AquaTools AT2407122 User manual

SWIMMING POOL PUMP
O W N E R’ S M A N U A L
INSTALLATION, OPERATION & PARTS
SERIES
Single Speed
3/4 HP 1 HP 1-1/2 HP 2 HP
Vertical Discharge: AT2407122 AT2410122 AT2411120 AT2412610
AT2407120 AT2410120 AT2411122 AT2412630
AT2407140 AT2410140 AT2411140
AT2408540 AT2411630
AT2408610
AT2408630
Horizontal Discharge: AT2307120 AT2310120 AT2311120
AT2307122 AT2310140 AT2311122
AT2310122 AT2311140
AT2308540 AT2415110
Two Speed
Vertical Discharge: AT24102 AT24112 AT24162
AT2408710 AT2411710 AT2412710
Horizontal Discharge: AT23102 AT23112 AT23162
AT23152
Aquatools
293 Wright Street, Delavan, WI 53115
North America: 800-752-0183, FAX [phone]
International: 262-728-5551, FAX: [phone], TELEX: ITT 4970245
© 2008 AT357 (Rev. 7/18/06)
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.
779 0294

2
AQUATOOLS POOL PUMPS
To avoid unneeded service calls, prevent possible injuries, and get the most out
of your pump, READ THIS MANUAL CAREFULLY!
The Aquatools Pool Pumps:
• Are designed to circulate water in above ground swimming pools.
• Are excellent performers; durable, reliable.
• With a 3’ cord or no cord, use with permanently installed pools ONLY
(see CAUTION #7, below).
• With a 25’ cord, use with storable pools ONLY (see CAUTION #8, below).
Table of Contents
Safety Instructions ......................................................................................3
Specifications/Dimensions........................................................................4-5
Installation...............................................................................................6-7
Electrical.....................................................................................................8
Operation ................................................................................................8-9
Pump Service.........................................................................................9-10
Storage/Winterizing...................................................................................11
Troubleshooting Guide..............................................................................12
Repair Parts List ...................................................................................13-15
Warranty...................................................................................................17
IMPORTANT SAFETY INSTRUCTIONS
When installing and using electrical equipment, basic safety precautions should always be followed,
including the following:
1. READ AND FOLLOW ALL SAFETY INSTRUCTIONS.
2. To reduce the risk of injury, do not permit
children to use this product unless they are closely super-
vised at all times.
3. Risk of electrical shock. Connect only to a
grounding type receptacle protected by a ground-fault cir-
cuit-interrupter (GFCI). Contact a qualified electrician if you
cannot verify that the receptacle is protected by a GFCI.
4. Do not bury cord. Locate cord to minimize abuse from
lawn mowers, hedge trimmers, and other equipment.
5. To reduce the risk of electrical shock,
replace a damaged cord immediately.
6. To reduce the risk of electrical shock, do
not use an extension cord to connect unit to electrical sup-
ply; provide a properly located outlet.
7. Permanent pool pumps are for use with per-
manently 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 cannot be readily dis-
assembled for storage. A storable pool is constructed so that
it may be readily disassembled for storage and reassembled
to its original integrity.
8. Storable pool pumps are for use with stor-
able pools only. Do not use with permanently installed
pools. A storable pool is constructed so that it is capable
of being readily disassembled for storage and reassembled
to its original integrity. A permanently installed pool is
constructed in or on the ground, or in a building, such that
it cannot be readily disassembled for storage.

3
READ AND FOLLOW ALL
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 in-
jury, or major property damage if ignored.
warns about hazards that can cause death, serious personal in-
jury, 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 perform all pres-
sure 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 Aquatools trap lids to 30 ft. lbs. (4.1 kg-cm) torque for testing.
•Water pressure for test must be less than 25 PSI (172 kPa).
• 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 Aquatools equipment only. For
non-Aquatools equipment, consult manufacturer.
Sudden motor starts. Motor is equipped with thermal overload
protector which will stop motor if it overheats. Motor may restart without warn-
ing after it has cooled.
Risk of electrical shock. Unplug pump motor before servicing or
repairing pump or motor.

