STA-RITE DURA-GLAS II P4R Series User manual

DURA-GLAS IITM CENTRIFUGAL PUMPS
WITH INTEGRAL TRAP
O W N E R’ S M A N U A L
INSTALLATION, OPERATION & PARTS
P4R and P4RA Series MODELS
HP
3/4 P4R62D3-150 P4R6D3-150
1 P4R62E3-151 P4R6E-151L P4R6E3-151
1-1/2 P4R62F3-152 P4R6F-152L P4RA6F-151L P4R6F3-152
1-3/4 P4RAA6F-177L
2 P4R62G3-153 P4R6G-153L P4RA6G-152L P4RA6GC-150 P4R6G3-153
2-1/2 P4RAA6G-153L
3 P4R6H3-154
Sta-Rite Pool/Spa Group
293 Wright Street, Delavan, WI 53115
North America: 800-752-0183, FAX [phone]
International: 414-728-5551, FAX: [phone], TELEX: ITT 4970245
Oxnard, CA • Union City, TN • Delavan, WI • Mississauga, Ont.
© 1998, Sta-Rite Industries, Inc. Printed in U.S.A. S272 (Rev. 2/12/98)
This manual should be furnished to
the end user of this pump; its use will
reduce service calls and chance of
injury and will lengthen pump life.

2
‘P4R’ and ‘P4RA’ SERIES II PUMP
WITH TRAP
To avoid unneeded service calls, prevent possible injuries, and get the most
out of your pump, READ THIS MANUAL CAREFULLY!
The Sta-Rite ‘P4R’ and ‘P4RA’ Series II Self-priming Centrifugal pumps:
• Are designed for use with swimming pools or as centrifugal pumps.
• Are excellent performers; durable, reliable.
Table of Contents
Safety Instructions ........................................................................................3
Installation.................................................................................................4-5
Electrical....................................................................................................5-6
Operation..................................................................................................7-8
Storage/Winterizing ......................................................................................8
Pump Service...........................................................................................9-11
Troubleshooting Guide...............................................................................11
Repair Parts List.....................................................................................12-14
Warranty.....................................................................................................15

3
READ AND FOLLOW SAFETY
INSTRUCTIONS!
This is the safety alert symbol. When you see this symbol on your system
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 death, serious personal
injury, or major property damage if ignored.
warns about hazards that can cause death, serious personal
injury, or major property damage if ignored.
warns about hazards that will or can cause minor personal injury
or property damage if ignored.
NOTICE indicates special instructions not related to hazards.
Carefully read and follow all safety instructions in this manual and on equip-
ment. Keep safety labels in good condition; replace if missing or damaged.
Incorrectly installed or tested equipment may fail, causing
severe injury or property damage.
Read and follow instructions in owner's manual when installing
and operating equipment. Have a trained pool professional per-
form all pressure tests.
1. Do not connect system to a high pressure or city water system.
2. Use equipment only in a pool or spa installation.
3. Trapped air in system can cause explosion. BE SURE all air is out of system
before operating or testing equipment.
Before pressure testing, make the following safety checks:
• Check all clamps, bolts, lids, and system accessories before testing.
• Release all air in system before testing.
• Tighten Sta-Rite trap lids to 30 ft. lbs. (4.1 kg-m) torque for testing.
•Water pressure for test must be less than 25 PSI (7.5 kg/cm2).
• Water Temperature for test must be less than 100oF. (38oC).
• Limit test to 24 hours. After test, visually check system to be sure it is ready
for operation. Remove trap lid and retighten hand tight only.
NOTICE: These parameters apply to Sta-Rite equipment only. For
non-Sta-Rite equipment, consult manufacturer.
IMPORTANT
SAFETY
INSTRUCTIONS
Always follow basic safety pre-
cautions with this equipment, in-
cluding the following.
To reduce the risk of
injury, do not permit children to
use this product unless they are
closely supervised at all times.
This pump is for use
with permanently installed pools
and may also be used with hot
tubs and spas if so marked. Do
not use with storable pools. A
permanently installed pool is con-
structed in or on the ground or in
a building such that it cannot be
readily disassembled for storage.
A storable pool is constructed so
that it may be readily disassem-
bled for storage and reassembled
to its original integrity.
SAVE THESE
INSTRUCTIONS

