STA-RITE MAX-E-GLAS IITM User manual

MAX-E-GLAS IITM and DURA-GLAS IITM
CENTRIFUGAL PUMPS
WITH INTEGRAL TRAP
O W N E R’ S M A N U A L
INSTALLATION, OPERATION & PARTS
Series P4E, P4EA, P4R, and P4RA
See Page 2 for Model Numbers
Sta-Rite Pool/Spa Group
293 Wright Street, Delavan, WI 53115
North America: 800-752-0183, FAX [phone]
International: 262-728-5551, FAX: [phone], TELEX: ITT 4970245
www.sta-ritepool.com
Union City, TN • Delavan, WI • Mississauga, Ont. • Murrieta, CA
©2002, Sta-Rite Industries, Inc. Printed in U.S.A. S454 (Rev. 12/5/02)
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 ‘P4E’ 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 ‘P4E’ 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.................................................................................................4-6
Electrical....................................................................................................6-8
Operation ................................................................................................9-10
Storage/Winterizing ....................................................................................10
Pump Service.........................................................................................11-12
Troubleshooting Guide ...............................................................................13
Repair Parts List .....................................................................................14-18
Warranty.....................................................................................................19
Max-E-Glas II™
HP
3/4 P4E6D-186L P4E62D-186L P4E6D-186LV
1 P4E6E-187L P4EA6E-186L P4E62E-187L P4E6E-187LV
1-1/2 P4E6F-188L P4EA6F-187L P4E62F-188L P4E6F-188LV
1-3/4 P4EAA6F-198L
2 P4E6G-189L P4EA6G-188L P4E62G-189L P4E6G36-189 P4E6SSG36-189
2 P4E6G-189LV P4EA6G-188LV
2-1/2 P4EAA6G-189L
3 P4E6H-190LV
3P4E6H-190L P4E62H-190L P4E6H36-190 P4E6SSH36-190
Dura-Glas II™
HP
3/4 P4R62D3-186 P4R6D3-186
1 P4R62E3-187 P4R6E-187L P4RA6E-186L P4R6E3-187
1-1/2 P4R62F3-188 P4R6F-188L P4RA6F-187L P4RA6YF-187L P4R6F3-188
1-3/4 P4RAA6F-198L
2 P4R62G3-189 P4R6G-189L P4RA6G-188L P4R6G3-189
2-1/2 P4RAA6G-189L P4RA6YG-188L
3P4R6H3-190

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. Install pump with at least 2 hydraulically balanced main drains equipped
with correctly installed, screw-fastened, anti-entrapment certified covers.
See Page 5.
4. 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.
INSTALLATION
Only qualified, licensed personnel should install pump and wiring.
Pump mount must:
Be located away from corrosive or flammable chemicals.
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
Have enough ventilation to maintain air temperature at less than the maximum
ambient temperature rating (Max. Amb.) listed on the motor model plate. If this
pump is installed in an enclosure/pump house, the enclosure must have ade-
quate ventilation and air circulation to keep the temperature in the enclosure at
or below the motor’s rated ambient temperature whenever the pump is running.
Be solid - Level - Rigid - Vibration free - Non-combustible. (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.
Fire and burn hazard. Modern motors run at high temperatures.
To reduce the risk of fire, do not allow leaves, debris, or foreign matter to col-
lect around the pump motor. To avoid burns when handling the motor, let it
cool for 20 minutes before trying to work on it.
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.
POOL PUMP SUCTION
REQUIREMENTS
Pump suction is hazardous and can trap and drown or disem-
bowel bathers. Do not use or operate swimming pools, spas, or hot tubs if a
suction outlet cover is missing, broken, or loose. Follow the guidelines below
for a pump installation which minimizes risk to users of pools, spas, and hot
tubs.
Entrapment Protection
The pump suction system must provide protection against the hazard of
suction entrapment or hair entrapment/entanglement.
Suction Outlet Covers
All suction outlet covers must be maintained. They must be replaced if
cracked, broken, or missing.
See below for outlet cover certification requirements.
All suction outlets must have correctly installed, screw-fastened covers in
place.
At Least
3 Feet
Suction Outlet
(Main Drain)
Suction Outlet
(Main Drain)
IAPMO Certified
Anti-entrapment
Cover or Suction Fitting,
screw-fastened to
Main Drain Sump
IAPMO Certified
Anti-entrapment
Cover or Suction Fitting,
screw-fastened to
Main Drain Sump
Pump
Valves OK between
pump and Tee
No valves between
Tee and Main Drains
2762 0197
Figure 2 – Recommended pump suction layout.

