Franklin Electric Inline 1100 User manual

franklinwater.com

INLINE 1100 CONSTANT PRESSURE SYSTEM

Installation and Operation Manual

Table of Contents

PRODUCT INFORMATION- - - - - - - - - - - - - - -3

Description - - - - - - - - - - - - - - - - - - - -3

Features - - - - - - - - - - - - - - - - - - - - -3

Models - - - - - - - - - - - - - - - - - - - - - -3

UNPACKING AND INSPECTION - - - - - - - - - - - 4

Unpacking - - - - - - - - - - - - - - - - - - - 4

What’s in the Box - - - - - - - - - - - - - - - - 4

INSTALLATION PLANNING - - - - - - - - - - - - - 4

Minimum Pressure Tank and Supply Pipe Sizing - 4

INSTALLATION- - - - - - - - - - - - - - - - - - - 6

Typical Installation - - - - - - - - - - - - - - - 6

Environmental Requirements - - - - - - - - - - 6

Physical Installation - - - - - - - - - - - - - - - -7

Dimensions - - - - - - - - - - - - - - - - - - - 8

Electrical Installation - - - - - - - - - - - - - - 8

OPERATION - - - - - - - - - - - - - - - - - - - - 10

Priming the System - - - - - - - - - - - - - - - 10

Maximum Operating Temperature - - - - - - - - 11

System Pressure Fluctuations - - - - - - - - - - 11

Status Display - - - - - - - - - - - - - - - - - 11

Operation Testing- - - - - - - - - - - - - - - - 12

DRIVE CONFIGURATION - - - - - - - - - - - - - - 12

Adjusting System Pressure - - - - - - - - - - - 12

DIP Switch Settings - - - - - - - - - - - - - - - 13

MAINTENANCE- - - - - - - - - - - - - - - - - - - 13

Draining the System - - - - - - - - - - - - - - 13

Troubleshooting - - - - - - - - - - - - - - - - 14

Replacement Parts - - - - - - - - - - - - - - - 15

SAFETY INSTRUCTIONS

Table of Contents

SAFETY INSTRUCTIONS

This equipment should be installed and serviced by technically qualified personnel who are familiar with the

correct selection and use of appropriate tools, equipment, and procedures. Failure to comply with national

and local electrical and plumbing codes and within Franklin Electric recommendations may result in electri-

cal shock or fire hazard, unsatisfactory performance, or equipment failure.

Read and follow instructions carefully to avoid injury and property damage. Do not disassemble or repair

unit unless described in this manual.

Refer to product data plate(s) for additional operating instructions and specifications.

Failure to follow installation or operation procedures and all applicable codes may result in the following

hazards:

Risk of severe injury or death.

• 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.

• Be certain that this pump is connected to a circuit equipped with a ground fault circuit interrupter

(GFCI) device if required by code.

• Check electrical outlets with a circuit analyzer to ensure power, neutral, and ground wires are prop-

erly connected. If not, a qualified, licensed electrician should correct the problem.

• Wire pump system for correct voltages.

• Make sure the ground terminal is connected to the motor, control enclosures, metal plumbing, and

other metal near the motor or cable using wire no smaller than motor cable wires.

• This pump has not been investigated for use in swimming pool or marine areas.

• 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).

• Some pumps are supplied with lead wires and are intended to be hardwired using a junction box or

other approved enclosure. The pumps include a grounding connector. To reduce risk of electric

shock, be certain that it is properly connected to ground.

• Some pumps are supplied with a power cord including a grounding conductor and an integral

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.

Risk of bodily injury, electric shock, or property 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. Lockout-Tagout before servicing equipment.

• 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.

• Keep work area clean, well-lit, and uncluttered.

• Pumping sand or other abrasives can damage the pump and void the warranty.

PRODUCT INFORMATION

Description

PRODUCT INFORMATION

Description

Little Giant's constant pressure boosting solutions help alleviate the challenges with inade-

quate or low water pressure. The Inline 1100 provides continuous pressure for private wells

and municipal/city water systems or multi-family dwellings. It also can be used in sprinkler,

farming, and commercial washdown or water storage/cistern system applications. This

pre-packaged all-in-one system includes a pump, motor, drive, and pressure switch.

Inline Systems are typically used to increase municipal water pressure anywhere from 10 to

70 psi (0.7 to 4.8 bars) above what is being supplied by the water utility.