4
INSTALLATION
Only qualified, licensed personnel should install pump and wiring.
Pump mount must:
Be solid - Level - Rigid - Vibration free. (To reduce vibration and pipe stress,
bolt pump to mount.)
Allow pump suction inlet height to be as close to water level as possible.
Allow use of short, direct suction pipe (To reduce friction losses).
Allow for gate valves in suction and discharge piping.
Have adequate floor drainage to prevent flooding.
Be protected from excess moisture.
Allow adequate access for servicing pump and piping.
NOTICE: Use Teflon tape or Plasto-Joint Stik1for making all threaded connec-
tions to the pump. Do not use pipe dope; pipe dope will cause stress cracking
in the pump.
NOTICE: Pump suction and discharge connections have molded in thread
stops. DO NOT try to screw pipe in beyond these stops.
Teflon Taping Instructions:
Use only new or clean PVC pipe fittings.
Wrap male pipe threads with one to two layers of Teflon tape. Cover entire
threaded portion of pipe.
Do not overtighten or tighten past thread stop in pump port!
If leaks occur, remove pipe, clean off old tape, rewrap with one to two addi-
tional layers of tape and remake the connection.
NOTICE: Support all piping connected with pump!
1Lake Chemical Co., Chicago, Illinois
Figure 1

5
Piping:
Use at least 2" IPS PVC (51mm) pipe. Increase size if a long run is needed.
To avoid strains on the pump, support both suction and discharge pipes inde-
pendently. Place these supports near the pump.
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 gate valves in suction and discharge pipes.
Fittings:
Fittings restrict flow; for best efficiency use fewest possible fittings.
Avoid fittings which could cause an air trap.
Pool fittings must conform to International Association of Plumbing and
Mechanical Officials (IAPMO) standards.
Use only non-entrapping suction fitting or double suction.
TABLE I - RECOMMENDED FUSING AND WIRING DATA
Serv. to Motor - Dist. in Ft. (M)
Motor Branch Fuse Max Load Voltage/ 0-100' 101-200' 201-300'
HP Rating Amps* Amps Hz/Phase (0-30 M) (30-60 M) (60-90 M)
P4R Models:
1 30 19.2 115/60/1 10(5.5) 8(8.4) 6(13)
115 9.6 230/60/1 14(2) 14(2) 12(3)
1-1/2 15 12.0 230/60/1 14(2) 14(2) 12(3)
215 11.2 230/60/1 14(2) 14(2) 12(3)
P4RA Models:
1-1/2 30 19.2 115/60/1 10(5.5) 8(8.4) 6(13)
1-1/2 15 9.6 230/60/1 14(2) 14(2) 12(3)
1-3/4 15 12.0 230/60/1 14(2) 14(2) 12(3)
215 12.0 230/60/1 14(2) 14(2) 12(3)
2-1/2 15 11.2 230/60/1 14(2) 14(2) 12(3)
P4R62 Models:
3/4 15 3.8 200/60/3 14(2) 14(2) 14(2)
115 5.6 200/60/3 14(2) 14(2) 14(2)
1-1/2 15 6.6 200/60/3 14(2) 14(2) 14(2)
215 9.8 200/60/3 14(2) 14(2) 14(2)
P4R6 3-Phase Models:
3/4 15/15 3.6/1.8 230/460/60/3 14(2) 14(2) 14(2)
1 15/15 4.7/2.35 230/460/60/3 14(2) 14(2) 14(2)
1-1/2 15/15 5.8/2.9 230/460/60/3 14(2) 14(2) 14(2)
2 15/15 7.0/3.5 230/460/60/3 14(2) 14(2) 14(2)
2-1/2 15/15 9.7/4.9 230/460/60/3 14(2) 14(2) 12(3)/14(2)
3 15/15 11.5/5.8 230/460/60/3 14(2) 14(2) 12(3)/14(2)
* Time delay fuses are recommended instead of standard fuses in any motor circuit.
Wire
Size
AWG
(mm2)
}
Wire
Size
AWG
(mm2)
}
Wire
Size
AWG
(mm2)
}
Wire
Size
AWG
(mm2)
}

