Flotec EP2-04 User manual

Installation/Operation/Parts
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Instalación/Operación/Piezas
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©2004 253P6360 (11/10/04)
OWNER’S MANUAL
50 Hz. Peripheral Vane
Booster System
NOTICE D’UTILISATION
50 Hz Pompe de surpression
à ailettes périphériques
MANUAL DEL USUARIO
50 Hz Sistema de bomba
de sobrepresión de
paletas periféricas
4546 0304
MOD. EP2-04
®
P.O. Box 342, Delavan, WI 53115
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web Site: http://www.flotecwater.com

Safety 2
For parts or assistance, call Flotec Customer Service at 1-262-728-5551
READ AND FOLLOW
SAFETY INSTRUCTIONS!
This is the safety alert symbol. When you see this
symbol on your pump 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 serious
personal injury, death or major property damage if
ignored.
warns about hazards that can cause serious
personal injury, death or major property damage if
ignored.
warns about hazards that will or can cause
minor personal injury or property damage if ignored.
The label NOTICE indicates special instructions which
are important but not related to hazards.
Carefully read and follow all safety instructions in this
manual and on pump.
Keep safety labels in good
condition.
Replace missing or dam-
aged safety labels.
Ground motor before
connecting to power
supply.
Meet all codes that
apply for all wiring.
ELECTRICAL SAFETY
Capacitor voltage may be hazardous. To
discharge motor capacitor, hold insulated handle screw-
driver BY THE HANDLE and short capacitor terminals
together. Do not touch metal screwdriver blade or capac-
itor terminals. If in doubt, consult a qualified electrician.
GENERAL SAFETY
Do not touch an operating motor. Modern
motors may operate at high temperatures. To avoid burns
when servicing pump, allow it to cool for 20 minutes
after shut-down before handling.
Do not allow pump or any system component to freeze.
To do so will void warranty.
Pump water only with this pump.
Periodically inspect pump and system components.
Wear safety glasses at all times when working on pumps.
Keep work area clean, uncluttered and properly lighted;
store properly all unused tools and equipment.
Keep visitors at a safe distance from the work areas.
Pump body may explode if used as a boost-
er pump unless relief valve capable of passing full pump
flow at 5 Bars (75 psi) is installed.
PERIPHERAL VANE BOOSTER PUMP
INSTALLATIONS:
•Have a vertical depth between the pump and the
water being pumped of 16’ (5m) or less.
•Have one pipe from the well to the pump case.
REPLACING AN OLD PUMP
Hazardous voltage. Disconnect power to
pump before working on the pump or motor.
1. Drain and remove the old pump. Check the old pipe
for scale, lime, rust, etc., and replace it if necessary.
2. Install the pump in the system. Make sure that all
pipe joints in the suction pipe are air-tight as well as
water tight. If the suction pipe can suck air, the
pump cannot lift water from the water source.
3. Adjust the pump mounting height so that the plumb-
ing connections do not put a strain on the pump
body. Support the pipe so that the pump body does
not take the weight of piping or fittings.
You have just completed the suction pipe plumbing for
your new peripheral vane pump. Please go to Page 4 for
discharge pipe and tank connections.
WARNING
Hazardous voltage. Can
shock, burn, or cause death.
Ground pump before connecting
to power supply. Disconnect
power before working on pump,
motor or tank.
WARNING
Hazardous pressure!
Install pressure relief
valve in discharge pipe.
Release all pressure on
system before working on
any component.

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Installation 3
INSTALLATION FOR SURFACE WATER
OR CISTERN (FIGURE 1)
1. The pump should be installed as close to the water
as possible, with the fewest possible fittings (espe-
cially elbows) in the suction pipe. The suction pipe
should be at least as large as the suction port on the
pump.
2. Assemble a foot valve and suction pipe (see Figure
1). Make sure that the foot valve works freely. Use
teflon tape on threaded pipe joints. Protect the foot
valve assembly from fish, trash, etc, by installing a
screen around it (see Figure 1).
3. Lower the pipe into the water until the strainer is five
feet above the bottom. It should also be at least
1-1/2 feet (.5m) below the water level in order to
prevent the pump from sucking air.
4. Install a priming tee, priming plug, and suction pipe
on the pump (see Figure 1). Support the pipe so that
there are no dips or sags in the pipe, so it doesn’t
strain the pump body, and so that it slopes slightly
upward from the water source to the pump (high
spots can cause air pockets which can air lock the
pump). Seal the suction pipe joints with teflon tape.
Joints must be air-tight and water-tight. If the suction
pipe can suck air, the pump cannot lift water from
the water source.
You have just completed the suction pipe plumbing for
your new peripheral vane pump. Please go to Page 4
for discharge pipe connections.
Circuit
Breaker
Box
115 VAC
115VAC
Hot
Hot - Brown
Neutral
Neutral
Neutral - Black
City Water Inlet
NOTE: If the pump is connected
directly to the city water line,
install a Flow Switch or
Low Pressure Cutoff if service
may be interrupted.
Float Switch:
Up = On
Down = Off
Foot Valve
Cistern
Pump
Circuit
Breaker
Box
Neutral
Neutral – Black
Cistern Float
Switch
Hot
Pump
Hot – Brown
Wiring Connections – Schematic
Pressure
Switch
Pressure
Tank
Pressure
Switch
Snifter Valve
4579 0404
Priming Tee
Float Valve
Figure 1 – Surface Water or Cistern Installation.

