Johnson Pump AQUA JET WD 3.4 User manual

Instruction Manual

AQUA JET

Wash Down Systems

WD 3.4 12/24 V DC

WD 5.0 12/24 V DC

IB-203/04 (0606)

Typical applications

The WD 3.4 and the WD 5.0 are both ve

chamber positive displacement diaphragm

pumps.

These pumps are the ideal choice for wash

down applications as they provide 5 bar

pressure (70psi), making clean-up faster and

easier.

Features

• Quiet operation

• Smooth owing

• Self priming

• Integrated pressure switch turns pump

on and off automatically when the

spray nozzle is opened and closed

• Dry running without damage

• Low power consumption

• Quick disconnect ttings

Working principle

As the pump runs, pressure builds until

reaching 5 bar/ 70 psi. At this point, the in-

tegrated pressure switch automatically shuts

the pump off.

The pump is equipped with positively

checking outlet valves which ensure that the

pressure is maintained after the pump shuts

off.

When water is demanded the pressure

decreases. After a moderate drop in pressure,

the integrated pressure switch automatically

turns the pump back on.

Due to their durable construction and

thoughtful design, the WD 3.4 and the WD

5.0 pumps will provide many years of ser-

vice.

Important! The pressure setting of this

pump is made at the factory. Warranty

invalidated by pressure switch inter-

ference.

Wash Down Systems 3.4 and 5.0 mounted to

DC motor 12/24 V

Technical description

Body: Nylon

Valve housing: Polypropylene

Valves: Nitrile

Diaphragm: Santoprene

Connection: 3/8" BSP, 1/2" hose

(ø 13 mm) or

US: 1/2" NPT, 3/4" hose

(ø 13 mm)

US: 3/4" Garden hose

thread (GHT)

Max. liquid

temperature: Max +50°C/+120°F

Fasteners: Stainless steel

Max. suction lift: WD 3.4 – 2.5 m/8.2 ft

WD 5.0 – 3 m/9.8 ft

Cut in pressure: 3.7 Bar/54 psi

Cut-off pressure: 5 Bar/70 psi

Duty cycle: Intermittent,

max 20 min

Motor: WD 3.4 – 130 W

WD 5.0 – 185 W

12/24 V DC

with built in thermal

protection

The motor is ignition protected according to

ISO 8846 (Small craft

– Electrical devices – Protection against igni-

tion of surrounding ammable gases).

Type designation

See page 39

ENGLISH

Pressure and capacity data

(based on water at +20°C/68°F and

at full voltage of the motor)

WD 3.4

Pressure Flow Amp. draw

Bar kPa psi l/min USGPM 12 V 24 V

0 0 0 13 3,4 2,3 A 1 A

0,5 50 7,3 12,1 3,2 3,3 A 1,4 A

1 100 14,5 10,9 2,9 4,5 A 2 A

1,5 150 21,8 10 2,6 5,5 A 2,5 A

2 200 29 9 2,4 6,4 A 2,8 A

2,5 250 36,3 8,3 2,2 7,2 A 3,2 A

3 300 43,5 7,5 2,0 8,1 A 3,6 A

3,5 350 50,8 6,8 1,8 8,9 A 4 A

4 400 58 6 1,6 9,7 A 4,4 A

4,5 450 65,3 5,3 1,4 11 A 4,8 A

5 500 72,5 4,5 1,2 11 A 5,1 A

Fuse required 15 A 8 A

Installation and maintenance

Installation

Locate the pump in a dry location.

If the pump is mounted vertically, the

motor shall face up.

Mark screw positions and drill pilot

holes (see drilling template page 45).

Mount the pump using stainless steel

screws taking care not to over compress

the vibration dampening rubber feet.

Reinforced, high pressure exible tubing

is recommended.

If rigid pipe is used, a length

(225 mm/9 inches minimum) of exible

tubing shall be installed between the pump

and the rigid pipe. This will address noise

and/or damage caused by vibration transmit-

ted to rigid pipe.

Use stainless steel hose clamps to secure

tubing to quick disconnect ttings and other

hose barbs in the system.

The strainer that follows the pump must

be installed in line before the pump intake, to

prevent debris from entering pump and inter-

fering with proper functioning of valves.

Electrical installation

The pump must be installed according to ISO

10133 (Small craft – Electrical system – Ex-

tra low voltage DC installation for continuous

current). Note: The fuse must be ignition

protected.