6
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.
Ground Fault Circuit Interrupter (GFCI) tripping indicates an electrical
problem. If GFCI trips and will not reset, have a qualified electrician
inspect and repair electrical system.
Exactly match supply voltage to nameplate voltage. Incorrect voltage
can cause fire or seriously damage motor and voids warranty.
If in doubt consult a licensed electrician.
Voltage
Voltage at motor must be not more than 10% above or below motor name-
plate rated voltage or motor may overheat, causing overload tripping and re-
duced component life. If voltage is less than 90% or more than 110% of rated
voltage when motor is running at full load, consult power company.
Grounding/Bonding
Install, ground, bond and wire motor according to local or National Electrical
Code requirements.
Permanently ground motor. Use green ground terminal provided under motor
canopy or access plate (See Figure 2); use size and type wire required by
code. Connect motor ground terminal to electrical service ground.
Bond motor to pool structure. Use a solid copper conductor, size No. 8 AWG
(8.4 sq.mm) or larger. Run wire from external bonding lug (see Figure 2) to re-
inforcing rod or mesh.
Connect a No. 8 AWG (8.4 sq.mm) solid copper bonding wire to the pressure
wire connector provided on the motor housing and to all metal parts of the
swimming pool, spa, or hot tub and to all electrical equipment, metal piping
or conduit within 5 feet (1.5 m) of the inside walls of swimming pool, spa, or
hot tub.
Wiring
Pump must be permanently connected to circuit. Match wire and circuit
breaker sizes to Table I (Page 5). If other lights or appliances are also on the
same circuit, be sure to add their amp loads to pump amp load. (If unsure how
to do this or if this is confusing, consult a licensed electrician.) Use the load
circuit breaker as the master on-off switch.
Install a Ground Fault Circuit Interrupter (GFCI) in circuit; it will sense a short-
circuit to ground and disconnect power before it becomes dangerous to pool
users. For size of GFCI required and test procedures for GFCI, see manufac-
turer’s instructions.
In case of power outage, check GFCI for tripping (which will prevent normal
water circulation). Reset if necessary.
NOTICE: If you do not use conduit when wiring motor, be sure to seal wire
opening on end of motor to prevent dirt, bugs, etc., from entering motor.
Bonding
Lug
Motor Nameplate
Green
Ground
Screw
Motor
Canopy
Through
Bolts 349 0893
Hazardous voltage.
Can shock, burn,
or cause death.
Ground pump before
connecting to
power supply.
Figure 2: Typical ground screw and
bonding lug locations.
Figure 3: Single-phase wiring hookup
diagram. For 3-phase
hookups, refer to motor
nameplate.
A
B
L2
L1
White
230
Volt
Lines
Blue
SINGLE
VOLTAGE
MOTORS
A
B
L2
L1
White w/
Black
Tracer
Black
230
Volt
Lines
DUAL
VOLTAGE
MOTORS
469 0194
A
B
L2
L1
White w/
Black
Tracer
Black
115
Volt
Lines
Motor Terminal Board Connections

7
OPERATION
NEVER run pump dry. Running pump dry may damage seals, causing
leakage and flooding. Fill pump with water before starting motor.
Before removing trap cover:
1. STOP PUMP before proceeding.
2. CLOSE GATE VALVES in suction and discharge pipes.
3. RELEASE ALL PRESSURE from pump and piping system.
4. NEVER tighten or loosen clamp while pump is operating!
If pump is being pressure tested, be sure pressure has been released be-
fore removing trap cover.
Do not block pump suction. To do so with body may cause severe or
fatal injury. Small children using pool must ALWAYS have close adult
supervision.
Priming Pump
Release all air from filter and piping system: see filter owner’s manual.
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, unscrew and remove trap cover;
fill trap and pump with water.
Lubricate trap cover “O” Ring with petroleum jelly each time it is removed.
Clean and inspect “O” Ring; reinstall on trap cover.
Replace trap cover on trap; turn clockwise to tighten cover.
NOTICE: Tighten trap cover by hand only (no wrenches)! Use a wrench only
if necessary to remove lid!
Pump should prime now. Priming time will depend on vertical length of suc-
tion lift and horizontal length of suction piping.
If pump does not prime, make sure that all valves are open, suction pipe end
is under water, and that there are no leaks in suction pipe.
See Troubleshooting Guide, Page 11.
Routine Maintenance
The only routine maintenance needed is inspection/cleaning of trap basket.
Debris or trash that collects in basket will choke off water flow through the
pump. Follow instructions below to clean trap:
1. Stop pump, close gate valves in suction and discharge, and release all pres-
sure from system before proceeding.
2. Unscrew trap lid (turn counterclockwise). If necessary, use a lever such as a
board or long screwdriver between lugs on trap cover.
3. Remove strainer basket and clean. Be sure all holes in basket are clear,
flush basket with water and replace in trap with large opening at pipe con-
nection port (between ribs provided). If basket is replaced backwards cover
will not fit on trap body.
4. Clean and inspect lid “O” Ring; reinstall on trap cover.
5. Clean “O” Ring groove on trap body and replace lid. To help keep lid from
sticking, tighten hand tight only (no wrenches!).
6. Prime pump (see priming instructions).
Hazardous suction.
Can trap hair or
body parts, causing
severe injury
or death.
Do not block
suction.

