Flofab 1.25FFGP Series Instruction manual

Installation, Operation &
Maintenance Manual
Submersible Grinder Pumps
1.25FFGP
2 HP @ 3450 RPM
IMPORTANT! - Read all instructions in this manual before operating or servicing
a pump.

01
General Safety Information
IMPORTANT! - Flo Fab Pumps is not
responsible for losses, injury or
death resulting from failure to
observe these safety precautions,
misuse, abuse or misapplication of
pumpsorequipment.
B r onze/brass tt e d
pumps may contain levels higher than
considered safe for potable water systems.
Government agencies have determined
that leaded copper alloys should not be
used in potable water applications.
WARNING
Installation and
servicing is to be conducted by
qualied personnel only.
WARNING
Do notuse these
pumps in water over 104º F. Do not
exceed manufacturers recommended
maximum performance, as this could
cause the motor to overheat.
WARNING
ALL R E TURNED
P R ODUC T S MUST B E
CLEANED, SANITIZED, OR
DECONTAMINATED PRIOR TO
SHIPMENT, TO INSURE EMPLOYEES
WILL NOT BE EXPOSED TO HEALTH
HAZARDS IN HANDLING SAID
MATERIAL. ALL APPLICABLE LAWS
AND REGULATIONS SHALL APPLY.
Keep clear of suction and
discharge openings. Do not
insert ngers in pump with
power connected; the rotating cutter
and/or impeller can cause serious
injury.
Always wear eye protection
when working on pumps. Do
not wear loose clothing that
may become entangled in moving
parts.
Pumps build up heat
and pressure during
operation. Allow time
for pumps t o c ool
DANGER
before handling or servicing the
pump or a n y a ccessor y i t ems
associated with or near the pump.
This pump is not
i n t ended for use in
swimming pools or water
installations where there is
DANGER
human contact with pumped uid.
Risk of electric shock. To
reduce risk of electric shock,
always disconnect pump
from power source before
DANGER
handling.Lockout powerand tag.
Do notlift, carry or
hang pump by the electrical
cables. Damage t o the
electrical cables can cause
DANGER
shock, burns or death. Never handle
connected power cords with wet
hands. Use appropriate lifting device.
Sump and sewage
pumps often handle materials which
could cause illness or disease. Wear
adequate protective clothing when
working on a used pump or piping.
Never enter a basin after it has been
used.
WARNING
Failure to permanently
ground the pump, motor and
controls before connecting
to power can cause shock,
DANGER
burns or death.
These pumps are not to
be installed in locations
classied as hazardous in
accordance with the National
Electric Code, ANSI/NFPA 70.
DANGER
Do not introduce into
any sewer, either directly, or through a
kitchen waste disposal unit or toilet:
seafood shells, aquarium gravel, cat
litter, plastic objects (toys, utensils, etc.),
sanitary napkins or tampons, diapers,
rags, disposable wipes or cloth,
medications, ammable material, oil or
grease,strongchemicals,gasoline.
WARNING
"Caution" indicates a
potentially hazardous situation
which, if not avoided, MAY result in
minor or moderate injury.
Before installation, read the following
instructions carefully. Failure to
follow instruction and safety
information could cause serious
bodily injury, death and/or property
damage. Each Flo Fab product is
carefully inspected to insure proper
performance. Closely following these
instructions will eliminate potential
operating problems, assuring years
of trouble-free service.
DANGER "Danger" indicates an
imminently hazardous situation
which, if not avoided, WILL result in
death or serious injury.
WARNING "Warning" indicates
an imminenty hazardous situation
which, if not avoided, MAY result in
death or serious injury.
CAUTION
Installation, wiring, and
junction connections must be in
accordance with the National Electric
Code and all applicable state and local
codes. Requirementsmay vary depending
on usage and location.
WARNING
1 Phase Models
Amps: Volts:
3 Phase Models
Amps L1-2: Volts L1-2:
Amps L2-3: Volts L2-3:
Amps L3-1: Volts L3-1:
Model Number: _____________________
Serial: ____________
PHASE: ______ HP: ________________ __
IMPORTANT! - Prior to installation,
record Model Number, Serial, Amps,
Voltage, Phase and HP from pump
name plate for the future reference.
Also record the Voltage and Current
Readings at Startup:

