Flotec EP2-04 Bedienungsanleitung

Installation/Operation/Parts

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English . . . . . . . . . . . . . Pages 2-10

Installation/Fonctionnement/Pièces

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Instalación/Operación/Piezas

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OWNER’S MANUAL

50 Hz. Peripheral Vane

Booster System

NOTICE D’UTILISATION

50 Hz Pompe de surpression

à ailettes périphériques

MANUAL DEL USUARIO

50 Hz Sistema de bomba

de sobrepresión de

paletas periféricas

4546 0304

MOD. EP2-04

P.O. Box 342, Delavan, WI 53115

Phone: 1-800-365-6832

Fax: 1-800-526-3757

E-Mail: info@flotecwater.com

Web Site: http://www.flotecwater.com

Safety 2

For parts or assistance, call Flotec Customer Service at 1-262-728-5551

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.

warns about hazards that will cause serious

personal injury, death or major property damage if

ignored.

warns about hazards that can cause serious

personal injury, death or major property damage if

ignored.

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 dam-

aged safety labels.

Ground motor before

connecting to power

supply.

Meet all codes that

apply for all wiring.

ELECTRICAL SAFETY

Capacitor voltage may be hazardous. To

discharge motor capacitor, hold insulated handle screw-

driver BY THE HANDLE and short capacitor terminals

together. Do not touch metal screwdriver blade or capac-

itor terminals. If in doubt, consult a qualified electrician.

GENERAL SAFETY

Do not touch an operating motor. Modern

motors may operate at high temperatures. To avoid burns

when servicing pump, allow it to cool for 20 minutes

after shut-down before handling.

Do not allow pump or any system component to freeze.

To do so will void warranty.

Pump water only with this pump.

Periodically inspect pump and system components.

Wear safety glasses at all times when working on pumps.

Keep work area clean, uncluttered and properly lighted;

store properly all unused tools and equipment.

Keep visitors at a safe distance from the work areas.

Pump body may explode if used as a boost-

er pump unless relief valve capable of passing full pump

flow at 5 Bars (75 psi) is installed.

PERIPHERAL VANE BOOSTER PUMP

INSTALLATIONS:

•Have a vertical depth between the pump and the

water being pumped of 16’ (5m) or less.

•Have one pipe from the well to the pump case.

REPLACING AN OLD PUMP

Hazardous voltage. Disconnect power to

pump before working on the pump or motor.

1. Drain and remove the old pump. Check the old pipe

for scale, lime, rust, etc., and replace it if necessary.

2. Install the pump in the system. Make sure that all

pipe joints in the suction pipe are air-tight as well as

water tight. If the suction pipe can suck air, the

pump cannot lift water from the water source.

3. Adjust the pump mounting height so that the plumb-

ing connections do not put a strain on the pump

body. Support the pipe so that the pump body does

not take the weight of piping or fittings.

You have just completed the suction pipe plumbing for

your new peripheral vane pump. Please go to Page 4 for

discharge pipe and tank connections.

WARNING

Hazardous voltage. Can

shock, burn, or cause death.

Ground pump before connecting

to power supply. Disconnect

power before working on pump,

motor or tank.

WARNING

Hazardous pressure!

Install pressure relief

valve in discharge pipe.

Release all pressure on

system before working on

any component.

For parts or assistance, call Flotec Customer Service at 1-262-728-5551

Installation 3

INSTALLATION FOR SURFACE WATER

OR CISTERN (FIGURE 1)

1. The pump should be installed as close to the water

as possible, with the fewest possible fittings (espe-

cially elbows) in the suction pipe. The suction pipe

should be at least as large as the suction port on the

pump.

2. Assemble a foot valve and suction pipe (see Figure

1). Make sure that the foot valve works freely. Use

teflon tape on threaded pipe joints. Protect the foot

valve assembly from fish, trash, etc, by installing a

screen around it (see Figure 1).

3. Lower the pipe into the water until the strainer is five

feet above the bottom. It should also be at least

1-1/2 feet (.5m) below the water level in order to

prevent the pump from sucking air.

4. Install a priming tee, priming plug, and suction pipe

on the pump (see Figure 1). Support the pipe so that

there are no dips or sags in the pipe, so it doesn’t

strain the pump body, and so that it slopes slightly

upward from the water source to the pump (high

spots can cause air pockets which can air lock the

pump). Seal the suction pipe joints with teflon tape.

Joints must be air-tight and water-tight. If the suction

pipe can suck air, the pump cannot lift water from

the water source.

You have just completed the suction pipe plumbing for

your new peripheral vane pump. Please go to Page 4

for discharge pipe connections.

