2840 SERIESBOOSTER PUMP SYSTEM
BEVERAGE/INDUSTRIALINSTALLATION & SERVICE INFORMATION FOR MODELS 2840-000 & 2840-010 (115 VOLTS AC)
AND MODEL 2840-210 (230 VOLTS AC)
STANDARD MODEL NUMBERING SYSTEMPRODUCT DATA
Pump Design ..............................................Quad Diaphragm
Motor ................Permanent Magnet ............................TENV
Wetted Parts ....Diaphragm Material ..................Santoprene
Check Valve Material ........................EPDM
Housing Material ..................Polypropylene
Accumulator Tank..Diaphragm Material ............................Butyl
Liner Material ........................Polypropylene
Ports ..............................3/4” HB Inlet & 1/2” HB/Qest Outlet
Net Weight ................................................8.8 Pounds (4 kgs)

28 X X - X X X
Pump Service
40 = Quad(4300)

Voltage

SwitchOptions

0 = 115V AC 0 = 40 PSI
2 = 230V AC 1 = 45 PSI
3 = 24V DC

0 = Std

The standard model numbering system is used for models up to 500. Numbers -500 and over are used for variations from standard
assemblies such as special pump or tank specifications. Consult
the factory for special models to meet specific requirements.

PERFORMANCE SPECIFICATIONS
PUMPMotor ................Max Amp Draw ....................1.5 @ 115 VAC
0.75 @ 230 VAC
Cycle ........................................50/60 Hertz
Liquid Temperature..Min. ..............................................45°F (7°C)
Max. ........................................140°F (60°C)
Priming ..............Dry ............................................5 ft. (1.5 M)
Wet ..........................................15 ft. (4.6 M)
Flow Rate ..........Max ..............3.5/4.5 GPM @ 0 PSI (0.0 bar)Pressure Switch Off ......................................45 PSI (3.1 bar)
On ......................................30 PSI (2.1 bar)50(3.4)Pressure in PSI (bar)40(2.8)30(2.1)ba20(1.4)

a:Model 2840-010
Model 2840-210b:Model 2840-00010(0.7)

TANK
Total Volume ....................................................1.1 gal. (4.1 It.
Operating Pressure ..............................................Gal (0.8 It.)
Air Pressure Setting........................................25 PSI (1.7 bar)1.0(3.8)02.0(7.6)

3.0(11.4)

4.0(15.1)

Flow in GPM (l/min)

DIMENSIONAL DRAWING
Inches (millimeters)

5.0(18.9)

11 1/4(286)

10 1/4(260)

7 1/2(191)

7 1/2(191)

4 3/16(106)

7 13/16(198)

1/2(13)10 1/4(260)

7 13/16(198)

12 7/8(327)

10 1/4(260)

GENERAL SAFETY INFORMATIONMOUNTING

Protect yourself and others by observing all safety
information. Shut off power and drain pressure fromsystem prior to service.

The FLOJET 2840 Series Water Pressure System should
be mounted in a dry and adequately ventilated area.

DESCRIPTION
The FLOJET 2840 series Booster Pump Systems aredesigned to provide a constant water pressure of 25 to45 psi (1.7 - 3.1 bar) and maximum flow of 3.5 or 4.5
GPM at 10 psi (0. 7 bar). The pump is fully automaticwith a built-in switch and check valve to maintainsystem pressure and will supply smooth water flow froma trickle to full flow Typical uses are; Commercial Ice
Machines, Pure Water Dispensing, Water Purifiers,
Small Domestic and Commercial Appliances where thewater supply pressure is very low or fluctuates widely.

Select a location where the plumbing is as direct as
possible and the inlet strainer is visible and accessible
for cleaning.
The unit can be floor or wall mounted. If wall mounted,
the Pump head should be down or lower than the motor.
Fasten base securely with the four rubber mounting feetassembled to base as shown below.

OPERATION
IMPORTANT - For correct operation, the tank must be
properly pressurized on the air side before the pump isstarted. Follow instructions on the tank label and check
air pressure after filling and before starting the pump.
The air valve is a standard tire valve. Compressed air
hose or hand pump may be used to pressurize.
Pressure can be reduced by pressing the center pin in
the valve.
Make sure pump inlet connection is securely connectedto the water supply and no inlet valves are open. Openall valves or taps on outlet side to purge air from thesystem. Turn power on to the pump, pump will start up.
Allow system to pump for a minute or until all the air has
been purged from the system. Close all valves in thesystem, the pump will pressurize the tank, shut off andoperate automatically to maintain pressure In the system.
To completely fill the pressure tank for maximum
volume, shut off power to pump and open faucet (or valve)closest to tank. Trapped air will be expelled. Turn on
power to pump. and close faucet when water is free of air.

