Franklin Electric Little GIANT 16 G Series Grinder Pumps Owner’s Manual

16 G Series Grinder Pumps
Owner’s Manual

littlegiant.com

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 Little Giant 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:

DANGER
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.

WARNING
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.
• 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).
• Wire pump system for correct voltage.
• This product is supplied with a grounding conductor and grounding-type attachment plug. To reduce risk of electric shock, be certain that it is connected only to a properly grounded grounding-type receptacle. Do not remove the third prong from the plug. The third prong is to ground the pump to help prevent possible electric shock hazard. Do not use an extension cord.
• A separate branch circuit is recommended for each pump.
• The pump should only be used with liquids compatible with pump component materials. If the pump is used with liquids incompatible with the pump components, the liquid can cause failure to the electrical insulation system resulting in electrical shock.

CAUTION

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 experience and expertise, unless supervised or instructed. Children may not use the equipment, nor may they play with the unit or in the immediate vicinity.
• Equipment can start automatically. Always unplug the pump power cord and disconnect the electrical power before servicing the pump.
• Do not run pump dry. If run dry, the surface of the pump will rise to a high temperature that could cause skin burns if touched, and will cause serious damage to the pump.
• Do not oil the motor. The pump’s motor housing is sealed, and contains a high-grade dielectric oil for heat transfer and lifetime lubrication. Use of other oils could cause serious electric shock and/or permanent damage to the pump
• Do not let the unit freeze. Freezing may cause cracking or distortion that may destroy the unit.
• In applications 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, an automatic back-up system and/or an alarm should be installed.
• Do not use the power cord for lifting the pump.
• Do not place hands, feet or clothing near the cutter mechanism when there is any possibility the pump is connected to a power source. This pump contains a cutting mechanism with very sharp edges that can cause severe bodily injury.
• The pump has been evaluated for use with water only. Pump should only be used with liquids compatible with pump component materials. If the pump is used with liquids incompatible with the pump components, the liquid can cause failure to the electrical insulation system resulting in electrical shock.
• Operation of this equipment requires detailed installation and operation instructions provided in this manual for use with this product. 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.

NOTICE

Risk of damage to pump or other equipment.

• Periodically inspect pump and system components. Regularly check hoses for weakness or wear, making certain that all connections are secure.
• Schedule and perform routine maintenance as required and in accordance with the Maintenance section of this manual.

PRODUCT DESCRIPTION

Submersible grinder pumps are recommended for use in basins or lift stations and are suitable for pumping residential sewage, effluent, wastewater, and other non-explosive, non-abrasive, and non-corrosive liquids. These pumps utilize a cutting mechanism, located on the suction side of the pump, that cuts solids into a slurry. A semi-vortex, non-clog impeller then passes this slurry directly through the volute and into the discharge line.
Little Giant automatic grinder pumps are equipped with a float switch that allows the pumps to operate automatically by cycling them on and off. The float switch is attached to the pump at a pre-determined tether length of 6 inches. Check the tether length on the pump to ensure it has not changed during shipping. Some pumps, however, come
with an unassembled mechanical vertical switch.
This product is covered by a Limited Warranty for a period of 36 months from the date of original purchase by the consumer. For complete warranty information, refer to www.LittleGiant.com; or call Customer Support for a printed copy.

Specifications

16G-F151-20
16G-V151-20
16G-M231-20| 230| 6.5| 1290
16G-F231-20
16G-V231-20

Flow Rates

Gallons/Liters per Minute at Height

10 ft (3 m)| 20 ft (6 m)| 30 ft (9.1 m)| 40 ft (12.1 m)| 50 ft (15.2 m)| Shut Off
49.3 / 186.6| 43.9 / 166.2| 37.5 / 142.0| 28.7 / 108.6| 15.3 / 57.9| 53 ft (16.15 m)

INSTALLATION

Physical Installation

CAUTION
Risk of personal injury, or damage to pump or other equipment.

• Check that lifting equipment complies with all safety rules, and is suitable to support the weight of the pump.

1. Install the provided leg accessory kit:
   • Remove the three shipping bolts from the volute casting legs using a 19 mm wrench or crescent wrench.
   • Screw the nut all the way onto the removable leg bolt.
   • Screw the leg bolt and its nut onto the volute casting legs hand tight.
   • Tighten the nut against the volute casting with a 19 mm wrench or crescent wrench.

2. If purchased with a vertical switch, install it using a P1 size Phillips screwdriver:
   • Screw the bracket onto the switch with the two self-tapping screws.
   • Assemble the vertical switch and its bracket onto the motor housing cover using the 2 M4 screws.

