W16G07S8-32P - Pump Little Giant - Free user manual and instructions

USER MANUAL W16G07S8-32P Little Giant

4” SUBMERSIBLE PUMP BEFORE INSTALLING PUMP, BE SURE TO READ THIS OWNER’S MANUAL CAREFULLY. Fill the pump with water before starting or the pump will be damaged. The motor on this pump is guaranteed by the manufacturer, and in the event of failure it must be returned to an authorized service station for repairs. The motor warranty is void if repairs are not made by an authorized repair station.

INSPECT THE SHIPMENT

Examine the pump when it is received to be sure there has been no damage in shipping. Should any be evident, report it immediately to the dealer from whom the pump was purchased. Please check the pump package to see that it includes pump, motor, and motor leads (if your pump purchase includes a motor). This pump includes either a built-in or externally-mounted check valve with the discharge head. Make certain that your available voltage corresponds to that of your motor. CAUTION

READ AND FOLLOW SAFETY

INSTRUCTIONS This is the safety alert symbol. When you see this symbol on your pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury: DANGER warns about hazards that will cause serious personal injury, death, or major property damage if ignored. WARNING warns about hazards that can cause serious personal injury, death, or major property damage if ignored. CAUTION warns about hazards that will or can cause minor personal injury or major property damage if ignored.The label NOTICE indicates special instructions, which are important but not related to hazards.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.Wire motor for correct voltage. See Electrical Information section of this manual and motor nameplate.Ground motor before connecting to power supply.Meet National Electrical Code, Canadian Electrical Code, and local codes for all wiring.Follow wiring instructions in this manual when connecting motor to power lines.Hazardous voltage.Can shock, burn, orcause death.Ground pump beforeconnecting to powersupply. Disconnectpower before workingon pump, motor or tank. WARNING Franklin Electric Co., Inc. www.franklinwater.com [e-mail] ATTENTION!

WORKING ON OR AROUND THE WATER SYSTEM. DO NOT USE MOTOR IN SWIMMING AREAS. INSTALLATION RECORDS It is a good idea to keep an accurate record of your installation. Be sure to record the data below: Purchased from: Date of installation: Pump model*: Pump date code*: Well inside diameter (in/mm): Depth of well (ft/m): Depth of water (ft/m): Pump setting (ft/m): Drop pipe size: Wire size (pump to control box): Wire size (control box to power source): Horizontal offset (between well & house): Make of motor* Amps HP Volts Phase Make of control box HP Volts Power supply Volts HZ Pressure switch limits Cut-in (PSI) Cut-out (PSI) *This information is on your pump or motor tag. It will help us identify your pump in case of later inquiries. TEST RUNNING If test running pump before installation:

1. Ensure that the power supply corresponds with that

shown on the nameplate of the motor and control box (if required).

2. Install pump and components appropriate for the test as

3. Make sure power supply is turned off and circuit

breaker or disconnect switch is open. Make electrical connections appropriate to your motor as shown in Figure 2, 3 or 4.

4. On a three-phase motor, use a magnetic starter equipped

with quick-trip, ambient compensated heaters of correct size for the horsepower of the motor. To ensure correct rotation of three-phase units, brace pump shell securely and apply power momentarily by snapping line switch quickly on and off. If rotation is correct, reaction of the shell will be clockwise when viewed from pump discharge (that is, pump shaft will rotate counter clockwise). Interchange any two leads at magnetic starter to reverse rotation.