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Installation / Electrical 4
DISCHARGE PIPE CONNECTION
(FIGURE 2)
Connect the 5-way tank tee to your plumbing system.
ELECTRICAL
Hazardous voltage. Risk of dangerous or
fatal electric shock. Plug the pump into a 115 Volt, 60
Cycle, Ground Fault Circuit Interrupter (GFCI) protect-
ed grounded outlet only. The pump is equipped with a
3-wire, grounded, cord and plug. Do not modify or
remove the plug. Make sure the pump circuit meets all
codes and ordinances that apply. To avoid dangerous
electrical shock hazard, keep the cord dry at all times.
Lubrication
The motor is lubricated at the factory for the life of
the bearings. The pump seal is water cooled and self
lubricating.
Pump Service
Hazardous voltage. Can shock, burn, or
cause death. Unplug the pump before servicing it. Do not
handle the pump or attempt to work on the pump with
wet hands or while standing on a wet or damp floor.
The motor has an auto-reset thermal overload protector.
If the motor overheats, the overload will cut off the
power to prevent damage and will reset after the motor
cools. If the overload trips repeatedly, check the pump
for the cause (low voltage, a clogged impeller, etc.).
Sealing Pipe Joints
Use only teflon tape for making all threaded connections to the pump itself. Do not use pipe joint compounds
on plastic: they can react with the plastic. Make sure that all pipe joints in the suction pipe are air tight as well
as water tight. If the suction pipe can suck air, the pump will not be able to pull water from the water source.
4555 0304
Pressure
Gauge
1" PipeTo
Household
Water System
Check Valve
(Purchase
Separately)
1" Pipe From
Water Source
Foot Valve
Water Level
Pressure
Switch
5-Way Tank Tee
Adapter
Pump Intake
Port
Discharge
Port
Priming
Port
Priming
Tee
Flow
Flow
Tank
Snifter Valve
Figure 2 – Suction and discharge connections for Model
EP2-04.
Volts/ Maximum Branch Distance in Feet (m) from Motor To Supply
Hz./ Load Circuit Breaker Wires Sizes AWG (mm2)
Model Phase Amps Rating (Amps)* 0-100 (0-30) 101-200 (31-61) 201-300 (62-91) 301-400 (92-122)
EP2-04 115/50/1 5.8 15 14 (2) 14 (2) 12 (3) 10 (5.5)
WIRING CHART – RECOMMENDED WIRE AND FUSE SIZES
* When using fuses, dual element or Fusetron time delay fuses are recommended for all motor circuits.

Electrical 5
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How To Set the Pressure Switch
Step 1: Unplug the pump and prime it (see Page 6 for
priming instructions).
Step 2: Loosen the Differential Pressure Nut until there
is no tension on the spring.
Step 3A: Plug in the pump. The pump should start, pres-
surize the system, and stop when the pressure
gauge reads 2.6 to 3.6 Bars (37 to 52 psi).
Step 3B: When the pump stops, open a faucet to bleed
pressure off the system. Watch the pressure
gauge and note the pressure when the pump
starts.
Step 3C: Unplug the pump and adjust the Minimum
Operating Nut.
Step 3D: Repeat steps 3A, 3B, and 3C until the pump
starts at 1.6 to 1.7 Bars (23 to 25 psi) on the
pressure gauge.
Step 4A: With pressure on the system, open a faucet to
bleed pressure off the system until the pump
starts. Close the faucet, watch the pressure
gauge, and note the pressure when the pump
stops.
Step 4B: Unplug the pump and adjust the Differential
Pressure Nut.
Step 4C: Plug in the pump and repeat steps 4A and 4B,
until the pump stops at 2.2 to 4.2 Bars (32 to
62 psi) on the pressure gauge.
NOTE: The total pressure MUST NOT exceed 5
Bars.
Step 5: With the pump plugged in, open a faucet to
bleed off pressure in the system. When the
pump starts, close the faucet and wait for the
pump to stop. As the pump runs through one
complete pressure cycle, check its operation
and its starting and stopping pressures.
Replace the pressure switch cover and the
pump is ready for operation.
2
4589 0504
3Increase
Pressure
Decrease
Pressure
6
0
1
234
5
BARS
Pressure Tank
Pre-Charge
1.5 Bars
(22 psi)
Pressure Switch Start
Setting 1.6-1.7 Bars
(23-25 psi)
To household
Water System Check
Valve Priming
Tee
1
4
2.2 4.2
6
0
1
234
5
BARS
(32 psi) (62 psi)

