Webtrol IN-LINE Series Installation instructions

Installation & Operating Manual

Congratulations On Your Choice

In Purchasing This Webtrol Pump

Its Quality is unsurpassed in material and workmanship and has been factory tested.

If properly installed, it will give many years of trouble free service.

IN-LINE Series

5-35 GPM BOOSTER

25I4TB-M

9/06 Edition

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Damaged material or shortages

Handling

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

In-Line Booster Exploded View . . . . . . . . . . . . .3

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . .4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Location

Mounting

Piping

Pre Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Typical installations, figures 1 & 2

Electrical Connections . . . . . . . . . . . . . . . . . . . .6

This manual was prepared to assist the installer and/or operator in understanding the proper method of

installing, operating and maintaining the In-Line Booster Pump. Prior to starting the pump, thoroughly understand

the correct installation and start-up procedures. If this is done, you will have years of trouble free service.

DAMAGED MATERIAL OR SHORTAGES

When the pump is received, examine the shipment to determine if it has been damaged or if any parts are miss-

ing. If so, note the damage or shortage on the bill of laden and the freight bill. Make any claims to the trans-

portation company immediately. Retain the packaging materials until the claim is resolved.

The pump should remain in the shipping carton until it is ready to be installed.

HANDLING

When handling the pump, support both the motor and pump housing. This can be done by wrapping a sling

around the pump and motor. To avoid damage, handle the pump and motor with care.

Table Of Contents

Introduction

- 2 -

Start-Up Procedures . . . . . . . . . . . . . . . . . . . . . .7

Valves

Priming

Shaft rotation

Suction flow

Final inspection

Maintenance And Repair

Motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Motor installation . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Removal of rotating assembly . . . . . . . . . . . . . . . . . . .8

Installation of rotating assembly . . . . . . . . . . . . . . . . . .9

Parts illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

System Trouble Shooting . . . . . . . . . . . . . . . . .11

Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1. Read these rules and instructions carefully. Failure to follow them could cause serious bodily injury and/or

property damage.

2. Check your local codes before installing.

3. For maximum safety, this product should be connected to a grounded circuit, equipped with a ground fault

interrupter device.

4. Before installing this product, have the electrical circuit checked by an electrician to make sure it is

properly grounded.

5. Before installing or servicing your pump, BE CERTAIN pump power source is disconnected.

6. Make sure the pump model, HP, voltage, phase and frequency, 50 or 60 Hz match the installation

requirements.

7. The pump is designed for potable water only. Do not pump chemicals or corrosive liquids with the pump

unless they are compatible with the pump component materials: (Consult Webtrol for verification at

314-631-9200).

WARNING

Rules For Safe Installation And Operation

- 3 -

In-Line Booster Cut-A-Way View

Rotating Assembly

Pump Housing Support

Pump Housing

O-ring

Motor Bracket

Motor Bolt (4)

Lock Washer, Flat Washer,

Stat-o-seal

O-ring

Suction Inlet

Discharge O-ring

Rotating Assembly

Hex Nut

Electrical Box

Spacer

Cord Seal

O-rings

Motor Housing

Motor Housing Support

Motor

- 4 -

Pre-Installation

Examine the components carefully to ensure that no damage has occurred to the liquid end, motor, cable, con-

trol box or magnetic starter during shipment. Report damage immediately to the shipping carrier or to your deal-

er. The Webtrol In-Line Booster Pump should remain in the shipping carton until it is ready to be installed. Do

not drop or mishandle the pump prior to installation.

The minimum inlet pressure is 2 PSI because allowable water temperature is based upon having at least atmos-

pheric pressure on the water surrounding the motor.

Maximum water temperature should not exceed 30 degrees celsius (86 degrees F). If warmer water is pumped,

the motor must be derated.

The 316SS motor housing is designed to operate at up to maximum service factor Hp in water up to 86 degrees

F. A flow of 0.25 ft./sec (3 GPM) is required for proper cooling. This minimum flow rate will prevent premature

motor failure.