Circuit

Breaker

Box

115 VAC

115VAC

Hot

Hot - Brown

Neutral

Neutral - Black

City Water Inlet

NOTE: If the pump is connected

directly to the city water line,

install a Flow Switch or

Low Pressure Cutoff if service

may be interrupted.

Float Switch:

Up = On

Down = Off

Foot Valve

Cistern

Pump

Circuit

Breaker

Box

Neutral

Neutral – Black

Cistern Float

Switch

Hot

Pump

Hot – Brown

Wiring Connections – Schematic

Pressure

Switch

Pressure

Tank

Pressure

Switch

Snifter Valve

4579 0404

Priming Tee

Float Valve

Figure 1 – Surface Water or Cistern Installation.

For parts or assistance, call Flotec Customer Service at 1-262-728-5551

Installation / Electrical 4

DISCHARGE PIPE CONNECTION

(FIGURE 2)

Connect the 5-way tank tee to your plumbing system.

ELECTRICAL

Hazardous voltage. Risk of dangerous or

fatal electric shock. Plug the pump into a 115 Volt, 60

Cycle, Ground Fault Circuit Interrupter (GFCI) protect-

ed grounded outlet only. The pump is equipped with a

3-wire, grounded, cord and plug. Do not modify or

remove the plug. Make sure the pump circuit meets all

codes and ordinances that apply. To avoid dangerous

electrical shock hazard, keep the cord dry at all times.

Lubrication

The motor is lubricated at the factory for the life of

the bearings. The pump seal is water cooled and self

lubricating.

Pump Service

Hazardous voltage. Can shock, burn, or

cause death. Unplug the pump before servicing it. Do not

handle the pump or attempt to work on the pump with

wet hands or while standing on a wet or damp floor.

The motor has an auto-reset thermal overload protector.

If the motor overheats, the overload will cut off the

power to prevent damage and will reset after the motor

cools. If the overload trips repeatedly, check the pump

for the cause (low voltage, a clogged impeller, etc.).

Sealing Pipe Joints

Use only teflon tape for making all threaded connections to the pump itself. Do not use pipe joint compounds

on plastic: they can react with the plastic. Make sure that all pipe joints in the suction pipe are air tight as well

as water tight. If the suction pipe can suck air, the pump will not be able to pull water from the water source.

4555 0304

Pressure

Gauge

1" PipeTo

Household

Water System

Check Valve

(Purchase

Separately)

1" Pipe From

Water Source

Foot Valve

Water Level

Pressure

Switch

5-Way Tank Tee

Adapter

Pump Intake

Port

Discharge

Port

Priming

Port

Priming

Tee

Flow

Tank

Snifter Valve

Figure 2 – Suction and discharge connections for Model

EP2-04.

Volts/ Maximum Branch Distance in Feet (m) from Motor To Supply

Hz./ Load Circuit Breaker Wires Sizes AWG (mm2)

Model Phase Amps Rating (Amps)*

0-100 (0-30) 101-200 (31-61) 201-300 (62-91) 301-400 (92-122)

EP2-04 115/50/1 5.8 15 14 (2) 14 (2) 12 (3) 10 (5.5)

WIRING CHART – RECOMMENDED WIRE AND FUSE SIZES

* When using fuses, dual element or Fusetron time delay fuses are recommended for all motor circuits.

Electrical 5

For parts or assistance, call Flotec Customer Service at 1-262-728-5551

How To Set the Pressure Switch

Step 1: Unplug the pump and prime it (see Page 6 for

priming instructions).

Step 2: Loosen the Differential Pressure Nut until there

is no tension on the spring.

Step 3A: Plug in the pump. The pump should start, pres-

surize the system, and stop when the pressure

gauge reads 2.6 to 3.6 Bars (37 to 52 psi).

Step 3B: When the pump stops, open a faucet to bleed

pressure off the system. Watch the pressure

gauge and note the pressure when the pump

starts.

Step 3C: Unplug the pump and adjust the Minimum

Operating Nut.

Step 3D: Repeat steps 3A, 3B, and 3C until the pump

starts at 1.6 to 1.7 Bars (23 to 25 psi) on the

pressure gauge.

Step 4A: With pressure on the system, open a faucet to

bleed pressure off the system until the pump

starts. Close the faucet, watch the pressure

gauge, and note the pressure when the pump

stops.

Step 4B: Unplug the pump and adjust the Differential

Pressure Nut.

Step 4C: Plug in the pump and repeat steps 4A and 4B,

until the pump stops at 2.2 to 4.2 Bars (32 to

62 psi) on the pressure gauge.

