Theralux Theraflo S Series Supplement

SELF-PRIMING SWIMMING POOL PUMP
INSTALLATION AND OPERATING INSTRUCTION MANUAL
Your Theralux self-priming centrifugal pump has been quality-built
and engineered to give you many years of efficient, dependable,
corrosion free service. The advanced design reduces operation and
maintenance to simple, common-sense procedures.
IMPORTANT
*This appliance is not intended for use by young children unless
they have been adequately supervised by a responsible
person to
ensure they can use the appliance. Young children should
be
supervised to ensure that they do not play with the appliance*
TROUBLESHOOTING

GENERAL TIPS ON PUMP INSTALLATION
Locate the pump as close to pool as practical and run suction line as direct as possible.
Secure pump to base with screws or bolts to reduce vibration and pipe stress.
Never overtighten pipe connections - use only pipe sealants formulated specifically
for plastics, i.e., Teflon tape, Permatex No. 2, etc.
Suction line should have continuous slope from lowest point in line.
Make sure suction joints are tight.
Suction pipe should be as large or larger than discharge pipe.
Damp, non-ventilated locations should be avoided.
Motors require free circulation of air to aid in cooling.
Ensure that the electrical supply available agrees with motor's voltage and is 50 Hz,
and that wire size is adequate for the KW rating and distance from power source.
Motor must always be properly earthed.
Electrical circuits must be supplied through a Residual Current Device- RCD (safety switch),
with a rated residual operating current of 30mA.
All electrical wiring must be performed by qualified electrical contractor and must conform to
electrical regulations and AS3000 wiring rules.
STARTING AND PRIMING INSTRUCTIONS
Fill strainer/housing with water to suction pipe level.
Never operate the pump without water. Water acts as a coolant and lubricant for the mechanical
shaft seal.
Open all suction and discharge lines and valves, as well as air bleed
(if available) on filter.
(The air that is to be displaced from the suction line must have some place to go).
CAUTION: All suction and discharge valves must be open when starting the system.
Failure to do so could cause severe personal injury and/or property damage.
STARTING AND PRIMING INSTRUCTIONS
Turn on power and allow a reasonable time for priming. Five minutes is not unreasonable. (Priming
time depends on suction lift and horizontal length
of suction piping). If the pump will not start, or will not prime, see TROUBLE SHOOTING GUIDE on
back page.
NOTICE FOR SOLAR APPLICATIONS
A check valve must be fitted to the discharge of the pump when installed with solar system.

SHAFT SEAL CHANGE INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS- PLEASE READ AND FOLLOW ALL
INSTRUCTIONS
When servicing electrical equipment, basic safety precautions should always
be observed including the following. Failure to follow the instructions may
result in injury.
• Disconnect the pump motor power cord from the power outlet before
beginning the shaft seal replacement.
• Only qualified personnel should attempt to replace the shaft seal. Contact
your local Authorised Theralux Service Centre if you have any questions.
• Exercise extreme care in handling both the rotating and stationary sections
of the two-part replacement seal. Foreign matter or improper handling will
easily scratch the graphite and ceramic sealing surfaces.
• See the "Parts Diagram" on page 5 for the pump component locations.
Removing the Motor Assembly
1. Remove the six (6) 3/8" x 2" hex head bolts (item 14), which hold the motor
assembly to the pump/strainer housing (item 1), using a 1/2" AF spanner or
socket.
2. Slide the motor assembly out of the pump/strainer housing (item 1),
exposing the diffuser (item 6). Pull the diffuser off the seal plate (item 10),
exposing the impeller. (The diffuser may remain in the pump/strainer housing.
To remove, pull it straight out of the pump/strainer housing.
Removing the Impeller
1. To prevent the motor shaft from turning, insert a flat blade screwdriver
through the centre hole in the fan cowling and into the slot on the end of the
motor shaft and hold it.
2. Remove the impeller (item 8) by rotating it counter- clockwise. The spring
portion of the seal assembly is now exposed. Note carefully the position of
the spring seal, and remove it. Also remove the impeller ring (item 7) from the
impeller and note the way it was installed.
Removing the Ceramic Seat
1. Remove the seal plate (item 10) from the motor mounting plate (item 13).
2. Press the ceramic seat with rubber cup out of the seal plate (item 10). If
tight, use a small screwdriver to tap the seal out from the back side of the
seal plate.
IMPORTANT - Clean all recesses and parts to be reassembled.
Inspect gaskets and replace if necessary.