3. Install the pump in a suitable gas-tight basin at least 20″ diameter and 24″ deep vented in accordance with local, state, and federal plumbing codes.

4. Place the pump-basin assembly on a hard, level surface.
   • Never place pump directly on clay, earth, or gravel surfaces. These surfaces contain small stones, gravel, sand, etc. that may clog or damage the pump and cause failure.
   • Secure the pump so the starting torque does not cause the pump to contact anyone or anything.

5. Install discharge piping.
   • Do not use piping smaller than the pump discharge.
   • Use ABS, PVC, polyethylene, or galvanized steel pipe.
   • For rail systems, use proper adapters to connect nonmetal pipe.

6. Install a full-flow check valve in the discharge line horizontally to prevent back flow of liquid into the basin.
   • A ball check valve is recommended.
   • If installed vertically, solids may settle in the valve and prevent it from opening at start-up.

7. Drill a 3/16″ diameter relief hole in the discharge pipe below the floor line between the pump discharge and check valve.
   • If not provided, the pump could “air lock” and will not pump water even though it will run.

8. Install a shut off valve following the check valve to allow for cleaning of the check valve or pump removal.

Electrical Connections

WARNING

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

• To minimize risk of electrical shock, disconnect power before working on or around the system.
• In a 200-208 and 230 VAC direct wire installation, one side of the line going to the pump is always electrically energized, regardless of whether the liquid level control switch is open or closed. To avoid hazards when installing or servicing, install a double-pole disconnect near the pump installation.
• The flexible jacketed cord assembly mounted to the pump must not be modified in any way, with the exception of shortening the cord to fit into a control panel. Any splice between the pump and the control panel must be made within a junction box mounted outside of the basin and comply with the National Electrical Code. Employ a licensed electrician.
• Check the pump label for proper voltage required. Do not connect to voltage other than that shown.
• Connect to a circuit equipped with a ground fault circuit interrupter (GFCI) device if required by code.
• The pump should be connected or wired to its own circuit with no other electric receptacles or equipment in the circuit.
• The fuses or circuit breaker should be of ample capacity in the electrical circuit. For amperage ratings, refer to “Specifications” on page 3.
• If a junction box is used, removal of plug is required. Little Giant assumes no responsibility for improper wiring of the pump/float switch in the junction box.
• Refer to alarm system’s manual for installation and electrical connections.

Automatic Pump Models
Models with a float switch include two power cords with a piggyback plug on the switch cord. For automatic operation, plug the pump cord into the switch cord. Plug the switch cord (with pump cord attached) into a GFCI outlet.
Manual Pump Models
Manual pumps are plugged into a dedicated GFCI receptacle and are controlled by either by switching the power or by unplugging the cord.
Manual, continuous pump operation should be used only for emergencies, or when a large volume of water is to be pumped. The pump must be continuously monitored
during manual operation and disconnected from power before the pump runs dry.
Manual pumps can be converted to automatic mode by installing a separate liquid level control. Install according to the manufacturer’s instructions.

OPERATION

CAUTION
Risk of personal injury or damage to pump or other equipment.

• This pump is equipped with a cutting mechanism that has very sharp edges. Use caution when working on or near these parts. Do not allow anything to enter the pump during testing.
• The float or ball portion of the switch must not touch the pump, the walls of the basin, the plumbing, or any wiring in the basin as it floats up or down. Contact with obstacles may cause the pump to continue running without water or to stop running when water is present, damaging the pump or other property.
• 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.

Testing Automatic Pump Operation
Some pumps have automatic switches with piggyback plugs on the switch cords. The pump must be plugged into piggyback switch cord for automatic operation.
When these pumps are installed in a basin with a sealed cover, switch operation cannot be observed. The basin cover will usually have a spare hole that is plugged with a rubber plug. This plug can be removed and switch operation can be observed.

1. Connect the pump to power with correct voltage. Refer to the pump nameplate.

2. Be sure the gate valve in the discharge line is open.

3. Run water into the basin until the pump is activated. Do not run pump without water.

4. Ensure the pump and its control switch are functioning as intended.

5. Confirm the ON/OFF levels are within specification.

6. Make sure no potential obstructions exist that could inhibit switch operation.

7. Verify that there are no leaks in the pump discharge plumbing and main home drain pipe plumbing.
   NOTE: It is normal for a stream of water to spray from the air bleed hole in the pump’s plumbing. Confirm that this spray is captured  withinthe basin.

8. Allow the pump to operate through several ON/OFF cycles.

Testing Manual Pump Operation

Risk of personal injury or damage to pump or other equipment.

