Star SJ05S User Manual

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SHALLOW WELL JET PUMP

STAR

MODEL SJ05S 1/2 HP

starwatersystems.com

Questions, problems, missing parts? Before returning to your retailer, call our customer service

STOP

department at 1-800-742-5044, 7:30 a.m. - 5 p.m., EST, Monday - Friday.

ATTACH YOUR RECEIPT HERE

Serial Number Purchase Date

Español p. 18

FW1626 A

Product Specications ......................................................................................................................2

Safety Information ............................................................................................................................2

Package Contents ............................................................................................................................4

Preparation .......................................................................................................................................4

General Pump Information ...............................................................................................................5

Well to Pump Connection .................................................................................................................6

Pump to Tank Connection ................................................................................................................9

Tank to House Connection .............................................................................................................10

Pump Electrical Connections..........................................................................................................11

Pump Priming and Startup .............................................................................................................13

Care and Maintenance ...................................................................................................................15

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

Troubleshooting ..............................................................................................................................16

Replacement Parts .........................................................................................................................17

PRODUCT SPECIFICATIONS

Power supply required ...........................................................................115 volts or 230 volts, 60 Hz

(Pump is set by the factory to run on 230 volts)

Maximum water temperature ...........................................................................................77°F (25°C)

Individual branch circuit required ............................................................................15 Amp minimum

Discharge connection .......................................................................................................... 1 in. NPT

Suction connection ........................................................................................................1-1/4 in. NPT

Motor duty..................... Continuous duty with enforced air cooling and thermal overload protection

Pressure switch ........................................................................... Preset at 20 PSI “on” / 40 PSI “off”

Water depth rating ................................................................................................. Maximum of 25 ft.

CAPACITY - U.S. GALLONS PER

MODEL HP VOLTAGE HZ AMP

SJ05S 1/2 115/230 60 7.8/3.6 9.5 6.5 3.5

SAFETY INFORMATION

Please read and understand this entire manual before attempting to assemble, operate or install the product.

MINUTE AT DISCHARGE 20 PSI

5 FT. 15 FT. 25 FT.

SAFETY INFORMATIONTABLE OF CONTENTS

DANGER

ELECTRICAL SHOCk HAZARD.

Always disconnect power source before performing any work on or near the motor or its connected load. If the power disconnect point is out-of-sight, lock it in the open position and tag it to prevent unexpected application of power. Failure to do so could result in fatal electrical shock.

ELECTRICAL SHOCk HAZARD.

Do not handle the pump with wet hands or when standing in water as fatal electrical shock could occur. Disconnect main power before handling unit for ANY REASON!

RISk OF ELECTRIC SHOCk.

These pumps have not been investigated for use in swimming pool areas.

WARNING

ELECTRICAL SHOCk ALERT.

Follow all local electrical and safety codes, as well as the National Electrical Code (NEC) and the Occupational Safety and Health Act (OSHA).

ELECTRICAL SHOCk ALERT.

Replace damaged or worn wiring cord immediately. Never use an extension cord.

ELECTRICAL SHOCk ALERT.

Do not kink power cable and never allow the cable to come in contact with oil, grease, hot surfaces, or chemicals.

ELECTRICAL SHOCk ALERT.

Wire motor to correct supply voltage. See motor nameplate and wiring diagrams and check voltage of power supply.

ELECTRICAL SHOCk ALERT.

Unit must be securely and adequately electrically grounded. This can be accomplished by wiring the unit to a ground metal-clad raceway system or by using a separate ground wire connected to the bare metal of the motor frame or other suitable means.

ELECTRICAL SHOCk ALERT.

Do not disassemble the motor housing. This pump has no repairable internal parts and disassembling may cause leakage or dangerous electrical wiring issues.

ELECTRICAL SHOCk ALERT.

Make certain the electrical power source is adequate for the requirements of the pump.

ELECTRICAL SHOCk ALERT.

Never use an extension cord with this pump.

CHEMICAL ALERT.

This product contains chemicals known to the state of California to cause cancer and birth defects or other reproductive harm.

HAZARDOUS PRESSURE ALERT.

Install pressure relief valve in discharge pipe. Release all pressure on system before working on any component.

ExPLOSION ALERT

Do not use to pump ammable or explosive uids such as gasoline, fuel oil, kerosene, etc. Do not use in ammable and/or explosive atmospheres.

SAFETY INFORMATION

GENERAL PUMP INFORMATION

CAUTION

PRODUCT DAMAGE MAY RESULT

This pump is not to be used for irrigation or water systems.