The system provides consistent water pressure regulation using advanced electronics to drive the pump/

motor according to the system’s real-time demand. The water pressure demand is under constant monitor-

ing through a highly accurate, heavy-duty, long-life pressure sensor, which is included with and wired into

the system at the time of installation.

Features

Configuration

• Pump speed is controlled to provide the optimum performance without overloading the motor

• Low current motor start-up (soft-starting)

• Quiet operation

• Single pump/motor/drive controller design

• Compact footprint, 19 in x 8 in (480 mm x 200 mm)

Operation

• Operates on a wide range of flows from flooded suction to 35 gpm (135 lpm)

• Requires minimum incoming pressure of 3 psi (0.2 bar), except that cisterns may be flooded suction

without vortexing

• Maximum system pressure is 80 psi with standard pressure sensor (25-80 psi range)

• Maximum system pressure is 150 psi with optional high pressure sensor accessory (75-150 psi range)

• Stainless steel construction for all wetted surfaces

Protection

• No in-rush (power-on transient) current

• Overpressure shutoff optional

• Low water shut-off

• Locked pump detection/shut-off

• Water over-temperature shut-off

• High voltage/lightning surge protection

• Low line voltage protection

• Motor under and overload protection

• Open and short circuit protection

• NEMA 4 enclosure

Models

Model Input Voltage

(VAC) Hz HP Input

FLA kW Phase Maximum Boost

psi (bar) Maximum Flow

gpm (lpm) Weight

lbs (kg)

Inline 1100 230 60 1.2 12 0.9 1 60 (4.1) 40 (151) 50 (22.7)

UNPACKING AND INSPECTION

Unpacking

UNPACKING AND INSPECTION

Unpacking

1. Inspect exterior of package for shipping damage.

• If there is damage, notify the shipping agent and your sales representative.

• The shipping carrier assumes full responsibility for the shipment’s safe arrival. Any claim for dam-

age to the shipment, either visible or concealed, must be made through the shipping carrier first.

2. Make sure the part number and product ratings on the identification label are correct for the applica-

tion.

What’s in the Box

• Inline 1100 Constant Pressure System pump and controller unit

• Pressure sensor and boot

• Sensor adjustment tool

• Owner’s manual

INSTALLATION PLANNING

Minimum Pressure Tank and Supply Pipe Sizing

Check that the pressure tank pre-charge setting is 70% of the system pressure sensor setting.

• To check the tank’s pre-charge, depressurize the water system by opening a tap.

• Measure the tank pre-charge with a pressure gauge at its inflation valve and make the necessary

adjustments.

NOTE: Tank pre-charge should be maintained for optimum pressure regulation.

• For 12 gpm (45 lpm) flow or greater, minimum pressure tank size is 4 gallons (15 L);

• For less than 12 gpm (45 lpm) pressure tank can be reduced to a minimum of 2 gallons (7.5 L).

The system is designed to operate as low as 3 psi (0.2 bar) at minimum incoming pressures.

NOTE: When used on a cistern, the incoming pressure requirement is waived, but a water level must be

maintained in the cistern to prevent a vortex from forming.

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

• Failure to maintain incoming water may result in heating of water, personal injury, pump damage

and/or property damage.

• Pressure tank failure may prevent the pump from shutting off. A run-on condition can heat the water

in the pump, which may cause pump failure, plumbing failure, and/or personal injury.

• Failure to install a pressure tank will prevent the pump from shutting off.

INSTALLATION PLANNING

Minimum Pressure Tank and Supply Pipe Sizing

Minimum Supply Pipes

Select the minimum supply pipe diameter that does not exceed a maximum water velocity of 8 ft/sec (2.4

m/s).

Pressure Tank Pre-charge

Check tank pre-charge regularly to maintain optimum pressure regulation.

Maximum Flow Rate

GPM (LPM) Minimum Pipe Diameter

inches

4.9 (18.5) 0.5

11.0 (41.6) 0.75

19.6 (74.2) 1

30.6 (116) 1.25

44.1 (167) 1.5

System Pressure (at Pressure Sensor) Pressure Tank Setting (± 2 PSI)

25 18

30 21

35 25

40 28

45 32

50 (Factor Set) 35

55 39

60 42

65 46

70 49

75 53

80 56

INSTALLATION

Typical Installation

INSTALLATION

Typical Installation

Environmental Requirements

Decide on a location for the pump installation that is:

• on a hard, level surface

• suitable to the enclosure rating of the system

• clean and well-ventilated

• protected from freezing, flooding, and excessive heat

• accessible for servicing

• convenient for draining of the pump housing, tank, and service pipes

• as close as possible to water source to minimize suction piping length

NOTE: When the pump is located at a distance from the water source, the piping may have to be

increased in diameter.