4
SPECIFICATIONS/DIMENSIONS
Table I – Recommended Circuit Breaker Size for 115V 60 Hz Motors
Pump Model Motor Voltage/ Full Load Circuit Breaker
No. H.P. Hz/Phase Amps Rating(Amps)
AT2307122, AT2307120, AT2407120, AT2407122 3/4 115/60/1 9.4 15
AT2310122, AT2310120, AT2410120, AT2410122 1 115/60/1 11.9 15
AT2311122, AT2311120, AT2411120, AT2411122 1-1/2SPL 115/60/1 11.9 15
NOTICE: Values given in table above are for pump motor only. Add the amp draw for any additional accessories in-
stalled on pump motor circuit (heater, blower, etc.) to the listed amp ratings when figuring circuit and circuit breaker
requirements.
23.08
10.12
8.00
4.00
4.25
17.08
7.00
10.69 11.50
1-1/2" NPT
Suction
Ø6.81
8.36
(586)
(257)
(102)
(203)
(434)
(178)
(272) (292)
(Ø173)
(212)
(108)
1-1/2" NPT
Discharge Port
Union Connection
13.09
(333)
7.47
(190)
8.31
(211)
15.31
(389)
4.50
(114)
6.09
(155)
781 0294
Figure 1A: Dimensions In Inches (mm)

5
Table II – Recommended Circuit Breaker Size for 115V 60 Hz Motors - Single Speed
Pump Model Motor Voltage/ Full Load Circuit Breaker
No. H.P. Hz/Phase Amps Rating(Amps)
AT23071, AT24071 3/4 115/60/1 9.0 15
AT23101, AT24101 1 115/60/1 12.0 15
AT2411630, AT23111, AT24111 1-1/2SPL 115/60/1 12.0 15
AT23151, AT24151 1-1/2 115/60/1 16.0 20
AT2408630, AT2408610 1SPL 115/60/1 9.2 15
AT2412610, AT2412630 2SPL 115/60/1 12.0 15
NOTICE: Values given in table above are for pump motor only. Add the amp draw for any addi-
tional accessories installed on pump motor circuit (heater, blower, etc.) to the listed amp ratings
when figuring circuit and circuit breaker requirements.
Table III – Recommended Circuit Breaker Size for 115V 60 Hz Motors - Two Speed
Pump Model Motor Voltage/ Full Load Circuit Breaker
No. H.P. Hz/Phase Amps Rating(Amps)
AT2410220 1 115/60/1 11.0/2.9 15
AT23102, AT24102 1 115/60/1 11.7/3.39 15
AT2408710 1SPL 115/60/1 8.8/2.6 15
AT2411220 1-1/2SPL 115/60/1 11.0/2.9 15
AT23112, AT24112 1-1/2SPL 115/60/1 11.7/3.39 15
AT23152 1-1/2 115/60/1 16.6/3.6 25
AT2411710 1-1/2SPL 115/60/1 11.0/2.9 15
AT23162, AT24162 2SPL 115/60/1 16.6/3.6 25
AT2412710 2SPL 115/60/1 11.0/2.9 15
NOTICE: Values given in table above are for pump motor only. Add the amp draw for any addi-
tional accessories installed on pump motor circuit (heater, blower, etc.) to the listed amp ratings
when figuring circuit and circuit breaker requirements.
Figure 1B: Dimensions In Inches (mm)

6
INSTALLATION
Locate pump as close to pool as possible and not more than 3 feet above pool
water level.
Pipe unions are provided with pump for ease of removal and installation.
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 at or below water level in pool.
• Allow use of short, direct suction pipe (to reduce friction losses).
• Allow for gate valves in suction and discharge piping.
• Have adequate drainage to prevent flooding around equipment.
• Allow adequate ventilation to prevent motor overheating.
• Be protected from excess moisture.
• Allow adequate access for servicing pump and piping.
Use only teflon tape or Plasto-Joint Stik* if it is necessary to use a sealant be-
tween pipe and union adapter. Assemble union collar to pump dry and hand-
tight.
NOTICE: Do not use pipe joint compound with plastics; it causes cracking in
some plastics and may damage components in piping system.
NOTICE: Pump suction and discharge connections have molded in thread
stops. DO NOT try to screw pipe in beyond these stops.
Tighten the pump/trap fittings only as much as it is required to insure a tight
connection (1-1/2 turns past hand tight is sufficient). Overtightening may dam-
age the pump or trap. Use care when using teflon tape as friction is reduced
considerably; do not overtighten connections or you may damage pump or
trap. See Figure 4.
* Lake Chemical Co., Chicago, Illinois
Trap Lid 1-1/2" Discharge Port
1-1/2" NPT
Suction Port
780 0294
748 0993
Don’t Hit
Thread Stops
D
on
’
t
Overtighten
r
om
W
ell Pump
Body
Hand Tight Plus 1-1/2 Turns With Wrench.
Figure 2: Typical Pump/Filter
Installation
Figure 3: Use only teflon tape or
Plasto-Joint Stik on plastic pipe joints.
Figure 4: Be careful when tightening
11
No Air Leaks
in Suction Pipe.
Pipe Joint
Compound Will
Damage Plastic.
If Air Flows
W
ater Won’t
Use Teflon Tape.
Return Line To Pool
To Separation Tank
or Waste
Skimmer
Pool
Water
Pool Drain Line

