STA-RITE DURA-GLAS II P4R Series Bedienungsanleitung

DURA-GLAS IITM CENTRIFUGAL PUMPS

WITH INTEGRAL TRAP

O W N E R’ S M A N U A L

INSTALLATION, OPERATION & PARTS

P4R and P4RA Series MODELS

3/4 P4R62D3-150 P4R6D3-150

1 P4R62E3-151 P4R6E-151L P4R6E3-151

1-1/2 P4R62F3-152 P4R6F-152L P4RA6F-151L P4R6F3-152

1-3/4 P4RAA6F-177L

2 P4R62G3-153 P4R6G-153L P4RA6G-152L P4RA6GC-150 P4R6G3-153

2-1/2 P4RAA6G-153L

3 P4R6H3-154

Sta-Rite Pool/Spa Group

293 Wright Street, Delavan, WI 53115

North America: 800-752-0183, FAX 800-582-2217

International: 414-728-5551, FAX: 414-728-4461, TELEX: ITT 4970245

Oxnard, CA • Union City, TN • Delavan, WI • Mississauga, Ont.

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.

‘P4R’ and ‘P4RA’ SERIES II PUMP

WITH TRAP

To avoid unneeded service calls, prevent possible injuries, and get the most

out of your pump, READ THIS MANUAL CAREFULLY!

The Sta-Rite ‘P4R’ and ‘P4RA’ Series II Self-priming Centrifugal pumps:

• Are designed for use with swimming pools or as centrifugal pumps.

• Are excellent performers; durable, reliable.

Table of Contents

Safety Instructions ........................................................................................3

Installation.................................................................................................4-5

Electrical....................................................................................................5-6

Operation..................................................................................................7-8

Storage/Winterizing ......................................................................................8

Pump Service...........................................................................................9-11

Troubleshooting Guide...............................................................................11

Repair Parts List.....................................................................................12-14

Warranty.....................................................................................................15

READ AND FOLLOW SAFETY

INSTRUCTIONS!

This is the safety alert symbol. When you see this symbol on your system

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 death, serious personal

injury, or major property damage if ignored.

warns about hazards that can cause death, serious personal

injury, or major property damage if ignored.

warns about hazards that will or can cause minor personal injury

or property damage if ignored.

NOTICE indicates special instructions not related to hazards.

Carefully read and follow all safety instructions in this manual and on equip-

ment. Keep safety labels in good condition; replace if missing or damaged.

Incorrectly installed or tested equipment may fail, causing

severe injury or property damage.

Read and follow instructions in owner's manual when installing

and operating equipment. Have a trained pool professional per-

form all pressure tests.

1. Do not connect system to a high pressure or city water system.

2. Use equipment only in a pool or spa installation.

3. Trapped air in system can cause explosion. BE SURE all air is out of system

before operating or testing equipment.

Before pressure testing, make the following safety checks:

• Check all clamps, bolts, lids, and system accessories before testing.

• Release all air in system before testing.

• Tighten Sta-Rite trap lids to 30 ft. lbs. (4.1 kg-m) torque for testing.

•Water pressure for test must be less than 25 PSI (7.5 kg/cm2).

• Water Temperature for test must be less than 100oF. (38oC).

• Limit test to 24 hours. After test, visually check system to be sure it is ready

for operation. Remove trap lid and retighten hand tight only.

NOTICE: These parameters apply to Sta-Rite equipment only. For

non-Sta-Rite equipment, consult manufacturer.

IMPORTANT

SAFETY

INSTRUCTIONS

Always follow basic safety pre-

cautions with this equipment, in-

cluding the following.

To reduce the risk of

injury, do not permit children to

use this product unless they are

closely supervised at all times.

This pump is for use

with permanently installed pools

and may also be used with hot

tubs and spas if so marked. Do

not use with storable pools. A

permanently installed pool is con-

structed in or on the ground or in

a building such that it cannot be

readily disassembled for storage.

A storable pool is constructed so

that it may be readily disassem-

bled for storage and reassembled

to its original integrity.

SAVE THESE

INSTRUCTIONS

INSTALLATION

Only qualified, licensed personnel should install pump and wiring.

Pump mount must:

Be solid - Level - Rigid - Vibration free. (To reduce vibration and pipe stress,

bolt pump to mount.)

Allow pump suction inlet height to be as close to water level as possible.