8
Draining Pump
1. Pump down water level below all inlets to the pool.
To avoid dangerous or fatal electrical shock hazard, turn OFF power to
motor before draining pump.
2. Remove trap cover and use low pressure air to blow accumulated water
from the piping system. Lugs have been provided on the trap lid to use a
lever or pry bar for loosening.
3. Cap inlet piping after draining to keep water out of the pipes.
4. To prevent pump from freezing, remove trap cover and drain the tank body
through the drain plugs (Key No. 22, Pages 12 - 15). Clean pump and trap
basket thoroughly; replace trap cover.
NOTICE: Tighten trap cover by hand only (no wrenches)! Use a lever or
wrench only if necessary to remove cover! If pump is not anchored, use
caution not to break attached piping!
5. Be sure motor is kept dry and covered.
Storage/Winterizing:
Explosion hazard. Purging the system with compressed air can
cause components to explode, with risk of severe injury or death to anyone
nearby. Use only a low pressure (below 5 PSI), high volume blower when air
purging the pump, filter, or piping.
NOTICE: Allowing pump to freeze will damage pump and void warranty!
NOTICE: Do not use anti-freeze solutions (except propylene glycol) in your
pool/spa system. Propylene glycol is non-toxic and will not damage plastic
system components; other anti-freezes are highly toxic and may damage plas-
tic components in the system.
Drain all water from pump and piping when expecting freezing temperatures
or when storing pump for a long time (see instructions below).
Keep motor dry and covered during storage.
To avoid condensation/corrosion problems, do not cover pump with plastic.
For outdoor/unprotected installations:
1. Gravity drain system as far as possible.
2. Protect areas which retain water with non-toxic propylene glycol antifreeze
(“RV antifreeze”).
3. Enclose entire system in a weatherproof enclosure.
4. To avoid condensation/corrosion damage, allow ventilation; do not wrap
system in plastic.
5. Use a 40% propylene glycol/60% water solution to protect pump to -50°F
(-46°C).
Startup For Winterized Equipment
1. Remove any temporary weather protection placed around system.
2. Follow filter manufacturer’s instructions for reactivation of the filter.
3. Inspect all electrical wiring for damage or deterioration over the shutdown
period. Have a qualified serviceman repair wiring as needed.
4. Inspect and tighten all watertight connections.
5. Open all valves in suction and return piping.
6. Remove any winterizing plugs in piping system.
7. Drain all antifreeze from system.
8. Close all drain valves and replace all drain plugs in piping system.
9. Prime pump according to instructions on Page 7.
Hazardous voltage.
Can shock, burn,
or cause death.
Disconnect power
before working
on pump or motor.