7
Teflon Taping Instructions:
• Use only new or clean PVC pipe fittings.
• Wrap male threads with one or two layers of teflon tape, winding tape
clockwise as you face the start of the thread. Cover entire threaded portion
of pipe (see Figure 5).
• If leaks occur, remove pipe, clean off old tape, rewrap with one to two ad-
ditional layers of tape and remake the connection.
Piping:
• Use at least 1-1/2" (38mm) pipe. Increase size if a long run is needed. If
pipe larger than 1-1/2" (38mm) is used, connect to pump with 1-1/2" to 2"
(38 to 51mm) reducing adapter at the pump.
• To avoid strains on the pump, support both suction and discharge pipes in-
dependently. Place these supports near the pump. See Figure 6.
• 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 the trap suction connection.
• To avoid airlocking, slope suction pipe slightly upward toward the pump.
See Figure 7.
NOTICE: To prevent flooding when removing pump for service, all flooded
suction systems must have gate valves in suction and discharge pipes.
• Plastic pipe will expand and contract as the temperature changes. To
allow for this, use an expansion joint or flexible piping.
Fittings:
Hazardous suction. Can trap and tear hair or body parts. Can
cause drowning. Use only non-entrapping suction fitting or double suction.
Pool fittings must conform to International Association of Plumbing and
Mechanical Officials (IAPMO) standards.
Fittings restrict flow; for best efficiency use fewest possible fittings.
Avoid fittings which could cause an air trap.
Unions are provided. Use as follows for leak-free connections to pump:
1. O-Ring and sealing surfaces must be clean.
2. Assemble handtight only! (NO WRENCHES!)
3. NO pipe compound or Teflon tape on unions.
4. Bond pipe to unions with PVC cement.
Use PVC cement only in a well ventilated area away from flame;
FOLLOW MANUFACTURER‘S INSTRUCTIONS!
Hazardous suction.
Can trap hair or
body parts, causing
severe injury
or death.
Do not block
suction.
Figure 5: Teflon tape application
Figure 6: Rigid Mount
Support
Pipe Rigid
Mount
765 0294
Figure 7: No Air Pockets
Keep Pipe Straight and Angled up to Pump.
742 0993

8
ELECTRICAL
Plug pump into a grounded, GFCI-protected 115 Volt circuit only.
Incorrect voltage can cause fire or seriously damage motor and voids
warranty.
Risk of electrical shock. Connect only to a grounded type re-
ceptacle protected by a ground-fault circuit-interrupter (GFCI).
GFCI tripping indicates an electrical problem. If GFCI trips and will not
reset, have a qualified electrician inspect and repair electrical system.
Risk of electrical shock. Unplug motor before servicing or re-
pairing pump or motor.
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:
Pump is supplied with grounded 3-wire cord and plug. Do not modify cord or
plug. Plug into GFCI protected, grounded outlet only.
Wiring:
Table I, Page 4, and Table II, Page 5, give correct 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 li-
censed electrician.) Use the load circuit breaker as the master on-off switch.
Plug into a GFCI receptacle on a 115 Volt, 60 Hertz grounded circuit only;
the GFCI will sense a short-circuit to ground and disconnect power before it
becomes dangerous to pool users. For size of GFCI required and test proce-
dures for GFCI, see manufacturer’s instruction.
In case of power outage, check GFCI for tripping (which will prevent normal
pump operation). Reset if necessary.
Do not modify cord, plug or receptacle! If an existing circuit must be used
and the receptacle and factory installed plug do not match exactly, consult a
licensed electrician.
Do not use an extension or drop cord.
Match circuit breaker size to Table I, Page 4, or Table II, Page 5 (depending
on pump model).
OPERATION
Hazardous suction. Can trap and tear hair or body parts. Can
cause drowning. Small children using pool/spa must ALWAYS have close
adult supervision.
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.
If pump is being pressure tested, be sure pressure has been released be-
fore removing trap cover.
Priming Pump
Open gate valves before starting system.
Release all air from filter and piping system: see filter owner’s manual.
Hazardous voltage.
Can shock, burn,
or cause death.
Disconnect power
before working
on pump or motor.