DISCHARGE: 1¼" NPT, vertical.
LIQUIDTEMPERATURE: Continuous: 120° F (48° C) max.
Intermittent: 140° F (60° C) max.
VOLUTE: Cast iron ASTM A-48 class 30.
MOTOR HOUSING: Cast iron ASTM A-48 class 30.
SEAL PLATE: Cast iron ASTM A-48 class 30.
IMPELLER: 12 vanes, vortex, with vanes on back side, dynamically balanced. Cast iron ASTM A-
48 class 30.
Radialcutter: hardened 440C, stainless steel, hardness Rockwell C-55.
Shredding ring: hardened 440C, stainless steel, hardness Rockwell C-55.
SHAFT: 420 series stainless steel.
O-RINGS: Buna-N.
PAINT: Air dry enamel, water based.
SEAL: Double mechanical, oil lubricated. Ceramic stationary part, carbon ring seal and
exclusion in the rotating part. Buna-N elastomer and stainless steel spring.
HARDWARE: Stainless steel.
CORD ENTRY: 30 ft of neoprene cord, sealed against moisture.
BEARINGS: Ball, single row, oil lubricated.
MOTOR: Single phase: permanent split capacitor, oil lled, with overload protection in
motor. Class F insulation. Model BGP202DS requires capacitors and relay to be
installed in control panel. Model BGPC202DS oers internal capacitor design.
Three phase: oil lled, with overload protection in motor. Class F insulation.
MOISTURE SENSOR: Normally open (N/O) included.
OPTIONAL EQUIPMENT: Additional cord, slide rail coupling (SRC-1¼").
02
Specications & Dimensions
8.15"
10"
5.6"
27.7"
* Includes the level control with the pump.
MODEL HP VOLTS PHASERPM
(nominal)
MAX
AMPS
LOCKED
ROTOR AMPS
CORD
SIZE
CORD
TYPE
INTERNAL
CAPACITOR
MOISTURE
SENSOR
WEIGHT
(pounds)
1.25FFGP202 2 230 1 3450 14.5 23 12/3 SOOW No Yes 130
1.25FFGP203 2 230 3 3450 8.8 22.5 12/4 SOOW n/a Yes 130
1.25FFGP204 2 460 3 3450 4.4 11.3 12/4 SOOW n/a Yes 130
1.25FFGPC202 2 230 1 3450 14.5 23 12/3 SOOW Yes No 130
1.25FFGPC202A*2 230 1 3450 14.5 23 12/3 SOOW Yes No 130

03
Recommendations and Warnings
Receiving inspection
Upon receiving the pump, it should
be inspected for damage or
shortages. If damage has occurred,
le a claim immediately with the
company that delivered the pump. If
the manual is removed from the
packaging, do not lose or misplace.
Storage
Any product that is storedfor a
period longer than six (6) months
from the date of purchase should
be bench tested prior to
installation. A bench testconsists
of, checking the impeller to assure
it is freeturning. DO NOT TURN
IMPELLER WITH FINGERS AS
EDGES ARE SHARP, use allen
wrench in the impeller screw to
turn the impeller. Run test to assure
the motor(and switch if
provided) operate properly.
Controls
FFBGP series grinders require
a separate approved pump
control device or panel for
automatic operation. Be sure the
electrical specification of the
control selected properlymatch
the electrical specifications of the
pump.
Submergence
Thepump should always be
operatedin the submerged
condition. The minimum sump liquid
level should never be less than above
the pump’s volute (See Figure 1).
Installation
There are several methods of
installing grinder pumps. See
contract plans and/or specication: A
slide rail in a package system or
concrete wet well is the most
common, which allows the pump(s)
to be installed or removed without
requiring personnel to enter the wet
well.
The installation should be at a
sucient depth to ensure that all
plumbing is below the frost line. If
this is not feasible, remove the check
valve and size the basin to
accommodate the additional
backow volume.
Liquid Level Controls
The level control(s) should be
mounted on the discharge piping, a
cable rackor lf oat pole. The level
control should have adequate
clearance so it cannot hang up in it’s
swing and that the pump is
completely submerged when the
level control is in the "Off " mode. By
adjusting the cord tether the control
level can be changed. One cycle of
operation should be observed, so
that any potential problems can be
corrected.
It is recommended that the level
control lf oat should be set to insure
that the liquid in the sump never
drops below the top of the motor
housing or a minimum level of 10
inches above the basin lf oor.
Location
The grinder pump is designed to t
in basin or wetwell by using a slide
rail coupling (SRC-1¼").
IMPORTANT! - A clearance
under the pump for
entrance of sewage solids
must be a minimum of 3" to a
maximumof 4.5".
These pumps are recommended for
use in a sump, basin or lift station.
The sump, basin or lift station shall
be sealed and vented in accordance
with local plumbing codes. This
pump is designed to pump grinder
or wastewater, non-explosive and
non-corrosive liquids and shall
NOT be installed in locations
classied as hazardous in
accordance with the National
Electrical Code (NEC) ANSI/NFPA
70 or Canadian Electric Code (CEC).
The pump should never be installed
in a trench, ditch, or hole with a dirt
bottom. The legs will sink into the
dirt and the suction will become
plugged.
Discharge Piping
Discharge piping should be as short
as possible and sized no smaller than
the pump discharge. Do not reduce
the discharge pipe size below that
which is provided on the pump.
Both a check valve and a shut-o
valve are recommended for each
pump. The check valve is used to
prevent backow into the sump. The
shut-o valve is used to manually
stop system low during pump
servicing.
Recommended
Submergence Level
Minimum
Submergence Level
Bottom of Feet
5"
Figure 1
Electrical Connections
Power cable:
The power cable mounted to the
pumpmust not be modiied in anyf
way except for shortening to a
speci ic application.f