PRODUCT DAMAGE MAY RESULT

Protect the power cable from coming in contact with sharp objects.

PRODUCT DAMAGE MAY RESULT

Do not run pump dry.

PRODUCT DAMAGE MAY RESULT

Pump and plumbing must be full of water before startup.

PRODUCT DAMAGE MAY RESULT

Do not pump water which contains sand, mud, silt, or debris.

INJURY MAY RESULT

Be careful when touching the exterior of an operating motor. It may be hot enough to be painful or cause injury.

PACkAGE CONTENTS

Description Quantity

Pump 1

Typical Pump Setup

1. Shallow well jet pumps are designed for use where the suction lift is 25 ft. or less. They can be used with drilled or cased wells.

2. Jet pumps can also be used with dug wells, driven wells or with cisterns or lakes.

Suction Lift

25 ft.

Max

Suction Lift

25 ft.

Max

Discharge to Home

Pipe Support

Water Level

Foot Valve

Check Valve

Discharge to Home

Pipe Support

Water Level

3/4 or 1 in. Discharge Pipe

1-1/4 in. Suction Pipe

IL1104

3/4 or 1 in. Discharge Pipe

1-1/4 in. Suction Pipe

PREPARATION

Before beginning installation of product, make sure all parts are present. If any part is missing or damaged, do not attempt to assemble the product. Compare parts to package contents list.

Estimated Installation Time: 2 hours.

Tools Required for New Installation (not included): pipe wrench, pliers, Phillips screwdriver, pipe clamp, 2-step PVC glue system (primer and sealer), thread tape, tire gauge or compressor

Parts Required for New Installation (not included): well seal, 1-1/4 in. to 1 in. male PVC adapter (2), 1-1/4 in. male PVC adapter, 1 in. male PVC adapter, 1-1/4 in. foot valve, 1-1/4 in. PVC pipe and couplings, 1 in. PVC pipe and couplings, 1-1/4 in. PVC elbow, 1 in. PVC elbow, 1 in. discharge tee, galvanized bushing, pressure gauge (optional) or pipe plug, 1-1/4 in. union (optional), 1 in. union (optional), electrical wire, electrical wire strain relief, 1 in. x 1 in. x 1 in. tee, 3/4 in. x 3/4 in. slip coupling, 1 in. x 1 in. slip adapter, 1 in. x 3/4 in. slip adapter

Drive Point

IL1472

Ventilation - Ventilation and drainage must be provided to prevent damage to the motor from heat and moisture. Freezing - Pump and all piping must be protected from freezing. If freezing weather is forecast, drain pump or remove completely from the system. Water Supply - The water source must be able to supply enough water to satisfy the capacity of pump and water needs. See performance chart on page 2. Suction Lift - Suction lift is the vertical distance from the lowest level of the water to the pump intake. Pump will move water as long as it is within 25 vertical ft. of the water source. Horizontal Distance - The horizontal distance is the horizontal measurement between pump suction and the water source. This distance may affect the ability of pump to operate. If it is more than 100 ft., call the manufacturer for assistance: 1-800-742-5044.

GENERAL PUMP INFORMATION

WELL TO PUMP CONNECTION (SUCTION PIPE)

Pipe And Fittings

3. Use galvanized steel or NSF PW Schedule

40 PVC pipe and ttings. This material is

designed for water pressure and will seal

1 in. NPT Discharge

1-1/4 in. Suction

against air and water under pressure. Do

not use DWV ttings, as these are designed

for drains without pressure and will not seal properly.

CAUTION: The entire system must be

air and water tight for efcient operation and to

maintain prime.

Wire Size:

The wire size is determined by the distance from the power source to the pump motor and the horsepower rating of the motor. See the wire chart on page 11 for proper wire size.

WELL TO PUMP CONNECTION (SUCTION PIPE)

CAUTION: Dry-t entire assembly to ensure proper t before gluing or taping parts.

2. Using a 2-step PVC system (not included),

attach enough 1-1/4 in. PVC pipe and couplings (not included) to the adapter to equal the depth of the well, minus 5 ft.

3. Before sliding the pipe assembly into the

well, rmly clamp the assembly with a pipe

clamp (not included) to prevent the assembly from sliding down into the well.

1-1/4 in. PVC pipe

Pipe clamp

25 ft. maximum

Water level

CAUTION: Follow all proper gluing procedures as specied by the glue manufacturer. Always

glue in a vertical direction whenever possible to prevent glue from dripping inside pipe or ttings

CAUTION: Use pipe tape and pipe paste compound on all male threads. Tighten with wrench to

a snug t and add another 1/4 turn to ensure proper seal.