5. Run pump and motor unit for a few seconds to ensure

that it is in working order. FIGURE 1 Installation Diagram Pressure tankPressure switchGate valve Service pipePressure gaugePressure relief valveSpring-loadedcheck valveSee Wiring DiagramsSanitary well sealor pitless adapterDischarge pipeSubmersible cableSpring-loadedcheck valve(Recommended every 100’/30m)Safety cable Drop pipe Cable(secured to droppipe with tape orclamps every 10’/3m)Well casingSpring-loadedcheck valveat pump dischargeSubmersible pump Suction screenMotorWell screen orcasing perforationsNote: Keep pump at least 5' (1.5 m) frombottom of well and above well screenor casing perforations.Torque arrestor

Install the pump only in a well that has been properly developed. Water from an undeveloped well often contains an excessive amount of sand, dirt, and abrasives which can damage the pump. Check that the well is large enough to3 allow the pump to be set at the required depth. Do not set the pump below the casing perforations or well screen unless you make arrangements to ensure an adequate ow of water over the motor for cooling purposes. Determine the correct pump setting from the driller’s record by taking into account the static water level and the drawdown at the proposed pumping rate. Keep the pump at least ve feet from the bottom of a drilled well.

SPLICING THE POWER CABLE

Follow the instructions enclosed in the cable splicing kit (purchased separately). DROP PIPE Submersible drop pipe manufacturer’s usage guidelines should always be followed when suspending a submersible pump in a well. Generally either galvanized steel or plastic are used for the pump drop pipe. When using plastic piping it is important to follow the manufacturer’s depth and pressure rating. Give special consideration to:

1. A safety cable to prevent loss of pump if pipe should break.

2. A torque arrestor just above pump to prevent chang the

cable when pump and pipe twist during the starting and stopping cycle. (See Figure 1.) Schedule 40 galvanized pipe is suitable for settings to 600 feet (180m). For deeper settings, use schedule 40 pipe for the bottom 600 feet (180m), and schedule 80 for the remainder. NOTICE: Drop pipe sizes and usages depths should be considered as general guidelines only. Drop pipe manufacturer data and recommendations supersedes these instructions. Take great care to keep pipes clean and free from pebbles, scale, and thread chips. Make sound, air-tight connections at all ttings. Pipe sealant is recommended. CHECK VALVES It is recommended that one or more check valves always be used in submersible pump installations. If the pump does not have a built-in check valve, an inline check valve should be installed in the discharge line within 25 feet of the pump and below the draw down level of the water supply. If permitted by local codes it is recommended that an additional check valve be installed in the system plumbing between the wellhead and the system’s pressure tank. For pump installations that are more than 200 feet (60m) below the wellhead; additional check valves should be installed in the drop pipe. This should be done at intervals of 200 feet (60m) or at the check valve manufacturer’s specied installation interval. More than one check valve is often needed, but more than the recommended number of check valves should not be used. Swing type check valves are not acceptable and should never be used with submersible motors/pumps. Swing type check valves have a slower reaction time which can cause water hammer (see next page). Internal pump check valves or spring loaded check valves close quickly and help eliminate water hammer. Check valves are used to hold pressure in the system when the pump stops. They also prevent backspin, water hammer and upthrust. Any of these can lead to early pump or motor failure. NOTE: Only positive sealing check valves should be used in submersible installations. Although drilling the check valve or using drain-back check valves may prevent back spinning, they create upthrust and water hammer problems. A. Backspin - With no check valve or a failed check valve, the water in the drop pipe and the water in the system can ow down the discharge pipe when the motor stops. This can cause the pump to rotate in a reverse direction. If the motor is started while it is back spinning, an excessive force is placed across the pump-motor assembly that can cause impeller damage, motor or pump shaft breakage, excessive bearing wear, etc. B. Upthrust - With no check valve, a leaking check valve, or drilled check valve, the unit starts under a zero head condition. This causes an uplifting or upthrust on the impeller-shaft assembly in the pump. This upward movement carries across the pump-motor coupling and creates an upthrust condition in the motor. Repeated upthrust can cause premature failure of both the pump and the motor. C. Water Hammer - If the lowest check valve is more than 30 feet above the standing (lowest static) water level, or a lower check valve leaks and the check valve above holds, a vacuum is created in the discharge piping. On the next pump start, water moving at very high velocity lls the void and strikes the closed check valve and the stationary water in the pipe above it, causing a hydraulic shock. This shock can split pipes, break joints and damage the pump and/or motor. Water hammer can often be heard or felt. When discovered, the system should be shut down and the pump installer contacted to correct the problem.