NOTE: The total pressure MUST NOT exceed 5

Bars.

Step 5: With the pump plugged in, open a faucet to

bleed off pressure in the system. When the

pump starts, close the faucet and wait for the

pump to stop. As the pump runs through one

complete pressure cycle, check its operation

and its starting and stopping pressures.

Replace the pressure switch cover and the

pump is ready for operation.

4589 0504

3Increase

Pressure

Decrease

Pressure

234

BARS

Pressure Tank

Pre-Charge

1.5 Bars

(22 psi)

Pressure Switch Start

Setting 1.6-1.7 Bars

(23-25 psi)

To household

Water System Check

Valve Priming

Tee

2.2 4.2

234

BARS

(32 psi) (62 psi)

Operation 6

For parts or assistance, call Flotec Customer Service at 1-262-728-5551

PRIMING / OPERATION

Never run pump dry. Running pump with-

out water may cause it to overheat, damaging the seal

and possibly causing burns to persons handling the

pump. Fill the pump with water before starting.

Never run the pump with the discharge

closed. To do so can boil water inside the pump, caus-

ing hazardous pressure in the unit, risk of explosion,

and possibly scalding persons handling the pump.

Cistern Installation

1. Remove the priming plug from the priming port. Fill

the pump from the tee and let it vent through the

port. Fill all piping between the pump and the water

source and make sure that all vertical suction piping

is full.

2. Replace all priming plugs (use teflon tape).

3. Power on! Start the pump. If you don’t have water in

2 minutes, stop the pump and remove the fill plugs.

Refill the pump and piping. You may have to repeat

this several times in order to remove all the trapped

air from the piping. A pump lifting water 15’ (4.5m)

may take as long as 15 minutes to prime.

4. After the pump has built up pressure in the system

and shut off, check the pressure switch operation by

opening a faucet or two and running enough water

out to bleed off pressure until the pump starts. The

pump should start when pressure drops to 1.6 Bars

(22 psi) and stop when pressure reaches 2.2 to 4.2

Bars (32 to 62 psi), depending on the setting (Step 4,

Page 5). Run the pump through one or two complete

cycles to verify correct operation. This will also help

clean the system of dirt and scale dislodged during

installation.

Circuit

Breaker

Box

115 VAC

115VAC

Hot

Hot - Brown

Neutral

Neutral - Black

City Water Inlet

NOTE: If the pump is connected

directly to the city water line,

install a Flow Switch or

Low Pressure Cutoff if service

may be interrupted.

Float Switch:

Up = On

Down = Off

Foot Valve

Cistern

Pump

Circuit

Breaker

Box

Neutral

Neutral – Black

Cistern Float

Switch

Hot

Pump

Hot – Brown

Wiring Connections – Schematic

Pressure

Switch

Pressure

Tank

Pressure

Switch

Snifter Valve

4579 0404

Priming Tee

Float Valve

Figure 4 – Cistern Booster Application.

Foot Valve

Priming

Tee

4560 0304

Figure 3 – Prime the Pump.

Operation 7

For parts or assistance, call Flotec Customer Service at 1-262-728-5551

Operation As A Rooftop

Reservoir Booster Pump

1. Open a faucet near the pump.

2. Plug the pump into a GFCI-protected, grounded,

3-wire outlet. The pump should start.

3. Let the pump run until all air is out of the system and

the faucet is running solid water.

4. When the faucet is running solid water, close the

faucet. The pump should run until the water pressure

rises to the pressure switch’s OFF setting. The pump

should then stop.

NOTE: Check the system by running it through one

complete pumping cycle to make sure it works. To do

this, open a faucet and bleed off pressure until the

pump starts. Close the faucet, and when the pressure

in the system has built up again, the pump should

stop.

Congratulations on a successful installation.

If you were unsuccessful, please refer to the

Troubleshooting section (Page 8) or call our customer

service technical staff at 1-262-728-5551.

Pump

115V

Hot

Neutral

Black

Brown

City Water Inlet

NOTE: If the cistern pump is

connected directly to the city

water line, install a Flow Switch

or Low Pressure Cutoff if city

service may be interrupted.

