices, on/off switches, or the like (control devices). Controls should be wired in at this time, utilizing whatever instructions come with the controls. All units supplied with cords, will run whenever cord is plugged into power
   and will turn off whenever cord is disconnected from power.

MOTOR PROTECTION

• All single phase motors have built in thermal protection for all voltages. The overload protects the motor against burnout from overload of low voltage, high voltage and other causes. The device is automatic and resets itself once the temperature has dropped to a safe point. Frequent tripping of the device indicates trouble in the motor or power lines and immediate attention is needed.
• WARNING
• Never examine, make wiring changes or touch the motor before disconnecting the main electrical supply switch. The thermal device may have opened the electrical circuit.
• Three phase motors do not have a built in thermal protection. 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 instructions 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 protection. Consult local or United States National Electric Codes for proper fuse protection based on motor data chart (See Charts C, D and Wire

Operation

CAUTION

• Unit must be full of fluid before operating.  Do not run dry, or against a closed discharge. Do not pump dirty water or abrasive liquids. To do so will cause pump failure and will void the warranty.

• VALVES
  The inlet valve should be in the full open position and the discharge valve should be partially open, permitting some back pressure to be exerted against the pump when starting up. Open valve after  start up is completed.

• PRIMING

• NOTE: Before starting the pump it is absolutely necessary that both the pump and the inlet pipe be completely filled with water.

• Pressure Boost Installations

• Priming is automatic when pump is connected to a pressure source such as a hydrant or city main (See Figures 6, 7 & 8).

  1. Open valves or nozzle on inlet and discharge side of pump.

  2. To relieve trapped air, allow water supply to run a minimum of 30 seconds before starting the pump.
     IMPORTANT: An adequate flow of water going into the pump is required so that the pumps impellers and shaft seal do not run dry and fail.

  3. If you installed a pressure gauge at the pump inlet, a 3. If you installed a pressure gauge at the pump inlet, a This reading insures that there is an ample supply of water into the pump inlet housing.

MOTOR/PUMP ROTATION

1.  Single phase models are one (1) rotation only (counterclockwise when facing the pump end) and cannot be reversed.
2. Proper rotation of pump impeller is critical for three phase pumps. Pump motor should turn counterclockwise (CCW) when facing pump end. Momentarily “bump” (apply power for less than a second) the motor to check for proper rotation. To change rotation on three phase units, interchange any two (2) incoming line (power) leads.

CAUTION

• Do not go over recommended maximum operating pressure (see Specifications), while maintaining minimum flow of 1.5 GPM thru the pump. Do not restrict the 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 and reduce driver loading.

START – UP PROCEDURE
Once the preceding instructions have been completed, the pump can be started.

START – UP PROCEDURE
Once the preceding instructions have been completed, the pump can be started

1. During the first few hours of operation, inspect the pump, piping and any auxiliary equipment used in connection with the unit.
2. Check for leaks, excessive vibration or unusual noises.

NOTE: See rotation arrow on inlet casting.

Maintenance

Disconnect power supply and depressurize system before servicing pump or removing  any component.

• ROUTINE
  • Pump should be checked routinely for proper operation. Replace or clean all filters and line strainers on a regular basis.
• DRAINING
  • This pump cannot be completely drained because of internal design. Most of the liquid can be drained by tilting the discharge forward after removing discharge casting; or, the liquid can be drained  through the inlet port. Store in heated areas.
• CLEANING
  • If used for spraying insecticides, pump should be thoroughly flushed with clean water after using.
• LUBRICATION
  • The motor has prelubricated bearings. No lubrication is required.
• SERVICING THREE-PHASE UNITS
  • Loctite (thread sealer) is used on the threads between the motor shaft and the pump shaft coupling. When reassembling, reapply thread sealer.
• PUMP DISASSEMBLY
  • To disassemble the pump, refer to the exploded parts view and Figures 17, 18 & 19
• 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, turning CCW (counter clockwise).

