Operation – Flint & Walling Constant Pressure Pumping Stations - Add-On Kit User Manual

Page 3

(FW1442)

95 North Oak St. • Kendallville, IN 46755 • 1-800-742-5044

(FW1442)

95 North Oak St. • Kendallville, IN 46755 • 1-800-742-5044

• Install provided heaters onto starter. Note: the heat-

ers provide over current protection for the motor.
This starter with heaters installed does not provide
protection from short circuits.

• Connect Starter L1 and Overload relay terminal X2

with wire rated for system power and route enough
wire to connect them to Drive terminals T5 & T6
respectively.

• IMPORTANT: For priming purposes only, temporarily

wire nut the wires together instead of connecting
to T5 and T6. After full prime, connect to T5 and T6.

• Connect Starter L2 to Coil terminal W with wire

rated for system power.

• Install temperature sensor wire provided onto ¼”

quick connect terminals of the temperature sensor
located near the pump discharge (Figure 2) to drive
terminals B2 & B7 (Figure 3) (Note: The new tem-
perature sensor wires will share B2 & B7 drive termi-
nals with factory installed wires.)

figure 2 temperature Sensor location

Operation

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 suction inlet valve should be in the full open posi-
tion and hose bib valve should be partially open, allow-
ing some back pressure to be exerted against the pump
when starting up. Close hose bib valve after priming up
is completed.

PrIMInG
IMPORTANT: Before starting the pump it is absolutely
necessary that both pumps and the suction pipe be
completely filled with water. Before the entire duplex
pump system is fully operational, the single phase
pump, needs to be completely primed and run before
returning power to the variable frequency drive.

IMPORTANT: Before priming, verify control wires are
temporarily connected with a wire nut instead of being
connected to drive terminals T5 & T6.

PrIMInG Of PreSSure BOOSt InStAllAtIOnS
Priming is simple when pump is connected to a pressure
source such as a city main or above ground tank filled
to a level of 4 ft. above pump inlet.
1. Open inlet valves fully on suction and open hose

bib on skid system manifold.

2. To relieve trapped air, allow water supply to run a

minimum of 2 minutes before starting the pump.

3. Turn on power to the single phase pump and run

no longer than two (2) minutes. Unit should build
pressure & pump water. If not, repeat the sequence
above.

4. Once all air has been evacuated and the pump has

been primed, close hose bib and turn off power.

5. IMPORTANT: Once priming has been completed &

power has been turned off, remove the wire nut
connecting control wires and connected them to
drive terminals T5 & T6 (Figure 3).

Temperature Sensor Wire - Red

Temperature Sensor Wire - Black

Transducer Wire - Black

Transducer Wire - Red

ansduc

er C

able

Star

ter

Con

trol W

ires

Temper

atur

e S

ensor C

able

Jumper Wire

IL1140

figure 3 Drive Control Circuit terminals

IL1139

L1 L2 L3

Pump

Motor

To Properly Protected

Disconnect Circuit

Motor Starter

Drive

Terminals

Line Terminals

Coil Terminals

Install Heaters

Load Terminals

Overload Relay

Terminals

Starter Control Wires

figure 4 Starter Wiring

PrIMInG fOr SuCtIOn lIft InStAllAtIOnS
On suction lift applications prime the unit as follows:
1. Remove priming plug from service tee and fill pump

and suction pipe with water.

2. Jog the pump motor by applying power on and off

several times to free air trapped inside the pump.

3. After jogging the pump, refill with water and

repeat the priming sequence several times to be
sure all air is out of the pump and suction pipe.

4. Open hose bib on skid system manifold, start the

pump and run no longer than two (2) minutes. Unit
should build pressure & pump water. If not, repeat
the sequence above.

NOTE: On first use of pump, it may be necessary to re-
prime the unit three (3) or four (4) times before all air is
out of the suction pipe.
5. Once all air has been evacuated and the pump has

been primed, close hose bib and turn off power.

6. IMPORTANT: Once priming has been completed &

power has been turned off, remove the wire nut
connecting control wires and connected them to
drive terminals T5 & T6 (Figure 3).

StArt-uP PrOCeDure
Once the preceding instructions have been completed,
the entire system can be started:
1. Verify that all values installed on the intake side of

the pumps are open & the isolation value is closed
if installed on the discharge side of the system.

2. Verify that the 3-phase pump is primed. For gravity

fed systems, this can be accomplished by opening
hose bib valve installed on the system manifold to
allow the water pressure to push out the air from
the pump. For suction lift systems, fill the pump
and intake piping with external water source until
water begins coming out the open hose bib valve.

3. Close hose bib valve.
4. Supply electrical power to Pump Station by turning

on the user installed disconnect to the ON position
and allow system to pressurize and check for leaks
on plumbing installed.

5. Once pressure has been established, partially crack

open the station isolation valve (while maintaining
pressure) and open valves farthest away from pump
station to bleed air out of the system & piping

6. When the whole Main Line has been bled of air,

fully open the discharge isolation valve.

7. Supply electrical power to single phase pump by

truing on the user installed disconnect to the ON
position. When demand exceeds the capacity of the
three phase pump, the single phase motor will start
up for a minimum of one minute.

8. During the first few hours of operation, inspect the

pump, piping and any auxiliary equipment used in
connection with the unit.

9. Check for leaks, excessive vibration or unusual

noises.

MAIntenAnCe:
For proper maintenance of the pump, please follow
instructions in enclosed End suction centrifugal pumps
instructions FW0300/134984.