SEAL, IMPELLER AND DIFFUSER INSTALLATION
1. Clean and lightly lubricate the motor shaft and seal recess in the seal plate
(item 10) with a dilute solution of non-granulated liquid type soap. Gently wipe
the polished face of the ceramic seal with a soft, lint free cotton cloth.
Lubricate the rubber cup on the ceramic seat and press it firmly into the recess
of the seal plate (item 10), with the polished ceramic surface facing towards
you. Ensure the motor shaft slinger (item 12) is slid all the way down the shaft.
2. Place the seal plate (item 10) onto the motor mounting plate (item 13), align
the tabs on the seal plate with the grooves on the motor mounting plate. The
outside profile of the two parts should be the same.
3. Gently wipe the black, polished surface of the carbon spring seal assembly
(item 9) with a soft, lint free cotton cloth.
4. Clean and lubricate the impeller (item 8) and press the carbon spring seal
assembly (item 9) onto the impeller hub with the black, polished surface
facing away from the impeller.
5. Screw the impeller (item 8) onto the motor shaft in a clockwise direction
and tighten snugly by holding the motor shaft with the flat blade screwdriver
as explained earlier. Place the impeller ring (item 7) back onto the impeller
(item 8), with its flange facing towards the diffuser (item 6)
6. Place the diffuser (item 6) over the impeller (item 8) and onto the seal plate
(item 10), aligning the word "TOP" and the arrow to the top of the motor, or,
the top ridge of the seal plate. Give it a tap with the heal of your hand to make
it seat into position on the seal plate. Ensure the diffuser gasket is fitted to the
diffuser to the outside of the diffuser inlet.
7. Replace the motor assembly into the pump/strainer housing in the reverse
order of the removal steps. Ensure the housing gasket (item 5) is lubricated
and tighten the housing bolts (item 14) in a cross pattern and evenly.
MAINTENANCE
1.Clean strainer basket regularly. Do not strike basket to clean.
2. Inspect strainer cover 0-ring regularly and replace as necessary. Keep
cover 0-ring lubricated.
3. This pump has self-lubricating motor bearings and shaft seals. No
lubrication is necessary.
4. Keep motor clean. Ensure air vents are free from obstruction.
NB: Do not use petroleum based lubricants on gaskets, 0-rings or plastic
components. Use only silicone based lubricants.
MAXIMUM TOTAL HEAD - IMPORTANT INSTALLATION INFORMATION
MODEL
MAX TOTAL
METRES HEAD
MAX PRES
-
SURE kPA
MODEL
MAX TOTAL
METRES HEAD
MAX PRES
-
SURE kPA
Theraflo .75hp
16.3
159
Theraflo 1.5hp
19.7
193
Theraflo 1hp
16.5
161
Theraflo 2hp
22.1
217
Theraflo 1.25hp
18.3
179

THERAFLO S-SERIES REPLACEMENT PARTS
REF NO. PART NO. DESCRIPTION
1 THERA F4301 Pump Housing/Strainer - 50mm, w/Drain Plugs. threaded style
2 THERAF4302 Basket
3 THERAF4303 Strainer Cover O-Ring
4 THERAF4304 Strainer Cover, Hand- Knob Style, Clear
5 THERA F4305 Housing Gasket
6 THERAF4306A Diffuser (suit Theraflo .75hp, Theraflo 1hp)
THERAF4306B Diffuser (suit Theraflo 1.5hp. Theraflo 2hp)
THERAF4323 Diffuser Gasket - not shown
7 THERAF4307A Impeller Ring (suit Theraflo .75hp, Theraflo 1hp)
THERAF4307B Impeller Ring (suit Theraflo 1.5hp, Theraflo 2hp)
8 THERAF4308A Impeller (suit Theraflo .75hp)
THERAF4308B Impeller (suit Theraflo 1hp)
THERAF4308D Impeller (suit Theraflo 1.5hp)
THERAF4308 E Impeller (suit Theraflo 2hp)
9 THERAF4309 Seal Assembly
10 THERAF4310 Seal Plate
11 THERAF4311 Motor Cap Screw
12 THERAF4312 Slinger
13 THERAF4313 Motor Mounting Plate
14 THERAF4314 Housing Cap Screw
15 THERAF4315A Motor (suit Theraflo .75hp)
THERAF4315B Motor (suit Theraflo 1hp)
THERAF4315D Motor (suit Theraflo 1.5hp)
THERAF43 15E Motor (suit Theraflo 2hp)
16 THERAF4316 Mounting Bracket with Adaptor and 2 Cap Screws
17 THERAF4317 Mounting Foot Cap Screws (set of 2)
18 THERAF4318 Drain Plug with O-Ring
THERA F4320 Hand Knob Kit for Strainer Cover (inc Hand Knob & Swivel Nut) - not shown
THERAF4321 Union Kit (2) 40mm - 50mm - not shown
THERAF4322 Union Gasket (T-Seal) - not shown

