Webster Pumps "S" SERIES IMMERSIBLE PUMP OWNER'S MANUAL INSTALLATION OPERATION PARTS Models S2 S4 S5 SS6 SS7 S8 PLEASE READ THE FOLLOWING INFORMATION PRIOR TO INSTALLING AND USING Webster PUMPS or HAYWARD VALVES, STRAINERS, FILTERS, AND OTHER ASSOCIATED PRODUCTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS INJURY. 1. Webster and Hayward guarantees their products against defective material and workmanship only. Webster and Hayward assume no responsibility for damage or injuries resulting from improper installation, misapplication, or abuse of any product. 2. Webster and Hayward assume no responsibility for damage or injury resulting from chemical incompatibility between their products and the process fluids to which they are subjected. Compatibility charts provided in Webster and Hayward literature are based on ambient temperatures of 70 ºF and are for reference only. Customer should always test to determine application suitability. 3. Consult Webster and Hayward literature to determine operating pressure and temperature limitations before installing any Webster and/or Hayward product. Note that the maximum recommended fluid velocity through any Webster and Hayward product is eight feet per second. Higher flow rates can result in possible damage due to the water hammer effect. Also note that maximum operating pressure is dependent upon material selection as well as operating temperature. 4. Webster and Hayward products are designed primarily for use with non-compressible liquids. They should NEVER be used or tested with compressible fluids such as compressed air or nitrogen. 5. Systems should always be depressurized and drained prior to installing or maintaining Webster and Hayward products. 6. Temperature effect on piping systems should always be considered when the systems are initially designed. Piping systems must be designed and supported to prevent excess mechanical loading on Webster and Hayward equipment due to system misalignment, weight, shock, vibration, and the effects of thermal expansion and contraction. 7. Because PPL, PVC and CPVC plastic products become brittle below 40 ºF, Webster and Hayward recommends caution in their installation and use below this temperature. 8. Published operating torque requirements are based upon testing of new valves using clean water at 70 ºF. Valve torque is affected by many factors including fluid chemistry, viscosity, flow rate, and temperature. These should be considered when sizing electric or pneumatic actuators. Due to differential thermal expansion rates between metal and plastic, transmittal of pipe vibration, and pipe loading forces DIRECT INSTALLATION OF METAL PIPE INTO PLASTIC CONNECTIONS IS NOT RECOMMENDED. Wherever installation of plastic valves into metal piping systems is necessary, it is recommended that at least 10 pipe diameter in length of plastic pipe be installed upstream and downstream of the plastic valve to compensate for the factors mentioned above This manual should be furnished to the end user of this pump; its use will reduce service calls and chance of injury and will lengthen pump life. Page 1 of 10
S2 S4 S5 SS6 SS7 S8 SERIES CHEMICAL PUMPS To avoid unneeded service calls, prevent possible injuries, and get the most out of your pump, READ THIS MANUAL CAREFULLY! Webster Specialty Pumps: Are easy to install and operate. Have no bearings or shaft seals in the fluid being pumped. Can handle moderately abrasive liquids. Are designed to run dry without damage. Are virtually maintenance free. TABLE OF CONTENTS SAFETY INSTRUCTIONS...2 INSTALLATION... 3-4 OPERATION...5 MAINTENANCE Disassembly...6 Spacing... 7 Reassembly... 8 REPAIR PARTS LIST... 9-10 READ AND FOLLOW SAFETY INSTRUCTIONS! This is the safety-alert symbol. When you see this symbol on your pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury: DANGER warns about hazards that will cause serious personal injury, death or major property damage if ignored. WARNING warns about hazards that can cause serious personal injury, death or major property damage if ignored. CAUTION warns about hazards that will or can cause minor personal injury or property damage if ignored. The label NOTICE indicates special instructions which are important but not related to hazards. Carefully read and follow all safety instructions in this manual and on pump. Keep safety labels in good condition. Replace missing or damaged safety labels. Page 2 of 10