• Manual, continuous pump operation should be used only for emergencies, or when a large volume of water is to be pumped. The pump must be continuously monitored during operation and disconnected from power before the pump runs dry.
• If an accessory float switch or other liquid level control is installed, refer to manufacturer’s instructions. ailure to install control in compliance with national and local
  electrical and plumbing codes and within manufacturer’s recommendations may result in electrical shock or fire hazard, unsatisfactory performance, or equipment failure.

Manual pumps do not include an automatic liquid level control. The pump cord for these pumps can be plugged directly into a properly grounded receptacle with voltage consistent with the pump nameplate for continuous operation.

For automatic operation of a manual pump, a separate float switch or other liquid level control may be used.
If a float switch or level control has been added, refer to “Testing Automatic Pump Operation” on page 6.

1. Connect a discharge hose to the pump’s discharge port.

2. Place pump into a basin or test reservoir.

3. Direct the opposite end of the discharge hose back into the basin or test reservoir so that the water discharged from the hose during testing will be contained within the
   basin or test reservoir.
   • Secure the hose to prevent the water pressure created during testing from causing the hose to exit the basin or test reservoir.

4. If there is a valve on the discharge hose, be sure the valve is open.

5. Using a separate water source, fill the basin or test reservoir until the pump is fully submerged.
   • Do not attempt to run the pump without water; this could result in permanent damage to the pump.
   • Do not overfill the basin or test reservoir.

6. Plug the pump’s power cord into a ground fault circuit interrupter (GFCI) receptacle with voltage consistent with the pump voltage, as indicated on the pump nameplate.

7. Confirm that the pump is functioning as intended.
   NOTE: It is normal for a stream of water to spray from the air bleed hole in the pump’s plumbing. Confirm that this spray is captured within the basin.

8. If pump is not functioning as intended, unplug the pump’s power cord from the receptacle and refer to “Troubleshooting” on page 12. If the solution still cannot be found, please contact the place of purchase or an authorized service center.

9. If the pump is functioning as intended, unplug the pump’s power cord from the receptacle before attempting to remove it from the basin or test reservoir.

MAINTENANCE

CAUTION
Risk of personal injury or damage to pump or other equipment.

• Before working on pump, always disconnect pump power cord in addition to shutting off circuit breaker or removing the fuse. Always wear eye protection.
• This pump is equipped with a cutting mechanism that has very sharp edges. Use caution when working on or near these parts.
• Do not remove motor housing seal plate screws or top motor housing screws. The motor section of the pump is permanently lubricated with dielectric oil and sealed at the factory. Removal of these screws by anyone other than an authorized service center will break the seal and void the warranty.

Disconnect Power

• The pump and surrounding areas may be covered with water. Never plug in or unplug the device while standing in wet or damp surfaces. Do not stand in water and do not touch any other conductive sur- faces.
• If necessary, remove power at the breaker panel or have certified electrician remove power before attempting to service. Serious or fatal shocks could result if proper procedures are not followed. Disconnect the power at the main electrical service box by switching off the appropriate circuit breaker or removing fuse.
• In applications where screw type fuses are used, remove using only one hand while the other hand and torso are free from contact with anything.

Periodic Service
Inspect and test the pump system condition and operation every three months—more frequently in heavy use applications.
Let pump cool for a minimum of 2 hours before attempting to service. Submersible pumps contain oil that becomes pressurized and hot under normal operating conditions.

1. Check the power cords and electrical outlet for damage or corrosion.
2. Remove all debris (gravel, sand, floating debris, etc.) from the basin.
3. Check the pump system components (basin, pump, switch, etc.) for any build-up (sludge, sediment, minerals, etc.) that would inhibit functionality of the components. If significant, remove build-up or replace affected components.
4. Confirm that all flexible coupling hose clamps are fully engaged with plumbing and fully tightened.
5. Test operation of the pump system. Refer to “Operation” on page 6.
6. While the pump is running, make sure a stream of water is escaping from the air bleed hole. If not, clear the hole of any deposits or debris.

Thermal Protection
The motor is a continuous duty type equipped with an automatic resetting heat sensor and may restart unexpectedly. Heat sensor opening is an indication of motor  overloading/overheating, which can be caused by application issues such as:

• an obstructed pump impeller
• switch stuck in the ON position
• pump running dry
• pump air locked
• pump short cycling
• operating the pump at low heads (low discharge restriction)
• excessively high or low voltage supply
• inadequate wiring
• incorrect motor connections
• mis-application of the product
• pump, motor, bearings, or seal that have reached the end of their useful life.

Any of these conditions must be corrected to extend the life of the pump.