REMOVABLE POPPET CHECK VALVE

4” submersible pumps with a 1-1/4” discharge are supplied with a spring-loaded, removable poppet check valve assembly. This check valve can be removed from the pump discharge when drain back is desired. WARNING Fluid draining back through the pump can cause the pump to rotate backwards. If pump/motor starts during this time, damage to the pump can occur. The check valve can be removed using a T-handle poppet wrench (purchased separately), or with standard needle-nosed pliers. The poppet assembly is left-hand threaded and is removed by turning clockwise. When reinstalling a poppet check valve assembly, tighten it to 15 inch-pounds. Poppet Assembly T-Handle Poppet Wrench

INSTALLATION OF PUMP, DROP PIPE, AND

ASSOCIATED EQUIPMENT Figure 1 illustrates a typical well installation showing in ground components. Adhere to the following items when installing the pump and drop pipe:

1. Fasten the submersible cable to the drop pipe with clamps

or appropriate tape every 10 ft. (3m) to prevent tangling and4 damage to the cable. The cable must remain slack when using plastic drop pipe to allow for stretching of pipe when installed in the well.

2. Take care not to scrape or pinch the submersible cable

against the well casing. One sentence needs to be together on same page

3. Use an ohmmeter or megger to make insulation and

continuity checks on the cable once the pump is installed. This locates any fault in the cable.

4. Make sure a check valve is in accordance with the

guidelines in this manual.

5. Install a torque arrestor just above the pump to prevent

chang the cable when pump and pipe twist during starting and stopping.

6. Attach a safety cable to pump to prevent loss of pump if

7. Place a sanitary well seal or pitless adapter with an

approved cover plate over top of well per manufacturers recommendations.

8. Keep pump at least 5’ (1.5m) from bottom of well and above

well screen or casing perforations. ELECTRICAL INFORMATION

1. Employ a licensed electrician to perform the wiring. All

wiring must be done in accordance with applicable national and local electrical codes.

2. Check that the power supply corresponds with the electrical

rating of the submersible motor and the control box (if required). Make sure that the control box electrical rating matches the motor electrical rating.

3. Every installation requires a fused disconnect switch or

4. Every installation must be grounded. There must be a

reliable ground connection between the pump and the distribution panel. The motor lead incorporates a green grounding conductor.

5. Lightning arrestors are recommended for every installation.

All stainless steel, single phase motors through 5CV have built-in lightning arrestors. 3-phase motors require a separate lightning arrestor installed as close to the wellhead as possible. Install the arrestor in accordance with manufacturer’s recommendations. Lightning arrestors provide protection against only induced voltage surges on secondary power lines; they are not effective against direct hits.

6. Mount the control box in an area protected from rain, snow,

direct sunlight, or other high temperatures as this may cause tripping of the overload protector. Also protect the control box from extreme cold (below 25

C) as this may have adverse effects on the starting capacitor.

7. A two-wire pump does not require a motor control box; all

electrical components are built inside the motor. Figure 2 shows a typical wiring diagram for a two-wire installation. FIGURE 2 2-wire, 1-phase, 1/3 through 1-1/2 HP Pump Wiring Diagram Incoming 1-phase power 1-phase submersible motor Submersible cable Switch or timerCircuit breaker orfuse disconnect switch

8. A three-wire, 1-phase pump requires a motor control box

incorporating overload relays. Figure 3 shows a typical wiring diagram for a three-wire, single-phase installation. Note that a magnetic contactor must be used if the pressure switch electrical rating is not sufcient to handle the submersible motor electrical rating. The pressure switch would then be incorporated into a pilot circuit to control the magnetic contactor. Make the connections at the control box in accordance with the wiring diagram in the control box to avoid damage to the motor. FIGURE 3 3-wire, 1-phase, 1/3 through 15 HP Pump Wiring Diagram Circuit breakeror fused disconnect switch Pressure switch for pilot circuit(if magnetic contactor is usedfor starting) Single-phase control box Red YellowBlack1-phase sumbersible motorSwitch or timer (for direct switching) ORmagnetic contactor (w/pilot circuit)Incoming 1-phase power Note: Order of red, yellow, and black may vary from control box to control box.Always connect like colors.