Allow use of short, direct suction pipe (To reduce friction losses).

Allow for gate valves in suction and discharge piping.

Have adequate floor drainage to prevent flooding.

Be protected from excess moisture.

Allow adequate access for servicing pump and piping.

NOTICE: Use Teflon tape or Plasto-Joint Stik1for making all threaded connec-

tions to the pump. Do not use pipe dope; pipe dope will cause stress cracking

in the pump.

NOTICE: Pump suction and discharge connections have molded in thread

stops. DO NOT try to screw pipe in beyond these stops.

Teflon Taping Instructions:

Use only new or clean PVC pipe fittings.

Wrap male pipe threads with one to two layers of Teflon tape. Cover entire

threaded portion of pipe.

Do not overtighten or tighten past thread stop in pump port!

If leaks occur, remove pipe, clean off old tape, rewrap with one to two addi-

tional layers of tape and remake the connection.

NOTICE: Support all piping connected with pump!

1Lake Chemical Co., Chicago, Illinois

Figure 1

Piping:

Use at least 2" IPS PVC (51mm) pipe. Increase size if a long run is needed.

To avoid strains on the pump, support both suction and discharge pipes inde-

pendently. Place these supports near the pump.

To avoid a strain left by a gap at the last connection, start all piping at the

pump and run pipe away from the pump.

Never use a suction pipe smaller than pump suction connection.

To avoid airlocking, slope suction pipe slightly upward toward the pump.

NOTICE: To prevent flooding when removing pump for service, all flooded

suction systems must have gate valves in suction and discharge pipes.

Fittings:

Fittings restrict flow; for best efficiency use fewest possible fittings.

Avoid fittings which could cause an air trap.

Pool fittings must conform to International Association of Plumbing and

Mechanical Officials (IAPMO) standards.

Use only non-entrapping suction fitting or double suction.

TABLE I - RECOMMENDED FUSING AND WIRING DATA

Serv. to Motor - Dist. in Ft. (M)

Motor Branch Fuse Max Load Voltage/ 0-100' 101-200' 201-300'

HP Rating Amps* Amps Hz/Phase (0-30 M) (30-60 M) (60-90 M)

P4R Models:

1 30 19.2 115/60/1 10(5.5) 8(8.4) 6(13)

115 9.6 230/60/1 14(2) 14(2) 12(3)

1-1/2 15 12.0 230/60/1 14(2) 14(2) 12(3)

215 11.2 230/60/1 14(2) 14(2) 12(3)

P4RA Models:

1-1/2 30 19.2 115/60/1 10(5.5) 8(8.4) 6(13)

1-1/2 15 9.6 230/60/1 14(2) 14(2) 12(3)

1-3/4 15 12.0 230/60/1 14(2) 14(2) 12(3)

215 12.0 230/60/1 14(2) 14(2) 12(3)

2-1/2 15 11.2 230/60/1 14(2) 14(2) 12(3)

P4R62 Models:

3/4 15 3.8 200/60/3 14(2) 14(2) 14(2)

115 5.6 200/60/3 14(2) 14(2) 14(2)

1-1/2 15 6.6 200/60/3 14(2) 14(2) 14(2)

215 9.8 200/60/3 14(2) 14(2) 14(2)

P4R6 3-Phase Models:

3/4 15/15 3.6/1.8 230/460/60/3 14(2) 14(2) 14(2)

1 15/15 4.7/2.35 230/460/60/3 14(2) 14(2) 14(2)

1-1/2 15/15 5.8/2.9 230/460/60/3 14(2) 14(2) 14(2)

2 15/15 7.0/3.5 230/460/60/3 14(2) 14(2) 14(2)

2-1/2 15/15 9.7/4.9 230/460/60/3 14(2) 14(2) 12(3)/14(2)

3 15/15 11.5/5.8 230/460/60/3 14(2) 14(2) 12(3)/14(2)

* Time delay fuses are recommended instead of standard fuses in any motor circuit.

Wire

Size

AWG

(mm2)

}

Wire

Size

AWG

(mm2)

}

Wire

Size

AWG

(mm2)

}

Wire

Size

AWG

(mm2)

}

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.

Ground Fault Circuit Interrupter (GFCI) tripping indicates an electrical

problem. If GFCI trips and will not reset, have a qualified electrician

inspect and repair electrical system.

