Flofab 2FFEV512 Instruction manual

Installation, Operation &
Maintenance Manual
nt Pumps
2FFEV512
0.5 @ 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.
Installation, wiring, and
junction connections must be i n
accordance with the National Electric
Code and all applicable state and local
codes. Requirementsmay vary depending
on usage and location.
WARNING
Installation and
servicing is to be conducted by
qualied personnel only.
WARNING
Do notuse these
pumps in water over 77º F. Do not
exceed manufacturers recommended
maximum performance, as this could
cause the motor to overheat.
WARNING
Ground Fault Circuit
Interrupter (GFCI) to be used with
plug-in type power cord.
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 connec ted; the rotating
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 any aspect of the pumping
system.Lock out power andtag.
Do notlift, carry or
hang pump by the electrical
cables. Damage to 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
The Uniform Plumbing
Code (UPC ) states that sewage
systems shall have an audio and visual
alarm that signals a malfunction of the
systems, that are required to reduce
the potencial for property damage.
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
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:
Model Number: ____________________
Serial: ____________________
Amps:_______ Voltage:_______
Phase:_______ HP:_______

02
Specications & Dimensions
DISCHARGE: 2" NPT, female, vertical.
SPHERICAL SLD HNDLG: 3/4"
LIQUIDTEMPERATURE: 104° F (40° C) max.
VOLUTE: Cast iron ASTM A-48 class 30.
MOTOR HOUSING: Cast iron ASTM A-48 class 30.
IMPELLER: Vortex. Cast iron ASTM A-48 class 30, dynamically balanced, ISO G6.3.
SHAFT: 416 series stainless steel.
O-RINGS: Square shaped Buna-N.
PAINT: Air dry enamel, water based.
SEAL: Single mechanical, oil lled chamber. Carbon / ceramic / Buna-N, with stainless steel
hardware.
HARDWARE: 300 series stainless steel.
CORD ENTRY: 20 ft of neoprene cord SJTOW 16/3, sealed against moisture.
UPPER BEARING: Ball, single row, oil lubricated, for radial load.
LOWER BEARING: Ball, single row, oil lubricated, for radial and axial loads.
MOTOR: NEMA L, single phase, permanent split capacitor, 115 volts, 60 Hz, 3450 RPM, oil
lled, with overload protection in motor.
OPTIONAL EQUIPMENT: Additional cord, slide rail coupling (SRC200).
1.22"
3.17"
13.7"
6.45"
3.23" 4.82"
9.43"
2" NPT
MODEL PART No. HP VOLTS PHASE RPM
(Nominal)
MAX
AMPS
LOCKED
ROTOR AMPS
CORD
SIZE
CORD
TYPE
WEIGHT
(pounds)
2FFEV512 62180201 0.5 115 1 3450 8 16 16/3 SJTOW 50
FFBPEV512A 62180202 0.5 115 1 3450 8 16 16/3 SJTOW 49
A = Automatic Float Switch

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 stored for a
period longer than six (6) months
from the date of purchase should be
bench tested prior to installation. A
bench test consists of, checking the
impeller to assure it is free turning
and a run test to assure the motor
(and switch if provided) operate
properly.
Controls
Manual models require a separate
approved pump control device or
panel for automatic operation. Be
sure the electrical specication of the
control selected properly match the
electrical specications of the pump.
Submergence
The pump should always be
operated in the submerged
condition. The minimum sump liquid
level should never be less than above
the pump’s volute (See Figure 1).
03
Receiving & Installation
Figure 1
Recommended
Submergence Level
Minimum
Submergence Level
6"
Bottom of Feet
Liquid Level Control
Typical Discharge Pipe Mounted:
Refer to Figure 2 below which shows
a typical installation of a 1 phase 115
volt pump using a level control
mounted to the discharge piping
with a piggyback plug. 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 "O" mode. By
adjusting the cord tether the control
level can be changed.
Typical Discharge Pipe Mounted
Level Control
DISCHARGE
VENT
INLET
GATE
VALVE
UNION
CHECK VALVE
Drill  " dia. vent hole
to prevent air locking
Level Control Basic instructions:
Plug the level control plug into the
GFI receptacle, then plug the pump
into the piggy-back plug (See Figure
3). One cycle of operation should be
observed, so that any potential
problems can be corrected.
It is recommended that the level
control 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 6
inches above the basin oor.
Installation
These pumps are recommended for
use in a sump or basin. The sump or
basin shall be sealed and vented in
accordance with local plumbing
codes. This pump is designed to
pump euent or wastewater,
nonexplosive and noncorrosive
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.
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.
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.
Figure 3