INSTALLATION Install pump inside tank (see Figure 1). Mount pump vertically with motor above highest liquid level in the tank. Be sure that highest liquid level in tank is below `Maximum Immersion' line located below bossed weep hole on pump column (Figure 1). Pump inlet opening must always be at least one foot above tank bottom. Inlet pipe (if used) must be at least as large as the pump inlet port. PLUMBING Fig 1 NOTICE: Thermoplastic pumps will not tolerate plumbing stress. To prevent distortion (cold flow) of pump body and possible damage to pump, be sure your plumbing is properly aligned and supported. Mount pump in tank so that pump inlet opening is at least one foot above tank bottom. Be sure that any foot valve or other hardware on inlet pipe will not stick closed or partially closed. Restricting flow can starve inlet, causing cavitation (which can damage pump). To be sure of priming on restart, install an inlet foot valve and discharge check valve or Be sure that fluid level covers discharge port after shutoff (see Fig. 1). When a foot valve is installed, manually prime pump for initial start-up. With both foot valve and discharge check installed, pump should not need priming for restart even if liquid level in tank falls below discharge port. NOTICE: To prevent liquid rising up the pump's vertical flange on shutoff, discharge check valve must be installed between one to three feet of the pump discharge port. Page 3 of 10
Hazardous voltage. Can shock, burn, or cause death. Ground pump before connecting to power supply. ELECTRICAL Ground motor before connecting to electrical power supply! Failure to ground motor can cause severe or fatal electrical shock hazard! Do not ground to a gas supply line! To avoid dangerous or fatal electrical shock, turn OFF power to motor before working on electrical connections. Motor wiring and supply voltage must match exactly to prevent poor performance and motor damage. Running the motor at the wrong voltage will void the warranty. ROTATION Motor shaft rotation is counterclockwise (CCW) viewed from suction end of pump. Running pump backwards may loosen impeller and will reduce performance. Single Phase Motors: Pre-wired for correct rotation and highest nameplate voltage. For lower voltage operation follow motor manufacturer's instructions inside wiring access cover or on motor. Three Phase Motors: Follow directions on motor nameplate to connect for desired voltage and rotation. See Table I for fusing and wiring data. TABLE 1 - MOTOR FUSING AND WIRING DATA PUMP MOTOR BRANCH FUSE MAX LOAD VOLTAGE/ WIRE SIZE (AWG) DIST. IN FEET (SERVICE TO MOTOR) MODEL NO. H.P. RATING (Amps) (Amps) HZ/PHASE 0-100' 101-200' 201-300' S2 15-61 1 /3 15 4.6/2.3 115/230/60/50/1 14 14 14 15-142 1/3 15 1.2/0.6 208-230/460/60/50/3 14 14 14 S4 15-203 1 /2 15 6.0/3.0 115/230/60/50/1 14 14 14 15-288 3/4 15 2.4/1.2 208-230/460/60/50/3 14 14 12 S5 15-204 3/4 20 8.6/4.3 115/230/60/50/1 14 12 12 15-74 1 15 3.5/1.6 208-230/460/60/50/3 14 14 14 SS6 15-204 3/4 20 8.6/4.3 115/230/60/50/1 14 14 14 15-288 3/4 15 2.4/1.2 208-230/460/60/50/3 14 14 14 SS7 15-62 1 20 10.8/5.4 115/230/60/50/1 12 10 8 15/74 1 15 3.5/1.6 208-230/460/60/50/3 14 14 14 S8 15-173 1-1/2 30 14.8/7.4 115/230/60/50/1 10 10 8 15-174 1-1/2 15 4.4/2.2 208-230/460/60/50/3 14 14 14 Page 4 of 10
