Pentair ONGA FARMMASTER JJ Series User manual

FARMMASTER
JJ & OJ Series
Farm Pumps for Stock Watering,
Irrigation & Water transfer
OWNER`S MANUAL
Should the installer or owner be unfamiliar with the
correct installation
or operation
of this type of
equipment,
contact the distributor
or manufacturer
for correct
advice before proceeding
with installation
or operation of the product
1
Distributed in NZ By:
Freephone 0508 634 341
7 Monier Pl, Mt Wellington, Auckland
1060, New Zealand

2
Relax - you’ve bought an Onga ...
Congratulations on your decision to purchase an Onga
product. Onga is one of the best known brands in its field,
with a proud local and International reputation.
Onga is a brand for reliability, value for money and technological
innovation.
You will find Onga product wherever people need to move water in
3 broad markets covering:
Technologically advanced solutions
for moving and treating water in the
Home, Garden, Pool and Spa.
Innovative Stock and Crop water
management solutions for Primary
Industries.
Water movement products for
Building services, Emergency
services and Original Equipment
manufacturers.

Onga is a byword for reliability, value
3
1. Continual Product Improvement
We employ the best engineers both in Australia and
around the world to develop new and better ways to
take water further.
2. Operational Excellence
There is only one standard that we set ourselves for both
product quality and the quality of our service. That
standard is excellence... to have no-one better than us
at what we do... nothing short of that is acceptable.
3. A Fair Price
Onga products are neither the cheapest nor the most
expensive in their field. Our products do, on the other
hand, always represent very good value for money - they
always have and they always will.
4. Our Team of Dealers
The hand picked authorised Onga dealer network
throughout Australia and worldwide are second to none.
We invest considerable time and resources training and
supporting them through the Onga Training Academy.
for money and technological innovation.
y ngaSo
wh does O lead its
field? Here are a few simple reasons ...

Table of contents
Introduction
Technical Data
Application
Installation
Electrical
Operation
Maintenance & Service
Troubleshooting Guide
Repair Parts
2,3
5
6
6,7,8,9,10
10,11
11,12,13
14
15,16,17
18,19,20,21,22,23
Pages
4

5
IMPORTANT!
The operator must be provided with this owner’s manual. This must be read before
operation and followed during operation.
These instructions are a guide only. Users not familiar with pumping equipment should
seek advice from people with experience in pump installation and operation.
Model Data - JJ400, JJ600, OJ700 & OJ800
Technical Data
Voltage 230V / 415V
Motor Watts 750W (JJ400); 1800W (JJ600)
1800W (OJ700); 3000W (OJ800)
Suction / Discharge Refer Product Guide.
IP Rating IP44
Motor Frequency 50Hz
Water temperature range 2 - 40oC
Maximum ambient temperature 40oC (for effective motor cooling
ensure the ambient temperature
does not exceed 40oC).
Incorrectly installed or tested equipment may fail,
causing severe injury or property damage.
Pump
Model
Supply
voltage Phase Nominal
Horsepower
Motor
input
power
(P1)
Starting
current
(Amps)
Full Load
current
(Amps)
Power
Supply
Lead
(Amps)
Outlet
(BSP)
JJ400 230 1 1 1 19 4.6 10A 3/4' F
JJ600 230 1 1.1/2 1.6 31.4 7.7 10A 3/4' F
JJ600 415 3 2.1/2 2.451 25 2.9 N/A 3/4' F
OJ700 230 1 2.1/2 2.61 47.5 8.9 10A 1' F
OJ700 415 3 2.1/2 2.451 25 3.6 N/A 1' F
OJ800 230 / 480 1 3.3/4 3.569 71.2 14 / 7 15A 1' F
OJ800 415 3 3.3/4 3.569 38.69 5.5 N/A 1' F