1. Thread 1-1/4 in. male PVC adapter (not

included) into a 1-1/4 in. foot valve (not included). Hand tighten, then tighten 1/2 turn with a pipe wrench.

1-1/4 in. male PVC adapter

1-1/4 in. Foot valve

4. Remove the pipe clamp and slide a well seal

(not included) over the PVC pipe and onto the well casing. The PVC pipe should extend approximately 12 in. above the top of the well seal, depending on the height of the pump.

NOTE: Do not let the assembly slide down into the well. Tighten the well seal until the rubber gaskets are tight against the well casing and the PVC pipe.

5. Using a 2-step PVC system, attach a 1-1/4 in.

PVC elbow (not included) onto the rigid PVC pipe extending from the well seal.

Well Seal

5 ft. minimum

Approx. 12 in.

1-1/4 in. PVC Elbow

WELL TO PUMP CONNECTION (SUCTION PIPE)

PUMP TO TANk CONNECTION (DISCHARGE PIPE)

6. Wrap thread tape (not included) around the

threads of a 1-1/4 in. male PVC adapter (not included). Thread the adapter into the 1-1/4 in. opening in the front of pump.

7. An optional 1-1/4 in. union (not included)

is recommended for easy connection and disconnection.

1-1/4 in. male PVC adapter

1-1/4 in. Union

1. Wrap thread tape around threads of a 1 in.

discharge tee (not included). Using a pipe wrench, thread the 1 in. discharge tee into the 1 in. opening in the top of pump.

2. Install a 1 in. MPT x 1/4 in. FPT galvanized

bushing and (optional) pressure gauge (both not included), or a pipe plug (not included). Do not tighten, as you will prime pump later at this location.

1 in. Discharge Tee

Pressure Gauge or Pipe Plug with Bushing

8. Using 2-step PVC system, attach 1-1/4 in.

PVC pipe and couplings as needed to connect the 1-1/4 in. male PVC adapter to the 1-1/4 in. PVC elbow attached to the top of the well pipe in Step 5.

NOTE: Be sure the pipe slopes downward slightly from pump to the well to prevent air pockets.

1-1/4 in. PVC Pipe

Well

3. Wrap thread tape around the threads of a 1 in.

male PVC adapter (not included) and thread the adapter into the discharge tee.

4. Continue with 1 in. ttings and pipe to

the pressure tank. An optional 1 in. union (not included) is recommended for easy connection and disconnection.

1 in. male PVC adapter

To pressure tank

1 in. union

TANk TO HOUSE CONNECTION

1. Most pressure tanks will have a 1 in. inlet

elbow on the bottom. Connect to this elbow with a 1 in. MPT x 1 in. slip (glue) adapter and short piece of pipe.

2. Attach a 1 in. elbow (not included) to the pipe.

Glue

Adapter

Pipe

Elbow

5. Attach the pipe from the pump to the tee

installed in Step 4. Then, from the tee, install 3/4 in. pipe and optional shut off valve (not included) to connect tee to house plumbing.

6. IMPORTANT: Air pressure in the tank

must be 2 PSI lower than the “cut-in” of the pressure switch. Pump has a 20/40 PSI pressure switch, so tank pressure must be set at 18 PSI. Locate the air valve/stem on the tank and check pressure with a tire gauge (not included). If air needs to be removed, press down on valve to bleed off air. Use a tire pump or air compressor to add air if needed.

From Pump

Air Valve/Stem

Glue

Shut off valve

To House Plumbing

Tank

Tire gauge

3. Attach a 1 in. pipe (not included) to the elbow and a 1 in. x 3/4 in. reducer bushing (not included) to the pipe.

4. Attach a 3/4 in. pipe (not included) to the

reducer bushing. Install an optional 3/4 in. union (not included) and continue with pipe and 3/4 in. x 3/4 in. x 3/4 in. tee (not included).

1 in. x 3/4 in. Reducer Bushing

1 in. Pipe

Glue

Tee

Glue

Union

3/4 in. pipe

Reducer bushing

PUMP ELECTRICAL CONNECTIONS

WARNING:

• Always disconnect pump from electricity before performing any work on the motor.

• Under-sized wiring can cause motor failure and even re. Use proper wire size specied in the

Wire Size Chart.

• Replace damaged or worn wiring cord immediately.

• Do not kink power cable and never allow the cable to come in contact with oil, grease, hot surfaces, or chemicals.

• The pump must be properly grounded using the proper wire cable with ground.

