Challenger Pump Owner`s Manual
Contents
1. CHALLENGER Centrifugal Pump Installation and User s Guide Motor P N 354806 354808 355019 355021 355025 355034 355015 355017 Dimension A Pump Performance Curves Feet of Water Challenger High Flow Pump Performance Curves 110 100 EN NR e BEST EFFICIENCY SIZING 20 40 60 80 100 120 140 160 U S Gallons per Minute Feet of Water Challenger High Pressure Pump Performance Curves EFFICIENCY SIZING 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 U S Gallons per Minute 15 High Flow Performance Curve Key MOTOR 1 2F and 3 4A B C 3 4F and 1A C 1FE 1F and 1 1 2A D 1 1 2FE 1 1 2F and 2A 2FE 2F and 2 1 2A High Pressure Performance Curve Key pu MOTOR G G 1 2FE 1 2F and 3 4A 3 4FE 3 4F and 1A 1FE 1F 1 1 2A and 1FE 3PH J K 2FE 2 1 2AE 2F 2 1 2A and 2FE 3PH L L 3FE 3F and 3FE 3PH 1 1 2FE 1 1 2F 2A and 1 1 2FE 3PH CHALLENGER Centrifugal Pump Installation and User s Guide gt PENTAIR 1620 HAWKINS AVE SANFORD NC 27330 e 919 566 8000 10951 WEST LOS ANGELES AVE MOORPARK CA 93021 e 805 553 5000 W2. La versi n en espafiol de este manual del producto se puede encontrar en l nea a Versiones en franc s de este manual est disponible en linea en http www pentairpool com products pumps inground challenger high pressure pumps 24 html P N 355031 Rev E 4 13 15 CHALLENGER Centrifugal Pump Installation and User s Guide IMPORTANT PUMP WARNING AND SAFETY INSTRUCTIONS I i IMPORTANT NOTICE This guide provides installation and operation instructions for this product Consult Pentair with any questions regarding this equipment Attention Installer This guide contains important information about the installation operation and safe use of this product This information should be given to the owner and or operator of this equipment after installation Attention User This manual contains important information that will help you in operating and maintaining this product Please retain it for future reference READ AND FOLLOW ALL INSTRUCTIONS This is the safety alert symbol When you see this symbol on your system or in this manual look for SAVE THESE INSTRUCTIONS A one of the following signal words and be alert to the potential for personal injury Warns about hazards that can cause death DANGER serious personal injury or major property damage if ignored if ignored Warns about hazards that may or can cause minor personal injury or property damage if ignored AWARNING Warns about hazards
3. cover filter lid and valves to violently separate which can result in severe personal injury or death Filter tank lid and strainer cover must be properly secured to prevent violent separation Stand clear of all circulation system equipment when turning on or starting up pump Before servicing equipment make note of the filter pressure Be sure that all controls are set to ensure the system cannot inadvertently start during service Turn off all power to the pump IMPORTANT Place filter manual air relief valve in the open position and wait for all pressure in the system to be relieved Before starting the system fully open the manual air relief valve and place all system valves in the open position to allow water to flow freely from the tank and back to the tank Stand clear of all equipment and start the pump IMPORTANT Do not close filter manual air relief valve until all pressure has been discharged from the valve and a steady stream of water appears Observe filter pressure gauge and be sure it is not higher than the pre service condition General Installation Information All work must be performed by a qualified service professional and must conform to all national state and local codes Install to provide drainage of compartment for electrical components These instructions contain information for a variety of pump models and therefore some instructions may not apply to a specific model All models are intended for u
4. gt PENTAIR CHALLENGER CENTRIFUGAL PUMP INSTALLATION AND USER 5 GUIDE IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS CUSTOMER SERVICE TECHNICAL SUPPORT If you have questions about ordering Pentair Aquatic Systems replacement parts and pool products please contact Customer Service and Technical Support USA 8 A M to 7 30 P M Eastern Time Phone 800 831 7133 Fax 800 284 4151 Web site Visit www pentairpool com or www staritepool com TABLE OF CONTENTS Important Pump Warning and Servicing RE 7 Safety Instructions ssssssssss ii Pump Disassembly 7 Introduction iter eres 1 The Shaft Seal 8 Pump Overview 1 Pump Reassembly 8 Pump Strainer Basket 1 Restart Instructions sseussssss 9 Installation tb tas 2 Priming the Pump 9 Location 2 Troubleshooting sseeeeseesee 10 Piping Pings And Mace 2 Replacement Parts 2 12 Wiring Installation 2 Grounding 3 lllustrated Parts View 12 Bonding 3 High Pressure Pump Parts List 12 High Flow Pump Parts List 13 Operating the Pump sesseeeese 4 g T Technical Data 14 Initial Start Up 4 5 Dimensional Drawings 14 Maintenance ssessssemme Pump Performance Curves 15 Cleaning the Strainer Basket 5 Winterizing 6 Electric Motor Care 6 Translated versions of this manual are available online at