NOTE: The system is not designed to draw/lift water from a source below the pumping unit. There is

not an incoming flow requirement, other than that the system needs to be supplied with a constant

supply of water to keep the unit completely full of water at all times.

7 9

1 Water Supply 5 Union Coupling 9 Pressure Shut-off 13 Pressure Gauge

2 Check Valve 6 Inline System 10 2 Gallon Tank 14 Pressure Relief Valve

3 Optional Bypass 7 Flow 11 5 feet or less 15 Discharge

4 Ball Valve 8 Power 12 Pressure Sensor 16 To home

Risk of malfunction can occur due to improper handling, installation, or

environment.

• Handle with care to prevent damage to the plastic components.

• Do not mount on equipment with excessive vibration.

• Install in a location where temperature is within the range of product rating.

• Do not install in corrosive environments.

• Liquid-tight conduit and fittings must be used to maintain NEMA 4 rating.

• Installation in direct sunlight can reduce system power and reduce drive life.

INSTALLATION

Physical Installation

NOTE: Refer to “Typical Installation” on page 6.

1. Disconnect electrical power at the main breaker.

2. Close all water supply valves necessary to turn off the incoming water supply.

3. Carefully drain the existing plumbing system of all water.

4. Mount the system using mounting screws.

• The system may be installed in any orientation.

5. Install inlet plumbing to the unit.

• Install a check valve in the inlet plumbing when no other backflow prevention device is present.

• If a bypass loop is used in the plumbing, install the check valve before it.

• It is recommended to supply the system with inlet line ¾-inch diameter or larger.

NOTE: It is recommended that all system check valves are spring-loaded.

6. Connect the piping.

• Keep the suction and discharge lines as large as possible.

• Avoid using bends, elbows, and fittings whenever possible.

• Ensure all suction connections are airtight.

• Use pipe joint compound or PTFE tape at all threaded connections.

• Use a suction strainer when applicable to prevent solids and foreign matter from being drawn into

the pump.

7. Install a check valve in the outlet plumbing between the pump and pressure tank.

8. Add a small pressure tank on the pump outlet to maintain constant pressure.

NOTE: The tank supplies water while the pump ramps up to speed and when only a small amount of

water is required for a short period of time. Tanks prevent water hammer and prevent pressure spikes

when there is a sudden change in demand.

9. Install a shut-off valve in the plumbing near the discharge of the pump.

10. Install the pressure sensors at the pressure tank tee downstream of the pressure tank.

• The pressure sensor has a 1/4-18 NPT connection.

• Install the pressure sensor in an inverted orientation (upside down).

• Mount the pressure sensor in a vertical position.

• Make sure the pressure sensor and tank are not located more than 5 feet off the main piping.

11. Install a pressure relief valve downstream of the check valve, near the pressure tank.

• Plumb this discharge to a drain rated for maximum pump output at relief pressure settings.

Risk of bodily injury, property damage, or damage to system by pressurized

fluids.

• A pressure relief valve rated to handle full pump flow at 100 psi (6.9 bar) should be installed in the

system to prevent personal injury or property damage.

Risk of damage to pump or other property.

• A missing, improperly installed, or malfunctioning check valve can cause a pump to short-cycle due

to back-flow of the pumped fluid from the discharge plumbing back into the basin, significantly

shortening the life of the pump.

INSTALLATION

Dimensions

Electrical Installation

1. Disconnect electrical power at the main breaker.

2. Connect the pump to its own circuit, with no other electric receptacles or equipment in the circuit.

3. Check that the power supply corresponds with the electrical rating of the pump being installed.

• Supply voltage must be ± 10% of the nameplate voltage (230 V).

4. Connect to a circuit equipped with a ground fault circuit interrupter (GFCI) device if required by code.

5. Pull black, red, and green (ground) wires though Listed liquid-tight conduit to connect directly to a

dedicated mains circuit junction box or panel with 15A Listed fuses or 15A Listed circuit breaker.