4. With the strap wrench, loosen the barrel, turning CCW (counter clockwise). DO NOT use pipe wrench on pump barrel.

5. Holding the impeller stack in place, position pump in upright position, standing unit on the motor end cover.

6. Use the 1/4” dowel rod to hold the stages down and in place on the pump shaft. Remove pump barrel.

7.  Slide the stages off the pump shaft onto the 1/4” dowel rod. Leave stages on rod and carefully set aside.
   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

1. Follow instructions under “Pump Disassembly”.

2. Remove the mechanical seal assembly.

   • The rotary portion of the seal assembly (carbon ring, Buna-N gasket and spring will slide easily off the end of shaft).
   • Using two (2) screwdrivers, pry the ceramic seal and rubber  gasket from the recess of the mounting ring (See Figure 17).
     CAUTION
     The precision lapped faces of the mechanical seal are easily damaged. Handle the replacement seal carefully. Short seal life will result if seal faces (ceramic & carbon) are nicked, scratched or dirty.

3. Clean the seal cavity of the mounting ring and the motor thoroughly.

4. Wet outer edge of rubber cup on ceramic seat with liquid soap solution. Use sparingly (one drop only).
   NOTE: Liquid soap solution – one drop of liquid soap combined with one teaspoonful of water.

5. With thumb pressure, press ceramic seal half firmly and squarely into seal cavity. Polished face of ceramic seat is up. If seal will not seat correctly, remove, placing seal face up on bench. Reclean cavity. Seal should now seat correctly (See Figure 18).

6. If seal does not seat correctly after recleaning cavity, place a cardboard washer over polished seal face and carefully press into place using a piece of standard clean 3/4” pipe as a press (See Figure 19).
   IMPORTANT: Do not scratch seal face.

7. Dispose of cardboard washer and recheck seal face to be sure it is free of dirt, foreign particles, scratches and grease.

8. Inspect shaft to be sure it is free of nicks and scratches.

9. Apply liquid soap solution sparingly (one drop is sufficient) to inside diameter of rubber rotating member.

10. Slide rotating seal member (carbon face down toward ceramic face) and spring over the shaft.

IMPORTANT: Do not nick or scratch carbon face of seal when handling.
MOTOR REPLACEMENT
The motor can be replaced with any standard Nema 56J jet pump motor (of proper HP for each pump) by referring to the following instructions.

1. Follow steps as outlined under Rotary Seal Replacement and Pump Disassembly.
2.  Remove cap screws that connect the motor to the mounting ring and pull motor away.
3. Replace 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 component 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 20 for proper facing and parts arrangement. If damage to Stage components is evident, a complete cartridge assembly or individual stage assemblies are available for replacement (See Replacement Parts List).

1. Reassembly should follow the reverse order of the disassembly procedure with special care given to replacement of the rotary seal.
2. Check top and bottom of o-rings for damage. It is recommended that new o-rings be used.
3. Do not use pipe compound of Teflon tape on barrel threads. The o-rings will prevent pump from leaking.
4. After pump is reassembled, tighten the discharge head to a torque of 45-50 ft/lbs. If torque wrench is not available, tighten firmly but avoid distortion or damage to plastic internal parts.
5. After reassembly, apply power momentarily to unit (15 to 30 seconds). The pump and motor should rotate freely or with a light rubbing.