9. A three-wire, three-phase pump does not require a motor

control box . Figure 4 shows a typical wiring diagram for a three-wire, three-phase installation. A magnetic contractor with three-leg protection and quick-trip ambient compensated overload relays must be used. FIGURE 4 3-wire, 3-phase, 1-1/2 thru 50 HP Pump Wiring Diagram Incoming 3-phase power3-phase submersible motorCircuit breaker ORfused disconnect switchPressure switchMagnetic contactor with3-leg protection andquick-trip ambient compensated overload relays5

10. Use an ohm meter to make continuity and insulation

checks after the installation is completed.

11. Place the additional pump nameplate onto the submersible

label and place both onto disconnect switch or circuit breaker box for future reference. WELL TEST Check the pump and well performance before making the nal connection to the discharge system.

1. Install a gate valve on the end of the pipe. Partially

3. Open the valve gradually to give full ow.

4. If the discharge is not clear, let the pump run until

water clears. If water does not clear in 30 minutes, stop the pump and take the necessary steps to correct the condition. After the water appears clear, check for sand by discharging into a clean bucket or suitable container.

5. Close valve until maximum required system ow

rate is obtained. This should correspond to the cut-in pressure of the pressure switch. Ensure that the output of the pump at this setting is not greater than the yield of the well. This can be checked by monitoring the well drawdown level and ensuring that the level is stable at the maximum required system ow rate. CAUTION Never run the pump unless it is completely submerged in water. If run without water, the pump and motor could be damaged. Note also that air drawn into the pump can cause an airlock under certain conditions. LOW-YIELDING WELL A low-yielding well exists when the output from the pump is greater than the yield of the well. It can reduce the water level to the suction screen so that a mixture of air and water enters the pump. Pumping may stop since the pump cannot generate pressure with insufcient water. In this case, the column of water already in the drop pipe holds the check valve closed and an airlock may develop inside the pump. Because the conditions ensure neither adequate lubrication of the pump nor proper cooling for the motor, damage can result if power is not cut off quickly. Use one or more of the following methods to correct and/or protect this installation.

1. Install an additional length of drop pipe to place pump lower

in well if possible.

2. Install a Franklin Pumptec or similar electronic drawdown

3. Install a oatless liquid level control. This device consists of

an electrical relay activated by currents owing through the ground-return circuits of electrodes hung in the well. The lower (stop) electrode, just above the pump, ensures that the water level can never be pumped down to the suction screen. The upper (start) electrode, just below the lowest static water level, ensures that the pump can start again as soon as the well has recovered. A oatless liquid level control works in series with the pressure switch. Refer to the manufacturers instructions provided with the control.

4. Install a ow control valve in the discharge line upstream

from the pressure switch. This restricts the output from the pump without affecting the rate that water can be drawn from the pressure tank. Nevertheless, a heavy demand for water could empty the pressure tank, so a tank with a bonded diaphragm, air cell, or water bag is recommended.

5. Install a smaller pump to avoid over-pumping the well. Have

the dealer size the pump to the well yield.

6. Install a low pressure cut off switch, or a pressure switch

with such an arrangement built in. This protects a shallow- well pump from losing its prime, but it does not always provide satisfactory protection to a submersible pump from the effects of over-pumping the well. This is because it responds to a loss of pressure at the surface, which may occur after an air lock has formed inside the pump. Either a oatless liquid level control or a ow control valve, in that order, is recommended in preference to a low-pressure cutoff switch as protection against over-pumping. DISCHARGE PLUMBING Figure 1 illustrates a typical well installation showing above- ground components. Refer to Figure 1 and the following steps when installing the discharge plumbing.

