FLOJET 02840100A Operating and installation instructions

2840 Series
RV Water Booster System
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 PSI (2 bar); Others........40 PSI (2.8 bar)
On (-120) 22 PSI (1.5 bar); Others......27 PSI (1.9 bar)
Tank
Total Volume ....................................................1.1 gal. (4.1 It.)
Air Pressure Setting ......................................25 PSI (1.7 bar)
Note: The 12, 24 and 32 VDC models meet the USCG Electrical
Requirement (Title 33, Chapter I, Part 183, Subpart 1). All
pumphead wetted materials meet IAPMO 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
Inches (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 Tank Diaphragm Material.............................Butyl
Liner Material........................Polypropylene
Ports....................3/4” (19 mm) HB Inlet
...................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)
Model 2840 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. If 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) I.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 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.
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
IMPORTANT - For correct operation, the tank must be
properly pressurized on the air side beforepump 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
Tank
Autofill Tank Valve,
Plumb to Tank
Check
Valve
Water Pressure
System
Water
Heater
Do Not Plumb Autofill
to Pump Suction Line
Vertical Horizontal
DO NOT USE PUMP IN A FLAMMABLE
ENVIRONMENT DO NOT USE TO PUMP
FLAMMABLE OR EXPLOSIVE FLUIDS
SUCH AS GASOLINE, FUEL OIL,
KEROSENE, ETC.
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 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.
5. 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
(3-13) 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).
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: DISCONNECT POWER TO PUMP AND OPEN VALVE TO
RELIEVE WATER PRESSURE PRIOR TO 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 PSI 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, Inline 3/4” Hose Barb 1
Key Part No. Description Qty
0 20409-043 Service Kit*
1 20404-003 Upper Housing Assy Kit 1
220407-030 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
502009-080A 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
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
• Inlet line valve closed • Open valve
Motor runs too hot • Voltage incorrect • Check voltage
• Insufficient ventilation for motor • Insure 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
TO CONVERTTO 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
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