04
Installation & Service
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.
Electrical Connections
Power cable:
The power cable mounted to the
pump must not be modied in any
way. This pump is provided with a 3
wire cord and 3 prong grounded
plug that must be connected into a 3
wire grounded Ground Fault
receptacle. Do not bypass grounding
wires or remove ground prongs from
plug. This pump requires separate,
properly fused and grounded branch
circuit. Use of a ground fault circuit
interrupter (GFCI) is strongly
recommended.
The electrical outlet or panel shall be
within the length limitations of the
pump power cord, and at least 4 feet
above oor level to minimize
possible hazards from ood
conditions. Do Not use an extension
cord.
IF USED with Control Panel - 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 if located within the wet
well. DO NOT USE THE POWER
CABLE TO LIFT PUMP. Always rely
upon a Certied Electrician for
installation.
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.
DO NOT ALLOW THE
PUMP TO CYCLE OR RUN IF AN
OVERLOAD CONDITION OCCURS.
WARNING
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
Wire Size:
If longer power cable is required
consult a qualied electrician for
proper wire size.
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.
Incorrect rotation for Single-Phase
pumps is unlikely. If the rotation is
incorrect contact factory.
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.
No lubrication or maintenance is
required. Perform the following
checks when pump is removed from
operation or when pump
performance deteriorates:
Maintenance
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.
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.
Cooling Oil - Anytime the pump is
removed from operation, the cooling
oil in the motor housing should be
checked visually for oil level and
contamination.
Servicing
To check oil, set unit upright. Remove
pipe plug from housing.

Oil Replacement - Set unit upright
and rell with new cooling oil as per
table below. Fill to just above motor,
but below capacitor as an air space
must remain in the top of the
housing to compensate for oil
expansion.
Cooling Oil
Recommended Supplier/Grade
BP Enerpar SE100
Conoco Pale Paran 22
Mobile D.T.E. OilLight
Shell Canada Transformer-10
Texaco Diala-Oil-AX
Disassembly
Impeller and Volute:
1. Disconnect power.
05
Service
Pressure builds up extremely
fast, increase pressure by
"TAPPING" air nozzle. Too
much pressure will damage
seal. DO NOT exceed 10 PSI.
DO NOT overll oil.
Overlling of housing with oil
can create excessive and
dangerous hydraulic pressure
which can destroy the pump
and create a hazard.
Overlling oil voids warranty.
2. Remove cap screws, volute and
gasket.
12. Remove seal’s rotating member,
spring and retaining ring from seal
plate. Examine all seal parts, if seal
faces show signs of wear, uneven
wear pattern, chips or scratches
replace entire seal. DO NOT
interchange seal components,
replace the entire shaft seal. If
replacing seal, remove stationary by
prying out with at screwdrive.
Shaft Seal:
11. Remove snap ring from seal plate.
Remove shaft and motor rotor from
seal plate.
Oil Testing
Drain oil into a clean, dry
container by placing pump on it’s
side, remove pipe plug, from
housing.
Check oil for contamination using
an oil tester with a range to 30
kilovolts breakdown.
If oil is found to be clean and
uncontaminated (measuring
above 15 kV breakdown), rell the
housing.
If oil is found to be dirty or
contaminated (or measures below
15 kV breakdown), the pump
must be carefully inspected for
leaks at the shaft seal, cable
assembly, square ring and pipe
plug, before relling with oil. To
locate the leak, perform a
pressure test.
After leak is repaired, dispose of old
oil properly, and rell with new oil.
3. Clean and examine impeller, for
cracks or breakage and replace if
required. To remove impeller, place a
at screwdriver in the slot of the end
of the shaft to hold the shaft
stationary while unscrewing.
4. Check v-ring and remove if
damaged.
Power Cord and Motor:
5. Remove pipe plug and drain oil
from housing.
6. Remove gland nut, washer and
nylon housing from motor housing.
Pull cord through and disconnect the
wires from the terminals on power
cord.
7. Remove screws and washers and
lift motor housing and stator from
seal plate.
8. Remove o-ring, replace if damaged.
9. Check motor capacitor with an
Ohm meter by rst grounding the
capacitor by placing a screwdriver
across both terminals and then
removing screwdriver. Connect Ohm
meter (set on high scale) to terminals.
If needle moves to innity (∞) then
drifts back, the capacitor is good. If
needle does not move or moves to
innity (∞) and does not drift back,
replace capacitor.
10. Inspect motor winding for shorts
and check resistance values. Check
rotor for wear. If rotor or the stator
windings are defective, the complete
motor must be replaced.
Bearings:
13. Examine lower bearing, and
upper bearing, if replacement is
required, remove by using a wheel
puller.
With a ashlight, visually inspect the
oil in the housing to make sure it is
clean and clear, light amber in color
and free from suspended particles.
Milky white oil indicates the presence
of water. Oil level should be just
above the motor when pump is in
vertical position.
Apply pipe thread compound to
threads of pipe plug then assemble
to housing.