These situations ma a falsey induce
signal in the moisture etectingd
circuit. If none of the above test
prove conclusive, the pump(s) should
be pulled and the source of the
failure repaired. IF A MOISTURE
DETECT HAS OCCURRED
MAINTENANCE SHOULD BE
PERFORMED AS SOON AS
POSSIBLE!
If current through the temperature
sensor exceeds the values listed, an
intermediate control circuit relay
must be used to reduce the current
or the sensor will not work properly.
TEMPERATURE SENSOR ELECTRICAL
RATINGS
Volts Continuous
Amperes
Inrush
Amperes
110-120 3.00 30.0
220-240 1.50 15.0
440-480 0.75 7.5
600 6.00.60
Wire Size:
If longer power cable is required
c a qualied electrician foronsult
proper wire size.
DO NOT ALLOW THE
PUMP TO CYCLE OR RUN IF AN
OVERLOAD CONDITION OCCURS.
WARNING
Pre-Operation
1. Check Voltage and Phase -
Compare the voltage and phase
information stamped on the
pump name plate.
2. Check Pump Rotation - Improper
motor rotation can result in poor
pump performance and can
damage the motor and/or pump.
Check rotation on three phase
units by momentarily applying
power and observe the "kickback".
Kickback should always be in a
counter-clockwise direction as
viewed from motor end or opposite
to impeller rotation. Impeller rotation
is counter-clockwise as viewed from
bottom of pump.
3. Name Plate - Record the
information from the pump name
plate to drawing in front of manual
for future reference.
4. Insulation Test - An insulation
(megger) test should be performed
on the motor. Before the pump is put
into service. The resistance values
(ohms) as well as the voltage (volts)
and current (amps) should be
recorded.
5.Pump-Down Test - Be sure pump
has been properly wired, lowered
into the basin, sump or lift station,
check the system by lling with liquid
and allowing the pump to operate
through its pumping cycle. The time
needed to empty the system, or
pump-down time along with the
volume of water, should be recorded.
04
Installation & Service
Moisture Sensors - A normally open
(N/O) sensor rated of 1 watt @330K
ohms, 500 volt, is installed in the
pump seal chamber which will detect
any moisture present. It is
recommended that this detector be
wired in series to an alarm device or
motor starter coil to alert the
operator that a moisture detect has
occurred. In the event of a moisture
detect, check the individual moisture
sensor probe leads for continuity, (∞
resistance = no moisture) and the
junction ox/control box forb
moisture content.
No lubrication or maintenance is
required. Perform the following
checks when pump is removed from
operation or when pump
performance deteriorates:
a) Inspect motor chamber for oil
level and contamination.
b) Inspect impeller and body for
excessive build-up or clogging.
c) Inspect motor, bearings and shaft
seal for wear or leakage.
Maintenance
Always rely upon a C ederti
Electrician for installation.
Overload Protection:
Single Phase - The stator in-winding
overload protector used is referred to
as an inherent overheating protector
and operates on the combined eect
of temperature and current. This
means that the overload protector
will trip out and shut the pump o if
the windings become too hot, or the
load current passing through them
becomes too high.
IMPORTANT! - The overload will then
automatically reset and start the
pump up after the motor cools to a
safe temperature. In the event of an
overload, the source of this condition
should be determined and corrected
immediately.
Any splice between the pump and
the control panel must be made in
accordance with the electric codes. It
is recommended that a junction box,
if used, be mounted outside the
sump or be of at a minimum Nema 4
construction iocated within the wet
well. DO NOT USE THE POWER
CABLE TO LIFT PUMP.