Exactly match supply voltage to nameplate voltage. Incorrect voltage

can cause fire or seriously damage motor and voids warranty.

If in doubt consult a licensed electrician.

Voltage

Voltage at motor must be not more than 10% above or below motor name-

plate rated voltage or motor may overheat, causing overload tripping and re-

duced component life. If voltage is less than 90% or more than 110% of rated

voltage when motor is running at full load, consult power company.

Grounding/Bonding

Install, ground, bond and wire motor according to local or National Electrical

Code requirements.

Permanently ground motor. Use green ground terminal provided under motor

canopy or access plate (See Figure 2); use size and type wire required by

code. Connect motor ground terminal to electrical service ground.

Bond motor to pool structure. Use a solid copper conductor, size No. 8 AWG

(8.4 sq.mm) or larger. Run wire from external bonding lug (see Figure 2) to re-

inforcing rod or mesh.

Connect a No. 8 AWG (8.4 sq.mm) solid copper bonding wire to the pressure

wire connector provided on the motor housing and to all metal parts of the

swimming pool, spa, or hot tub and to all electrical equipment, metal piping

or conduit within 5 feet (1.5 m) of the inside walls of swimming pool, spa, or

hot tub.

Wiring

Pump must be permanently connected to circuit. Match wire and circuit

breaker sizes to Table I (Page 5). If other lights or appliances are also on the

same circuit, be sure to add their amp loads to pump amp load. (If unsure how

to do this or if this is confusing, consult a licensed electrician.) Use the load

circuit breaker as the master on-off switch.

Install a Ground Fault Circuit Interrupter (GFCI) in circuit; it will sense a short-

circuit to ground and disconnect power before it becomes dangerous to pool

users. For size of GFCI required and test procedures for GFCI, see manufac-

turer’s instructions.

In case of power outage, check GFCI for tripping (which will prevent normal

water circulation). Reset if necessary.

NOTICE: If you do not use conduit when wiring motor, be sure to seal wire

opening on end of motor to prevent dirt, bugs, etc., from entering motor.

Bonding

Lug

Motor Nameplate

Green

Ground

Screw

Motor

Canopy

Through

Bolts 349 0893

Hazardous voltage.

Can shock, burn,

or cause death.

Ground pump before

connecting to

power supply.

Figure 2: Typical ground screw and

bonding lug locations.

Figure 3: Single-phase wiring hookup

diagram. For 3-phase

hookups, refer to motor

nameplate.

White

230

Volt

Lines

Blue

SINGLE

VOLTAGE

MOTORS

White w/

Black

Tracer

Black

230

Volt

Lines

DUAL

VOLTAGE

MOTORS

469 0194

White w/

Black

Tracer

Black

115

Volt

Lines

Motor Terminal Board Connections

OPERATION

NEVER run pump dry. Running pump dry may damage seals, causing

leakage and flooding. Fill pump with water before starting motor.

Before removing trap cover:

1. STOP PUMP before proceeding.

2. CLOSE GATE VALVES in suction and discharge pipes.

3. RELEASE ALL PRESSURE from pump and piping system.

4. NEVER tighten or loosen clamp while pump is operating!

If pump is being pressure tested, be sure pressure has been released be-

fore removing trap cover.

Do not block pump suction. To do so with body may cause severe or

fatal injury. Small children using pool must ALWAYS have close adult

supervision.

Priming Pump

Release all air from filter and piping system: see filter owner’s manual.

In a flooded suction system (water source higher than pump), pump will prime

itself when suction and discharge valves are opened.

If pump is not in a flooded suction system, unscrew and remove trap cover;

fill trap and pump with water.

Lubricate trap cover “O” Ring with petroleum jelly each time it is removed.

Clean and inspect “O” Ring; reinstall on trap cover.

Replace trap cover on trap; turn clockwise to tighten cover.

NOTICE: Tighten trap cover by hand only (no wrenches)! Use a wrench only

if necessary to remove lid!

Pump should prime now. Priming time will depend on vertical length of suc-

tion lift and horizontal length of suction piping.

If pump does not prime, make sure that all valves are open, suction pipe end

is under water, and that there are no leaks in suction pipe.

See Troubleshooting Guide, Page 11.

Routine Maintenance

The only routine maintenance needed is inspection/cleaning of trap basket.

