Page 1
PRODUCT DATA
Pump Design ..............................................Quad Diaphragm
Motor ................Permanent Magnet ............................TENV
Wetted Parts ....Diaphragm Material ..................Santoprene
Check Valve Material ........................EPDM
Housing Material ..................Polypropylene
Accumulator Tank
..Diaphragm Material ............................Butyl
Liner Material ........................Polypropylene
Ports ..............................3/4” HB Inlet & 1/2” HB/Qest Outlet
Net Weight ................................................8.8 Pounds (4 kgs)
PERFORMANCE SPECIFICATIONS
PUMP
Motor ................Max Amp Draw ....................1.5 @ 115 VAC
0.75 @ 230 VAC
Cycle ........................................50/60 Hertz
Liquid Temperature
..Min. ..............................................45°F (7°C)
Max. ........................................140°F (60°C)
Priming ..............Dry ............................................5 ft. (1.5 M)
Wet ..........................................15 ft. (4.6 M)
Flow Rate ..........Max ..............3.5/4.5 GPM @ 0 PSI (0.0 bar)
Pressure Switch
Off ......................................45 PSI (3.1 bar)
On ......................................30 PSI (2.1 bar)
TANK
Total Volume ....................................................1.1 gal. (4.1 It.
Operating Pressure ..............................................Gal (0.8 It.)
Air Pressure Setting........................................25 PSI (1.7 bar)
STANDARD MODEL NUMBERING SYSTEM
2840 Series
Booster Pump System
DIMENSIONAL DRAWING
Inches (millimeters)
The standard model numbering system is used for models up
to -500. Numbers -500 and over are used for variations from
standard assemblies such as special pump or tank
specifications. Consult the factory for special models to meet
specific requirements.
INSTALLATION & SERVICE INFORMATION FOR MODELS 2840-000 & 2840-010 115 VOLTS AC
AND MODEL 2840-210 230 VOLTS AC
a:
Model 2840-010
Model 2840-210
b:
Model 2840-000
2840 Series Booster Pump System
28 X X - X X X
Pump Service Voltage Switch Options
20 = Duplex 0 = 115V AC 0 = 40 PSI 0 = Std
(2130) 1 = 12V DC 1 = 45 PSI 1 = Timer
40 = Quad 2 = 230V AC 4 = 70 PSI 2 = Inlet Sw.
(4300) 3 = 24V DC 6 = 95 PSI
Pentaflex
50 =
50
(3.4)
40
(2.8)
30
(2.1)
20
(1.4)
10
(0.7)
Pressure in PSI (bar)
0
4 = 36V DC
b
a
3.0
4.0
1.0
2.0
(7.6)
(11.4)
(3.8)
Flow in GPM (l/min)
(15.1)
5.0
(18.9)
7 1/2
(191)
7 13/16
(198)
(13)
11 1/4
(286)
10 1/4
(260)
7 13/16
(198)
7 1/2
(191)
4 3/16
(106)
1/2
10 1/4
(260)
10 1/4
(260)
12 7/8
(327)
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GENERAL SAFETY INFORMATION
Protect yourself and others by observing all safety
information. Shut off power and drain pressure from
system prior to service.
DESCRIPTION
The FLOJET 2840 series Booster Pump Systems are
designed to provide a constant water pressure of 25 to
45 psi (1.7 - 3.1 bar) and maximum flow of 3.5 or 4.5
GPM at 10 psi (0. 7 bar). The pump is fully automatic
with a built-in switch and check valve to maintain
system pressure and will supply smooth water flow from
a trickle to full flow Typical uses are; Commercial Ice
Machines, Pure Water Dispensing, Water Purifiers,
Small Domestic and Commercial Appliances where the
water supply pressure is very low or fluctuates widely.
OPERATION
IMPORTANT - For correct operation, the tank must be
properly pressurized on the air side before the pump is
started. Follow instructions on the tank label and check
air pressure after filling and before starting the pump.
The air valve is a standard tire valve. Compressed air
hose or hand pump may be used to pressurize.
Pressure can be reduced by pressing the center pin in
the valve.
Make sure pump inlet connection is securely connected
to the water supply and no inlet valves are open. Open
all valves or taps on outlet side to purge air from the
system. Turn power on to the pump, pump will start up.
Allow system to pump for a minute or until all the air has
been purged from the system. Close all valves in the
system, the pump will pressurize the tank, shut off and
operate automatically to maintain pressure In the system.
To completely fill the pressure tank for maximum
volume, shut off power to pump and open faucet (or valve)
closest to tank. Trapped air will be expelled. Turn on
power to pump. and close faucet when water is free of air.
WINTERIZING TIP
When units are exposed to freezing conditions.
1. Open discharge valve (Faucet nearest to the
Booster System).
2. Open inlet side to pump (Remove inlet hose to the
Booster System).
3. Run Pump for approximately 2 minutes, (Dry) or
until system is out of fluid.
4. Leave discharge. value open and inlet hose
removed until next usage.
DO NOT USE PUMP IN A FLAMMABLE
ENVIRONMENT. DO NOT USE TO PUMP
FLAMMABLE OR EXPLOSIVE FLUIDS
SUCH AS GASOLINE, FUEL OIL,
KEROSENE, ETC.