Hazardous voltage.
Can shock, burn,
or cause death.
Ground pump before
connecting to
power supply.
6
Testing and Certification
Suction outlet covers must have been tested by a nationally recognized testing
laboratory and found to comply with the latest ASME/ANSI Specification for
Suction Fittings For Use in Swimming Pools, Spas, Hot Tubs, and Whirlpool
Bathtub Applications.
Outlets Per Pump
Provide at least two hydraulically balanced main drains, with covers (see Page
5), for each swimming pool pump suction line. The centers of the main drains
(suction fittings) must be at least three feet apart.
The system must be built so that it cannot operate with the pump drawing
water from only one main drain (that is, there must be at least two main drains
connected to the pump whenever it is running). (See Figure 2). However, if
two main drains run into a single suction line, the single suction line may be
equipped with a valve which will shutoff both main drains from the pump
(see Figure 2).
More than one pump can be connected to a single suction line as long as the
requirements above are met.
Water Velocity
The maximum water velocity through any suction outlet must be 1.5 feet per
second unless the outlet complies with the latest ASME/SNSI Specification for
Suction Fittings For Use in Swimming Pools, Spas, Hot Tubs, and Whirlpool
Bathtub Applications. In any case, do not exceed the suction fittings maxi-
mum designed flow rate.
If 100% of the pump’s flow comes from the main drain system, the maximum
water velocity in the pump suction hydraulic system must be six feet per sec-
ond or less even if one main drain (suction fitting) is completely blocked. The
flow through the remaining main drain(s) must comply with the latest
ASME/ANSI Specification for Suction Fittings For Use in Swimming Pools,
Spas, Hot Tubs, and Whirlpool Bathtub Applications.
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.
NOTICE: 3 phase
models require mag-
netic motor starters
and external overload
protection.
If in doubt about the
procedure, consult a
licensed electrician.

7
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 3); 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 3) to
reinforcing 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. See Figures 4A, 4B, and 4C
for wiring connection diagrams. Match wire and circuit breaker sizes to cor-
rect Fusing and Wiring Data Chart (Page 8). 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
GREEN
GROUND
SCREW
510 0993
Figure 3: Typical ground screw and
bonding lug locations.
Figure 4A: Single-phase, single speed
wiring connection diagram.
For 3-phase connection, refer
to motor nameplate.
Figure 4B: Wiring connections for
plug-in type terminal board
(Single speed, single phase
motors)
Figure 4C: Single-phase, 2-speed wiring hookup diagram
(Models P4RA6YF-187L and P4RA6YG-188L).
A
B
L2
L1
White
230
Volt
Lines
Blue
469 0194A
Power Supply for
Optional Timer.
Low Spd
High Spd Circuit
Protector
Remote
SPDT
Switch
Ground (Green)
Common
If using timer, Connect
Timer Motor to Low Speed Only
Minimum switch and timer amp rating must equal Branch Fuse
Rating given in "Recommended Fusing and Wiring Data" table.
A
B
L2
L1
230
Volt
Lines
Back of
motor
with
Terminal
Board
1168 0794
Pull plug
straight
out from
terminal
board.
1.
1.
2.
2.
Plug in again
with arrow
on plug
pointing to
'115 Volts'.
A
L1
230 Volts
115 Volts
A
L1
230 Volts
115 Volts
Ground
Screw
3962 0401 A
115 V
230 V
230 Volt to 115 Volt Conversion. Move plug to change voltage.
Ground
Screw
230V
115V
230V
115V
A
A
L2
L2
L1
L1
230V
115V
A
A
L2
L2
L1
L1
230V
115V
Power Supply
Wires
230 Volt to 115 Volt Conversion. Move plug to change voltage.