The motor is equipped with built in thermal

protection to prevent the motor from overhea-

ting. The protection is automatically restored

when the motor

is cooled.

If the pump is connected with separate

earth lead, this should be yellow/green and

connected to the motor base.

See the wiring table (next page) for

correct installation. Negative wire must

be black.

Choose wire size in accordance with

total wire lenght (see table next page).

The wire connections must be sealed with a

marine sealant.

Note: Before installation with

electrical control systems, check that equip-

ment to be used is of sufcient rated capacity

to accept amperage draw of motor. Low

voltage will cause motor to overheat.

WD 5.0

Pressure Flow Amp. draw

Bar kPa psi l/min USGPM 12 V 24 V

0 0 0 18,9 5 3,6 A 1,7 A

0,5 50 7,3 17,8 4,7 5 A 2,4 A

1 100 14,5 16,6 4,4 6,6 A 3 A

1,5 150 21,8 15,5 4,1 7,8 A 3,6 A

2 200 29 14,5 3,8 9,1 A 4,2 A

2,5 250 36,3 13,4 3,5 10,4 A 4,8 A

3 300 43,5 12,4 3,3 11,7 A 5,2 A

3,5 350 50,8 11,4 3 13 A 5,7 A

4 400 58 10,6 2,8 13,8 A 6,2 A

4,5 450 65,3 9,7 2,6 14,8 A 6,5 A

5 500 72,5 8,7 2,3 15,9 A 7 A

Fuse required 20 A 10 A

ENGLISH

Wiring dimensions

(based on 3% voltage drop)

WD 3.4

Wire size Max wirelenght* in m

12 V 24 V

2.5 mm2# 14 AWG 5.4 20.6

4 mm2# 12 AWG 8.6 32.9

6 mm2# 10 AWG 12.9

10 mm2# 6 AWG 21.4

16 mm2# 4 AWG 34.3

Start-up procedure

After pump installation, the system can be

started by using the following procedure:

• Make sure suction hose is connected

to the water supply.

• Open the spray nozzle and start

the pump.

• Close the spray nozzle when water

begins owing and all air has been

purged from the system.

• If additional spray nozzles or taps are

in use after the pump, open each

additional nozzle/tap until all air has

been purged from the system.

• Pump will cut off after taps are

closed and pressure builds to the

setpoint of the pressure switch

Other electrical devices, eg switch, circuit

breaker, must be installed between the

pump and the positive (+) lead on the bat-

tery (on the red wire).

Wiring table

WD 5.0

Wire size Max wirelenght* in m

12 V 24 V

2.5 mm2# 14 AWG 3.9 17.6

4 mm2# 12 AWG 6.2 28.2

6 mm2# 10 AWG 9.3 42.3

10 mm2# 6 AWG 15.5

16 mm2 # 4 AWG 24.8

* The wire length is the total distance from the

battery to the pump and back to the battery.

It is recommended to use a relay with a light

wire from main cable to switch to shorten the

main leaders.

Self-priming

Pump is self-priming up to 2.5 m/8.2 ft. for

WD 3.4 and 3 m/9.8 ft. for WD 5.0. Intake

lines must be air-tight to ensure self-pri-

ming.

Dry running

Pump will not be damaged by shorter

period of dry running. It will, however, un-

necessary reduce your battery power.

Caution

Do not use pump for any other liquids than

fresh-water and sea-water.

Winterizing

If water is not drained from the system

during freezing temperatures, damage is

likely to be sustained in the plumbing and

in the pump. To prevent damage follow

the instructions beneath:

1. Disconnect suction hose from water

supply (sea water supply) or if

water supply is taken from a tank,

drain water storage tank.

Pump

Terminal

fuse Switch

Max 0.2

Red

Black

Green/yellow

–

ENGLISH

Temperature

Max liquid temperature: +50°C/+120°F

Max ambient temperature: +60°C/+140°F

Service instructions

(see page 42-43)

Never start a frozen pump. Even if it is

drained it might contain a small amount of

frozen water that locks the rotor.

Change of Switch (pos A)

1. Remove the screws (28) and then

remove the complete switch

including diaphragm (19).

2. Remove the cables (30 and 31) from

the motor cable and power source.

3. Take the new switch and attach the

cables to motor and power source.

4. Locate the new diaphragm (19) and

then the new complete switch.