05
Service
IMPORTANT! - This pump is
not to be disassembled in
the eld except at certied
service stations or at the factory.
Warranty is void if pump is taken
apart for any reason other than to
replace grinder impeller and grinder
ring, which is covered in these
instructions.
Disassembly
This is the only disassembly
operation permitted in the eld. All
other repairs must be performed at
an authorized service center or the
factory.
Standard tools required:
Standard socket wrench set.
Standard set of open end
wrenches.
Hammer.
Vise grip pliers.
Allen head socket set.
Screwdrivers.
Wire brush.
IMPORTANT! - The pump
should be sanitized with
bleach and thoroughly
cleaned of trash and deposits before
starting disassembly operations.
Wear protective gloves and
clothing. Always use a rag on the
impeller when turning to prevent
cutting hands on the sharp edges of
the shredding ring.
Disconnect all power
and control wires to motor at
the control panel before
starting the disassembly
operations. Do not rely upon opening
the circuit breaker only.
WARNING
Shredding Ring and Grinder
Impeller
1. Hold the grinder impeller by
prying against the impeller cutting
bar and remove the allen head cap
screw from the end of the shaft.
2. Use a large screwdriver in the slot
end of the shaft and tap
(counterclockwise) on one of the
large cutter vanes with a hammer.
Tap in a counterclockwise direction
(thread is right hand).
3. If the impeller removes easily, clean
and replace if worn.
4. Make sure the pump impeller has
not loosened when the grinder
impeller was removed. This can be
checked on reassembly of grinder
impeller and shredding ring. The tips
of the impeller cutter vanes should
extend 1/8" below the bottom of the
shredding ring. If the distance is
greater, the pump impeller has
loosened. If the distance is less, the
shredding ring is not properly seated.
5. After the volute case has been
removed, insert screwdriver in slot
end of shaft and tap hammer against
the outer vane of the ductile iron
pump impeller (clockwise) to ensure
it is threaded tight against shoulder
on shaft.
6. Use large screwdriver to tap
stainless steel cutter ring from cast
iron volute.
7. Clean all threads with a wire brush
and le smooth any nicked threads.
Use NEVER-SEEZEor other graphite
compound on threads before
replacing grinder impeller.
8. Make sure allen head cap screw in
bottom of pumpshaft is tight. Make
sure the impeller turns freely by hand
after reassembly. Some drag will be
present due to the shaft seals. There
should not be any binding or tight
spots when turning the grinder
impeller.
Motor Power Cords
Pump models with seal leak detector
use a 5 conductor, #12 gauge cord.
The three power conductors are
BLACK, WHITE and RED. The BLUE or
ORANGE conductor connects to the
seal leak probe and GREEN
conductor connects to the ground
screw inside the cord cap. For single
phase, BLACK is "Common", WHITE is
"Run", and RED is "Start".
Cord Seal - The lines from the motor
chamber are sealed with a rubber
sealing grommet that prevents oil
from leaking into the cord cap
compartment. If it is necessary to
replace the power cord, the sealing
grommet must not be loosened. This
wire seal is removed only for
complete motor repair that must be
done at an authorized service center.
IMPORTANT! - Ground
wires must be connected in
the control box to a
grounding bar, which is connected
to a good suitable ground. MOTOR
IS NOT SAFE UNLESS PROPERLY
GROUNDED.

06
Wiring Schematics
Figure 2
208/230 volts, single phase

Figure 3
208/230 volts, single phase
07
Wiring Schematics

Figure 4
230/460 volts, three phase
08
Wiring Schematics

09
Repair Parts
Figure 5
1
11
12
214
13
15
3
416
17
5
619
20
8
921
10
7
18
ITE M Q TY . DE S C R IP T ION MAT E R IAL
1 1 P U MP C O VE R C AS T IR O N
2 1 MOTOR H O U S IN G C AS T IR ON
3 1 R OTOR -
4 1 B E AR IN G 6 2 0 5 -
5 1 L OWE R B E AR IN G H O U S IN G C AS T IR O N
6 1 ME C H AN IC AL S E AL S iC - S iC
7 1 S E AL P L ATE C AS T IR O N
8 1 IMP E L L E R C AS T IR ON
9 1 R AD IAL C U TT E R S TAIN L E S S
1 0 1 S H R E DDIN G R IN G S TAIN LE S S
1 1 1 H AN DL E S TAIN LE S S
1 2 1 B E AR IN G 6 2 0 5 -
1 3 1 U P P E R B E AR IN G H O U S IN G C AS T IR O N
1 4 1 TH E R MAL P R O TE C TOR -
1 5 1 S T AT OR -
1 6 4 O- R IN G B U N A- N
1 7 1 MOIS TU R E S E N S O R -
1 8 1 ME C H AN IC AL S E AL S iC - S iC
1 9 1 F L AN G E C AS T IR O N
2 0 1 V O L UTE C AS T IR O N
2 1 3 L E G E X T E N S I ON
P AR T L I S T
For Repair Part Please supply: Model Number and Serial as shown on
Name Plate, and Part Description and Part Number as shown on Parts List.