To prevent upthrust, the maximum flow rate for the 5 GPM Series is 8 GPM, 10 GPM Series is 15 GPM, 15

GPM Series is 19 GPM, 20 GPM Series is 28 GPM and the 35 GPM Series is 38 GPM.

Pump performance is base upon pumping clear and cold water that is free of air or gases.

The pump should be sized properly for flow and Total Dynamic Head (TDH).

The electrical wiring must be done by qualified personnel. All wiring must meet National Electrical Code or

Canadian Electrical Code as well as local code requirements and regulations.

Control boxes and panels should never be mounted in high temperature locations as this will cause a reduction

in capacitor live and unnecessary tripping of the overload protectors. Check that the electrical installation and

controls meet all safety regulations and match the motor requirements, including fuse or circuit breaker size and

over load protection.

Connect all metal plumbing and electrical enclosures to the power supply ground.

Water should never be forced through the pump (more than momentarily in either direction) without the pump

running as failure due to up-thrust or bearing wear may occur.

Pressure relieving valves should be used to prevent running the pump at shut-off pressure. This will prevent the

water from heating up and damaging the motor and thermoplastic pump components.

Horizontal operation is acceptable so long as the pump transmits thrust to the motor. For vertical operation, the

motor/inlet end must be down to prevent undue wear to the motor up-thrust bearing.

The pump must never run dry or both the motor and rotating assembly will be damaged and require replace-

ment.

The entire pump must be supported sufficiently to prevent binding or over-stressing the motor, pump and piping.

Voltage must be within + 10% of the motor nameplate voltage.

Never run the pump with a closed discharge. To do so will cause the water to heat up and damage the pump

components and motor.

Note: For three phase motors, ambient compensated overload protection to be sized for the service factory

current of the motor and not full load current.

Important: Use a regulating valve in the discharge line to prevent the pump from going into upthrust.

Installation

LOCATION

Locate the pump as close to the liquid source as possible, so that a direct suction pipe may be used. Place the

unit so that it is readily accessible for service and maintenance. Avoid air pockets in the suction piping that will

make priming difficult. (See Figures 1 & 2, Pages 5 & 6 )

Note! Provide adequate space for the use of a tow - motor or hoist if required. Also, never position the pump in

such a way that will allow a person to use it as a step.

MOUNTING

The pump can be mounted in a horizontal or vertical position. To avoid excessive wear on the upthrust bearing

in the vertical position, the motor/suction inlet must be down. Bolt the pump to a secure and dry base. This will

prevent noise, vibration, or creeping. A mounting angle with two holes for two 3/8-16NC bolts are provided at

each end of the pump. U-bolts or clamps should not be used because they could damage the pump/motor hous-

ing.

PIPING

To minimize friction losses, the 1 1/2" suction line should be short with as few elbows as possible. The piping

should be galvanized, rigid plastic or other suitable pipe that will not collapse or burst when exposed to suction

or discharge pressure. Never use quick closing valves or throttle the pump on the inlet side. Install a pressure

gage next to the inlet connection to the pump. The gage reading should not be less than 2 PSI while the pump

is running. Whenever possible, place a pipe union close to the pump inlet and discharge connection as you can.

This will make removal of the pump easier should it ever need to be repaired.

- 5 -

Pre Start-Up

Prior to installing the piping and wiring the motor, rotate the pump shaft. To do this, insert a 7/16" nut driver into

the discharge and rotate the hex head cap screw clockwise. Clockwise rotation will avoid releasing the compres-

sion on the impeller, which can cause the pump to fail. The pump shaft must rotate freely. If the pump shaft can-

not be rotated, do not proceed. Contact your Webtrol representative or call the Webtrol factory at 314-631-9200

and ask for assistance.

Important: Use a regulating valve in the discharge line to prevent the pump from going into upthrust.

Figure 1 - This pump installation is designed to boost water pressure obtained from a water tank, which pro-

vides a gravity flow, flooded suction.