6
Application
The Farmmaster JJ & OJ range of self-priming jet pumps are suitable
for mid to large size domestic and rural applications. Typical
applications include: tank filling; household water supply; stock
watering; irrigation and water transfer from dams, creeks, wells and
bores.
If the pump is to be used for pumping liquids other than water, ask
your pump supplier for advice as to which model is best suited to
your particular requirements. Special pump configurations are
available for pumping aggressive fluids.
Installation
a) Preparation for operation
Read these instruction first
Inspect your pump for shipping damage. Report any
damage to your Onga dealer. Make sure the suction
piping is free of air leaks and is laid so that there can
be no rises for potential airlocks.
b) Pump Protection
Warranty of this pump is void unless it is operated in
accordance with this owner’s manual. The pump
should be housed in a weather proof, well ventilated
enclosure, to protect from the weather, flooding,
chemicals, dust, vermin, insects etc.
c) Pump Mounting
The pump must be mounted on a solid, level, vibra-
tion free surface. Dependent on the application, the
pump may not have to be ‘bolted down’. To obtain
the best possible performance, the pump should be
located as close to the water source as possible.
To protect pipe fittings, fit the pressure tank last (for
installations where a pressure tank is used).
This appliance is not intended for use by young
children or infirm persons without supervision. Children
should be supervised at all times when near this
appliance.

7
Installation (continued)
d) Suction
To maintain optimum performance from your pump, the suction pipe
should be:
• Kept to the shortest length possible - place the pump as close to
the water source as possible.
• Re-enforced crush resistant (non-collapsible) hose or pipe.
• All fittings should be air tight.
• Pipes should be equal to or larger than the diameter of the suction/
inlet port.
• Ensure that the suction is completely submersed.
• Ensure a footvalve is fitted to the suction line if the pump is installed
in a suction lift application.
• A checkvalve should be fitted on a flooded suction installation.
For further information on suction piping, refer page 8.
e) Discharge
The length and diameter of the discharge hoses or pipe will effect the
pressure and flow rate at which your pump operates. Pressure ratings of
all components must exceed the maximum pressure of the pump by an
appropriate safety factor. For correct sizing of the delivery line refer to the
relevant pipe friction tables for the type and grade of pipe used.
Galvanised steel, PVC or polythene pipe may be used for the delivery line.
A short length of polythene pipe should be used on the suction and
discharge sides of the pump to prevent noise from being transmitted.
A shut-off valve should be installed on the discharge line so that the
system can be isolated if required.
f) Pressure Switch
All manufacturer supplied pressure switches are factory preset to the
lowest pressure setting of the pump range. This suits most requirements.
If high pressure injectors are used the pressure switch settings will need to
be altered to the new cut-in and cut-out settings. If you are unsure as to
what the settings should be for your particular installation, seek advice
from your local pump dealer.

8
Installation (continued)
g) Valves
Onga recommend the use of shut off valves in suction & discharge pipe to
assist when maintenance is required. Closed loop systems or applications
where the pump is installed vertically higher than the water source will
require an additional check valve or footvalve. On suction lifts, a foot valve
MUST be used.
h) Electrical:
230 volt single phase motors are supplied as standard with thermal over-
load protection and are designed to plug directly into a 10 amp domestic
power supply to local electrical authority specifications.
The power supply lead has a type “Y” connector and if service is required to
the power lead, it must be replaced with the appropriate specialised power
lead assembly. Warranty is void if unauthorised modifications are made to
any component.
For further information refer to page 5.
Pumps fitted with 415 volt three phase electric motors should be protected
with the recommended contactor and thermal overloads in accordance with
local electrical authority specifications. Direction of rotation must be checked
by switching power on momentarily and observing motor rotation. If the
direction is not correct as per motor label have a qualified electrician make
the change.
For further information refer to page 10.
Fire and burn hazard. Modern motors run at high temperatures. To
reduce risk of fire, do not allow leaves, debris, or foreign matter to collect
around the pump motor. To avoid burns when handling the motor, let it
cool for at least 20 minutes before trying to work on it. A thermal overload
switch protects the motor from heat damage during operation.
For shallow well applications it is recommended to set the pressure switch
cut-out to 30kPa (5psi) below the maximum pump pressure when the
system is operating with maximum suction lift.