Operation 6
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PRIMING / OPERATION
Never run pump dry. Running pump with-
out water may cause it to overheat, damaging the seal
and possibly causing burns to persons handling the
pump. Fill the pump with water before starting.
Never run the pump with the discharge
closed. To do so can boil water inside the pump, caus-
ing hazardous pressure in the unit, risk of explosion,
and possibly scalding persons handling the pump.
Cistern Installation
1. Remove the priming plug from the priming port. Fill
the pump from the tee and let it vent through the
port. Fill all piping between the pump and the water
source and make sure that all vertical suction piping
is full.
2. Replace all priming plugs (use teflon tape).
3. Power on! Start the pump. If you don’t have water in
2 minutes, stop the pump and remove the fill plugs.
Refill the pump and piping. You may have to repeat
this several times in order to remove all the trapped
air from the piping. A pump lifting water 15’ (4.5m)
may take as long as 15 minutes to prime.
4. After the pump has built up pressure in the system
and shut off, check the pressure switch operation by
opening a faucet or two and running enough water
out to bleed off pressure until the pump starts. The
pump should start when pressure drops to 1.6 Bars
(22 psi) and stop when pressure reaches 2.2 to 4.2
Bars (32 to 62 psi), depending on the setting (Step 4,
Page 5). Run the pump through one or two complete
cycles to verify correct operation. This will also help
clean the system of dirt and scale dislodged during
installation.
Circuit
Breaker
Box
115 VAC
115VAC
Hot
Hot - Brown
Neutral
Neutral
Neutral - Black
City Water Inlet
NOTE: If the pump is connected
directly to the city water line,
install a Flow Switch or
Low Pressure Cutoff if service
may be interrupted.
Float Switch:
Up = On
Down = Off
Foot Valve
Cistern
Pump
Circuit
Breaker
Box
Neutral
Neutral – Black
Cistern Float
Switch
Hot
Pump
Hot – Brown
Wiring Connections – Schematic
Pressure
Switch
Pressure
Tank
Pressure
Switch
Snifter Valve
4579 0404
Priming Tee
Float Valve
Figure 4 – Cistern Booster Application.
Foot Valve
Priming
Tee
4560 0304
Figure 3 – Prime the Pump.

Operation 7
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Operation As A Rooftop
Reservoir Booster Pump
1. Open a faucet near the pump.
2. Plug the pump into a GFCI-protected, grounded,
3-wire outlet. The pump should start.
3. Let the pump run until all air is out of the system and
the faucet is running solid water.
4. When the faucet is running solid water, close the
faucet. The pump should run until the water pressure
rises to the pressure switch’s OFF setting. The pump
should then stop.
NOTE: Check the system by running it through one
complete pumping cycle to make sure it works. To do
this, open a faucet and bleed off pressure until the
pump starts. Close the faucet, and when the pressure
in the system has built up again, the pump should
stop.
Congratulations on a successful installation.
If you were unsuccessful, please refer to the
Troubleshooting section (Page 8) or call our customer
service technical staff at 1-262-728-5551.
Pump
115V
Hot
Hot
Hot
Neutral
Neutral
Neutral
Black
Brown
City Water Inlet
NOTE: If the cistern pump is
connected directly to the city
water line, install a Flow Switch
or Low Pressure Cutoff if city
service may be interrupted.
Float Valve
Float Switch:
Up = On
Down = Off
Foot Valve
Cistern
Pump Pump
Tinaco
Pump-Up
Float Switch:
Up = Off
Down = On
Booster Pump
Float Switch:
Up = On
Down = Off
Circuit
Breaker
Box
Circuit
Breaker
Box
Neutral Neutral – Black
Cistern Float
Switch
Hot
Cistern
Pump
Pressure
Booster
Pump
Hot – Brown
Pump-Up
Float Switch
Booster Pump
Float Switch
Wiring Connections – Schematic
115 VAC
Pressure
Tank
Pressure Booster Pump
Cistern Pump
(In Tinaco)
(In Cistern)
(In Tinaco)
4581 0404
Figure 5 – Cistern/Tinaco Booster Application.

