ITT Industries FLOJET 2100 Series User manual

Model 2100
Industrial Series
Bypass Pump
MOUNTING
Flojet 2100 is a self-priming pump. It may be located
several feet from the tank, above or below the liquid
leveL (lt is not a submersible pump.) For vertical pump
mounting be sure that the motor is located on top. This
will prevent water from entering the motor chamber in
event of a leak. Pump head may be rotated in 90°
increments to simplify plumbing.
PLUMBING
For best performance, flexible 3/8-inch minimum hose is
recommended instead of rigid piping at the pump. Use
plastic fittings at the pump port. Brass fittings will break
pump housing if over tightened. Do not install pump
such that plumbing causes excessive stress on either
port.
It is essential that a 20 mesh strainer or filter be installed
in the tank or in the pump inlet line to keep large foreign
particles out of the system. The use of check valves in
the plumbing system may interfere with the priming
ability of the pump. Check valves, if used, must have a
cracking (opening) pressure of no more than 2 psi.
ELECTRICAL
On 115 Volt AC pumps, the black wire lead is common,
the white is neutral and green/yellow is ground. On 230
Volt AC pumps, the brown wire lead is common, the blue
is neutral and the green/yellow is ground. Never connect
the green (or green/yellow) wire to a live terminal On 12
and 24 Volt DC pumps, match red (+) and black (-) power
leads with red and black leads on motor or switch.
The bypass and standard pump (no bypass, no switch)
must be started and stopped by an electrical (on-off)
switch.
OPERATION
Allow pump to prime with discharge line (or spray valve)
open, to avoid airlock. Built-in bypass will allow the
pump to bypass internally when discharge is restricted
or closed and will stop bypassing when the discharge
valve is open.
When liquid supply to pump is depleted pump will
continue to operate. Running dry will not damage the
pump. Turn off manually.
When the bypass type pump is allowed to run against a
closed valve the internal bypass will automatically
recirculate the flow within the pump at the preset bypass
pressure.
Caution: The standard series pump is not equipped with
a bypass or pressure switch. Allowed to run against a
closed valve the excessive pressure developed by the
pump will cause system or pump damage.
Model 2100 Bypass Pump
PUMP INSTALLATION
Failure to Prime–
Motor operates, but no pump discharge
• Restricted intake or discharge line. Open all line
valves, check for ‘’jammed’’ check valve poppets
and clean clogged lines.
• Air leak in intake line.
• Punctured pump diaphragm.
• Defective pump check valve.
• Crack in pump housing.
• Debris in check valves.
Motor Fails to Turn On
• Pump or equipment not plugged in electrically.
Loose wiring connection.
• Defective motor or rectifier.
• Frozen cam/bearing.
Low Flow and Pressure
• Air leak at pump intake.
• Accumulation of debris inside pump and plumbing.
• Worn pump bearing (excessive noise).
• Punctured pump diaphragm.
• Defective rectifier or motor
• Insufficient voltage to pump
TROUBLESHOOTING
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, with a new or reconditioned
product, but not to include costs of removal or
installation. No product will be accepted for return
without a return material authorization number. All return
goods must be shipped with transportation charges
prepaid. This is only a summary of our Limited Warranty.
For a copy of our complete warranty, please request
Form No. 100-101.
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 authorization
number. Include your name, address and phone
number.

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]
© Copyright 2001, ITT Industries Printed in U.S.A. All Rights Reserved Form: 81000-123 12/00
2100 SERIES DEMAND PUMP
3 45
1218 7
26 110 8910
16
13
KEY PART NO. DESCRIPTION QTY.
1 02029-000 Motor 115 Volt AC TENV 1
02039-001 Motor 230 Volt AC TENV
02009-004 Motor 12 Volt DC TENV
02019-001 Motor 24 Volt DC TENV
2 20115-111 Brush Endbell/Rect. 1
Assy. (AC) TENV
20115-219 Brush Endbell/Rect.
Assy. (AC) TEFC N/BRG.
20115-116 Brush Endbell Assy. (DC) TENV
20115-213 Brush Endbell/Rect.
Assy. (DC) TEFC N/BRG.
