STA-RITE DURA-GLAS P2R Series Leitfaden

DURA*GLASTM CENTRIFUGAL PUMPS

WITH INTEGRAL TRAP

O W N E R’ S M A N U A L

INSTALLATION, OPERATION & PARTS

P2R AND P2RA Series MODELS

H.P. P2R Series P2RA Series

1/2 P2R5C-120L P2RA5C-119L

3/4 P2R5D-124L P2RA5D-120L

1 P2R5E-125L P2RA5E-124L P2RAXE-124L

1-1/2 P2R5F-126L P2RA5F-125L P2RA6F-125L

1-1/2 – – P2RAXF-125ULS P2RAXF-125LS

2 – P2RA5G-126L P2RA6G-126L P2RAXG-126LS

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.

‘P2R’ and ‘P2RA’ SERIES 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 ‘P2R’ and ‘P2RA’ Series Self-priming Centrifugal pump:

• Is designed for use with swimming pools or as a centrifugal pump.

• Is an excellent performer; durable, reliable.

Table of Contents

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

Installation..................................................................................................4

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

Operation...................................................................................................7

Storage/Winterizing.................................................................................7-8

Pump Service ........................................................................................9-10

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 sys-

tem 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.

Motor normally operates at high temperature and will be too

hot to touch. It is protected from heat damage during operation by an auto-

matic internal cutoff switch. Before handling pump or motor, stop motor and

allow it to cool for 20 minutes.

IMPORTANT

SAFETY

INSTRUCTIONS

Always follow basic safety pre-

cautions with this equipment,

including 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

constructed in or on the ground

or in a building such that it can-

not be readily disassembled for

storage. A storable pool is con-

structed so that it may be readily

disassembled 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

connections 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

additional 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 1-1/2" (38mm) IPS PVC pipe with 5” (127mm) trap. Use at least

2” (51mm) pipe with 6” (152mm) trap. Increase size if a long run is needed.

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

independently. 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

P2RA Series

Motor Branch Fuse Max Load Voltage/ Dist. in Ft. (m) (Serv. to Motor)

H.P. Rating Amps* Amps Hz/Phase 0-100’ (0-30) 101-200’ (31-60) 201-300’ (61-90)

1/2 15 8.8 115/60/1 14 (2) 12 (3) 10 (5.5)

3/4 20 12.4 115/60/1 12 (3) 10 (5.5) 8 (8.4)

1 20 15.4 115/60/1 12 (3) 8 (8.4) 6 (14)

1-1/2 30 18.2 115/60/1 10 (5.5) 8 (8.4) 6 (14)

1/2 15 4.4 230/60/1 14 (2) 14 (2) 14 (2)

3/4 15 6.2 230/60/1 14 (2) 14 (2) 14 (2)

1 15 7.7 230/60/1 14 (2) 14 (2) 12 (3)

1-1/2 15 9.1 230/60/1 14 (2) 14 (2) 12 (3)

2 20 12.0 230/60/1 14 (2) 14 (2) 12 (3)

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

P2R Series

Motor Branch Fuse Max Load Voltage/ Dist. in Ft. (m) (Serv. to Motor)

H.P. Rating Amps* Amps Hz/Phase 0-100’ (0-30) 101-200’ (31-60) 201-300’ (61-90)

1/2 20 12.4 115/60/1 12 (3) 10 (5.5) 8 (8.4)

3/4 20 15.4 115/60/1 12 (3) 8 (8.4) 6 (14)

1 30 18.2 115/60/1 10 (5.5) 8 (8.4) 6 (14)

1/2 15 6.2 230/60/1 14 (2) 14 (2) 14 (2)

3/4 15 7.7 230/60/1 14 (2) 14 (2) 14 (2)

1 15 9.1 230/60/1 14 (2) 14 (2) 12 (3)

1-1/2 20 12.0 230/60/1 14 (2) 14 (2) 12 (3)

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

Wire

Size

AWG

(mm)

}

Wire

Size

AWG

(mm)

}

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 electri-

cal 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

reduced 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 reinforcing rod or mesh.