Troubleshooting 8
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SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
Motor will not run Disconnect switch is off Be sure switch is on.
Fuse is blown or circuit breaker tripped Replace fuse or reset circuit breaker.
Wires at motor are loose, DISCONNECT POWER; check and tighten all wiring.
disconnected, or wired incorrectly
Pressure switch contacts are dirty DISCONNECT POWER and clean the electrical contacts.
Motor runs hot and Voltage is too low Check with power company. Install heavier wiring if wire size is too small.
overload kicks off Pump cycles too frequently See section below on too frequent cycling.
Motor runs but no Pump in new installation did In new installation:
water is delivered* not pick up prime through:
1. Improper priming 1. Re-prime according to instructions.
2. Air leaks 2. Check all connections on suction line with
shaving cream.
3. Leaking foot valve or check valve 3. Replace foot valve or check valve.
Pump has lost prime through: In installation already in use:
1. Air leaks 1. Check all connections on suction line and well seal.
2. Water level below suction pipe inlet 2. Lower suction line into water and re-prime. If receding water level
in well exceeds 16’ (5M), a deep well pump is needed.
Foot valve or strainer is plugged Clean foot valve or strainer.
Ejector or impeller is plugged Clean ejector or impeller (See Repair Parts page).
Check valve or foot valve is stuck shut Replace check valve or foot valve.
Pipes are frozen Thaw pipes. Bury pipes below frost line. Heat pit or pump house.
Foot valve and/or strainer are Raise foot valve and/or strainer above bottom of water source.
buried in sand or mud Clean foot valve and strainer.
Water level is too low for shallow well A deep well pump may be needed (over 16’ (5M) to water)
setup to deliver water to deliver water.
Pump does not Water level in well is lower than A deep well jet will be needed if your well is more than 16’ (5M)
deliver water to full estimated depth to water.
capacity Steel piping (if used) is corroded or Replace with plastic pipe where possible, otherwise with new steel pipe.
limed, causing excess friction
Piping is too small in size Use larger piping.
Packed well point Backflush well point or sink new point.
Pump delivers water but Pressure switch is out of adjustment or DISCONNECT POWER; adjust or replace pressure switch.
does not shut off or contacts are welded together
pump cycles too Faucets have been left open Close faucets.
frequently Venturi, nozzle or impeller is clogged Clean venturi, nozzle or impeller (See Repair Parts page).
Standard pressure tank is waterlogged Drain tank to air volume control port. Check AVC for defects. Check
and has no air cushion all connections for air leaks.
Pipes leak Check connections.
Foot valves leak Replace foot valve.
Air charge too low in pre-charged tank DISCONNECT POWER and open faucets until all pressure is relieved.
Using tire pressure gauge, check air pressure in tank at valve stem
located on the tank. If necessary, adjust air pressure in tank to 1.5 Bars
(22 psi). Check air valve for leaks (use shaving cream) and replace core
if necessary.
Air spurts from faucets Pump is picking up prime When pump has picked up prime, it should pump solid water with no air.
Leak in suction side of pump Suction pipe is sucking air. Check joints for leaks with shaving cream.
Well is gaseous Consult factory about installing a sleeve in the well.
Intermittent over-pumping of well Lower foot valve if possible, otherwise restrict pump discharge.
(Water drawn down below foot valve)
* (Note: Stop pump;
then check prime
before looking for
other causes.
Unscrew priming
plug and see if water
is in priming hole).

Repair Parts 9
For parts or assistance, call Flotec Customer Service at 1-262-728-5551
1
2
345
10
6
8
9
7
11
4587 0504
Model
EP2-04
Key Part No. Model
No. Description Used EP2-04
1Pump Body 1 731S7050
2Priming Plug 1 171P2370
3Impeller 1 731S6510
4C-Clip 1 121P1130
5Washer 1 121P1140
6Shaft Seal 1 ZBR02600
7Adapter 1 171P1680
8Pressure Switch 1 751S5050
95-Way Tank Tee 1 ZA009710
10 Pressure Tank 1 ZA000140
11 Pressure Gauge 1 ZA005170
Repair Parts

10
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