9
Piping
All pipe threads should be tightened correctly to prevent leaks. An air leak in
the suction pipe will prevent the pump from operating. Galvanised or poly-
thene pipe can be used. For correctly sized pipe refer to pipe friction tables.
Always use suction pipe that is the same size or larger than the pump suc-
tion port. For long suction or discharge lines, increase pipe size appropri-
ately to minimise friction loss.
Installation (continued)
NOTICE: Use Teflon tape for making all threaded connections to the
pump. Do not use pipe dope (glue) as this will cause stress fractures in the
pump.
Deep Well
The correct grade of polythene pipe should be used. Use teflon tape on all
threaded joints as air leaks will prevent the pump from operating.
When installing the injector, cut pipes so that the pressure line and the
suction line lay straight, side by side. Adequate heating of the pipe makes
it easy to push on the barbed injector fittings. Use two stainless steel hose
clamps per fitting to ensure that under load the pipes do not come free.
Teflon Taping Instructions:
Use only new or clean PVC or galvanised pipe fittings.
Wrap male pipe threads with one to two layers (or a sufficient number of
layers) of Teflon tape. Cover entire threaded portion.
Do not overtighten.
If leaks occur, remove pipe, clean off old tape, rewrap as previously with
one to two additional layers of tape and remake the connection.
NOTICE: Support all piping connected with pump.
To avoid stress on the pump, support both suction and discharge pipes
independently. Place these supports as close to the pump as possible.
To avoid a strain left by a gap at the last connection, start all piping at the
pump and run pipe away from the pump.
Never use a suction pipe smaller than pump suction connection.
To avoid airlocking, slope suction pipe slightly upward toward the pump.
NOTICE: To prevent flooding when removing pump for service, all flooded
suction systems must have shut-off valves in suction and discharge
pipes.

10
Installation (continued)
Do not connect system to a high pressure or city water
system.
Fittings:
Fittings restrict flow; for best efficiency use fewest possible fittings.
Avoid fittings which could cause an air trap.
Electrical
Ground motor before connecting to electrical power
supply. Failure to ground motor can cause severe or
fatal electrical shock hazard.
Do not ground to a gas supply line.
To avoid dangerous or fatal electrical shock, turn
OFF power to motor before working on electrical
connections.
Residual Current Device (RCD) tripping indicates an
electrical problem. If RCD trips and will not reset,
have a qualified electrician inspect and repair
electrical system. Onga recommends that a RCD of
30mA trip current be installed and/or be in
compliance with local regulations.
Exactly match supply voltage to motor nameplate
voltage. Incorrect voltage can cause fire or seriously
damage motor and voids warranty. If in doubt
consult a licensed electrician.
The power supply lead has a type “Y” connector and
if service is required to the power lead, it must be
replaced with the appropriate specialised power lead
assembly. Warranty is void if unauthorised
modifications are made to any component.

11
Voltage
Voltage at motor must not be more than 1% above or 6% below motor
nameplate rated voltage or motor may overheat, causing overload tripping
and reduced component life.
Electrical (Continued)
Operation
NEVER run pump dry. Running pump dry may damage
seals, causing leakage and flooding. Fill pump with
water before starting motor.
Do not block pump suction. To do so with body may
cause severe or fatal injury.
Fire and burn hazard. Modern motors run at high tem-
peratures. To reduce the risk of fire, do not allow leaves,
debris, or foreign matter to collect around the pump motor.
To avoid burns when handling the motor, let it cool for at
least 20 minutes before trying to work on it.
An internal thermal overload switch protects the motor
from heat damage during operation.
NOTICE: Maximum ambient temperature for motor opera-
tion must not exceed maximum ambient
temperature rating.
This appliance is not intended for use by young children or
infirm persons without supervision. Young children should
be supervised at all times when near this appliance.
Priming Pump - General
In a flooded suction system (water source higher than pump), pump will
prime itself when suction and discharge valves are opened.
If pump is not in a flooded suction system, disconnect power supply to
pump and remove priming plug; fill pump with water and replace plug.
Pump should prime now. Priming time will depend on vertical height of
suction lift and horizontal length of suction piping.
If voltage is less or more than the above when
the motor is running at full load, consult power company.