CAUTION:

• Protect the power cable from coming in contact with sharp objects.

• All wiring should be performed by a qualied

electrician in accordance with the National Electric Code and local electric codes.

• Connect the pump to a separate electrical circuit with a dedicated circuit breaker. Refer to the Wire Size Chart for proper fuse size.

Distance from Motor to Meter

0-50 Ft. 50-100 Ft. 100-150 Ft. 150-200 Ft. 200-300 Ft.

Fuse Size (Amps) (*)

Not economical to run in 115 V, use 230 V

WIRE SIZE CHART

Recommended Copper

Wire and Fuse Sizes Single Phase Motors

1/2 HP

115 Volt 230 Volt

14 12 10

15 15

14 14 14 14 12

PUMP ELECTRICAL CONNECTIONS

Wire from

Ground Screws

Priming plug

Discharge Tee

Vent plug

Vent plug opening

Priming plug opening

PUMP ELECTRICAL CONNECTIONS

Wiring the pressure switch

CAUTION: Make certain that the power source matches the pump requirements. This pump has a dual voltage motor and can run on either 115 V or 230 V.

Pump is pre-set at the factory to run on 230 V.

1. To change pump voltage, remove the square voltage switch cover at the top of pump and move the voltage switch as shown.

2. To connect the pressure switch, remove the switch cover and insert an electrical wire strain relief (not included) into the opening in the side of the pressure switch.

Strain Relief

Pressure Switch

115 V

Setting

230 V

Setting

Wire from motor

5. Connect the green ground wire from the power supply to the remaining green ground screw in the pressure switch and re-attach the pressure switch cover.

PUMP PRIMING AND STARTUP

PRIMING

CAUTION: All pumps must be primed

(lling the cavity with water) before they are rst operated. This may take several gallons of water, as the suction pipe will be lled in

addition to the cavity of pump.

1. Remove pipe plug or pressure gauge (not

included) at the top of the discharge tee and the vent plug in front of the discharge tee.

Wire from power supply

Wire from motor

or pressure

gauge

Vent plug

Suction Pipe

3. Thread the electrical wire (not included) from the power supply through the strain relief and tighten both screws on the strain relief. Do not crush wire.

4. Connect the two wires from the power supply to the two outside terminals on the pressure switch.

Wire from power supply

Outside terminal

motor

Outside terminal

2. Slowly ll the discharge tee with water until

water overows the vent plug opening.

Replace the vent plug loosely.

NOTE: It will take several minutes to fill pump and suction pipe completely.

3. Be sure entire suction pipe is filled when priming. Depending on the length of suction pipe, many gallons will be needed to fill the entire system.

Suction Pipe

PUMP PRIMING AND STARTUP

Water Level

Check for leaks

Suction pipe

Vent Plug

Pressure Gauge or Discharge Tee Plug

Plug

CARE AND MAINTENANCE

4. Check to be sure water in the cavity of pump stays constant. If water level goes down, it could indicate a leak in the foot valve, check valve or suction pipe.

5. Once pump is lled, wrap the pressure

gauge or discharge tee plug and vent plug threads with thread tape and thread into pump. Tighten with wrench.

NOTE: Before turning on breaker, open several

outlets or faucets to allow water ow during

priming.

6. Turn on breaker to start pump.

IMPORTANT: If the pump hums instead

of pumping or turns off repeatedly, shut pump off immediately. Check voltage. Make sure your incoming voltage matches the pump wiring voltage. See PUMP ELECTRICAL CONNECTIONS.

IMPORTANT: If pump fails to prime within

ve minutes:

Turn power off at the breaker box and check all pipe connections for leaks. All connections must be water and air tight in order for pump to operate.

7. Check suction pipe for any sagging. Support suction pipe in a straight line to the pump.

NOTE: Look for leaks or a milky color in the discharged water, which indicates an air leak. Re-prime if necessary, following steps 1 through 6 above. Reset breaker at the breaker box. All connections must be water and air tight in order for pump to operate.

Breaker Box

1 in. Discharge Pipe

To Pressure Tank

1-1/4 in. Suction Pipe

Well

Foot Valve

Winterizing

Vent Plug

CAUTION: Drain the entire system if

there is danger of freezing.

1. To drain pump, remove the drain plug located on the front of pump and the vent plug located on the top of pump.

Drain

WARRANTY

This product is warranted for one year from the date of purchase or two years from the date of manufacture, whichever occurs first. Subject to the conditions hereinafter set forth, the manufacturer will repair or replace to the original consumer, any portion of the product which proves defective due to defective materials or workmanship. To obtain warranty service, contact the dealer from whom the product was purchased. The manufacturer retains the sole right and option to determine whether to repair or replace defective equipment, parts or components. Damage due to conditions beyond the control of the manufacturer is not covered by this warranty.