Debris or trash that collects in basket will choke off water flow through the

pump. Follow instructions below to clean trap:

1. Stop pump, close gate valves in suction and discharge, and release all pres-

sure from system before proceeding.

2. Unscrew trap lid (turn counterclockwise). If necessary, use a lever such as a

board or long screwdriver between lugs on trap cover.

3. Remove strainer basket and clean. Be sure all holes in basket are clear,

flush basket with water and replace in trap with large opening at pipe con-

nection port (between ribs provided). If basket is replaced backwards cover

will not fit on trap body.

4. Clean and inspect lid “O” Ring; reinstall on trap cover.

5. Clean “O” Ring groove on trap body and replace lid. To help keep lid from

sticking, tighten hand tight only (no wrenches!).

6. Prime pump (see priming instructions).

Hazardous suction.

Can trap hair or

body parts, causing

severe injury

or death.

Do not block

suction.

Draining Pump

1. Pump down water level below all inlets to the pool.

To avoid dangerous or fatal electrical shock hazard, turn OFF power to

motor before draining pump.

2. Remove trap cover and use low pressure air to blow accumulated water

from the piping system. Lugs have been provided on the trap lid to use a

lever or pry bar for loosening.

3. Cap inlet piping after draining to keep water out of the pipes.

4. To prevent pump from freezing, remove trap cover and drain the tank body

through the drain plugs (Key No. 22, Pages 12 - 15). Clean pump and trap

basket thoroughly; replace trap cover.

NOTICE: Tighten trap cover by hand only (no wrenches)! Use a lever or

wrench only if necessary to remove cover! If pump is not anchored, use

caution not to break attached piping!

5. Be sure motor is kept dry and covered.

Storage/Winterizing:

Explosion hazard. Purging the system with compressed air can

cause components to explode, with risk of severe injury or death to anyone

nearby. Use only a low pressure (below 5 PSI), high volume blower when air

purging the pump, filter, or piping.

NOTICE: Allowing pump to freeze will damage pump and void warranty!

NOTICE: Do not use anti-freeze solutions (except propylene glycol) in your

pool/spa system. Propylene glycol is non-toxic and will not damage plastic

system components; other anti-freezes are highly toxic and may damage plas-

tic components in the system.

Drain all water from pump and piping when expecting freezing temperatures

or when storing pump for a long time (see instructions below).

Keep motor dry and covered during storage.

To avoid condensation/corrosion problems, do not cover pump with plastic.

For outdoor/unprotected installations:

1. Gravity drain system as far as possible.

2. Protect areas which retain water with non-toxic propylene glycol antifreeze

(“RV antifreeze”).

3. Enclose entire system in a weatherproof enclosure.

4. To avoid condensation/corrosion damage, allow ventilation; do not wrap

system in plastic.

5. Use a 40% propylene glycol/60% water solution to protect pump to -50°F

(-46°C).

Startup For Winterized Equipment

1. Remove any temporary weather protection placed around system.

2. Follow filter manufacturer’s instructions for reactivation of the filter.

3. Inspect all electrical wiring for damage or deterioration over the shutdown

period. Have a qualified serviceman repair wiring as needed.

4. Inspect and tighten all watertight connections.

5. Open all valves in suction and return piping.

6. Remove any winterizing plugs in piping system.

7. Drain all antifreeze from system.

8. Close all drain valves and replace all drain plugs in piping system.

9. Prime pump according to instructions on Page 7.

Hazardous voltage.

Can shock, burn,

or cause death.

Disconnect power

before working

on pump or motor.

PUMP SERVICE

Pump should only be serviced by qualified personnel.

Be sure to prime pump (Pg. 7) before starting.

Before removing clamp or trap cover:

1. STOP PUMP before proceeding.

2. CLOSE GATE VALVES in suction and discharge pipes.

3. RELEASE ALL PRESSURE from pump and piping system.

4. NEVER tighten or loosen clamp while pump is operating!

To avoid dangerous or fatal electrical shock hazard, turn OFF power to

motor before working on pump or motor.

Aside from lubricating trap cover “O” Ring, no lubrication or regular mainte-

nance is needed beyond reasonable care and periodic cleaning of strainer

basket.

If shaft seal is worn or damaged, repair as follows:

Pump Disassembly/Removing Old Seal

Disconnect power to pump motor.

Be sure gate valves on suction and return piping are closed before start-

ing work.