12
The self-priming time range is 1 to 5 minutes for a height difference of 2 to
3 metres, under normal installation conditions. Normal conditions are
understood to be: with suction having an internal diameter of DN 50mm,
water temperature at 20oC, and 50Hz mains power supply.
Should the pump not prime, ensure that all valves are open, a footvalve is
fitted and suction pipe end is submersed in water, and that there are no
leaks in suction pipe.
See Troubleshooting Guide if the pump will still not prime.
Operation (Continued)
Shallow Well Priming Instructions
Remove the priming plug and fill the pump and suction line(s) with water.
Fill as much of the suction line as possible. Replace the priming plug -
screw the plug down loosely to allow for trapped air to bleed out of the
line - while maintaining 70kPa - 140kPa (10-20psi) discharge pressure
(utilise a pressure gauge on the discharge tee to check this pressure).
Operate the pump until fully primed, tighten the priming plug fully, then
open the shut-off valve so that the remaining air can be purged from the
system.
If there is a long or difficult suction, the pump may need to be refilled
several times at intervals as priming ability decreases as the water heats.
If only a small amount of water is pumped, then flow stops, switch off the
pump and check the suction pipe for possible air leaks. Ensure the suc-
tion line is airtight and free of leaks before starting the priming
procedure again.
Deep Well Priming Instructions
Close the gate valve, unscrew the priming plug and fill the pump and
suction lines with water. Replace the priming plug tightly, and turn the
pump on. Pressure should rise above 275kPa (40psi). Open the gate
valve slowly to purge remaining air from the pump and suction lines.
Maintain discharge pressure above the minimum operating pressure of the
pump 174kPa (25 psi).
Deep well pumps are sensitive to air ingress and it may be necessary to
repeat the priming procedure to completely fill the pump and suction lines
and ensure there is no air in the system.

13
Operation (continued)
Do not remove any caps while the pump is operating.
If an ‘offset’ injector installation is used, it may not be practical to ensure
an even suction rise from the water source to the pump. If this is the case,
install a tee in both the suction and pressure pipes at the highest point(s)
for ease of priming. Install a plug in the unused branch of each tee.
To obtain maximum capacity from your deep well pump, it should run at
the minimum recommended operating pressure. If pressure is allowed to
fall below this level, the injector may not operate correctly and the pump
will lose prime.
The minimum operating pressure can be maintained by partially closing
the gate valve. To set the valve turn on all taps and any other outlets
that are likely to operate together, pump the bore/well down to it’s lowest
level and adjust the valve so that the minimum operating pressure is
maintained.
Pressure Tank Air Charge
Follow these steps to correctly set the pressure tank air charge.
1. Switch the power to the pump OFF and ensure the pump is
electrically isolated.
2. Turn on all taps and let them run. This will empty the pressure tank.
3. Check the air charge in the tank with a tyre gauge or similar.
4. Inflate the tank to 10% below the cut-in pressure of the pressure
switch setting e.g. 125kPa if pressure switch setting is 140 -280kPa;
190kPa if pressure switch setting is 210 - 350kPa.

14
Pump Maintenance & Service
Pump should only be serviced by qualified personnel. For best
results, use only genuine Onga factory parts.Be sure to prime pump
before starting.
Before removing pump for maintenance or service:
1. SWITCH OFF POWER to pump before proceeding. Disconnect
the pump from the mains/power supply. If the connection plug
or power outlet are wet, isolate that circuit at the meter board.
2. CLOSE SHUT-OFF VALVES in suction and discharge pipes.
3. RELEASE ALL PRESSURE from pump and piping system before
disconnecting fittings.
4. NEVER tighten or loosen pump fittings while pump is
operating!
To avoid dangerous or fatal electrical shock hazard, turn OFF power
to motor and remove plug from power outlet before working on pump
or motor.
No lubrication or regular maintenance is needed beyond reasonable care.
When pump is not in use and there is a risk of frost, empty it completely
through the drain plug.
If shaft seal is worn or damaged, have a qualified pump service agent
replace it.