5. pump should be visually inspected at least once a week Remove the clear lid and the basket and clean debris from basket Inspect the lid o ring if damaged replace The pump seal requires no lubrication and skimmer baskets regularly may contain scalding hot water Opening the pump may cause serious personal injury In order to avoid the possibility of personal injury make sure the suction and discharge valves are open and strainer pot temperature is cool to touch then open with extreme caution A WARNING DO NOT open the strainer pot if pump fails to prime or if pump has been operating without water in the strainer pot Pumps operated in these circumstances may experience a build up of vapor pressure and AcaurioN To prevent damage to the pump and filter and for proper operation of the system clean pump strainer Turn off the pump at the breaker Close the inlet and discharge valves Relieve pressure in the system peg I Turn the strainer lid in a counter clockwise direction to remove the lid and remove the basket from the pump 5 Remove the debris from the strainer basket and rinse out the basket Replace the basket if it is cracked 6 Replace the basket Fill the pump strainer pot and volute up to the suction inlet port with water 8 Clean the lid O ring and sealing surface of the strainer pot Note Itisimportantthatthe O Ring be kept clean and well lubricated 9 Reinstall the lid by placing the lid ba
6. pump strainer pot should be filled with water up to suction inlet port on the pump It is good practice to lubricate the lid o ring with silicone lubricant each time the lid is removed The o ring should be cleaned and inspected every time the strainer pot is opened The lid should be replaced by pressing the lid down and twisting the lid clockwise The pump is now ready to prime Energize the motor and the pump will prime The time to prime will depend on the suction lift and the distance and size of suction piping Turn off power if the pump does not prime within thirty 30 minutes and refer to Troubleshooting on page 11 ACAUTION DO NOT run the pump dry If the pump is run dry the mechanical seal will be damaged and the pump will start leaking If this occurs the damaged seal must be replaced ALWAYS maintain proper water level in your pool half way up skimmer opening If the water level falls below the skimmer opening the pump will draw air through the skimmer losing the prime and causing the pump to run dry resulting in a damaged seal Continued operation in this matter could cause a loss of pressure resulting in damage to the pump case impeller and seal and may cause property damage and personal injury CHALLENGER Centrifugal Pump Installation and User s Guide 5 MAINTENANCE This section describes how to maintain the Challenger Centrifugal Pump Cleaning the Pump Strainer Basket The strainer basket in the
7. that may cause death serious personal injury or major property damage NOTE Indicates special instructions not related to hazards Carefully read and follow all safety instructions in this manual and on equipment Keep safety labels in good condition replace if missing or damaged When installing and using this electrical equipment basic safety precautions should always be followed include the following AWARNING Do not permit children to use this product AWARNING For all permanently installed units intended for use on 15 or 20 ampere 125 through 240 volt single phase branch circuits This unit must be connected only to a supply circuit that is protected by a ground fault circuit interrupter GFCI Such a GFCI should be provided by the installer and should be tested on a routine basis To test the GFCI push the test button The GFCI should interrupt power Push the reset button Power should be restored If the GFCI fails to operate in this manner the GFCI is defective If the GFCI interrupts power to the pump without the test button being pushed a ground current is flowing indicating the possibility of an electric shock Do not use this pump Disconnect the pump and have the problem corrected by a qualified service representative before using ACAUTION This pump is for use with permanent swimming pools and may also be used with hot tubs and spas if so marked Do not use with storable pools A permanently insta
8. the impeller screw located in the center ofthe pump s impeller Note The impeller screw is a left handed thread and loosens in a clockwise direction CHALLENGER Centrifugal Pump Installation and User s Guide 8 Pump Disassembly continued 8 Use the 1 4 inch flat blade screwdriver to hold the motor shaft in place The motor shaft is accessible through the back of the motor Note If the torque is too high to hold the screwdriver by hand then an adjustable wrench may be used to hold the screwdriver shaft in place Use locking pliers instead if your screwdriver has a round shaft 9 Unscrew the impeller from the motor shaft by twisting the impeller counter clockwise 10 Remove the rotating portion of the spring seal by hand Note When placing the rotating seal to the side ALWAYS place flat side down The portion of the rotating spring seal that contacts the white ceramic seal must be kept as free from contaminants dust dirt debris etc as possible 11 Use the 9 16 inch wrench to remove the four 4 bolts that hold the motor to the seal plate The Shaft Seal The mechanical seal can be changed without disconnecting piping by removing the band clamp and pulling the motor with pump bracket diffuser and impeller assembly away from front pump housing body The Shaft Seal consists primarily of two parts a rotating spring seal and a ceramic seal See Figure 3 The Challenger Centrifugal Pump requires little or no service othe