Troubleshooting Chart

Symptom| Possible Cause(s)| Corrective Action
Pump won’t start or run at full speed| 1.| Blown fuse or open circuit breaker| 1.| Replace fuse or close circuit breaker. See wire size chart for proper break/fuse size
2.| Power supply in OFF position| 2.| Turn power on
3.| Incorrect voltage at motor (check voltage with motor running)| 3.| Low voltage
| | a.| Voltage must be within ± 10% of motor rated voltage. Check incoming voltage. Contact power company
| | | b.| Make certain that voltage of motor matches voltage of power supply. See motor name plate and motor wiring dia- grams
| | | c.| Check wire size from main switch to pump. See wire size chart for correct wire size
4.| Loose, broken or incorrect wiring| 4.| Rewire any incorrect circuits. Tighten connections, replace defective wires
5.| Defective motor| 5.| Replace motor
6.| Pump hydraulic components clogged/ worn/damaged| 6.| Replace worn parts or entire pump. Clean parts if required
Pump operates, but delivers little or no water| 1.| Manual or solenoid valves plumbed into system restricting flow| 1.| a| Check all valves on pump inlet and discharge sides of system to be sure they are opened properly to allow flow to and from the pump
| | | 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 pump| 4.| Check pressure on inlet side of booster to be sure positive 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 valve and/or strainer| 7.| Clean, repair or replace as needed
8.| Worn or defective pump parts or pump.| 8.| Replace worn parts or entire plugged impeller Clean parts if
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 backwards| 11.| Reverse motor rotation can occur on three phase units. To correct, interchange any two incoming power leads.
Excessive noise while pump in| 1.| Pump not secured to firm foundation| 1.| Secure properly
2.| Piping not supported| 2.| Make necessary adjustments
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

Booster Pump Parts Drawing

*See note below parts included in cartridge assembly. †ODP Motor Only

Internal Parts Detail

Figure 21 – 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.

PRESSURE BOOSTER PUMP REPAIR PARTS
(For Pricing Refer To Repair Parts Price List) Replacement Motors

ITEM| REPLACEMENT MOTORS| QTY| CAST IRON| POWDER COATED| STAINLESS STEEL| CAST IRON| POWDER COATED| STAINLESS STEEL
---|---|---|---|---|---|---|---|---
| SINGLE PHASE 60 HZ| THREE PHASE 60 HZ

9

| ODP NEMA J 1/3 HP| ****

1

| 98J103| 98J103| 98S103| | |
ODP NEMA J 1/2 HP| 98J105| 98J105| 98S105| 98J305| 98J305| 98S305
ODP NEMA J 3/4 HP| 98J107| 98J107| 98S107| 98J307| 98J307| 98S307
ODP NEMA J 1 HP| 98J110| 98J110| 98S110| 98J310| 98J310| 98S310
ODP NEMA J 1-1/2 HP| 98J115| 98J115| 98S115| 98J315| 98J315| 98S315
ODP NEMA J 2 HP| 98J120| 98J120| 98S120| 98J320| 98J320| 98S320
ODP NEMA J 3 HP| 98J630| 98J630| 98S630| N/A| N/A| N/A
10| Motor Cover w/Screws| 1| 023212| 023212| 023212| 023212| 023212| 023212
*| Screws, Motor Cover| 2| 021302| 021302| 021302| 021302| 021302| 021302
| SINGLE PHASE 50 HZ| THREE PHASE 60/50 HZ

9

| ODP NEMA J 1/3 HP| ****

1

| 98J003| 98J003| 98S003| | |
ODP NEMA J 1/2 HP| 98J005| 98J005| 98S005| 98J305| 98J305| 98S305
ODP NEMA J 3/4 HP| 98J007| 98J007| 98S007| 98J307| 98J307| 98S307
ODP NEMA J 1 HP| 98J010| 98J010| 98S010| 98J310| 98J310| 98S310
ODP NEMA J 1-1/2 HP| 98J015| 98J015| 98S015| 98J315| 98J315| 98S315
ODP NEMA J 2 HP| 98J820| 98J820| 98S820| 98J320| 98J320| 98S320
10| Motor Cover w/Screws| 1| 023212| 023212| 023212| 023212| 023212| 023212
*| Screws, Motor Cover| 2| 021302| 021302| 021302| 021302| 021302| 021302
| SINGLE PHASE 60/50 HZ| THREE PHASE 60/50 HZ