15
Troubleshooting Guide
Symptom Cause Remedy
Pump must be primed; make
sure that the pump casing is
full of water. Refer priming
instructions.
Make sure there are no leaks
in suction piping.
Suction leaks / lost prime
Make sure suction pipe inlet
is well below the water level
to prevent pump from
sucking air.
Make sure that the impeller
is not clogged. This should
be checked by qualified
personnel only.
Impeller and diffuser may be
worn. If so, check with your
local Onga dealer or suitably
qualified personnel.
Clogged pipe / impeller,
worn impeller.
Pump may be trying to push
too high a column of water. If
so, a “higher head” pump is
required.
No power at outlet. Use another electrical
appliance that is known to
work to check the power
outlet.
Blown fuse. Check fuse and replace if
necessary.
Cavitation. Close gate valve on
discharge to increase
pressure to above minimum
operating pressure of
selected injector.
Incorrectly sized pipe. Check pipe work pressure
losses and replace with
larger diameter pipe if
required.
Motor burnt out due to
voltage spike or flooded by
water.
The motor may need
replacing.
Valves turned to the closed
position.
Check the plumbing to
ensure the valves are in the
correct position for pumping
on the suction and
discharge.
Pump failure or reduced
capacity or reduced
discharge pressure.
Air ingress to system. Prime the pump. Check that
there are no air leaks in the
suction piping or fittings.
Check that there are no leaks
coming from beneath the
pump.

16
Troubleshooting Guide (Continued)
Symptom Cause Remedy
Low voltage. Check voltage at motor
terminals and at meter while
pump is running – this check
should be performed by a
qualified electrician only. If
voltage is low check for
loose connections or consult
your power company.
Pump running too slowly.
Pump may be too hot. Check line voltage; if less
than 6% or more than
1% of rated voltage
consult a licensed
electrician.
Increase ventilation. Reduce
ambient temperature.
Tighten any loose
connections.
Pump leaking from between
the casing and motor.
Casing bolts are not
tightened sufficiently; Casing
O’ring is worn; Mechanical
seal requires replacing.
Switch off the power to the
pump. Loosen the casing
bolts. Check the alignment
and condition of the casing
o’ring before retightening the
bolts. Replace the o’ring if
leaking persists.
Replace the mechanical seal.
Pump not running. Check power supply. No water.
Gate valve closed. Open gate valve.
Foot valve leaking. Check foot valve for seal, fix
or replace if necessary.
Air lock. Check suction line for
‘humps’. Have your local
pump professional prime the
pump with an engine drive
pump to score air from lines.
Incorrect injector for
application.
Have your local pump
professional re-evaluate site
for pressure and flow
requirements. Select an
injector that will provide
enough pressure at the
required flow rate.
Water source has been
drawn down so that suction
is above the water line.
Check suction is submerged.
Pump will not prime.
Pressure switch cut-in
pressure is set too low.
Have your local pump
professional reset the
pressure switch settings.

17
Troubleshooting Guide (Continued)
Symptom Cause Remedy
Pressure tank too small. Fit a larger capacity or
secondary pressure tank.
Pressure tank has incorrect
air charge.
Check pressure with tyre
gauge or similar. Adjust
pressure to 10% below the
cut-in pressure of the pump.
Pressure switch setting
incorrect.
Have your local pump
professional adjust the
pressure switch and tank
pressure accordingly.
Rapid Cycling.
Pump injector combination
too large for application.
Consult your local pump
professional to ascertain the
correct injector for your
application.
Should problems persist, contact your nearest Onga service agent.

18
Repair Parts - JJ400

19
Repair Parts Table - JJ400
Item Description Qty.
1 Casing & Studs Assy. 1
2 Separator Plate 1
3 Impeller 1
4 Diffuser 1
5 Mechanical Seal 1
6 O’ring – Casing 1
7 O’ring – Shaft Sleeve 1
8 Baffle 1
9 Motor 1
10 Shaft Sleeve 1
11 Tee – Assembled 1
12 Mounting Assy. Pressure Switch 1
13 Priming Plug & O’ring 1
14 O’ring 1
15 Pressure Switch Assy. 1
16 Pressure Gauge 1
17 Screw - Casing 4
18 Bush 1
19 Nut - Casing 4
20 Base & Screws Kit 1
21 Foot – Casing 1
22 O’ring – Tee (Top) 1
23 Tee 1
24 Locknut – Tee 1
25 O’ring – Tee (Bottom) 1

20
Repair Parts - JJ600