THIS WARRANTY WILL NOT APPLY: (a) To defects or malfunctions resulting from failure to properly install, operate or maintain the unit in accordance with printed instructions provided; (b) to failures resulting from abuse, accident or negligence or use of inappropriate chemicals or additives in the water; (c) to normal maintenance services and the parts used in connection with such service; (d) to units which are not installed in accordance with normal applicable local codes, ordinances and good trade practices; and (e) the unit is used for purposes other than for what it was designed and manufactured.

RETURN OF WARRANTED COMPONENTS: Any item to be repaired or replaced under this warranty must be returned to the manufacturer at Kendallville, Indiana or such other place as the manufacturer may designate, freight prepaid.

THE WARRANTY PROVIDED HEREIN IS IN LIEU OF ALL OTHER EXPRESS WARRANTIES, AND MAY NOT BE EXTENDED OR MODIFIED BY ANYONE. ANY IMPLIED WARRANTIES SHALL BE LIMITED TO THE PERIOD OF THE LIMITED WARRANTY AND THEREAFTER ALL SUCH IMPLIED WARRANTIES ARE DISCLAIMED AND EXCLUDED. THE MANUFACTURER SHALL NOT, UNDER ANY CIRCUMSTANCES, BE LIABLE FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO DAMAGE TO, OR LOSS OF, OTHER PROPERTY OR EQUIPMENT, LOSS OF PROFITS, INCONVENIENCE , OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY TYPE OR NATURE. THE LIABILITY OF THE MANUFACTURER SHALL NOT EXCEED THE PRICE OF THE PRODUCT UPON WHICH SUCH LIABILITY IS BASED.

This warranty gives you specific legal rights, and you may have other rights which vary from state to state. Some states do not allow limitations on duration of implied warranties or exclusion of incidental or consequential damages, so the above limitations may not apply to you.

FOR YOUR WARRANTY PROTECTION, THE WARRANTY REGISTRATION MUST BE COMPLETED AND RETURNED TO THE WARRANTY INFORMATION CENTER WITHIN TEN DAYS OF INSTALLATION. WARRANTY VALID IN CANADA AND MEXICO.

TROUBLESHOOTING

REPLACEMENT PARTS LIST

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

Little or no discharge

1. Pump is not primed 1. Follow priming instructions (page 13)

2. Suction lift too high or too long 2. Move pump closer to water source. Lift should be less than 25 ft.

3. Hole or air leak in suction line 3. Repair or replace. Use pipe tape and pipe sealing compound

4. Foot valve too small 4. Match foot valve to piping or install one size larger foot valve

5. Foot valve or suction line not

5. Submerge lower in water

submerged deep enough in water

6. Voltage switch incorrect 6. Be sure 115 V or 230 V power supply

matches voltage switch setting on pump

7. Casing gasket leaking 7. Replace

Pump will not deliver water or develop pressure

1. Pump is not primed 1. Follow priming instructions (page 13)

2. Leak in suction line 2. Repair or replace. Pipe dope all

threads

3. Discharge line is closed and priming

air has nowhere to go

3. Open several outlets or faucets during priming procedure

4. Foot valve is leaking 4. Replace foot valve

5. Foot valve not submerged below

5. Lower foot valve and reprime

water level

Pump vibrates and/or makes excessive noise

Pump will not start or run

1. Mounting plate or foundation not rigid

1. Reinforce

enough

2. Foreign material in pump 2. Disassemble pump and clean

3. Impeller damaged 3. Replace

1. Voltage switch incorrect 1. Be sure 115 V or 230 V power supply matches voltage switch setting on motor

2. Blown fuse or open circuit breaker 2. Replace fuse or close circuit breaker

3. Loose or broken wiring 3. Tighten connections, replace broken wiring

4. Stone or foreign object lodged in

impeller

4. Disassemble pump and remove foreign object

5. Thermal overload has opened circuit 5. Allow unit to cool, restart after reason for overload has been determined

For replacement parts, call our customer service department at 1-800-742-5044, 7:30 a.m. - 5 p.m., EST, Monday - Friday.

PART DESCRIPTION PART NO.

B O-rings / Nozzle / Venturi Kit 023735 C Diffuser 023707 D Impeller 023709 E Mechanical Seal 023720 F O-Ring 023721

G Pressure Switch 023722

Star SJ05S User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual