FLOJET 2840 Series Operating and installation instructions

PERFORMANCE SPECIFICATIONS
Pump
Motor Max Amp Draw (A)
(-100) 10.0 @ 12 Vdc
(-110) 8.5 @ 12 Vdc
(-120) 7.0 @ 12 Vdc
(-300) 5.0 @ 24 Vdc
(-400) 3.8 @ 32 Vdc
(-000) 1.5 @115 Vac
Priming ................Dry........................................................10 ft (3 M)
Wet.......................................................20 ft (6 M)
Flow Rate ..........Max...............................(-110) 3.5 GPM (13 LPM)
Max...............................(-120) 3.3 GPM (12 LPM)
Max...........................................4.5 GPM (Others)
Pressure Switch Off (-120) 35 PS (2 bar); Others........40 PS (2.8 bar)
On (-120) 22 PS (1.5 bar); Others......27 PS (1.9 bar)
ank
otal Volume ....................................................1.1 gal. (4.1 t.)
Air Pressure Setting ......................................25 PS (1.7 bar)
Note: The 12, 24 and 32 VDC models meet the USCG Electrical
Requirement (Title 33, Chapter , Part 183, Subpart 1). All
pumphead wetted materials meet APMO TSC-14-90 and TSC
31- 90 for potable water.
Models are available in 12 and 24 Volt models, and are
identified
by a prefix “R” and a CE mark on the label (i.e. R2840-100). Self
Declaration Of Conformance (SDOC) is available upon request.
10 1/4
(260)
10 1/4
(260)
1/2
(13)
10 1/4
(260)
11 1/4
(286)
7 13/16
(198)
7 13/16
(198)
4 3/16
(106)
7 1/2
(191)
7 1/2
(191)
12 7/8
(327)
40
(2.8)
35
(2.4)
30
(2.1)
25
(1.7)
20
(1.4)
15
(1.0
10
(0.7)
5
(0.4)
0

1.0
(3.8)

2.0
(7.6)

3.0
(11.4)

4.0
(15.1)

5.0
(18.9)
6.0
(22.7)
7.0
(26.5)
8.0
(30.3)
Flow in GPM (LPM)
Pressure on PSI (bar)

Pump &
Fully Charged
Tank
27 PSI Cut-In Pressure
Pump
Only
INSTALLATION & SERVICE INFORMATION
Dimensional Drawing
nches (Millimeters)
Description
The FLOJET 2840 Series Water Booster System is designed to
provide steady water pressure and generous water flow. 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. Typically used in large yachts, motor
homes & bus conversions where high volume flow is required for
multiple fixtures and amenities (e.g. washing machine,
dishwasher, ice maker and water purifier).
Product Data
Pump Design ..............................................Quad Diaphragm
Motor ...............................................Permanent Magnet TENV
Wetted Parts ......Diaphragm Material...................Santoprene
Check Valve Material..........................EPDM
Housing Material...................Polypropylene
Accumulator ank Diaphragm Material.............................Butyl
Liner Material........................Polypropylene
Ports....................3/4” (19 mm) HB nlet
...................1/2” (13 mm) HB Outlet
Net Weight ........2840-100 Type................8.8 Pounds (4 kgs)
2840-110 Type.............7.3 Pounds (3.3 kgs)
2840-120 Type.............6.9 Pounds (3.1 kgs)
2840 SERIES RV/MARINE
WATER BOOSTER SYSTEM

Protect yourself and others by observing all safety
information. Shut off power and drain pressure from
system prior to service.
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 deck or bulkhead mounted. f bulkhead
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” (19 mm) .D. hose between
pump inlet & strainer. Connect strainer inlet to water
supply line from tank and clamp all hose connections
securely to avoid air leaks.
City water supply may be connected at any location in
the pressurized cold water line.
GENERAL SAFETY INFORMATION ELECTRICAL
RISK OF AN ELEC RICAL 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 PRODUC DAMAGE!
Make certain the power source conforms to the pump
voltage. Be sure all power is disconnected before
installation or removal.
For 12 VDC, 24 VDC and 32 VDC models, the red wire is
positive and black is negative. 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 115 VAC models plug AC cord into a conventional
115V AC outlet.
OPERATION
IMPOR AN - For correct operation, the tank must be
properly pressurized on the air side before pump is
started. Follow instructions on the tank label and check
air pressure after filling and before starting the pump.
The air valve is 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.
To start up the Water Pressure System, make sure water
supply tank is at least 1/4th full and is open to pump
inlet. 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 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.
City Water
Inlet
Water
Ta n k
Autofill Tank Valve,
Plumb to Tank
Check
Valve
Water Pressure
System
Water
Heater
Do Not Plumb Autofill
to Pump Suction Line
Vertical Horizontal
DO NO USE PUMP IN A FLAMMABLE
ENVIRONMEN DO NO USE O PUMP
FLAMMABLE OR EXPLOSIVE FLUIDS
SUCH AS GASOLINE, FUEL OIL,
KEROSENE, E C.
WARNING
WARNING

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 N CENTER OF SW TCH.
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.
5. Remove Check Valve (2) and inspect for debris.
Check Valve Assembly (2) Follow Steps 1, 3 & 4
6. nspect 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 nner Pistons (3-A). (Both
pistons (3-A & C) should be replaced when a new Diaphragm
(3-13) is installed.)
Motor (5) Follow Steps 1, 7, 8 & 9
REASSEMBLE
Diaphragm (3-B)
1. nsert 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 nner Piston (3-A)
through the Diaphragm and Lower Housing (4-A) into Outer
Piston (3-C). Hex stem of nner 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 nner 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).
5. 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.
WARNING: DISCONNEC POWER O PUMP AND OPEN VALVE O
RELIEVE WA ER PRESSURE PRIOR O SERVICING PUMP
2
1
4
6
9
3
A
5
B
A
BC
D
C
7Includes items 1 thru 4
8
Key Part No. Description Qty
“ 120796-000A Base 1
6 20381-022 Port Kit - (set of 2)
Hose Barb, 90° 3/4” 1
Hose Barb, Straight 3/4” 1
7 20406-002A Pump Head Assy. 1
8 20408-000 Port Clips (Set of 2) 1
9 02090-118 Pressure Switch - 40 PS Off, Sealed 1
“ 04325-143A Complete MPU w/Strainer - 12V 4.5 GPM 1
“ 04305-144A Complete MPU w/Strainer - 12V 3.5 GPM 1
“ 04305-500A Complete MPU w/Strainer - 12V 3.3 GPM 1
“ 04325-343A Complete MPU w/Strainer - 24V 4.5 GPM 1
“ 04325-443A Complete MPU w/Strainer - 32V 4.5 GPM 1
“ 04325-043A Complete MPU w/Strainer - 115V 4.5 GPM 1
“ 01740-000 Strainer, nline 3/4” Hose Barb 1
Key Part No. Description Qty
0 20409-043 Service Kit*
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 20419-002 Lower Housing 1
5 02009-080A Motor 12 Volt DC 2840-100 1
02009-087A Motor 12 Volt DC 2840-110 1
02009-073A Motor 12 Volt DC 2840-120 1
02019-027A Motor 24 Volt DC 2840-300 1
02049-026A Motor 32 Volt DC 2840-400 1
02029-091A Motor 115 Volt AC 2840-000 1
“ 20799-000A Accumulator Tank 1
*Service Kit includes #2, #3, #8 and drive cam assembly.
!!

TROUBLESHOOTING CHART
CONVERSION TABLE
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 in material or workmanship,
with a new or reconditioned product, but not to include costs of
removal or installation.
This is only an overview of our limited warranty. f you would like a
copy of our warranty, please call or write FLOJET.
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 authori zation number. nclude your name, address and
phone number.
Symptom Possible Cause(s) Corrective Action
Pump will not prime or retain • Air leak in suction line • Repair or replace
prime after operating • Defective check valve • Replace
• Upper housing leaking • Tighten bolts
• Suction lift too high • Lower pump
• Debris in check valve(s) • Clean check valve(s)
Pump runs but no fluid • Faulty suction piping • Repair or replace
• Defective check valve • Replace
• Suction lift too high • Lower pump
• Clogged inlet • Clean or replace
• nlet line valve closed • Open valve
Motor runs too hot • Voltage incorrect • Check voltage
• nsufficient ventilation for motor • nsure proper ventilation
Flow rate is low • Piping or hose is damaged • Clean or replace
• Clogged check valve • Clear obstruction
• Worn check valve • Replace
• Voltage incorrect • Check voltage
• Tank over pressurized • Check tank pressure
Pump leaks • Upper housing loose • Tighten screws
• Pistons loose • Tighten pistons
• Pump head loose on motor • Tighten pump head
• Switch loose • Tighten switch
• Defective Diaphragm • Replace
Pump will not run • No electricity • Check connections, fuse, breakers
• Defective pressure switch • Replace switch
• Motor has open circuit • Replace
• Thermal protector has cut off • Allow motor to cool 15-30 min
O CONVER O MUL IPLY BY
Gallons, U.S. Liters 3.785
Liters Gallons, U.S. 0.264
Pounds/Sq. nch Bar 0.069
Bar Pounds/Sq. nch 14.5
Fahrenheit Celsius (°F-32) .556
Celsius Fahrenheit (°C X 1.8) + 32
Flojet is a trademark of X lem Inc. or one of its subsidiaries.
© 2012 X lem, Inc. 81000-290 Rev F 10/2012
www.flojet.com
U.S.A.
Flojet
17942 Cowan Avenue
rvine, CA 92614
Phone: [phone]
Fax: [phone]
UN TED K NGDOM
Flojet
Bingley Road, Hoddesdon
Hertfordshire EN11 OBU
Tel: [phone]
Fax: [phone]
JAPAN
NHK Jabsco Company Ltd.
3-21-10, Shin-Yokohama
Kohoku-Ku, Yokohama, 222
Tel: [phone]
Fax: [phone]
GERMANY
Jabsco GmbH
Oststrasse 28
22840 Norderstedt
Tel: [phone]
Fax: [phone]
TALY
Jabsco Marine talia
Via Tommaseo, 6
20059 Vimercate, Milano
Tel: [phone]
Fax: [phone]