6. Connect wire assembly to the pump per “Power Wiring Connections” on page 9.

NOTE: Wire liquid-tight conduit, assembly, and all connections to comply with local codes.

Item Dimensions

in (mm)

1 8 (203.2)

2 7 (177.8)

3 5.72 (1452)

4 3.45 (87.7)

5 10.43 (265)

6 9.31 (236.4)

7 6.65 (168.9)

8 2.92 (74.1)

9 1.50 (38.1)

10 18.84 (478.5)

11 17.32 (439.9)

Risk of severe injury or death by electrical shock.

• Always disconnect the electrical power before working on or around the system.

• Capacitors inside the drive can still hold lethal voltage even after power has been disconnected.

Allow 5 minutes for dangerous internal voltage to discharge before removing cover.

• Employ a licensed electrician.

Control PCB Assembly

Connection between the two PCB assemblies

Motor

Over

Temp.

Switch

Pressure

Sensor

Incoming

Power

Power Supply

PCB Assembly

Red

Black

Yellow

Green

Black

Red

INSTALLATION

Electrical Installation

Power Wiring Connections

1. Disconnect electrical power at the main breaker.

2. Remove the four access panel screws.

3. Remove the access panel.

4. Check that the pressure sensor (red and black wires) is pre-

wired inside the unit.

5. Verify the over-temperature switch (white and green wires) is

pre-wired inside the unit.

6. To install the optional overpressure shut-off switch, wire in

series with the over-temperature switch.

• Remove one wire connected to the over-temperature ter-

minals.

• Connect to the wire from the shut-off switch.

• Connect the other switch wire to the open terminal.

NOTE: The overpressure shut-off switch is non-adjustable, set

at 100 psi, and includes a quick connect and lead connect.

7. Install the liquid-tight conduit fitting into its hole in front of the

L1, L2 connector.

IMPORTANT: If mounting or in wet environments, a liquid-tight

conduit and fitting are required (not supplied) to ensure that

the enclosure maintains a watertight NEMA 4 rating.

8. Route supply wires through the conduit fitting into the wiring

chamber.

9. Connect the supply ground wire.

NOTE: The safety earth ground connection is marked at its ter-

minal using the ground symbol.

10. Connect the supply 230 V wires to the screw terminal marked L1

and L2.

• Supply should be 60/75 °C (140/167 °F) copper wires.

• Tighten the terminals to a torque of 12 in-lbs (1.35 Nm).

11. Replace the access panel.

• Tighten the four lid screws to a torque of 10 in-lbs (1.13 Nm).

2341

OFF

L1 L2

OPERATION

Priming the System

OPERATION

By adjusting the pump/motor speed, the system automatically reacts to any change in system demand

while maintaining a constant output pressure. The system’s constant output pressure should not fluctuate

more than a psi or two, even though the overall system’s water flow requirement may change dramatically.

Maximum suction pressure is 70 psi (4.8 bar).

NOTE: The drive electronics provide motor overload protection by preventing motor current from exceeding

the maximum Service Factor Amps (SFA). Motor over-temperature sensing is not provided by the drive.

Priming the System

1. Fill the suction pipe, pump, and discharge piping completely with water.

NOTE: If the system contains a tank or pressurized water source (creating a flooded suction condition),

this step may be unnecessary.

2. Close all system water outlets.

3. Slightly crack one system outlet to allow excess air to bleed out of the system.

4. Start the pump.

5. Slowly open the discharge valve to halfway.

6. If after a few minutes of running water does not appear, repeat priming process.

NOTE: The pump may be locked by excess air that is trapped in the unit.

7. Once the pump is operating, open the discharge valve and a system outlet fully, letting the pump oper-

ate until the water is running without any air sputtering.

NOTE: No further priming is necessary unless the pump is drained or a leak develops in the suction plumb-

ing.

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

• Maximum operating pressure should be limited to whatever level is needed to protect the rest of

the existing system plumbing. When required, a pressure relief valve should be installed, and/or the

optional over pressure switch can be used.

• Do not run pumps against a closed discharge, or at a system operating pressure above 145 psi (10

bar).

Risk of damage to pump or other equipment.

• The pump has been evaluated for use with water only.

• Do not run the pump dry, which can cause overheating and damage to the unit. This will void the

warranty.

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