FLOJET R4515-743 User manual

Models R4515-743
Models R4525-743
Variable Speed Water System
SENSOR VSD™
WATER SYSTEM
FEATURES
• Variable Speed Control
• Solid State Pressure Sensor
• Nearly Silent Operation / No Cycling
• Operates on 12Vdc or 24Vdc
• Controls Pressure by Changing
Motor Speed
• Speeds Up As Demand Increases
• Self-priming / Runs Dry
• No Accumulator Tank Needed
• CSA Listed / EN ISO 8846 Marine /
C.E. Certified
• Patent Pending
SPECIFICATIONS
Motor: Permanent magnet, double ball bearing arma-
ture. Electronic speed control built into rear
endbell.
Pump: Four chamber positive displacement
diaphragm design. Self-priming up to 10 feet
suction lift. Pump able to run dry without
damage. Removable port adapters.
Mount the pump in a dry, ventilated location. The inlet
strainer must be installed between the fresh water
supply and the pump inlet port. The supply tank should
be at least half full prior to initial operation.
IMPORTANT: Polarity of electrical connections is very
important. Insure that the RED (+) motor lead is
connected to a fused positive d.c. circuit. The BLACK (-)
motor lead must be connected to the negative DC
circuit. In the event that polarity is reversed fuse found in
the “EMI Filter Box” must be replaced.
Sensor VSD™ pumps require a battery to be installed
in the DC power supply when using an AC to DC
converter or battery charging system.
To prime the plumbing system, open all the faucets and
turn on the power to the pump. Shut off each faucet as
it begins to run free of air. As the last faucet is closed the
pump will slow down and shut off.
OPERATION
AUTOMATIC VARIABLE SPEED MOTOR DRIVEN
Pump Series Dimensions - Inches (mm) Weight
Height Width Length lb. (kg)
R4515-743 3.75 (95) 6.3 (160) 9.0 (221) 4.3 (2)
R4525-743 3.75 (95) 6.3 (160) 10.3 (252) 6.3 (3)
Amp Draw Max Flow Sensor Cut-out Inlet
Model Volts (24V) Fuse GPM (LPM) Pressure Pressure Strainer
R4515-743 12-24Vdc 8.0 (4.0) 15A 3.7 (13.5) 25 (1.7 bar) 35 psi (2.4 bar) Yes
R4525-743 12-24Vdc 12.0 (6.0) 15A 4.5 (16.3) 30 (2.1 bar) 40 psi (2.8 bar) Yes
Models R4515-743 & R4525-743

STEP 1
Remove the shipping plugs from the Quad pump ports.
Some water from factory testing may spill out.
STEP 2
Install both the A. inlet and B. outlet port adapters as
shown in the figure above or install strainer on inlet A.
Firmly push C. slide clips forward to lock adapters in place.
STEP 3
Push the 4 rubber grommets into base plate mounting
holes, where a base plate is used.
STEP 4
Mount pump horizontally, or vertically with the pump-
head lower than the motor. Any plumbing leak should
not drip on the motor.
STEP 5
3/4" I.D. hose may be used (preferably braided or
reinforced) to isolate pump from plumbing system.
1/2" I.D. hose may be used on 3.5 GPM model. Use
hose clamps on hose barb connectors.
STEP 6 (OPTION)
Install a 40 mesh in-line strainer in an accessible location
between the supply and the pump inlet A.
INSTALLATION
The Automatic Variable Speed Motor Driven Pumps will
operate in either a 12 or 24 volt dc system. The unique
electronics adjust the voltage and current to the motor as
needed.
STEP 1
Use 14 AWG stranded wire to 20 feet, 12 AWG to 50 feet
from distribution panel or power source.
STEP 2
Install a 15 amp rated on-off switch on the positive (+)
lead from the power source.
STEP 3
Use a 15A fuse/breaker in the circuit at the distribution
panel.