WINTERIZING TIP
When units are exposed to freezing conditions.
1. Open discharge valve (Faucet nearest to theBooster System).
2. Open inlet side to pump (Remove inlet hose to theBooster System).
3. Run Pump for approximately 2 minutes, (Dry) oruntil system is out of fluid.
4. Leave discharge. value open and inlet hoseremoved until next usage.

WARNING
DO NOT USE PUMP IN A FLAMMABLE
ENVIRONMENT. DO NOT USE TO PUMPFLAMMABLE OR EXPLOSIVE FLUIDS
SUCH AS GASOLINE, FUEL OIL,KEROSENE, ETC.

VerticalHorizontalPLUMBING
Fasten strainer in a visible and accessible location forfuture cleaning. Use 3/4” ID hose between pump inlet &strainer. Connect strainer inlet to water supply line andclamp all hose connections securely to avoid air leaks.
IMPORTANT - if water supply line has pressure
fluctuations that may exceed 30 psi (2.1 bar) - use apressure regulator to limit inlet pressure to 30 psi (2.1bar) maximum.
Regulator may be installed at any convenient location
between water supply and inlet strainer.
1/2” NPTPressureOutWaterSupplyOptionalRegulator
If Required

ELECTRICAL

InletStrainer

WARNINGRISK OF AN ELECTRICAL SHOCK!
When wiring an electrically driven pump, follow allelectrical and safety codes, as well as the most recent
National Electrical Code (NEC) and the Occupational
Safety and Health Act (OSHA).

RISK OF PRODUCT DAMAGE!
Make certain the power source conforms to the pumpvoltage. Be sure all power is disconnected before
installation or removal.
Use the maximum recommended fuse for pumpprotection. Recommended fuse amp rating is locatedon pump label. Failure to provide correct overloaddevice may result in motor failure.
For 115V AC plug AC cord into a conventional 115V AC outlet.

!

WARNING: DISCONNECT POWER TO PUMP AND OPEN VALVE TO
RELIEVE WATER PRESSURE PRIOR TO SERVICING PUMP
1BAB

6Key Part No.
1 20404-003
2 20407-030
320403-040

420419-00
20419-002
02029-091A
02039-087A
20381-022567720406-000A
20406-002A

Description
Upper Housing Assy Kit
Check Valve Kit - EPDM
w/O-Ring & Ferrules
Diaphragm Kit, Santow/Pistons & Screws
Lower Housing 3.5 GPM
Lower Housing 4.5 GPM
Motor 115 Volt AC
Motor 230 Volt AC
Port Kit - (set of 2)
EDPM, 3/4” Barb, 90°& EDPM, 5/8” Barb, Straight
Pump Head Assy. 3.5 GPM
Pump Head Assy. 4.5 GPM

AQty
1111111
1111!

C

32

5

Key Part No.
8 20408-000
9 02096-540

4CD

7 Includes items 1 thru 4Description
Port Clips (Set of 2)
Pressure Switch - 40 PSI Off
Sealed** 04325-042A Complete MPU
115 Volt - 3.5 GPM** 04325-242A Complete MPU
230 Volt - 3.5 GPM** 04325-043C Complete MPU
115 Volt - 4.5 GPM** 01740-002 Strainer** 20799-000A Accumulator Tank** 20796-000A Base**Not Shown in Diagram

Qty
11111
111

DISASSEMBLEREASSEMBLEPressure Switch (9)1. Disconnect power to pump and open a faucet or valve torelieve system pressure.
2. Remove the two visible Pressure Switch Screws located oneach side of the Pressure Switch (9). DO NOT ADJUSTALLEN HEAD SCREW IN CENTER OF SWITCH.
Upper Housing (1)3. Loosen but DO NOT remove the four Pump Head Screws andcarefully remove Upper Housing Assembly (1).
4. Slide Port Clip (8) back and unplug from Tank Plumbing.
6. Remove Check Valve (2) and inspect for debris.
Check Valve Assembly (2) Follow Steps 1, 3 & 4
6. Inspect Check Valve (2) and O-RingLower Housing (4) Follow Step 1
7. Remove pump from both Base and Tank Plumbing.
8. Remove Rubber Feet by pulling out and sliding to the rearand follow step 3.
9. Rotate Lower Housing (4), so access Rubber Grommet footnotch is aligned with Cam Bearing Set Screw (4-C), loosen
set screw with a 1/8” Allen Wrench and slide pump head offmotor shaft.
Diaphragm (3-B)
10. Loosen four cam piston screws with Phillips head screw
driver and pull apart cam (4-B) from Inner Pistons (3-A). (Bothpistons (3-A & C) should be replaced when a new Diaphragm(3-B) is installed.)
Motor (5) Follow Steps 1, 7, 8 & 9