MOUNTING
The FLOJET 2840 Series Water Pressure System should
be mounted in a dry and adequately ventilated area.
Select a location where the plumbing is as direct as
possible and the inlet strainer is visible and accessible
for cleaning.
The unit can be floor or wall mounted. If wall mounted,
the Pump head should be down or lower than the motor.
Fasten base securely with the four rubber mounting feet
assembled to base as shown below.
PLUMBING
Fasten strainer in a visible and accessible location for
future cleaning. Use 3/4” ID hose between pump inlet &
strainer. Connect strainer inlet to water supply line and
clamp all hose connections securely to avoid air leaks.
IMPORTANT - if water supply line has pressure
fluctuations that may exceed 30 psi (2.1 bar) - use a
pressure regulator to limit inlet pressure to 30 psi (2.1
bar) maximum.
Regulator may be installed at any convenient location
between water supply and inlet strainer.
ELECTRICAL
RISK OF AN ELECTRICAL SHOCK!
When wiring an electrically driven pump, follow all
electrical and safety codes, as well as the most recent
National Electrical Code (NEC) and the Occupational
Safety and Health Act (OSHA).
RISK OF PRODUCT DAMAGE!
Make certain the power source conforms to the pump
voltage. Be sure all power is disconnected before
installation or removal.
Use the maximum recommended fuse for pump
protection. Recommended fuse amp rating is located
on pump label. Failure to provide correct overload
device may result in motor failure.
For 115V AC plug AC cord into a conventional 115V AC outlet.
WARNING
WARNING
Vertical Horizontal
1/2” NPT
Pressure
Out
Water
Supply
Optional
Regulator
If Required
Inlet
Strainer
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DISASSEMBLE
Pressure Switch (9)
1. Disconnect power to pump and open a faucet or valve to
relieve system pressure.
2. Remove the two visible Pressure Switch Screws located on
each side of the Pressure Switch (9). DO NOT ADJUST
ALLEN HEAD SCREW IN CENTER OF SWITCH.
Upper Housing (1)
3. Loosen but DO NOT remove the four Pump Head Screws and
carefully remove Upper Housing Assembly (1).
4. Slide Port Clip (8) back and unplug from Tank Plumbing.
6. Remove Check Valve (2) and inspect for debris.
Check Valve Assembly (2) Follow Steps 1, 3 & 4
6. Inspect Check Valve (2) and O-Ring
Lower Housing (4) Follow Step 1
7. Remove pump from both Base and Tank Plumbing.
8. Remove Rubber Feet by pulling out and sliding to the rear
and follow step 3.
9. Rotate Lower Housing (4), so access Rubber Grommet foot
notch is aligned with Cam Bearing Set Screw (4-C), loosen
set screw with a 1/8” Allen Wrench and slide pump head off
motor
shaft.
Diaphragm (3-B)
10. Loosen four cam piston screws with Phillips head screw
driver and pull apart cam (4-B) from Inner Pistons (3-A). (Both
pistons (3-A & C) should be replaced when a new Diaphragm
(3-B) is installed.)
Motor (5) Follow Steps 1, 7, 8 & 9
REASSEMBLE
Diaphragm (3-B)
1. Insert Outer Pistons (3-C) into Lower Housing (4-A) by
bending pistons at center fold.
2.
Placing the Diaphragm (3-B) (flatter side of Diaphragm facing the
motor) on the Lower Housing (4-A). Press each Inner Piston (3-A)
through the Diaphragm and Lower Housing (4-A) into Outer
Piston (3-C). Hex stem of Inner Pistons (3-A) must be aligned into
hex holes in Outer Pistons (3-C). Tighten cam piston screws
partially, center piston in diaphragm, and tighten screws securely
(18 in. lbs. torque). Also, the Outer Pistons (3-C) must be aligned
with alignment slots on Cam Assembly (4-B) making sure screw
holes align in cam assembly, otherwise diaphragm will leak.
Cam Bearing (4-B)
3. Place Cam Bearing (4-B) over Inner Pistons (3-C) and tighten
down with four Phillips Head Screws. (18 in. lbs. torque)
Lower Housing (4) to Motor (6)
Coat motor shaft with grease prior to installing Cam Bearing
(4-B).
4. When installing the Lower Housing (4), rotate mounting foot
notch to align with Cam Bearing Set Screw (4-C).
6. Attach Cam Bearing (4-B) to motor shaft indentation with
Cam Bearing Set Screw (4-C). (35 in. lbs. torque)
6. Reinsert Rubber Feet.
Check Valve (2)
7. Place Ferrules (Rubber Cones) in the Upper Housing (1)
coned side first.
8. Properly seat O-Ring in Check Valve (2) and insert Check
Valve (2) into the Upper Housing (1).
Upper Housing (1)
9. Place Upper Housing (1) on top of the Lower Housing (4-A)
and tighten Hex Bolts (30 in. lbs. torque) through the Upper
Housing (1) to the Motor.