1. Install an above-ground check-valve upstream from the

valve should be capable of discharging the ow rate of the pump at the rated working pressure of the pressure tank. Locate the relief valve close to the pressure tank.

3. Install a pressure switch between the check valve and the

pressure tank. Refer to Figure 2, 3, or 4 for proper wiring connections of pressure switch.

4. Install a pressure tank as close as possible to the pressure

switch. Refer to manufacturer’s recommendations for installation.

INSTALLATION IN LAKE OR STREAM

A submersible pump is usually isolated at the bottom of a well, where electrical leakage from its motor and cable presents no hazard to life. This natural protection is lost when it is installed it in a lake, pond, stream, or fountain because there is no way to stop people and animals from entering or touching the surrounding water. It is recommended that such an installation be done by a licensed electrician in conformance with all applicable national and local electrical codes. Grounding as described in this manual is a minimum requirement, and a ground fault circuit interrupter (GFCI) is advisable. But in the absence of explicit national or local regulations, ask the local electric utility for guidance. In any case, support the pump from the shore or bottom at a 15

slant to assure proper motor bearing lubrication. Shield the pump from direct physical contact by people and animals. Protect and screen the pump intake to prevent blockage by leaves and weeds, but remember the need for adequate ow over the motor for cooling purposes. In addition, protect the entire underwater installation from water currents, ice, boats, anchors, debris, vandalism, and other hazards.6 TROUBLESHOOTING

1. PUMP FAILS TO START

a) Electrical trouble - call dealer or electrician b) Drawdown protection device has pump turned off c) Overload tripped d) Reset low pressure cutoff switch (if installed)

2. PUMP FAILS TO DELIVER WATER

a) Air lock in pump b) Clogged intake screen c) Insufcient well yield

3. PUMP GIVES REDUCED OUTPUT

a) Insufcient well yield b) Worn pump c) Clogged intake screen d) Low voltage e) Incorrect rotation (3-phase only)

4. PUMP CYCLES TOO FREQUENTLY

a) Excessive pressure drop between pressure switch and pressure tank b) Cut-in pressure at pressure tank too high c) Cut-out pressure at pressure tank too low d) Waterlogged pressure tank e) Start and stop electrodes of oatless liquid level control set too close together f) Tank sized too small to meet system requirements

PUMP STARTS a) Pressure switch too far from pressure tank b) Improper air charge of tank - adjust to manufacturer’s recommendationsMANUEL DU PROPRIETAIRE 4” POMPES SUBMERSIBLES

FOR DEFECTIVE PRODUCT. Franklin Electric Company, Inc. and its subsidiaries (hereafter “the Company”) warrants that the products accompanied by this warranty are free from defects in materials or workmanship of the Company that exist at the time of sale by the Company and which occur or exist within the applicable warranty period. Any distributor, sub-distributor, recipient, end- user and/or consumer agrees that by accepting the receipt of the products, the distributor, sub-distributor, recipient, end user and/or consumer expressly agrees to be bound by the terms of the warranty set forth herein.

I. Applicable Warranty Period

The products accompanied by this warranty shall be covered by this Limited Warranty for a period of 12 months from the date of original purchase by the consumer. In the absence of suitable proof of purchase date, the warranty period of this product will begin to run on the product’s date of manufacture.

II. Instructions Applicable to this Limited Warranty

1. Consumers wishing to submit a warranty claim must return the products

accompanied by this warranty to the point of purchase for warranty consideration.

2. Upon discovery of a defect, any personal injury, property damage

or any other type of resulting damage, if applicable, shall be reasonably mitigated to the extent possible.