Diaphragm (3-B)
1. Insert Outer Pistons (3-C) into Lower Housing (4-A) bybending pistons at center fold.
2. Placing the Diaphragm (3-B) (flatter side of Diaphragm facing themotor) on the Lower Housing (4-A). Press each Inner Piston (3-A)
through the Diaphragm and Lower Housing (4-A) into OuterPiston (3-C). Hex stem of Inner Pistons (3-A) must be aligned intohex holes in Outer Pistons (3-C). Tighten cam piston screws
partially, center piston in diaphragm, and tighten screws securely(18 in. lbs. torque). Also, the Outer Pistons (3-C) must be alignedwith alignment slots on Cam Assembly (4-B) making sure screw
holes align in cam assembly, otherwise diaphragm will leak.
Cam Bearing (4-B)
3. Place Cam Bearing (4-B) over Inner Pistons (3-C) and tighten
down with four Phillips Head Screws. (18 in. lbs. torque)
Lower Housing (4) to Motor (6)Coat motor shaft with grease prior to installing Cam Bearing(4-B).
4. When installing the Lower Housing (4), rotate mounting footnotch to align with Cam Bearing Set Screw (4-C).
6. Attach Cam Bearing (4-B) to motor shaft indentation with
Cam Bearing Set Screw (4-C). (35 in. lbs. torque)
6. Reinsert Rubber Feet.
Check Valve (2)7. Place Ferrules (Rubber Cones) in the Upper Housing (1)coned side first.
8. Properly seat O-Ring in Check Valve (2) and insert CheckValve (2) into the Upper Housing (1).
Upper Housing (1)9. Place Upper Housing (1) on top of the Lower Housing (4-A)
and tighten Hex Bolts (30 in. lbs. torque) through the Upper
Housing (1) to the Motor.

TROUBLESHOOTING CHART
Symptom

Possible Cause(s)Corrective Action

Pump will not prime or retain
prime after operating• Air leak in suction line
• Defective check valve• Upper housing leaking• Suction lift too high• Debris in check valve(s)• Repair or replace• Replace• Tighten bolts• Lower pump
• Clean check valve(s)Pump runs but no fluid• Faulty suction piping• Defective check valve• Suction lift too high• Clogged inlet• Inlet line valve closed• Repair or replace• Replace• Lower pump
• Clean or replace• Open valve

Motor runs too hot• Voltage incorrect• Insufficient ventilation for motor• Check voltage• Insure proper ventilation

Flow rate is low• Piping or hose is damaged• Clogged check valve• Worn check valve• Voltage incorrect• Clean or replace• Clear obstruction• Replace• Check voltage

Pump leaks• Upper housing loose• Pistons loose• Pump head loose on motor• Switch loose• Tighten screws• Tighten piston screws• Tighten pump head screws• Tighten switch

Pump will not run• No electricity• Defective pressure switch• Motor has open circuit• Thermal protector has cut off••••

TO CONVERTTO

MULTIPLY BY

Gallons, U.S.
LitersLitersGallons, U.S.

3.785
0.264

Pounds/Sq. InchBarBar
Pounds/Sq. Inch0.069
14.5

Fahrenheit
Celsius

Celsius
Fahrenheit(°F-32) .556(°C X 1.8) + 32

Check connections, fuse, breakers
Replace switch
Replace
Allow motor to cool 15-30 min

CONVERSION TABLEWARRANTY

RETURN PROCEDUREFLOJET warrants this product to be free of defects in material and/or
workmanship for a period of one year after purchase by the customer
from FLOJET. During this one year warranty period, FLOJET will at its
option, at no charge to the customer, repair or replace this product if
found defective, with a new or reconditioned product, but not toinclude costs of removal or installation. No product will be accepted
for return without a return material authorization number. All return
goods must be shipped with transportation charges prepaid. This is
only a summary of our Limited Warranty. For a copy of our complete
warranty, please request Form No. 100-101.

Prior to returning any product to FLOJET, call customer service for an
authorization number. This number must be written on the outsideof the shipping package. Place a note inside the package with an
explanation regarding the reason for return as well as theauthorization number. Include your name, address and phone number.

www.flojet.com
U.S.A.
Flojet17942 Cowan Avenue
Irvine, CA 92614
Phone: 949.608.3900
Fax:949.608.3887
Flojet is a trademark of Xylem Inc. or one of its subsidiaries.
© 2012 Xylem, Inc. 81000-298 Rev D 10/2012

UNITED KINGDOM
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Hertfordshire EN11 OBU
Tel: +44 (0) 1992 450145
Fax:+44 (0) 1992 467132