2
1
4
6
3
A
5
B
A
B
C
D
C
7 Includes items 1 thru 4
Key Part No. Description Qty
8 20408-000 Port Clips (Set of 2) 1
9 02096-540 Pressure Switch - 40 PSI Off 1
Sealed
** 04325-143A
Complete MPU
1
115 Volt -
3.5 GPM
** 04325-242A
Complete MPU
1
230 Volt -
3.5 GPM
** 04325-043C
Complete MPU
1
115 Volt -
4.5 GPM
** 01740-002 Strainer 1
** 20799-000A Accumulator Tank 1
** 20796-000A Base 1
**Not Shown in Diagram
Key Part No. Description Qty
1 20404-003 Upper Housing Assy Kit 1
2 20407-030 Check Valve Kit - EPDM 1
w/O-Ring & Ferrules
3 20403-040 Diaphragm Kit, Santo 1
w/Pistons & Screws
4 20419-00 Lower Housing 3.5 GPM 1
20419-002 Lower Housing 4.5 GPM 1
5 02029-091A Motor 115 Volt AC 1
02039-087A Motor 230 Volt AC 1
6 20381-022 Port Kit - (set of 2)
EDPM, 3/4” Barb, 90° 1
& EDPM, 5/8” Barb, Straight 1
7 20406-000A Pump Head Assy. 3.5 GPM 1
7 20406-002A Pump Head Assy. 4.5 GPM 1
WARNING: DISCONNECT POWER TO PUMP AND OPEN VALVE TO
RELIEVE WATER PRESSURE PRIOR TO SERVICING PUMP
!!
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UNITED KINGDOM
Jabsco/Flojet
Bingley Road, Hoddesdon
Hertfordshire EN11 OBU
Tel: +44 (0) 1992 450145
Fax: +44 (0) 1992 467132
CANADA
Fluid Products Canada
55 Royal Road
Guelph, Ontario N1H 1T1
Tel: (519) 821-1900
Fax: (519) 821-2569
JAPAN
NHK Jabsco Company Ltd.
3-21-10, Shin-Yokohama
Kohoku-Ku, Yokohama, 222
Tel: 045-475-8906
Fax: 045-475-8908
U.S.A.
Flojet
20 Icon
Foothill Ranch, CA 92610-3000
Tel: (949) 859-4945
Fax: (949) 859-1153
GERMANY
Jabsco GmbH
Oststrasse 28
22844 Norderstedt
Tel: +49-40-53 53 73-0
Fax: +49-40-53 53 73-11
© Copyright 2001, ITT Industries Printed in U.S.A. All Rights Reserved Form: 81000-298 12/00
WARRANTY
FLOJET warrants this product to be free of defects in material and/or
workmanship for a period of one year after purchase by the customer
from FLOJET. During this one year warranty period, FLOJET will at its
option, at no charge to the customer, repair or replace this product if
found defective, with a new or reconditioned product, but not to
include costs of removal or installation. No product will be accepted
for return without a return material authorization number. All return
goods must be shipped with transportation charges prepaid. This is
only a summary of our Limited Warranty. For a copy of our complete
warranty, please request Form No. 100-101.
RETURN PROCEDURE
Prior to returning any product to FLOJET, call customer service for an
authorization number. This number must be written on the outside
of the shipping package. Place a note inside the package with an
explanation regarding the reason for return as well as the
authorization number. Include your name, address and phone number.
CONVERSION TABLE
TO CONVERT TO MULTIPLY BY
Gallons, U.S. Liters 3.785
Liters Gallons, U.S. 0.264
Pounds/Sq. Inch Bar 0.069
Bar Pounds/Sq. Inch 14.5
Fahrenheit Celsius (°F-32) .556
Celsius Fahrenheit (°C X 1.8) + 32
TROUBLESHOOTING CHART
Symptom Possible Cause(s) Corrective Action
Pump will not prime or retain 1. Air leak in suction line 1. Repair or replace
prime after operating 2. Defective check valve 2. Replace
3. Upper housing leaking 3. Tighten bolts
4. Suction lift too high 4. Lower pump
5. Debris in check valve(s) 5. Clean check valve(s)
Pump runs but no fluid 1. Faulty suction piping 1. Repair or replace
2. Defective check valve 2. Replace
3. Suction lift too high 3. Lower pump
4., Clogged inlet 4. Clean or replace
5. Inlet line valve closed 5. Open valve
Motor runs too hot 1. Voltage incorrect 1. Check voltage
2. Insufficient ventilation for motor 2. Insure proper ventilation
Flow rate is low 1. Piping or hose is damaged 1. Clean or replace
2. Clogged check valve 2. Clear obstruction
3. Worn check valve 3. Replace
4. Voltage incorrect 4. Check voltage
Pump leaks 1. Upper housing loose 1. Tighten screws
2. Pistons loose 2. Tighten piston screws
3. Pump head loose on motor 3. Tighten pump head screws
4. Switch loose 4. Tighten switch
Pump will not run 1. No electricity 1. Check connections, fuse, breakers
2. Defective pressure switch 2. Replace switch
3. Motor has open circuit 3. Replace
4. Thermal protector has cut off 4. Allow motor to cool 15-30 min
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