WIRING
Red (+)
(+)
Switch
EMI
Filter Box
15 Amp
Automotive
Fuse Inside
Battery
(–)
Black (–)
City Water
Inlet
Water
Tank
Check
Valve
Do Not Plumb Autofill
to Pump Suction Line
Water
Heater
Flojet Inlet
Strainer
Autofill Tank Valve,
Plumb to Tank
B
A
C

DISASSEMBLE
Pressure Sensor
1. Remove cover and lift up clip (1a) to unplug the sensor.
Remove sensor housing
Upper Housing
2. Loosen but do not remove the four pump head screws
and carefully remove the upper housing assembly (1b).
3. Inspect the B/F valve in center behind sensor for debris.
4. Change the four ferrules sealing the screws.
Check Valve Assembly
5. Inspect the valve flappers for debris and resilience.
6. Replace if necessary.
Lower Housing, Diaphragm, Motor
7. Remove mounting feet to expose notches. Rotate the
lower housing (4) so notch opening exposes set screw
that holds bearing housing to motor shaft.
8. Loosen the set screw with an 1/8" Allen wrench inserted
through the notch opening. Finally, slide lower housing (4)
off motor shaft.
Diaphragm Cont’d
9. Remove four piston screws from cam bearing assembly
using a Phillips screw driver and pull apart cam bearing
assembly from inner pistons.
Motor Cont’d
10. Test motor by very carefully connecting red wire to posi-
tive (+) and black wire to negative ground (-) of a 12 or
24Vdc battery. Motor will run full speed and slow as sen-
sor is brought closer to a magnet’s south pole. Replace if
necessary.
REASSEMBLE
Motor
1. Assemble lower housing assembly (4) to motor. (Follow
steps 4 to 10.)
Diaphragm
2. Diaphragm (3) and lower housing (4) are assembled in
this way:
• Four black inner piston facing stem up on a flat surface,
diaphragm flat side up with piston stems through
diaphragm.
2. • White outer piston must be folded to insert into lower
housing, flat side up.
2. • Hex stem of inner pistons must align with hex holes in
outer pistons.
2. • Outer pistons must be aligned with alignment slots on
the cam bearing assembly.
2. • Drive each Phillips head screw partially tight, carefully
center each piston in its quadrant, and then tighten the
screws securely (18 in. lbs. torque).
Lower Housing
3. Attach lower housing to motor shaft by aligning indention
in shaft with set screw. Set screw must align with the
shaft indention or major damage, poor performance or
high amp draw may result.
Upper Housing, Check Valves
4. View the inside of the upper housing (1) and seat the four
ferrules in the pump head screw recesses.
5. Carefully seat the O-ring in the check valve assembly
(O-ring must not slip out of the check valve recess.)
6. Install check valve assembly into upper housing, pressing
firmly. Start the four pump head screws, turning by hand
through the ferrule seals, then push through about 11⁄2".
7. Assembly on to lower housing (4), align four screws to
motor by rotating lower housing if necessary to align feet.
8. Tighten pump head screws evenly to a watertight
30 in. lbs. torque.
Pressure Sensor
9. Place sensor housing (1a) and sealing disk against upper
housing (1b), insert screws and take care not to cross
thread or strip out threads in upper housing.
10. Slide the sensor under the clip on the sensor housing,
and install the cover.
21b1a
48
3 5
VARIABLE SPEED WATER PUMP SERVICE PARTS
Key Description Model #4515-743 Model #4525-743
0 Service Kit* 20409-043 20409-043
1 Upper Housing with Sensor Housing 20404-027 20404-028
2 Check Valve Assembly 20407-030 20407-030
3 Diaphragm Assembly (includes screws) 20403-040 20403-040
4 Lower Housing Assembly 20419-002 20419-002
5 Motors with Sensor R2009-128A R2009-127A
7 Pump Head Assembly 20406-037A 20406-038A
8 Side Clips (pair) 20408-000 20408-000
*Service Kit includes #2, #3, #8 and drive cam assembly.