Float Valve

Float Switch:

Up = On

Down = Off

Foot Valve

Cistern

Pump Pump

Tinaco

Pump-Up

Float Switch:

Up = Off

Down = On

Booster Pump

Float Switch:

Up = On

Down = Off

Circuit

Breaker

Box

Circuit

Breaker

Box

Neutral Neutral – Black

Cistern Float

Switch

Hot

Cistern

Pump

Pressure

Booster

Pump

Hot – Brown

Pump-Up

Float Switch

Booster Pump

Float Switch

Wiring Connections – Schematic

115 VAC

Pressure

Tank

Pressure Booster Pump

Cistern Pump

(In Tinaco)

(In Cistern)

(In Tinaco)

4581 0404

Figure 5 – Cistern/Tinaco Booster Application.

Troubleshooting 8

For parts or assistance, call Flotec Customer Service at 1-262-728-5551

SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION

Motor will not run Disconnect switch is off Be sure switch is on.

Fuse is blown or circuit breaker tripped Replace fuse or reset circuit breaker.

Wires at motor are loose, DISCONNECT POWER; check and tighten all wiring.

disconnected, or wired incorrectly

Pressure switch contacts are dirty DISCONNECT POWER and clean the electrical contacts.

Motor runs hot and Voltage is too low Check with power company. Install heavier wiring if wire size is too small.

overload kicks off Pump cycles too frequently See section below on too frequent cycling.

Motor runs but no Pump in new installation did In new installation:

water is delivered* not pick up prime through:

1. Improper priming 1. Re-prime according to instructions.

2. Air leaks 2. Check all connections on suction line with

shaving cream.

3. Leaking foot valve or check valve 3. Replace foot valve or check valve.

Pump has lost prime through: In installation already in use:

1. Air leaks 1. Check all connections on suction line and well seal.

2. Water level below suction pipe inlet 2. Lower suction line into water and re-prime. If receding water level

in well exceeds 16’ (5M), a deep well pump is needed.

Foot valve or strainer is plugged Clean foot valve or strainer.

Ejector or impeller is plugged Clean ejector or impeller (See Repair Parts page).

Check valve or foot valve is stuck shut Replace check valve or foot valve.

Pipes are frozen Thaw pipes. Bury pipes below frost line. Heat pit or pump house.

Foot valve and/or strainer are Raise foot valve and/or strainer above bottom of water source.

buried in sand or mud Clean foot valve and strainer.

Water level is too low for shallow well A deep well pump may be needed (over 16’ (5M) to water)

setup to deliver water to deliver water.

Pump does not Water level in well is lower than A deep well jet will be needed if your well is more than 16’ (5M)

deliver water to full estimated depth to water.

capacity Steel piping (if used) is corroded or Replace with plastic pipe where possible, otherwise with new steel pipe.

limed, causing excess friction

Piping is too small in size Use larger piping.

Packed well point Backflush well point or sink new point.

Pump delivers water but

Pressure switch is out of adjustment or DISCONNECT POWER; adjust or replace pressure switch.

does not shut off or contacts are welded together

pump cycles too Faucets have been left open Close faucets.

frequently Venturi, nozzle or impeller is clogged Clean venturi, nozzle or impeller (See Repair Parts page).

Standard pressure tank is waterlogged Drain tank to air volume control port. Check AVC for defects. Check

and has no air cushion all connections for air leaks.

Pipes leak Check connections.

Foot valves leak Replace foot valve.

Air charge too low in pre-charged tank DISCONNECT POWER and open faucets until all pressure is relieved.

Using tire pressure gauge, check air pressure in tank at valve stem

located on the tank. If necessary, adjust air pressure in tank to 1.5 Bars

(22 psi). Check air valve for leaks (use shaving cream) and replace core

if necessary.

Air spurts from faucets Pump is picking up prime When pump has picked up prime, it should pump solid water with no air.

Leak in suction side of pump Suction pipe is sucking air. Check joints for leaks with shaving cream.

Well is gaseous Consult factory about installing a sleeve in the well.

Intermittent over-pumping of well Lower foot valve if possible, otherwise restrict pump discharge.

(Water drawn down below foot valve)

* (Note: Stop pump;

then check prime

before looking for

other causes.

Unscrew

priming

plug and see if water

is in priming hole).

Repair Parts 9

For parts or assistance, call Flotec Customer Service at 1-262-728-5551

345

4587 0504

Model

EP2-04

Key Part No. Model

No. Description Used EP2-04

1Pump Body 1 731S7050

2Priming Plug 1 171P2370

3Impeller 1 731S6510

4C-Clip 1 121P1130

5Washer 1 121P1140

6Shaft Seal 1 ZBR02600

7Adapter 1 171P1680

8Pressure Switch 1 751S5050

95-Way Tank Tee 1 ZA009710

10 Pressure Tank 1 ZA000140

11 Pressure Gauge 1 ZA005170

Repair Parts

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