- 6 -

Electrical Connections

Before wiring the pump to the power source, verify that the motor voltage, phase and frequency match the

power supply. The supply voltage must be within plus or minus 10% of the nameplate voltage.

Note! Incorrect voltage can cause fire or seriously damage the motor and voids the warranty. On 3 phase instal-

lations, use a magnetic starter and three quick trip overload heaters. Failure to use quick trip heaters in all three

lines will not provide adequate motor protection and the warranty will be void.

Install the ground wire and maintain this pump in compliance with the National Electrical Code (NEC) or the

Canadian Electrical Code (CEC) and with all local codes and ordinances that apply. Consult your local building

inspector for local code information.

See tables 1 & 2 on pages 7 & 8 for motor specifications.

Figure 2 - Whenever dirt, sand or debris is present in the water supply, install a filter or strainer to prevent

clogging or damaging the pump. A clogged strainer will cause a pressure loss and the pump may cavitate. A low

pressure shut-off switch should be installed between the strainer and pump.

- 7 -

214508 1 0.75 230 60 1.4 Y6.6 1130 Y8.0 1490 M2.2-2.7 43 L 30 20 25

w/ 1 1/2 B6.6 B7.9 S9.9-12.1

CB R1.3 R1.3

224300 1 1/2 1.1 230 60 1.3 T10.0 1700 Y11.5 2150 M1.7-2.2 52 J 35 20 30

B9.9 B11.0 S8.0-9.7

R1.3 R1.3

4-Inch 224301 2 1.5 230 60 1.25 Y10.0 2100 Y13.2 2650 M1.8-2.3 51 G 30 20 25

3-Wire B9.3 B11.9 S5.8-7.2

R2.6 R2.6

224302 3 2.2 230 60 1.15 Y14.0 3020 Y17.0 3430 M1.0-1.5 83.5 H 45 30 40

B11.2 B12.6 S4.0-4.9

R6.1 R6.0

224303 5 3.7 230 60 1.15 Y23.0 5250 Y27.5 5960 M.68-1.0 121 F 80 45 60

B15.9 B19.1 S1.8-2.2

R10.8 R10.8

Single Phase Motor Specifications (60HZ) 3450 RPM

Table 1

Type Motor HP KW Volts HZ S.F.

Model (2) (2) Watts Res.

Amps Watts Amps S=Start M=Main

(1) Main winding - yellow to black Start winding - yellow to red

(2) Y=yellow lead, line amps B=black lead, main winding amps R=red lead, Start or auxiliary winding amps

Rated Input

(Full Load)

Maximum

(S.F. Load)

Winding (1)

(Resistance/

Ohm)

Standard

Fuse

Circuit

Breaker

Dual

Element

Time

Delay

Fuse

Locked

Rotor

Amps

Circuit Breaker Or Fuse Amps

(Maximum Per NEC)

KVA

Code

PRIMING - The pump will automatically fill with water when the pump is connected to a city main, hydrant or

water tank.To relieve the trapped air inside the pump, allow the water supply to run a minimum of 1 minute

before starting the pump. Then, turn the motor on and off several times to free the air trapped inside the pump.

Repeat this priming sequence several times to be sure that all the air has been removed from the pump.

SHAFT ROTATION - To determine if the 3-phase motor is rotating in the correct direction (clockwise) observe

the discharge gage pressure. If the motor is wired uncorrectly, the pressure will be less than half of what it

should be. To correct interchange any two motor leads.

SUCTION FLOW - To insure that the pump is adequately lubricated with water, the pressure gauge installed on

the suction line should read at least 2 PSI during operation. If necessary a switch can be used to shut the pump

off on low inlet pressure, 0 PSI.

FINAL INSPECTION - During the first few hours of operation, inspect the pump, piping and any auxiliary equip-

ment used in conjunction with the unit. Check for leaks, excessive vibration, and unusual noises.

If a problem arises, consult your Webtrol Representative or call the Webtrol Factory for assistance.

(314) 631-9200.

Start-Up Procedures

VALVES - The valve installed in the suction line should be fully opened and the discharge valve should be par-

tially open. This will allow the pump to rapidly build pressure.