Release all pressure by opening all vents before starting work.

1. Drain pump by removing drain plugs on bottom of pump body and trap

body.

2. Be sure there is no pressure in trap body; remove cover (unscrew by turn-

ing counterclockwise).

3. Remove clamp holding pump halves together. Motor and seal plate as-

sembly can now be pulled away from pump body.

4. Remove five screws and washers holding diffuser to seal plate. Remove

diffuser.

5. Remove motor canopy. Being careful not to touch capacitor terminals,

loosen capacitor clamp and move capacitor to one side.

6. Hold shaft with 7/16" open-end wrench on motor shaft flats.

7. Unscrew impeller from shaft (turn counterclockwise when facing it).

NOTICE: On models with impeller screw: Remove impeller screw

(left hand thread - turn clockwise) and gasket before removing impeller.

Inspect gasket for damage, cracks, etc. Replace if damaged.

8. Pull rotating member of seal off of impeller sleeve; clean sleeve.

9. Remove four screws holding seal plate to motor.

10. Place seal plate face down on flat surface and tap out ceramic seat.

NOTICE: Do not force out heat sink insert (Key. No. 8, Pages 12-15).

If insert has moved, pump will leak; see “Installing Heat Sink Insert,”

Page 10.

11. Clean seal cavity in seal plate and clean motor shaft.

Hazardous voltage.

Can shock, burn,

or cause death.

Disconnect power

before working

on pump or motor.

Figure 4

Pump Reassembly/Installing New Seal

1. Ceramic seat must be clean and free of dirt, grease, dust, etc. Wet outer

edge of “O” Ring with small amount of liquid detergent; press ceramic

seat into heat sink insert firmly and squarely with finger pressure (Fig. 5).

2. If ceramic seat will not locate properly, remove it, place face up on bench

and reclean cavity. Ceramic seat should now locate.

3. If seat still will not locate properly, place a cardboard washer over the

polished face and use a piece of 3/4" (19mm) standard pipe for pressing

purposes. NOTICE: Be sure not to scratch or mar polished surface or seal

will leak.

4. Remount seal plate on motor. Tighten bolts to 60-80 inch-lbs.

(69-92 kg/cm) torque.

5. Apply a small amount of liquid detergent to inside diameter of rotating

half of seal.

6. Slide rotating seal member, polished face last, over impeller sleeve until

rubber drive ring hits shoulder (Figure 3).

NOTICE: Be sure not to nick or scratch polished seal face; seal will leak if

face is damaged.

7. Screw impeller onto shaft (clockwise); this will automatically locate seal in

seal plate.

NOTICE: On models with impeller screw: Install impeller gasket and lock

screw (left-hand thread - turn counterclockwise). Torque lock screw to

50-55 inch-lbs. (57.6-63 kg/cm).

8. Mount diffuser on seal plate; tighten screws to 10-14 inch-lbs. (11.2-16.1

kg/cm) torque.

9. Assemble motor and seal plate to volute; be sure clamp is properly

seated.

NOTICE: Clamp knob can be located in any position around volute; if it

is moved after assembly, tighten knob while tapping around clamp to as-

sist sealing. Do not move clamp while pump is full of water.

Hazardous pressure. Release all pressure from pump and

piping system before working on pump or attempting to adjust or re-

move clamp. Clamp may blow off of pump if adjusted under pressure.

10. Prime pump according to instructions on Page 7.

Installing Heat Sink Insert:

1. If the heat sink insert moves or shifts during seal removal, remove and re-

place with a new insert to prevent leakage.

Removal:

1. Remove two screws holding heat sink insert to seal plate.

2. Place seal plate face down on bench and use a short length of 1/2” pipe

to push insert out of seal plate.

3. Remove “O” Ring from insert cavity in seal plate and discard.

NOTICE: Do not scratch “O” Ring seat in seal plate.

Installation:

1. Clean heat sink insert cavity in seal plate, including “O” Ring seat (step in

seal plate cavity - see Figure 7).

NOTICE: Do not scratch “O” Ring seat surface.

2. Lubricate new “O” Ring with petroleum jelly and insert into seat in seal

plate (Figure 8).

Figure 5: Press seal into heat sink in

seal plate

Figure 6: Seal Plate/Heat Sink

sectional drawing

Figure 7: Clean O-Ring Seat

Figure 8: Install O-Ring in Seal Plate

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