8
TABLE II - RECOMMENDED FUSING AND WIRING DATA – P4R, P4RA MODELS
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:
13019.2 115/60/1 10(5.5) 8(8.4) 6(14)
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:
120/15 15.3/7.6 115/230/60/1 12/14(3/2) 8/14(8.4/2) 6/14(14/2)
1-1/2 30 19.2 115/60/1 10(5.5) 8(8.4) 6(14)
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)
P4RA 2-Speed Models:
1-1/2 - 1/4 15 9.2/2.5 230/60/1 14(2) 14(2) 12(3)
2 - 1/3 15 10.2/3.7 230/60/1 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)
115/15 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)
215/15 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)
315/15 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)
}
Wire
Size
AWG
(mm2)
}
TABLE I - RECOMMENDED FUSING AND WIRING DATA – P4E, P4EA MODELS
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)
P4E Models:
3/4 20 13.8 115/60/1 12(3) 10(5.5) 8(8.4)
125 16.0 115/60/1 12(3) 8(8.4) 6(14)
115 8.0 230/60/1 14(2) 14(2) 14(2)
1-1/2 15 10.4 230/60/1 14(2) 12(3) 12(3)
215 11.2 230/60/1 14(2) 12(3) 12(3)
215 1.5 575/60/3 14(2) 14(2) 14(2)
315 3.4 575/60/3 14(2) 14(2) 14(2)
325 15.8 230/60/1 12(3) 12(3) 10(5.5)
P4EA Models:
12013.8 115/60/1 12(3) 10(5.5) 8(8.4)
1-1/2 25 16.0 115/60/1 12(3) 8(8.4) 6(14)
115 6.9 230/60/1 14(2) 14(2) 14(2)
1-1/2 15 8.0 230/60/1 14(2) 14(2) 12(3)
1-3/4 15 10.4 230/60/1 14(2) 12(3) 12(3)
215 10.4 230/60/1 14(2) 12(3) 12(3)
2-1/2 15 11.2 230/60/1 14(2) 12(3) 12(3)
P4E62 Models:
3/4 20 13.4 100/60/1 14(2) 12(3) 8(8.4)
3/4 15 6.7 200/60/1 14(2) 14(2) 14(2)
115 7.4 200/60/1 14(2) 14(2) 12(3)
1-1/2 15 10.5 200/60/1 14(2) 12(3) 12(3)
220 14.2 200/60/1 12(3) 12(3) 10(5.5)
325 17.6 200/60/1 10(5.5) 10(5.5) 10(5.5)
* 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)
}

9
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.
Fire and burn hazard. Modern motors run at high temperatures.
To reduce the risk of fire, do not allow leaves, debris, or foreign matter to col-
lect around the pump motor. To avoid burns when handling the motor, let it
cool for 20 minutes before trying to work on it. An automatic internal cutoff
switch protects the motor from heat damage during operation.
NOTICE: Maximum ambient temperature for motor operation must not
exceed maximum ambient temperature rating on motor model plate.
Priming Pump
Release all pressure from filter, pump, and piping system; see the 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.
Do not lubricate the trap cover O-Ring. The original equipment O-Ring con-
tains a permanent internal lubricant.
NOTICE: If you replace the O-Ring with a non-internally lubricated O-Ring,
you may need to apply a silicone based lubricant.
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 13.
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 valves in suction and discharge, and release all pressure
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.
Hazardous suction.
Can trap hair or
body parts, causing
severe injury
or death.
Do not block
suction.

10
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).
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. 19, Pages 14 - 18). 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).
Hazardous voltage.
Can shock, burn,
or cause death.
Disconnect power
before working
on pump or motor.