06
Service
4. With lapped surface of seal’s
rotating member facing outward,
slide over shaft using a seal tool,
being carefull not to damage seal
face. Make sure spring is seated in
retaining ring and spring is lined up
on rotating member and not cocked
or resting on bellows tail.
Motor:
5. Slide rotor/shaft with bearings and
seal parts into seal plate until bearing
seats into seal plate. Install snap ring
into seal plate.
6. Lower housing while stringing
motor leads through the cord entry
bore, with motor stator onto seal
plate.
7. Place screws with washers through
housing into seal plate and torque to
60 in/lbs.
Motor:
5. Slide rotor/shaft with bearings and
seal parts into seal plate until bearing
seats into seal plate. Install snap ring
into seal plate.
Power Cord:
8. Check power cord for cracks or
damage and replace if required.
Reconnect motor leads.
9. Place power cord with nylon
housing, ring, washer and gland nut
into housing and tighten gland nut
to 17.5 ft/lbs.
Impeller, V-ring and Volute:
10. Position v-ring into seal plate until
seated.
11. Clean the threads with thread
locking compound cleaner. Apply
removable Loctite® 242 or equivalent
to shaft threads. Screw impeller onto
the shaft hand tight while using a
screwdriver in the slot at the end of
the shaft to hold it stationary. Rotate
impeller to check for binding.
12. Position gasket on volute ange
and position impeller and motor
housing assembly on volute.
13. Place screws into volute and
torque to 11 ft/lbs. Check for free
rotation of impeller.
14. Rell with cooling oil.
Shaft Seal:
2. Clean seal cavity in seal plate and
oil. Press seal’s stationary member
rmly into seal plate, use a seal tool
or pipe. Nothing should come in
contact with the seal face except the
seal tool. Be sure the stationary is in
straight.
3. Place seal’s retaining ring, spring
onto shaft. Lightly oil (Do not use
grease) shaft and inner surface of
bellows.
Bearings:
1. Press bearings and onto shaft.
IMPORTANT! - All parts
must be clean before
reassembly. Handle seal
parts with extreme care. DO NOT
damage lapped surfaces.
Reassembly

07
Repair Parts
FFBPEV512
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.

08
Parts List
FFBPEV512
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.
ITEM DESCRIPTION QTY. MATERIAL
1 Cable assembly 20 ft -
2 Pump body 1 HT200
3 Capacitor 30uf/300V 90° C 1 Plastic Pin
4 Capacitance clip 1 08F
5 Cross recessed pan head screw M4x10 2 Q235A
6 Ground lead 1 -
7 Upper bearing plate 1 ZL102
8 Temperature protector 17AM032-05 1 -
9 Stator 1 -
10 Rotor 1 -
11 Lower bearing plate 1 HT200
12 Bearing 6203 Z3 1 -
13 Mechanical seal 1 CC/SiC
14 Impeller 1 HT200
15 Hex socket cap screws 1/4" - 20UNCx28 5 304
16 Casing 1 HT200
17 Handle 1 304+NBR40
18 Hex bolt 1/4" - 20UNCx13 2 304
19 Name plate 1 304
20 Nail for name plate 2x6 4 Cu
21 Hex socket pipe stropper 1/4" - 18 NPT 1 304
22 Vortex shell gasket 1 NBR41
23 Hex socket cap head screws 1/4" - 20UNCx18 2 304
24 O-ring Ø5.25" x 0.25" 1 NBR40
25 Lengthen bolt M4x100 2 Q235A
26 Bearing 6200 Z3 1 -
27 Wave washer Ø1.125" 1 65Mn
28 Cable guard 1 NBR40
29 Float switch 1 -
30 Clamp 1 2Cr13+NBR40
31 Cross recessed pan head screw #10 - 31UNFx12 1 304

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.
07
Troubleshooting Chart