OPERATION Webster pumps will handle temperatures from 20º F. to +260 ºF. and a wide range of chemicals (depending on pump materials; see catalog data). NOTICE: Liquid within impeller will cause heavy side loading and may cause motor bearing failure and pump damage. To prevent liquid from rising high enough to fill impeller: 1. Use a liquid level control on sump installations. 2. Set liquid level control to start pump when sump liquid level is between discharge port centerline and `Maximum Immersion' line on pump flange. 3. Pump should shut off before liquid level has reached bottom of pump inlet. NOTICE: Webster pumps are designed to allow dry running. However, do not run pump partially dry; that is, 1. Do not operate pump with impeller only partially submerged and 2. Do not operate pump with impeller alternately submerged and dry. Operating under these conditions will put shock loads on the pump which can cause early motor bearing or pump failure. Fig 2 CAUTION: If pump runs dry, NEVER allow pumping chamber to refill while pump is running! To avoid shock load, stop pump while liquid level rises into pumping chamber. START-UP 1. Manually prime pump before starting for the first time. 2. Close pump discharge. 3. Start pump. 4. Open discharge to desired flow rate. 5. With both foot valve and discharge check installed and operating correctly, pump will not need priming for restart even if liquid level in tank drops below discharge port. (Figure 2) Page 5 of 10
MAINTENANCE To avoid danger of injury from electrical shock or from motor unexpectedly starting, disconnect power to motor before working on pump. Disassembly: 1. Use a screwdriver to pry retaining ring (Key No. 9, Figure 3) toward suction port and out of its groove. 2. Pull end cover (Key No. 7) out of pump body (Key No. 5). Move end cover from side to side while pulling to loosen it. Do not remove end cover " 0 " Ring (Key No.8) unless you are replacing it. 3. Remove nosepiece (Key No. 6D) by holding motor shaft with a 1/8" Allen wrench inserted into shaft set screw (Key No. 3) through access hole closest to the motor and unscrewing nosepiece counterclockwise. 4. Unscrew impeller (Key No. 6 - counterclockwise) by again holding motor shaft with a 1/8" Allen wrench inserted into shaft set screw (Key No. 3) through access hole from shaft and lift out of pump body. 5. Remove four pump bolts and washers (KEY Nos. 10 and 11). Lift body (Key 5) off motor. 6. Loosen two shaft set screws (Key No. 3). Pry pump shaft off of motor with two screwdrivers. 7. Do not remove fume seal (Key No. 4) unless it needs replacement. 8. For pump motor maintenance, consult factory. NOTICE: Disassembly of motor will void motor manufacturer's warranty. NOTICE: To prevent impeller / pump body interference and damage to pump, pump shaft must be spaced. Fig 3 Page 6 of 10
Spacing: 1. Start shaft set screws (Key No. 1, Figure 4) in screw holes on pump shaft. Slide pump shaft onto motor shaft with screws aligned with flat or keyway. 2. Place spacing washers on motor face. (Key No. 2, Figure 4) Shim CPVC and polypropylene models to.060 ; shim PVDF models to.100 clearance. 3. Place pump body (Key No. 4, Figure 5) on motor face and install two body bolts on opposite sides of flange (180º apart). Hand tighten only. (Key No. 3, Figure 5) 4. Make sure that the pump body is mounted squarely on motor. 5. Hold motor shaft with 1/8" Allen wrench inserted through access hole into shaft set screw. NOTICE: Do not tighten set screw at this time. Screw impeller onto shaft (turn clockwise) until it bottoms out on shaft shoulder (not on pump body flange plate. (Key No. 6, Figure 6) 6. After impeller stops, press down on it until it hits baffle in pump body (Key No. 7, Figure 7). Tighten one set screw (Key No. 8, Figure 7) 7. Continuing to hold shaft, unscrew impeller (counterclockwise) and remove. 8. Remove pump body, bolts and spacing washers or shims. 9. Tighten remaining set screw. Torque both the set screws to 70 inch-lbs torque. Page 7 of 10
Spacing and Reassembly: Key 6A Key 2 Key 5 FIGURE 8 1. Slide " 0 " Ring (Key No. 6A, Figure 8) onto shaft (Key No. 2, Figure 8) to within 1/2" of coupling. Leave it far enough away from coupling so that impeller sleeve will push it into final position on shaft. (During operation, " 0 " Ring provides a back-up to liquid level control to help keep liquid out of the impeller.) 2. Place pump body (Key No. 5) on motor without shims or spacers. Bolt to motor. 3. Hold pump shaft (Key No. 2) with Allen wrench inserted into shaft set screw (Key No. 3) through access hole. Screw impeller (Key No. 6B) onto shaft (turn clockwise). 