9

| TEFC NEMA J 1/2 HP| ****

1

| | 020691| 020691| | 021011| 021011
TEFC NEMA J 3/4 HP| | 021008| 021008| | 021012| 021012
TEFC NEMA J 1 HP| | 021009| 021009| | 020688| 020688
TEFC NEMA J 1-1/2 HP| | 020692| 020692| | 020647| 020647
TEFC NEMA J 2 HP| | 020693| 020693| | 020689| 020689
TEFC NEMA J 3 HP| | 021010| 021010| | 025585| 025585

| ITEM| DESCRIPTION| QTY| CAST IRON| POWDER COATED| STAINLESS STEEL|
---|---|---|---|---|---|---|---
5 – 7 – 10 – 19 GPM,

60 HZ & 50 HZ

| 1| Discharge Head 3/4” NPT| 1| 132000| 136905| 136640|
2| Mounting Ring 3/4” NPT| 1| 132002| 136904| 136639
27 – 35 GPM,

60 HZ & 50 HZ

55 – 85 GPM,

60 HZ & 50 HZ

| 1| Discharge Head 1” NPT| 1| 136635| 137796| 139166| See replacement motors. ITEMS 9 & 10
2

1

|

• Mounting Ring 1” NPT
• Discharge Head 2” NPT

| 1

1

|

• 136634
  021585

| 137794
–| 139100
–
2| Mounting Ring 2” NPT| 1| 021584| –| –
ALL SERIES 60 HZ & 50 HZ| 3| Seal, Rotary w/Spring| 1| 131100 †| 131100 †| 136682 ‡|
4| O-Ring| 2| 131925 ■| 131925 ■| 136607 ▲
*| Hex Head Cap Screws 3/8” x 3/4”| 4| 121106| 121106| 121106

(†) Buna N – Carbon/Silicon Carbide (‡) Viton – Carbon/Silicon Carbide (■) Buna N (▲) Viton (*) Not Shown

60 HZ MODELS|

MATERIAL

| CAST IRON| PB0508AXXX| PB0512AXXX| PB0516AXXX| PB0712AXXX| PB1014AXXX| PB1016AXXX
---|---|---|---|---|---|---|---|---
POWDER COATED| PB0508CXXX| PB0512CXXX| PB0516CXXX| PB0712AXXX| PB1014CXXX| PB1016CXXX
STAINLESS STEEL| PB0508SXXX| PB0512SXXX| PB0516SXXX| PB0712SXXX| PB1014SXXX| PB1016SXXX
ITEM| DESCRIPTION| PART NUMBER
5| Cartridge Assembly ‡| 135163| 132939| 138447| 134097| 134998| 135814
6| Shaft & Coupling Assembly| 135161| 133336| 138446| 133336| 134996| 135813
7| Barrel/Shell| 135162| 132003| 138448| 132003| 134997| 135815
MATERIAL| CAST IRON| PB1914AXXX| PB2711AXXX| PB2714AXXX| | PB3506AXXX| PB3508AXXX
POWDER COATED| PB1914CXXX| PB2711CXXX| PB2714CXXX| | PB3506CXXX| PB3508CXXX
STAINLESS STEEL| PB1914SXXX| PB2711SXXX| PB2714SXXX| PB2717SXXX| PB3506SXXX| PB3508SXXX
ITEM| DESCRIPTION| PART NUMBER
5| Cartridge Assembly ‡| 137222| 135627| 136629| 020980| 136626| 136632
6| Shaft & Coupling Assembly| 137221| 136624| 136628| 020916| 136625| 136631
7| Barrel/Shell| 137223| 135628| 136630| 138947| 136627| 136633
MATERIAL| CAST IRON| PB5504XX| PB5506XX| PB8504XX| PB8505XX| |
ITEM| DESCRIPTION| PART NUMBER
5| Cartridge Assembly ‡| 022293| 022294| 022295| 022296| |
6| Shaft & Coupling Assembly| 022289| 022287| 022288| 022287| |
7| Barrel/Shell| 022291| 022292| 138151| 022290| |

(‡) Cartridge assembly includes: impellers, diffusers, o-rings and shaft & coupling assembly. Components not available individually. Sold as assembly only.

• © 2023 FLINT & WALLING, INC.
• 95 North Oak St.
• Kendallville, IN 46755 flintandwalling.com

References

• flintandwalling.com

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