Notice: Never operate the pump with the discharge valve completely closed. The pump can destroy itself if run

at shutoff pressure. Never start a pump with the discharge completely open. This can cause the pump to up

thrust on the impeller-shaft assembly, which can cause premature wear and failure.

- 8 -

234503 1 0.75 200 60 1.4 4.5 1070 5.4 1440 3.8-4.5 30.9 M 15 10 15

234513 1 0.75 230 60 1.4 3.9 1070 4.7 1440 4.9-5.6 26.9 M 15 8 10

234543 1 0.75 380 60 1.4 2.3 1070 2.8 1440 12.2-14.9 16.3 M 8 5 8

234523 1 0.75 460 60 1.4 2 1070 2.4 1440 19.9-23.0 13.5 M 6 4 5

234504 1 1/2 1.1 200 60 1.3 5.8 1460 6.8 1890 2.5-3.0 38.2 K 20 10 15

234514 1 1/2 1.1 230 60 1.3 5 1460 5.9 1890 3.2-4.0 33.2 K 15 10 15

234544 1 1/2 1.1 380 60 1.3 3 1460 3.6 1890 8.5-10.4 20.1 K 10 6 8

234524 1 1/2 1.1 460 60 1.3 2.5 1460 3.1 1890 13.0-16.0 16.6 K 8 5 8

234534 1 1/2 1.1 575 60 1.3 2 1460 2.4 1890 20.3-25.0 13.3 K 6 4 5

234305 2 1.5 200 60 1.25 7.7 2150 9.3 2700 1.8-2.4 53.6 L 25 15 20

234315 2 1.5 230 60 1.25 6.7 2150 8.1 2700 2.3-3.0 46.6 L 25 15 20

234345 2 1.5 380 60 1.25 4.1 2150 4.9 2700 6.6-8.2 28.2 L 15 8 15

234325 2 1.5 460 60 1.25 3.4 2150 4.1 2700 9.2-12.0 23.3 L 15 8 10

234335 2 1.5 575 60 1.25 2.7 2150 3.2 2700 14.6-18.7 18.6 L 10 5 8

234306 3 2.2 200 60 1.15 10.9 2980 12.5 3420 1.3-1.7 71.2 K 35 20 30

234316 3 2.2 230 60 1.15 9.5 2980 10.9 3420 1.8-2.2 61.9 K 30 20 25

234346 3 2.2 380 60 1.15 5.8 2980 6.6 3420 4.7-6.0 37.5 K 20 15 15

234326 3 2.2 460 60 1.15 4.8 2980 5.5 3420 7.2-8.8 31 K 15 10 15

234336 3 2.2 575 60 1.15 3.8 2980 4.4 3420 11.4-13.9 24.8 K 15 8 10

234307 5 3.7 200 60 1.15 18.3 5050 20.5 5810 .74-.91 122 K 60 35 50

234317 5 3.7 230 60 1.15 15.9 5050 17.8 5810 1.0-1.2 106 K 50 30 40

234347 5 3.7 380 60 1.15 9.6 5050 10.8 5810 2.9-3.6 64.4 K 30 20 25

234327 5 3.7 460 60 1.15 8 5050 8.9 5810 4.0-4.9 53.2 K 25 15 20

234337 5 3.7 575 60 1.15 6.4 5050 7.1 5810 6.4-7.8 42.6 K 20 15 20

4 Inch Three Phase Motor Specifications (60HZ) 3450 RPM

Table 2

Line to Line Locked KVA

Motor HP KW Volts HZ S.F. (Resistance Rotor Code

Model Ohm) Amps

Amps Watts Amps Watts

Rated Input

(Full Load)

Maximum

(S.F. Load)

Standard

Fuse

Circuit

Breaker

Dual

Element

Time

Delay

Fuse

Circuit Breaker Or Fuse Amps

(Maximum Per NEC)

- 9 -

Maintenance And Repair

Read this section thoroughly before making any repairs.

