Johnson pump Aqua jet wps 3.4 User manual

Instruction Manual

AQUA JET

Water Pressure Systems

WPS 3.4 12/24 V DC

WPS 5.0 12/24 V DC

IB-204/05 (0606)

Typical applications

The WPS 3.4 and the WPS 5.0 are both ve

chamber positive displacement diaphragm

pumps.

These pumps are the ideal choice for

pressurizing water in a closed system such

as that found in a boat or in a recreational

vehicle.

They can easily build the pressure requi-

red for a pressurized water supply system.

Features

• Quiet operation

• Smooth owing

• Self priming

• Integrated pressure switch turns pump

on and off automatically when tap is

opened and closed

• Dry running without damage

• Low power consumption

• Quick disconnect ttings

Working principle

As the pump runs, pressure builds until

reaching 2.8 bar/41 psi. At this point, the

integrated 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 (at the faucet,

shower et.c.) 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 WPS 3.4 and the

WPS 5.0 pumps will provide many years of

service.

Important! The pressure setting of this

pump is made at the factory. Warranty

invalidated by pressure switch inter-

ference.

Water Pressure Systems 3.4 and 5.0 mounted to

DC motor 12/24 V

Technical description

Body: Nylon/Polypropylene

Valve housing: Polypropylene

Valves: Santoprene/EPDM

Diaphragm: Santoprene

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

(ø 13 mm) and

1/2" BSP, 3/4" hose

(ø 18 mm) or

US 3/8" NPT, 1/2"

hose (ø 13 mm) and

US 1/2" NPT, 3/4"

hose (ø 18 mm)

Max. liquid

temperature: Max +50°C/+120°F

Fasteners: Stainless steel

Max. suction lift: WPS 3.4 – 2 m/6.5 ft

WPS 5.0 – 2.5 m/8.2 ft

Cut in pressure: 1.7 Bar/25 psi

Cut-off pressure: 2.8 Bar/41 psi

(Other pressure settings see page 39)

Duty cycle: Intermittent,

max 20 min

Motor: WPS 3.4 – 100 W

WPS 5.0 – 150 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

ignition of surrounding ammable gases).

Type designation

(See page 39)

ENGLISH

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 trans-

mitted to rigid pipe.

Use stainless steel hose clamps to secure

tubing to quick disconnect ttings and other

hose barbs in the system.

A strainer must be installed in line be-

fore 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

– Extra low voltage DC installation for

continuous current). Note: The fuse must be

ignition protected.

The motor is equipped with built in ther-

mal protection to prevent the motor from

overheating. 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

equipment to be used is of sufcient rated

capacity to accept amperage draw of motor.

Low voltage will cause motor to overheat.

Maintenance

The system shall be periodically

sanitized using the following procedure:

1. Fill the tank with a solution of house-

hold bleach and potable water –

1 ml (.03 oz.) bleach/1 l (32 oz.) water).

2. Open all faucets and run until water

owing smells of bleach.

3. Close all fauces.

4. Drain solution from tank.

Pressure and capacity data

(based on water at +20°C/68°F and

at full voltage of the motor)

WPS 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

0.4 40 6.2 12.2 3.2 3.1 A 1.3 A

0.8 80 11.6 11.4 3 4 A 1.7 A

1.2 120 17.4 10.6 2.8 4.8 A 2.1 A

1.6 160 23.2 9.9 2.6 5.4 A 2.5 A

2 200 29 9.1 2.4 6.2 A 2.8 A

2.4 240 34.8 8.5 2.2 7 A 3.1 A

2.8 280 40.6 7.7 2 8.1 A 3.6 A

Fuse required 10 A 5 A

WPS 5.0

Pressure Flow Amp. draw

Bar kPa Psi l/min USGPM 12 V 24 V

0 0 0 19.4 5.1 3.9 A 1.6 A

0.4 40 6.2 18.2 4.8 4.9 A 2.1 A

0.8 80 11.6 17 4.5 6 A 2.5 A

1.2 120 17.4 15.8 4.2 7.1 A 3.1 A

1.6 160 23.2 14.7 3.9 8 A 3.6 A

2 200 29 13.5 3.6 9.2 A 4.1 A

2.4 240 34.8 12.2 3.2 10.3 A 4.7 A

2.8 280 40.6 11.2 3 11.2 A 5.1 A

Fuse required 15 A 8 A

ENGLISH

Wiring dimensions

(based on 3% voltage drop)

WPS 3.4

Wire size Max wire

lenght* in m

12 V 24 V

2.5 mm2# 14 AWG 7.7 34.3

4 mm2# 12 AWG 12.3

6 mm2# 10 AWG 18.5

10 mm2# 6 AWG 30.8

Start-up procedure

After pump installation, the system can be

started by using the following procedure:

• Fill water tank

• Open one tap

• Turn on pump

• Close tap once water begins owing

• Open each additional tap until all air

has been purged from system

• Pump will shut off after taps are

closed and pressure builds to the set-

point 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

WPS 5.0

Wire size Max wire

lenght* in m

12 V 24 V

2.5 mm2# 14 AWG 5.2 23

4 mm2# 12 AWG 8.4

6 mm2# 10 AWG 12.6

10 mm2# 6 AWG 21

16 mm2 # 4 AWG 33.6

* 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 m/6 ft. for

WPS 3.4 and 2.5 m/8.2 ft. for WPS 5.0.

Intake lines must be air-tight to ensure self-

priming.

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.

Temperature

Max liquid temperature: +50°C/+120°F

Max ambient temperature: +60°C/+140°F

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. Drain water storage tank.

2. Open all taps.

3. Run pump until remaining water is

expelled.

4. Disconnect inlet and outlet tubes.

5. Rell tank with potable water.

6. Open all faucets and run until

bleach has been purged.

Pump

Terminal

fuse Switch

Max 0.2

Red

Black

Green/yellow

–

ENGLISH

Service instructions

(see page 42-43)

5. Run pump briey to conrm that

water has been expelled.

6. Taps shall remain open and pump

ttings shall remain disconnected

until temperatures are above

freezing

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

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,