Disassembly

CAUTION
Risk of personal injury or damage to pump or other equipment.

• This pump is equipped with a cutting mechanism that has very sharp edges. Use caution when working on or near these parts.
• Do not remove motor housing seal plate screws or top motor housing screws. The motor section of the pump is permanently lubricated with dielectric oil and sealed at the factory. Removal of these screws by anyone other than an authorized service center will break the seal and void the warranty.

NOTE: To replace the impeller or inspect the pump for worn components, disassemble both the cutter and volute.

Cutter Disassembly

1. Clean the pump of all debris and deposits.

2. Lay the pump on a smooth, hard surface.

3. Scribe a mark between the seal plate and volute.

4. Remove the stationary cutter and cutter plate:
   • Remove the three (3) 6M bolts and lock washers with a 10 mm socket or wrench.
   • Lightly tap the stationary cutter assembly with a rubber hammer to remove from the volute.

5. Remove the impeller bolt and washer with a 5 mm Allen wrench or hex head socket.
   • Use a channel lock to hold the rotation cutter to keep it from spinning.

6. Remove the rotating cutter from the motor shaft.

Volute Disassembly

1. Disassemble the cutter. Refer to “Cutter Disassembly” on page 9.
2. Remove the four (4) 8M bolts that hold the volute to the seal plate using a 13 mm socket.
3. If needed, lightly tap the volute with a rubber hammer to separate the volute from the seal plate.
4. Using 2 screwdrivers or gear puller, pull the impeller off of the motor shaft.

Reassembly

1. Insert key into motor shaft, ensuring the rounded end of the key matches with the bottom of the motor shaft keyway.

2. Assemble impeller onto the motor shaft until it bottoms out on the shaft shoulder.

3. Replace the volute, aligning it with the scribe marks made on it and the seal plate during disassembly.

4. Reassemble and tighten the four (4) 8M bolts and lock washers to 110 in/lbs using a 13 mm socket or wrench.

5. Assemble the rotation cutter to the motor shaft.
   • Apply Loctite 242 to the threads of the flat head bolt.
   • Reassemble the flat head bolt and washer to the motor shaft.
   • Use channel locks to hold the rotating cutter portion to keep the shaft from rotating.
   • Tighten the shaft bolt to 155 in/lbs using a hex head socket.

6. Replace the stationary cutter assembly on the volute.
   • Tighten the three (3) 6M bolts and lock washers to 110 in/lbs using a 10 mm socket or wrench.

7. Refer to “Operation” on page 6.

Replacement Parts

NOTE: Individual kit items are not available for purchase. For replacement float switches, contact Franklin Customer Support.
IMPORTANT: Do not remove motor housing seal plate screws or top motor housing screws.

Troubleshooting

fuse.
Accumulation of trash on float| Clean float.
Float obstruction.| Clean float path and provide clearance.
Defective switch.| Replace switch
Defective motor.| Replace pump.
Pump will not shut off.| Float or float rod obstruction.| Check float and float rod path and provide clearance.
Pump is air locked| Remove pump and clean air bleed hole.
Liquid inflow matches pump capacity.| Larger pump required.
Defective switch.| Replace switch
Pump runs but does not dis- charge liquid.| | Check flow indicating arrow on check valve body to ensure proper installation.
Check valve stuck or plugged.| Remove check valve and inspect for proper installation.
Lift too high for pump.| Check rated pump performance.
Inlet to impeller plugged.| Pull pump and clean.
Pump is air locked| Remove pump and clean air bleed hole.
Pump does not deliver rated capacity.| Lift too high for pump.| Check rated pump performance.
Low voltage, speed too slow.| Check that supply voltage matches nameplate rating.
Impeller or discharge pipe is clogged.| Pull pump and clean. Check pipe for scale or corrosion.
Impeller wear due to abrasives.| Replace worn impeller.
Pump cycles continually.| No check valve in long discharge pipe allowing water to drain back into basin.| Install a check valve in the discharge line.
Check valve leaking.| Inspect check valve for correct operation.
Basin too small for inflow.| Install larger basin.
Water sprays out of a hole a bolt on the base of the unit.| This pump comes with a bleed hole that allows trapped air to escape from the pump, preventing air lock. Water spraying out of this hole is completely normal.| No corrective action is required. No

For technical assistance, parts, or repair, please contact:
800.701.7894 | littlegiant.com
Form 10000004738 Rev. 001 12/20

Franklin Electric Co., Inc. | Oklahoma City, OK 73157-2010
Copyright © 2020, Franklin Electric, Co., Inc. All rights reserved.

References

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