THERAFLO REPLACEMENT PARTS DIAGRAM THERAFLO REPLACEMENT PARTS TABLE
REF NO. PART NO. DESCRIPTION
1 & 2 THERAF4320 Hand Knob Kit for Strainer Cover (inc Hand Knob &
Swivel Nut)
3 THERAF4304 Strainer Cover, Hand Knob Style - Clear
4 THERAF4303 Strainer Cover O-Ring
5 THERAF4302 Basket
6 THERAF4301B Pump Housing/Strainer - 50mm, w/Drain Plugs, threaded
external
7 & 8 THERAF4318 Drain Plug with O-Ring
9 THERAF4317 Mounting Foot Cap Screw (set of 2)
10 THERAF4316B Mounting Bracket, hps style
11 THERAF4323 Spacer for motor support (required only for 1hp model)
12, 13, 14 THERAF4321 Union Kit (set of 2) suit 40mm & 50mm w/Gasket (T-Seal)
15 THERAF4322 Union Gasket (T-Seal)
16 THERAF4305 Housing Gasket
17 THERAF4323B Diffuser Gasket
18 THERAF4306C Diffuser
19 THERAF4307B Impeller Ring
20 THERAF4308K Impeller 1HPVS (required only for 1hp model)
21 THERAF4309B Seal Assembly (inc, Mechanical Seal and Slinger)
22 THERAF4312B Slinger
23 THERAF4310B Seal Plate
24 THERAF4311B Motor Cap Screw (4 required)
25 THERAF4313B Motor Mounting Plate
26 THERAF4315K Motor 1HPVS (required only for 1hp model)
27 THERAF4314 Housing Cap Screw (6 required)
THERAF4308H Impeller 1.5HPVS (required only for 1.5hp model)
THERAF4315L Motor 1.5HPVS (required only for 1.5hp model)
THERAFLO REPLACEMENT PARTS DIAGRAM THERAFLO REPLACEMENT PARTS TABLE
REF NO. PART NO. DESCRIPTION
1 & 2 THERAF4320 Hand Knob Kit for Strainer Cover (inc Hand Knob &
Swivel Nut)
3 THERAF4304 Strainer Cover, Hand Knob Style - Clear
4 THERAF4303 Strainer Cover O-Ring
5 THERAF4302 Basket
6 THERAF4301B Pump Housing/Strainer - 50mm, w/Drain Plugs, threaded
external
7 & 8 THERAF4318 Drain Plug with O-Ring
9 THERAF4317 Mounting Foot Cap Screw (set of 2)
10 THERAF4316B Mounting Bracket, hps style
11 THERAF4323 Spacer for motor support (required only for 1hp model)
12, 13, 14 THERAF4321 Union Kit (set of 2) suit 40mm & 50mm w/Gasket (T-Seal)
15 THERAF4322 Union Gasket (T-Seal)
16 THERAF4305 Housing Gasket
17 THERAF4323B Diffuser Gasket
18 THERAF4306C Diffuser
19 THERAF4307B Impeller Ring
20 THERAF4308K Impeller 1HPVS (required only for 1hp model)
21 THERAF4309B Seal Assembly (inc, Mechanical Seal and Slinger)
22 THERAF4312B Slinger
23 THERAF4310B Seal Plate
24 THERAF4311B Motor Cap Screw (4 required)
25 THERAF4313B Motor Mounting Plate
26 THERAF4315K Motor 1HPVS (required only for 1hp model)
27 THERAF4314 Housing Cap Screw (6 required)
THERAF4308H Impeller 1.5HPVS (required only for 1.5hp model)
THERAF4315L Motor 1.5HPVS (required only for 1.5hp model)
THERAFLO WARRANTY
Theraflo S-Sieries carries a 3-year limited warranty and is structured in the
following way:
2 years warranty on motor
1 year warranty on mechanical seal
3 years on all other parts
Return to base.
Our warranty covers manufacturing faults, not wear and tear. We will, at our
discreon, repair or replace the faulty material or part. It is your responsibility to
nofy Theralux at the earliest possible me of any issues found within the
warranty period.
Proof of purchase is required to be presented with any warranty claim
submission.
This warranty does not apply to any misuse of the pool pump, negligence or
incorrect installaon. We will not cover any damage due to the pool pump
running dry, incorrect chemical balance of pool water, flood damage, damage
caused by running the pump off an extension cord, damage caused by foreign
material blocking the impeller (pebbles, organic maer, toys, etc.) or if the pool
pump is used for any other purpose other than a swimming pool.
We will not be liable for any incidental or consequenal damages, loss of me,
inconvenience, incidental expenses, labour or material charges in connecon
with the removal or replacement of the equipment, or costs of transporng the
goods.
We will not be liable for compensaon or damages to any person for any loss,
injury or damage to any person or property whatsoever, occasioned by or as a
result of the use of this equipment.
Please Note: Labour and service calls are not included in this warranty.
Any Theraflo pool pump found in a commercial application will only carry a 12
month warranty from date of purchase.
Register your product warranty online at www.theralux.com.au
or send a copy of proof of purchase to PO BOX 395 Padstow 2211
THERAFLO CARE & MAINTENANCE
It is strongly advised that you check the hair and lint pot basket area regularly for
any debris. If debris is found within the basket, you should empty the basket, as
a full basket can result in reduced water flow and an increased chance of
blocking the impeller.
To do this, please ensure that the power to the pump is turned off before you
remove the lid. You may also need to re-prime the pool pump once the clean
basket has been returned. Please follow priming instrucons found on start-up
page 10.
Regularly check the pump for any wet areas or leaks. If you find wet areas around
the pump, please check and re-tension the 2 connecng unions on the inlet &
outlet PVC lines.
If by chance you find water accumulang at the base of the motor, this could be
a sign of seal damage and acon should be taken immediately to avoid any
further damage. It is best to consult your local swimming pool professional if this
arises.
Please do not run your Theraflo TVS pool pump off an extension lead as this
results in a drop in voltage current which can damage the motor.
Always ensure that the pump itself is free of flooding.
Always ensure that the pump itself is well venlated. The pump motor will run
hot during its normal operaon and ulises the rear mounted fan to aid in
cooling. It is essenal that the rear of the pump is clear of all debris and fixtures
within 100mm.
Do not under any circumstances run your Theraflo TVS swimming pool pump
without water as this will damage the internal components. Running the pump
dry will void any warranty so it is imperave that you maintain adequate water
levels within your swimming pool at all mes. Please also be aware when using
any small pool toys in the swimming pool that may be small enough to block the
sucon line.