Motor Removal - Remove the cover of conduit box 19 and unscrew nut 7using a 3/4” open end wrench. Lift off

spacer 6, “O”-ring 5and conduit box 19. Unscrew (6) hex head bolts 4securing the motor mousing assembly 9.

Slide the motor housing off the motor 10. Unscrew (4) hex head bolts 14 holding the motor 10 to the motor brack-

et 11 and remove them along with assorted washers 15, 16, 17. Remove motor 10. Unscrew cord seal 1from the

motor using using a 3/4” open end wrench. Pull the motor lead 8out of the motor 10.

Motor Installation - Remove o-ring 2from cord seal 1and install a new o-ring lubricated with silicone grease.

Lubricate the rubber plug of a new motor lead 8and push it into the motor. Lubricate the larger threaded end of

cord seal 1with silicone grease and screw it into the motor with a torque of 60 to 70 ft. lb. Place the motor brack-

et 11 onto the motor with the cord seal 1passing through the hole in the motor bracket 11. Before bolting the

motor to the motor bracket, the three washers must be under the head of each screw. First slide a lockwasher 16

over the bolt. Then place a flat washer 15 against the lockwasher. Now lubricate the stat-o-seal 17 with Mobil

FM102 Food Grade Machinery Grease NLG1 #2 or equivalent. Secure the motor to the bracket with (4) 1/2-

20NF hex head screws 14 . Remove the o-ring 3from the motor bracket 11 and replace it with a new one lubri-

cated with silicone grease. Push the motor housing assembly 9over the motor bracket 11. Tighten (6) hex head

bolts 4into the motor bracket making sure the support on the end of the motor housing aligns with the discharge

end. Place a lubricated o-ring 5over the cord seal 1followed by the spacer 6with the chamfered end against the

o-ring. Place the conduit box 19 against the spacer and tighten nut 7against the conduit box 19. After insuring

that electrical power has been disconnected, make wiring connections with wire nuts and reconnect ground wire

to box. Replace conduit box cover.

Removal Of Rotating Assembly - Remove the (6) 3/8”-16NC hex head bolts 4with lock washers holding the

pump housing assembly 20 to the motor bracket 11. Pull off the pump housing assembly 20 along with the rotat-

ing assembly 21. Pull the rotating assembly out of the pump housing assembly.

Installation Of Rotating Assembly - Before installing the new rotating assembly, the motor shaft height must

be measured. Referring to Figure 3, if the dimension is greater than 3.378”, the motor thrust bearing has worn

excessively and the motor needs to be replaced. If this is ignored, the rotating assembly could be destroyed on

first start-up because the impellers will rub against the diffusers causing them to fuse together. Remove the o-

ring 18 from the motor bracket 11 and replace it with a new one lubricated with silicone grease. Place the 1 3/16”

wide spacer ring 22 removed from the old rotating assembly on the diffusers of the new rotating assembly 21.

Caution: Never attempt any repair work unless electrical supply has been disconnected.

Rotating Assembly

243

910 11 12 131415161718 20 22

15678194

- 10 -

One side of the ring is flat, while the other side has a step or shoulder which fits into the diffuser. Slide the rotat-

ing assembly 21 into the pump housing assembly 20 . Slip the pump housing 20 with the rotating assembly over

the motor bracket 11 making sure the shaft coupling spline engages the motor shaft spline. Insert the (6) 3/8-

16NC hex head bolts 4with lock washers through the pump housing flange and into motor bracket. Align the

support foot and tighten each screw one turn in a diagonal pattern until each bolt is tight and the tube is com-

pletely seated against the motor bracket 11.

Check For Free-Turning Pump - Prior to starting the pump, check to see if the pump shaft will turn by hand. To

do this, insert a 7/16” nut driver over the hex head screw located inside the discharge end of the pump. If you

can turn the shaft clockwise with minimal effort, the pump is operable. If the pump shaft cannot be turned, the

pump housing may not be tight against the motor bracket 11, or the plastic ring 22 was not installed correctly.

Motor 4.135 Max

Figure 3

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