Risk of electric shock. Always disconnect the pump from the power source before handling inspections or repairs.
Symptom Possible Cause(s) Corrective Action
Pump will not run
1. Poor electrical connection, blown fuse, tripped
breaker or other interruption of power;
improper power supply
2. Motor or switch inoperative (go to manual
operation)
2a. Float movement restricted
2b.Switch will not activate pump or is defective
2c. Defective motor
3. Insucient liquid level
1. Check all electrical connections for security.
Have electrician measure current in motor leads,
if current is within ± 20% of locked rotor Amps,
impeller is probably locked. If current is 0,
overload may be tripped. Remove power, allow
pump to cool, then re-check current.
2a. Reposition pump or clean basin as required to
provide adaquate clearance for oat
2b.Disconnect level control. Set ohmmeter for a
low rang, such as 100 ohms full scale and
connect to level control leads. Actuate level
control manually and check to see that
ohmmeter shows zero ohms for closed switch
and full scale for open switch. (Float Switch)
2c. Check winding insulation (Megger Test) and
winding resistance. If check is outside of range,
dry and re-check. If still defective, replace per
service instructions.
3. Make sure liquid level is above the pump
4. Re-check all sizing calculations to determine
proper pump size.
5. Check discharge line for restrictions, including
ice if line passes through or into cold areas.
6. Remove and examine check valve for proper
installation and freedom of operation
7. Open valve
8. Check impeller for freedom of operation,
security and condition. Clean impeller cavity
and inlet of any obstruction
9. Loosen union slightly to allow trapped air to
escape. Verify that turn-o level of switch is set
so that the suction is always ooded. Clean vent
hole
10. Check rotation. If power supply is three phase,
reverse any two of three power supply leads to
ensure proper impeller rotation
11. Repair xtures as required to eliminate leakage
12. Check pump temperature limits and uid
temperature
13. Replace portion of discharge pipe with exible
connector or tighten existing piping.
14. Turn to automatic position
15. Check for leaks around basin inlet and outlets
Pump will not turn o
2a. Float movement restricted
2b.Switch will not activate pump or is defective
4. Excessive inow or pump not properly sized for
application
9. Pump may be air locked causing pump not to ow
14. H-O-A switch on panel is in "HAND" position
Pump hums but doesn’t run
1. Incorrect low voltage
8. Impeller jammed or loose on shaft, or inlet
plugged
Pump delivers insucient capacity
1. Incorrect low voltage
4. Excessive inow or pump not properly sized for
application
5. Discharge restricted
6. Check valve partiallyclosed or installed backwards
7. Shut-o valve closed
8. Impeller jammed or loose on shaft, or inlet
plugged
9. Pump may be air locked causing pump not to ow
10. Piping xtures leaking or discharge before the
nozzle
Pump cycles too frequently or runs periodically
when fixtures are not in use
6. Check valve partiallyclosed or installed backwards
11. Fixtures are leaking
15. Ground water entering basin
Pump shuts off and turns on independent of
switch, (trips thermal overload protector).
CAUTION! Pump may start unexpectedly.
Disconnect power supply.
1. Incorrect low voltage
4. Excessive inow or pump not properly sized for
application
8. Impeller jammed or loose on shaft, or inlet
plugged
12. Excessive water temperature (internal
protection only)
Pump operates noisily or vibrates excessively
2c. Worn bearings, motor shaft bent
5. Debris in impeller cavity or broken impeller
10. Pump running backwards
13. Piping attachments to building structure too
loose or rigid
NOTE: Flo Fab Pumps assumes no responsibility for damage or injury due to disassembly in the eld. Disassembly of the pumps or supplied accessories other
than at Flo Fab Pumps or its authorized service centers, automatically voids warranty.
10
Troubleshooting Chart