Wiring:

Pump must be permanently connected to circuit. Table I, Page 5, gives cor-

rect wire and circuit breaker sizes for the pump alone. If other lights or

appliances are also on the same circuit, be sure to add their amp loads to

pump amp load before figuring wire and circuit breaker sizes. (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

manufacturer’s instruction.

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

pump operation). 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.

BONDING

LUG

MOTOR NAMEPLATE

GREEN

GROUND

SCREW

MOTOR

CANOPY

THROUGH

BOLTS

Hazardous voltage.

Can shock, burn,

or cause death.

Ground pump before

connecting to

power supply.

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

A: Typical ground screw and bond-

ing lug locations.

Figure 2 – Electrical connections; motor

terminal block and bonding.

B. Motor terminal block 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

before 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.

NOTICE: 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.

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

plastic 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, Page 8).

1. Gravity drain system as far as possible.

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

antifreeze (“RV antifreeze”).

Hazardous suction.

Can trap hair or

body parts, causing

severe injury

or death.

Do not block

suction.

Keep motor dry and covered during storage.

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

For outdoor/unprotected installations:

1. Enclose entire system in a weatherproof enclosure.

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

wrap system in plastic.

3. Use a 40% propylene glycol/60% water solution to protect pump

to -50°F.

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. Use a Sta-Rite U79-11 Lid Wrench to remove trap

covers that have been overtightened or have taken a set and cannot be

removed by hand.

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 plug (Key No. 16, Pages 12, 13, & 14). Clean

pump thoroughly; replace trap cover.

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

only if necessary to remove cover!

5. Be sure motor is kept dry and covered.

Startup For Winterized Equipment:

1. Remove any temporary weather protection placed around system for shut-

down.

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 (Page 7) before starting.

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!

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.

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 starting

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.

4. Remove pump base mounting bolts, if used. Motor and seal plate assem-

bly can now be pulled away from pump body.

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

diffuser.

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

loosen capacitor clamp and move capacitor to one side.

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

NOTICE: If impeller is secured by a screw, remove screw by turning

CLOCKWISE (Left-Handed thread) as you face it.

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

9. Remove four screws holding seal plate to motor.

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

(Figure 4).

NOTICE: Do not force out heat sink insert (Key No, 7, Pages 12, 13,

14). If insert has moved, pump will leak; see “Installing Insert”, Page 10.

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

FIGURE 3

Hazardous voltage.

Can shock, burn,

or cause death.

Disconnect power

before working

on pump or motor.

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 seal plate cavity firmly and squarely with finger pressure

(Figure 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" standard pipe for pressing purpos-

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

leak.

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

(69-92 cm/kg) torque.

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

half of seal.

6. Slide rotating seal member, polished face first, over threaded shaft end

and shaft shoulder until rubber drive ring hits shaft 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. Reinstall impeller screw (if used) by turning COUNTER-

CLOCKWISE (Left-Handed thread) as you face it.

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

(11.5-16 cm/kg) torque.

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

ed. NOTICE: Clamp knob can be located in any position around volute;

if it is moved after assembly, tighten knob while tapping around clamp

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

10. Reinstall pump base mounting bolts (if used) and prime pump according

to instructions on Page 7.

Installing Heat Sink Insert:

If the heat sink insert moves or shifts during seal removal, remove and

reinstall it to prevent leakage.

1. To remove heat sink insert, grasp with fingers at the large end and move

back and forth. Do not deform.

2. Replace heat sink insert as follows:

A.Clean off old sealant and foreign material; clean out insert cavity.

B. Apply a small amount of non-hardening silicone RTV on surface of

insert (see Figure 6).

C.Pull insert into cavity (see Figure 7).

D. Remove surplus silicone RTV from insert cavity (see Figure 8).

FIGURE 4

FIGURE 5

FIGURE 6

FIGURE 7

FIGURE 8

WIPE ON SMALL AMOUNT OF

NON-HARDENING PERMATEX

ON THIS SURFACE

7/8" SOCKET

BOLT

1-3/8" O.D.

WASHER 038 0893

REMOVE

SURPLUS

PERMATEX

PROPERLY

SEATED

039 0893

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