Pump Series
R4515-743
R4525-743
Strainer Number
1740-012
1740-002
1740-004
1740-014
1740-000
1740-004
1740-014
Inlet
1/2 Barb
1/2 Barb
1/2 M Qest
1/2 M Qest
3/4 Barb
1/2 M Qest
1/2 M Qest
Outlet
Quad Port
1/2 Barb
1/2 M Qest
Quad Port
3/4 Barb
1/2 M Qest
Quad Port
Screen
40 Mesh
40 Mesh
40 Mesh
40 Mesh
40 Mesh
40 Mesh
40 Mesh
STRAINERS
ACCESSORIES
20381-000
QUAD PORT x
1/2" MALE QEST.
STRAIGHT
20381-002
QUAD PORT x
1/2" HOSE BARB
STRAIGHT
20381-006
QUAD PORT x
3/4" HOSE BARB
STRAIGHT
20381-007
QUAD PORT x
GARDEN HOSE
STRAIGHT
20381-008
QUAD PORT x
1/2" MALE QEST.
90°ELBOW
20381-009
QUAD PORT x
1/2" HOSE BARB
90°ELBOW
20381-010
QUAD PORT x
3/4" HOSE BARB
90°ELBOW
Quick Connect
Port System
UNITED KINGDOM
Jabsco/Flojet
Bingley Road, Hoddesdon
Hertfordshire EN11 OBU
Tel: [phone]
Fax: [phone]
CANADA
Fluid Products Canada
55 Royal Road
Guelph, Ontario N1H 1T1
Tel: [phone]
Fax: [phone]
JAPAN
NHK Jabsco Company Ltd.
3-21-10, Shin-Yokohama
Kohoku-Ku, Yokohama, 222
Tel: [phone]
Fax: [phone]
U.S.A.
Flojet
20 Icon
Foothill Ranch, CA 92610-3000
Tel: [phone]
Fax: [phone]
GERMANY
Jabsco GmbH
Oststrasse 28
22844 Norderstedt
Tel: [phone]
Fax: [phone]
10/11643-00018:mroFdevreseRsthgiRllA.A.S.UnidetnirP1002thgirypoC©
Failure to Prime - Motor operates, but no water flows
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• Defective check valve assembly: Replace check valve assembly
gnibmulptcepsni,spmalcllanethgiT:enilekatninikaelriA•
• Restricted intake or discharge line: Remove lines and inspect
• Punctured diaphragm (pump leaks): Replace lower housing assembly
• Crack in pump housing (pump leaks): Replace housing or pump head
pmupotfforewopnrutrollifeR:knatylppusretawytpmE•
Motor fails to run
rekaerbroesuf,gniriwkcehC:rewoponsahtiucricpmuP•
• Loose or corroded wiring connection: Inspect wire connections
teserroecalpeR:rekaerbneporoesufnwolB•
• Open thermal protector (motor shell hot): Wait 20 to 30 minutes for auto reset
• Defective motor, drive control or pressure sensor: Contact factory, 1-800-2FLOJET
Pump fails to turn off after all fixtures are closed
llifeR:knatylppusretawytpmE•
pmupottsesolctecuafnepO:pmupnideppartriA•
tcepsnidnagnisuoh-reppuevomeR:pmupnisirbeD•
• Defective check valve assembly: Replace check valve assembly
• Punctured diaphragm (pump leaks): Replace lower housing assembly
skaelrofgnibmulptcepsnI:kaelenilegrahcsiD•
Low flow or pressure
neercsnaelcdnarevocevomeR:reniartstelninisirbeD•
egdirtracretlifecalpeR:gnign
ahcsdeenretlifretaW•
• Under size plumbing or long runs: Increase plumbing I.D.
• Defective motor, drive control or Contact factory, 1-800-2FLOJET
pressure sensor:
TROUBLESHOOTING
WARNING: BEFORE SERVICING PUMP, TURN OFF POWER TO PUMP AND DRAIN SYSTEM!!
WARRANTY
FLOJET warrants this product to be free of defects in material
and/or workmanship for a period of two years after purchase by
the customer from FLOJET. During this two 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. If 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 out-
side 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.