4. To lubricate nosepiece " 0 " Ring (Key No. 6C) and hold it in place in nosepiece groove, apply a small amount of compatible lubricant to " 0 " Ring; mount " 0 " Ring into nosepiece groove (Key No. 6D). 5. Hold impeller stationary. Using largest screwdriver that will fit nosepiece drive slot, install nosepiece and " 0 " Ring (Key Nos. 6C and 6D) Torque lock screw to 40 inch-lbs. Impeller should turn freely by hand. NOTICE: A small screwdriver may split nose piece. FIGURE 9 NOTICE: To properly seal impeller body and maintain locking tension, nose piece should seat against impeller at 40 inch-lbs torque. If not, remove nose piece and find cause. Do not operate pump until problem has been found and corrected; to do so could allow liquid into impeller body, throwing impeller out of balance and possibly damaging pump. 6. Inspect pump body " 0 " Ring (Key No. 8) for cuts, nicks, and abrasion. If worn or damaged, replace it. Stretch " 0 " Ring into groove in pump body without rolling or twisting it. Lubricant on " 0 " Ring will make installation easier. 7. Replace end cover (Key No. 7) in pump body, making sure that it is inserted past retaining ring groove. Seat end cover with a rubber mallet. 8. Replace retaining ring (Key No. 9) in groove in pump body. Make sure it is completely seated. 9. Check clearance A with bent wire feeler gauge (see Figure 9 Table III) Page 8 of 10
WEBSTER Seal-less Immersible Pump S2, S4, S5 SERIES MODEL NUMBER (CPVC) S2 S4 S5 1S2GX0009 1S2GX0003 1S2GX0008 1/3 Hp 1ph 1S4GX0009 1S4GX0003 1S4GX0008 3/4 HP 1ph 1S5GX0009 1S5GX0003 1S5GX0008 1 HP 1ph Key No. Part Description 1S2HX0009 1S2HX0003 1S2HX0008 1/3 HP 3ph 1S2HX0009 1S2HX0003 1S2HX0008 3/4 HP 3ph 1S2HX0009 1S2HX0003 1S2HX0008 1 HP 3ph 1 Motor 115/230V/60/50Hz/1 Ph 15-61 15-203 15-204 1 Motor 208-230/460V/60/50Hz/3Ph 15-142 15-288 15-74 2 Shaft (Incl. 2 No. 3) 4677 4657 4657 3 Set Screw, Allen Hd.(2 Req.) U30-893SS U30-893SS U30-893SS 4 Lip Seal (Fume Barrier) U29-112 U29-112 U29-112 5 Body Assembly 4654 5084 5084 Impeller Kit (Incl. Key #6A, 6B, 6C, 6D) N/A PK912 PK1089 6A Impeller *** 1072 912 1089 6B Nosepiece *** V6-112 2539 2539 6C Shaft "0" Ring ** V6-314 V6-314 6D Impeller "0" Ring ** V6-113 V6-113 7 End Cover 4615 4645 4645 8 " 0 " Ring (End Cover) V6-330 V6-335 V6-335 9 Retainer 4613 4643 4643 10 Screw, Hex Hd. (4 Req.) U30-74SS U30-74SS U30-74SS 11 Washer (4 Req.) U43-62SS U43-62SS U43-62SS Pump Hd. Ass'y*** 4660V 5920V 5080V Not illustrated. ** Not available separately. Order Impeller Kit. *** Includes all parts except motor. NOTE ON PART NUMBERS: For CPVC parts: use listed part number, no suffix added. For PVDF parts: use listed part number plus -2 suffix; for example 4654-2 For Polypropylene parts: use listed part number plus - 3 suffix: for example 4654-3. Page 9 of 10
WEBSTER Seal-less Immersible Pump SS6, SS7, S8 SERIES SS6 SS7 S8 1SS6GX009 1SS7GX009 1S8GX0009 1SS6GX003 1SS7GX003 1S8GX0003 1SS6GX008 1SS7GX008 1S8GX0008 3/4 HP 1 PH 1 HP 1PH 1 1/2 1PH 1SS6HX009 1SS7HX009 1S8HX0009 1SS6HX003 1SS7HX003 1S8HX0003 1SS6HX008 1SS7HX008 1S8HX0008 Key Part 3/4 HP 3 PH 1 HP 3 PH 1 1/2 3 PH No. Description 1 Motor 115/230V/60/50Hz/1 Ph 15-204 15-62 15-173 1 Motor 208/230/460V/60/50Hz/3Ph 15-288 15-74 15-174 2 Shaft (Incl. 2 No. 3) 4657 4657 4657 3 Set Screw, Allen Hd.(2 Req.) U30-893/SS U30-893/SS U30-893/SS 4 Lip Seal (Fume Barrier) U29-112 U29-112 U29-112 5 Body Assembly 4664 4664 4664 Impeller Kit (Incl. Key #6A, 6B, 6C, 6D) PK1078F PK1078G PK1078 6A Shaft "0" Ring*** V6-314 V6-314 V6-314 6B Impeller *** 1078F 1078G 1078 6C Impeller "0" Ring*** V6-113 V6-113 V6-113 6D Nosepeice*** 2546 2546 2546 7 End Cover***t 4625 4625 4625 8 " 0 " Ring (End Cover) V6-341 V6-341 V6-341 9 Retainer 4623 4623 4623 10 Screw, Hex Hd. (4 Req.) U30-74SS U30-74SS U30-74SS 11 Spacer Washer (4 Req.) U43-62SS U43-62SS U43-62SS Pump Hd. Ass'y*** 6080V 6090V 4650V Not illustrated. ** Entire liquid end; includes all parts except Key No. 1, Motor. *** Not available separately. Order Impeller Kit. NOTE ON PART NUMBERS: For CPVC parts: use listed part number, no suffix added. For PVDF parts: use listed part number plus -2 suffix; for example 4664-2 For Polypropylene parts: use listed part number plus -3 suffix: for example 4664-3. Page 10 of 10