20252-500 Internal Rectifier w/Leads** 1
3 11028-101 Motor Base Plate Assy. (Plastic) 1
4 20132-000 Grommets Set of 4
5 20131-002 Baseplate Screws Set of 2
CAM BEARING / DIAPHRAGM KIT
21004-100 #0 Cam, VITON ® Diaphragm 1
21004-200 #0 Cam, BUNA Diaphragm 1
21004-400 #0 Cam, SANTO Diaphragm 1
21004-101 #1 Cam, VITON ® Diaphragm 1
Kit 21004-201 #1 Cam, BUNA Diaphragm 1
Incl. 21004-401 #1 Cam, SANTO Diaphragm 1
6 21004-102 #2 Cam, VITON ® Diaphragm 1
7 21004-202 #2 Cam, BUNA Diaphragm 1
8 21004-402 #2 Cam, SANTO Diaphragm 1
10 21004-104 #4 Cam, VITON ® Diaphragm 1
12 21004-204 #4 Cam, BUNA Diaphragm 1
21004-404 #4 Cam, SANTO Diaphragm 1
21004-105 #5 Cam, VITON ® Diaphragm 1
21004-205 #5 Cam, BUNA Diaphragm 1
21004-405 #5 Cam, SANTO Diaphragm 1
® A registered trademark of E.l. duPont de Nemours & Co., Inc.
KEY PART NO. DESCRIPTION QTY.
9 20428-100 Bearing Cover Poly Pro 1
*13 Check Valve Assy. (Single Bypass) 1
20028-002 SANTOPRENE
20028-012 BUNA N/FAB
20028-045 VITON ®
Check Valve Assy (Double Bypass)
20028-003 SANTOPRENE
20028-022 BUNA N/FAB
20028-078 VITON ®
Check Valve Assy (Single Bypass Vented)
20028-048 SANTOPRENE
20028-079 VITON ®
20028-028 BUNA N/FAB
*14 Bypass Springs & Poppet Kit
*15 20378-000 For 30 PSI Bypass Nominal (Yellow) Set of 2
20378-001 For 50 PSI Bypass Nominal (Blue) Set of 2
Standard Bypass Springs shown
above. For correct bypass spring part
number for your model, request
specific parts list, giving the complete
pump model number.
20500-507 Pump Housing Poly Pro 1
16 21050** Pump Head Ass’y.
Use Pump Dash Number for
Pumphead Number
18 20131-001 Pump Screws Set of 6
6-18 Brush Kit Set of 2
20097-000 For 115 & 230 Volt AC Motor Set of 2
20097-001 For 12 & 24 Volt DC Motor Set of 2
20132-005 Fan Shroud Kit 1
* Parts included In Pump Service Kit ** Not shown in diagram
SERVICE TIPS
Refer to exploded view for key number. To disassemble, remove six
pump head screws (18), rotate bearing cover (9) so drain notch is aligned
with cam/bearing assembly set screw (7), loosen set screw (use 1/8” size
Allen Wrench) and slide pump head off shaft. Pistons (10) should always
be replaced when new diaphragm is installed. Replace worn parts and
reassemble. Be sure raised side of diaphragm faces the motor and
radiused corner of pistons face diaphragm. Hex stem of inner piston (10)
must be aligned (free to enter) into Hex hole in outer piston set (10).
Press pistons together by hand until pistons snap tight. Install flat head
screws (6) through outer piston set and tighten screws partially, center
pistons in diaphragm then tighten screws securely. Place cam bearing
assembly over outer piston set, align locating pins in the holes in cam
bearing assembly. Install round head screws and tighten securely. (Torque
to 18 inch pounds, coat motor shaft with grease prior to assembly.)
Reassemble bearing and cam bearing assembly to motor and retighten the
set screw securely. Set screw MUST be positioned in shaft indentation.
Position of the screw is critical to avoid misalignment and subsequent
diaphragm damage.
Reassemble pump head parts, using care to properly seat “O” ring (13) in
check valve assembly.
With lower housing held vertically, place bypass poppet(s) (14) and
spring(s) (15) on locating post(s) molded on diaphragm. Place pump head
with check valve and “O” ring installed, over bypass poppet(s) making
sure poppet(s) are aligned into bypass ports in check valve housing (13).
Tighten pump head screws (18) evenly.