9
PUMP SERVICE
Pump should only be serviced by qualified personnel.
Be sure to prime pump (Pg. 7) before starting.
Before removing clamp or trap cover:
1. STOP PUMP before proceeding.
2. CLOSE GATE VALVES in suction and discharge pipes.
3. RELEASE ALL PRESSURE from pump and piping system.
4. NEVER tighten or loosen clamp while pump is operating!
To avoid dangerous or fatal electrical shock hazard, turn OFF power to
motor before working on pump or motor.
Aside from lubricating trap cover “O” Ring, no lubrication or regular mainte-
nance is needed beyond reasonable care and periodic cleaning of strainer
basket.
If shaft seal is worn or damaged, repair as follows:
Pump Disassembly/Removing Old Seal
Disconnect power to pump motor.
Be sure gate valves on suction and return piping are closed before start-
ing work.
Release all pressure by opening all vents before starting work.
1. Drain pump by removing drain plugs on bottom of pump body and trap
body.
2. Be sure there is no pressure in trap body; remove cover (unscrew by turn-
ing counterclockwise).
3. Remove clamp holding pump halves together. Motor and seal plate as-
sembly can now be pulled away from pump body.
4. Remove five screws and washers holding diffuser to seal plate. Remove
diffuser.
5. Remove motor canopy. Being careful not to touch capacitor terminals,
loosen capacitor clamp and move capacitor to one side.
6. Hold shaft with 7/16" open-end wrench on motor shaft flats.
7. Unscrew impeller from shaft (turn counterclockwise when facing it).
NOTICE: On models with impeller screw: Remove impeller screw
(left hand thread - turn clockwise) and gasket before removing impeller.
Inspect gasket for damage, cracks, etc. Replace if damaged.
8. Pull rotating member of seal off of impeller sleeve; clean sleeve.
9. Remove four screws holding seal plate to motor.
10. Place seal plate face down on flat surface and tap out ceramic seat.
NOTICE: Do not force out heat sink insert (Key. No. 8, Pages 12-15).
If insert has moved, pump will leak; see “Installing Heat Sink Insert,”
Page 10.
11. Clean seal cavity in seal plate and clean motor shaft.
Hazardous voltage.
Can shock, burn,
or cause death.
Disconnect power
before working
on pump or motor.
Figure 4

10
Pump Reassembly/Installing New Seal
1. Ceramic seat must be clean and free of dirt, grease, dust, etc. Wet outer
edge of “O” Ring with small amount of liquid detergent; press ceramic
seat into heat sink insert firmly and squarely with finger pressure (Fig. 5).
2. If ceramic seat will not locate properly, remove it, place face up on bench
and reclean cavity. Ceramic seat should now locate.
3. If seat still will not locate properly, place a cardboard washer over the
polished face and use a piece of 3/4" (19mm) standard pipe for pressing
purposes. NOTICE: Be sure not to scratch or mar polished surface or seal
will leak.
4. Remount seal plate on motor. Tighten bolts to 60-80 inch-lbs.
(69-92 kg/cm) torque.
5. Apply a small amount of liquid detergent to inside diameter of rotating
half of seal.
6. Slide rotating seal member, polished face last, over impeller sleeve until
rubber drive ring hits shoulder (Figure 3).
NOTICE: Be sure not to nick or scratch polished seal face; seal will leak if
face is damaged.
7. Screw impeller onto shaft (clockwise); this will automatically locate seal in
seal plate.
NOTICE: On models with impeller screw: Install impeller gasket and lock
screw (left-hand thread - turn counterclockwise). Torque lock screw to
50-55 inch-lbs. (57.6-63 kg/cm).
8. Mount diffuser on seal plate; tighten screws to 10-14 inch-lbs. (11.2-16.1
kg/cm) torque.
9. Assemble motor and seal plate to volute; be sure clamp is properly
seated.
NOTICE: Clamp knob can be located in any position around volute; if it
is moved after assembly, tighten knob while tapping around clamp to as-
sist sealing. Do not move clamp while pump is full of water.
Hazardous pressure. Release all pressure from pump and
piping system before working on pump or attempting to adjust or re-
move clamp. Clamp may blow off of pump if adjusted under pressure.
10. Prime pump according to instructions on Page 7.
Installing Heat Sink Insert:
1. If the heat sink insert moves or shifts during seal removal, remove and re-
place with a new insert to prevent leakage.
Removal:
1. Remove two screws holding heat sink insert to seal plate.
2. Place seal plate face down on bench and use a short length of 1/2” pipe
to push insert out of seal plate.
3. Remove “O” Ring from insert cavity in seal plate and discard.
NOTICE: Do not scratch “O” Ring seat in seal plate.
Installation:
1. Clean heat sink insert cavity in seal plate, including “O” Ring seat (step in
seal plate cavity - see Figure 7).
NOTICE: Do not scratch “O” Ring seat surface.
2. Lubricate new “O” Ring with petroleum jelly and insert into seat in seal
plate (Figure 8).
Figure 5: Press seal into heat sink in
seal plate
Figure 6: Seal Plate/Heat Sink
sectional drawing
Figure 7: Clean O-Ring Seat
Figure 8: Install O-Ring in Seal Plate