Change of Diaphragm kit (pos B)

1. Remove the screws (18) with a

Torx #20 tool (a standard Phillips

type screw #20 tool). (Pos 18 screws

should be tted to the through holes

which can be seen on the backside of

the motor end bell).

2. Separate the pump assembly from

motor.

3. Remove the screws (17) with a Torx

#20 tool (a standard Phillips type

screw #20 tool). .

4. Hold the black pumpbody (14)

towards the ground. Carefully

remove the diaphragm kit (B) from

pump body (14). Ensuring that pos

10-14 still remains together with

pump body (14).

5. Locate the diaphragm kit into pump

body (14) incl pos 10-14 and mount

the ve short screws (17) into the

threaded holes in the motor ange.

6. Mount the complete pumphead kit

onto the motor coupling ange

taking notice to t the slot in cam (5)

in right position against motor shaft

and the three slots on motor end

bell.

7. Assemble the remaining long screws

(18) which will hold the motor/pump

unit together. (pos 18 screws should

be tted to the through holes that

can be seen on the backside of the

motor end bell).

Change of complete Pump kit (pos C)

1. Remove the screws (28) and then

remove complete switch including

diaphragm (19).

2. Remove the cables pos (30 and 31)

from the motor cable and power

source.

3. Remove the screws (18) with a Torx

#20 tool (a standard Phillips type

screw #20 tool). (pos 18 screws has a

through hole on the backside of the

motor end bell).

4. Separate the pump assembly from

the motor.

5. Mount the complete pumphead kit

onto the motor coupling ange

taking notice to t the slot in cam

(5) in right position against motor

shaft and the three slots on the

motor end bell.

6. Assemble the long screws (18) which

will hold the motor/pump unit

together. (pos 18 screws should be

tted to the through holes that can

be seen on the backside of the motor

end bell).

7. Locate the diaphragm (19) and then

the complete switch.

ENGLISH

2. Open all spray nozzles/taps.

3. Run pump until remaining water is

expelled.

4. Disconnect inlet and outlet tubes.

5. Run pump briey to conrm that

water has been expelled.

6. Spray nozzles/taps shall remain

open and pump ttings shall

remain disconnected until tempe-

ratures are above freezing

Accessories

See page 44

ENGLISH

Symptom

1. Pump does not run.

2. Pump does not prime.

3. Pump cycles on and off rapidly

while water is demanded.

4. Pump cycles on and off rapidly

while water is not demanded.

5. Pump will not stop

running when water is not

demanded.

6. Low flow/pressure.

7. Pump is excessively noisy.

Trouble-shooting chart

Cause

1.1 Tripped thermal protector or blown

fuse.

1.2 Faulty wire connection or power

source.

1.3 Pressure switch malfunctioning.

1.4 Motor malfunctioning.

1.5 Pump/motor frozen.

2.1 Water tank empty.

2.2 Debris under valves.

2.3 Perforated diaphragm.

2.4 Leak on inlet side of pump.

2.5 Inlet or outlet plumbing

restricted.

3.1 Restriction on outlet side of

pump/too high pressure.

4.1 Leak on outlet side of pump.

5.1 Leak on inlet side of pump.

5.2 Leak on outlet side of pump.

5.3 Perforated diaphragm.

5.4 Water tank empty

5.5 Pressure switch malfunctioning.

5.6 Low voltage to pump.

6.1 Leak on inlet side of pump.

6.2 Leak on outlet side of pump.

6.3 Perforated diaphragm.

6.4 Motor malfunction.

6.5 Debris under valves.

7.1 Pump is plumbed directly to

rigid tubing.

7.2 Pump head loose on motor.

7.3 Pump mounting is loose.

7.4 Pump mounting is too rigid.

7.5 Defective motor.

Remedy

1.1.1 Check fuse. If motor is overheated let

it cool down prior to restart.

1.1.2 Check battery/power supply,

main switch and wiring.

1.1.3 Change pressure switch.

1.1.4 Change pump.

1.1.5 Thaw pump and system and check for

damage. The pump/motor is liable to

damage when a frozen pump is

started

2.1.1 Fill up tank.

2.1.2 Carefully flush pump with tap water

at nominal pump flow. Note! Flush in

nominal flow direction.

2.1.3 Replace diaphragm kit.

2.1.4 Check tightness of hose

connections at pump, filter

and tank.

2.1.5 Check plumbing.

3.1.1 Outlet hose too small, must

be of same diameter as pump

connection.

4.1.1 Check tightness of hose connections,