A. MOTOR WON'T START
1. Check open switches, relays,
blown circuit breakers or fuses.
2. Ensure power cord is p lugged in
and power is switched on
(240v Models only).
3. Refer to Theralux Authorised
Service Agent or qualified technician.
B. MOTOR CUTS OUT
NOTE: Your Theraflo pump
motor is equipped with
Automatic Thermal Overload
Protection. Motor automatic
shut-off, under normal conditions,
before heat damage build up, due
to an improper operating condition.
The motor will auto-restart when a
safe heat level is reached. If motor
fails to restart switch power off and
contact an Authorised Theralux
Service Technician or service company.
C. MOTOR HUMS, BUT DOES NOT START
If motor fails to start, switch
power off and contact an
Authorised Theralux Service
Technician or other qualified service
company.
D. PUMP WON'T PRIME
1. Make sure pump/strainer is filled
with water. and that cover gasket is
clean and properly seated. Tighten hand
nuts.
2. Make sure all suction and discharge
valves are open and unobstructed,
and that pool water level is above all
suction openings.
E. LOW FLOW
Generally, check for:
1. Clogged or restricted strainer or
suction line.
2. Plugged or restricted discharge
line of filter (high discharge gauge
reading).
3. Air leak in suction (bubbles issuing
from return fittings).
F. NOISY PUMP
Check for:
1. Air leak in suction causing rumbling
in pump.
2. Cavitation due to restricted or
undersized suction line and restricted
discharge lines.
3. Vibration due to improper mounting,
etc.
4. Foreign matter in pump housing.
5. Motor bearings made
unserviceable by wear, rust, or continual
overheating. Refer to Authorised Theralux
Service Agent.
G. If SUPPLY CORD IS DAMAGED, it
must be replaced by the manufacturer. its
service agent or similarly, qualified
persons to avoid a hazard.
WARNING
The Pump Motor is an electrical device and as such, should not be dis-
assembled or serviced by anyone other than an Authorised Theralux Service
Technician or qualified Electrical Service
Company. An experienced Pool Service Technician should attend to all problems
that routine maintenance cannot correct.
International Quadratics
www.theralux.com.au
1300 131 788
[email protected]
A Division of
This user manual shall not be reproduced without
the prior permission of International Quadratics.