Figure 8: Prime Pump
9
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
(see Figure 8); fill trap and pump with water.
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)! A wrench may be
necessary to remove a stuck lid, but never use a wrench to tighten a 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 within 10 minutes, make sure that all valves are open,
suction pipe end is under water, pump is not trying to lift water more than
3'(1m), and that there are no leaks in suction pipe. See Troubleshooting
Guide, Page 12.
Water:
Keep water level at least two inches above bottom of skimmer opening when
system is not in use. Failure to do so can allow air to enter system, causing
pump to lose its prime.
Keep water temperature at or below 104°F (40°C) for spas and tubs. If in
doubt, start at a lower temperature and gradually increase it according to your
experience.
Keep an accurate thermometer in bath; check it before getting in.
Keep pool water “balanced”; that is, maintain the water’s pH between 7.2 and
7.6.
Do not use or allow the use of the spa/pool by anyone using alcohol or
drugs. The effects of hot water, alcohol and/or drugs can cause dizzi-
ness and falling, loss of consciousness, or heart attack
PUMP SERVICE
Pump should only be serviced by qualified personnel.
For continued protection against possible electric shock, use only iden-
tical replacement parts when servicing.
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.
To avoid dangerous or fatal electrical shock hazard, turn OFF power to
motor before working on pump or motor.
No lubrication of O-Ring or regular maintenance is needed beyond reasonable
care and periodic cleaning of strainer basket.
If shaft seal is worn or damaged, repair as follows:
Pump Disassembly:
1. Unplug motor before servicing or repairing pump or motor.
2. Close all valves in suction and discharge piping.
3. Remove drain plugs from the bottom of pump and trap; drain pump
completely.
4. Disconnect pipe unions (or clamps) on suction and discharge piping. Re-
move hold down bolts and withdraw complete pump/motor/trap assembly.
Too much heat
can cause nausea,
dizziness,
fainting, or death.
Check temperature.
before using tub or spa.

10
5. Remove cap screws (Key No. 16, Page 13) from front plate (Key No. 13).
Remove front plate with trap (Key No. 20) attached. Remove and inspect
O-Ring (Key No. 12).
6. Remove end cap from motor cover.
7. Hold motor shaft with screwdriver in slot in end of motor shaft or 7/16"
wrench on flats on motor shaft; unscrew impeller.
8. Carefully remove rotating half of seal from impeller sleeve. Twist as you
pull; make sure you do not damage surface of sleeve where seal both seats
and seals. See Figure 9.
9. Remove motor throughbolts (see Figure 10). Remove seal plate. Tap sta-
tionary half of seal out of seal plate (see Figure 11).
Pump Assembly:
1. Examine seal cup and O-Rings. Replace anything that shows signs of wear
or damage.
2. Check the shaft seal for scoring, scratches, chips, etc., and for any signs of
damage to spring or retainer. Replace if any wear or damage is visible.
3. Press stationary half of seal into seal plate using finger pressure only (see
Figure 12). Make sure seal is firmly and evenly seated.
4. Install rotating half of seal on impeller sleeve. Push it onto sleeve until it
butts against back of impeller.
5. Insert impeller sleeve through center hole in seal plate. Thread flinger over
the end of the impeller sleeve.
6. If motor has been removed from motor cover, reinstall it now. Set up seal
plate in front of motor cover; hold motor shaft with screwdriver or with
7/16" wrench on shaft flats (under cap) and thread impeller through center
hole in seal plate onto shaft. Make sure that flinger is in place on impeller
sleeve – not loose on shaft.
7. Install motor throughbolts; make sure seal plate butts firmly against motor
endbell. Reinstall end cap on motor cover.
8. Install wear ring on back of Front Plate. NOTICE: Teeth on wear ring inter-
lock with ribs in Front Plate.
9. Install front plate. Tighten cap screws in sequence as shown in Figure 13;
tighten to 30 inch-lbs. (34.5 cm-kg.) torque.
10. Reinstall drain plugs; reinstall pump, motor, and base. Reconnect unions;
tighten hand tight only.
11. Tighten hold-down bolts.
Figure 13 – Torque Sequence with upright discharge (left); with
horizontal discharge (right).
Figure 12
Figure 11
1
4
6
2
5
3
START HERE
604 099
Figure 9
#1
#6
#2
#5 #3
#4
Start
Here
Figure 10