3. At its discretion, the Company may inspect products either at its facilities or in

the field, and after determination of a warranty claim, will, at its option, repair or replace defective parts. Repaired or replaced parts will be returned freight prepaid by the Company.

4. This warranty policy does not cover any labor or shipping charges. The

Company shall not be liable for any costs or charges attributable to any product testing, maintenance, installation, repair or removal, or for any tools, supplies, or equipment needed to install, repair, or remove any product.

III. Limitations Applicable to this Limited Warranty

THIS WARRANTY DOES NOT APPLY TO ANY OF THE FOLLOWING:

1. Any product that is not installed, applied, maintained and used in

accordance with the Company’s published instructions, applicable codes, applicable ordinances and/or with generally accepted industry standards.

2. Any product that has been subject to misuse, misapplication, neglect,

alteration, accident, abuse, tampering, acts of God (including lightning), acts of terrorism, acts of war, fire, improper storage or installation, improper use, improper maintenance or repair, damage or casualty, or to an excess of the recommended maximums as set forth in the product instructions.

3. Any product that is operated with any accessory, equipment, component, or

part not specifically approved by the Company.

4. Use of replacement parts not sold by the Company, the unauthorized

addition of non-Company products to other Company products, and the unauthorized alteration of Company products.

5. Products damaged by normal wear and tear, normal maintenance

services and the parts used in connection with such service, or any other conditions beyond the control of the Company.

6. Any product that has been used for purposes other than those for which it was

designed and manufactured.

7. Any use of the product where installation instructions and/or instructions for

use were not followed. The Company reserves the right at any time, and from time to time, to make changes in the design and/or improvements upon its product without thereby imposing any obligation upon itself to make corresponding changes or improvements in or upon its products already manufactured and/or previously sold. The Company further reserves the right to substitute parts or components of substantially equal quality in any warranty service required by operation of this Limited Warranty. This written Limited Warranty is the entire warranty authorized and offered by the Company. There are no warranties or representations beyond those expressed in this document. THIS WARRANTY AND REMEDY IS IN LIEU OF ALL OTHER WARRANTIES AND REMEDIES INCLUDING WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A

VALUE. THE REMEDIES OF THE PURCHASER SET FORTH HEREIN ARE EXCLUSIVE, AND THE LIABILITY OF THE COMPANY SHALL NOT, EXCEPT AS EXPRESSLY PROVIDED HEREIN, EXCEED THE PRICE OF THE PRODUCTS UPON WHICH SUCH LIABILITY IS BASED. DAMAGES AS SET FORTH IN THIS PARAGRAPH SHALL BE REASONABLY MITIGATED TO THE EXTENT POSSIBLE. THIS PARAGRAPH SHALL ALSO APPLY TO ALL DAMAGES RESULTING FROM CONDITIONS SET FORTH IN SECTION III ABOVE AND (1) DEFECTS IN PRODUCT PROTOTYPES OR REPLACEMENT PART PROTOTYPES THAT HAVE NOT BEEN PUT INTO PRODUCTION, CIRCULATED AND SOLD BY THE COMPANY, AND/OR (2) DEFECTS THAT WERE NOT FOUND AT THE TIME OF SALE DUE TO SCIENTIFIC AND TECHNOLOGICAL REASONS. This Limited Warranty gives you specific legal rights. You may have other rights, which vary according to the applicable laws and regulations. Where any term of this warranty is prohibited by such laws, it shall be null and void, but the remainder of this warranty shall remain in full force and effect. DISCLAIMER: Any oral statements about the product made by the seller, the Company, the representatives or any other parties, do not constitute warranties, shall not be relied upon by the user, and are not part of the contract for sale. Seller’s and the Company’s only obligation, and buyer’s only remedy, shall be the replacement and/or repair by the Company of the product as described above. Before using, the user shall determine the suitability of the product for his intended use, and user assumes all risk and liability whatsoever in connection therewith.20