9. to hold the motor shaft in place when screwing down the impeller The motor shaft is accessible through the back of the motor Using a 1 4 inch flat blade screwdriver screw in the impeller lock screw Note The impeller screw is a left handed thread and tightens in a counter clockwise direction Remount the diffuser spacer and diffuser using a 1 4 inch flat blade screwdriver and the three 3 diffuser screws Reseat the pump housing strainer pot volute onto the rear sub assembly Place the band clamp around the pump housing an rear sub assembly Tighten with the band clamp knob Note The band clamp knob should be parallel to the floor of the equipment pad when the clamp is installed properly Reinstall the drain plugs Hand tighten only Fill the pump strainer pot with water 10 Refer to page 4 Initial Start Up procedures to restart the pump Pump Housing Motor Motor to Seal Plate Screws 4x Impeller Screw Diffuser Impeller Diffuser Spacer Diffuser Holidng Screws 3x Drain Plugs 2x Figure 4 CHALLENGER Centrifugal Pump Installation and User s Guide 10 RESTART INSTRUCTIONS If the Challenger Centrifugal Pump is installed below the water level of the pool close return and suction lines prior to opening hair and lint pot on pump Make sure to reopen valves prior to operating ACAUTION DO NOT run the pump dry If the pump is run dry the mechanical seal wi
10. 55021 355375 355023 355376 355025 355377 355027 355378 355034 ord 855009 8561 1 1 2FE 355013 354808 2FE 2 1 2AE 355015 354810 355017 354812 Impeller Diffuser Table Impeller Diffuser Diffuser P N P N Spacer P N HIGH PRESSURE MODELS 1 2F 3 4A 1 2FE 355147 355148 355384 3 4F 1A 3 4FE 355187 355188 355317 1F 1 1 2A 1FE 355369 355188 355317 1 1 2F 2A 1 1 2FE 355315 355270 355317 2F 2 1 2A 2FE 2 1 2AE 355604 355545 355317 3E 3FE 355544 355545 355317 High Flow Pump Parts List hem PIN Description 6 s fse fe mms me s wes sm 13 Motor Table Motor P N 3 4F 1A 355021 1F 1 1 2A 355023 1 1 2F 2A 355025 2F 2 1 2A 355027 355011 1 1 2FE 355013 2FE 2 1 2AE 355015 Impeller Diffuser Table Impeller Diffuser Diffuser P N P N Spacer P N HIGH FLOW MODELS 1 2F 3 4A 355043 355029 355028 CHALLENGER Centrifugal Pump Installation and User s Guide 14 TECHNICAL DATA Dimensional Drawings mi 10 0 3 DEI f ES M LC 16 1 1 LI ae Ir LE Li 10 1 gt IE a E OC E 2 Do LE FT s is
11. 8a and either A ASVRS meeting ASME ANSI A112 19 17 and or ASTM F2387 or B A properly designed and tested suction limiting vent system or C An automatic pump shut off system or D Disabled submerged outlets or E Suction outlets shall be reconfigured into return inlets For Installation of Electrical Controls at Equipment Pad ON OFF Switches Timers and Automation Load Center ACAUTION Install all electrical controls at equipment pad such as on off switches timers and control systems etc to allow the operation startup shut down or servicing of any pump or filter so the user does not place any portion of his her body over or near the pump strainer lid filter lid or valve closures This installation should allow the user enough space to stand clear of the filter and pump during system start up shut down or servicing of the system filter CHALLENGER Centrifugal Pump Installation and User s Guide AWARNING A clearly labeled emergency shut off switch for the pump must be in an easily accessible obvious place Make sure users know where it is and how to use it in case of emergency HAZARDOUS PRESSURE STAND CLEAR OF PUMP AND FILTER DURING START UP s Circulation systems operate under high pressure d When any part of the circulating system i e y locking ring pump filter valves etc is serviced air can enter the system and become pressurized Pressurized air can cause the pump housing
12. WW PENTAIRPOOL COM All Pentair trademarks and logos are owned by Pentair or one of its global affiliates Pentair Aquatic Systems and Challenger are trademarks and or registered trademarks of Pentair Water Pool and Spa Inc and or its affiliated companies in the United States and or other countries Unless expressly noted names and brands of third parties that may be used in this document are not used to indicate an affiliation or endorsement between the owners of these names and brands and Pentair Water Pool and Spa Inc Those names and brands may be the trademarks or registered trademarks of those third parties Because we are continuously improving our products and services Pentair reserves the right to change specifications without prior notice Pentair is an equal opportunity employer 2015 Pentair Water Pool and Spa Inc All rights reserved This document is subject to change without notice P N 355031 REV E 4 13 15
13. ck onto the strainer pot and turning the lid clockwise Note Be sure the lid O ring is properly placed around the entire sealing surface of the strainer pot 10 Open the inlet and discharge valves 11 Turn the power ON at the circuit breaker Strainer O Ring 6 Strainer Basket i Strainer Drain Plug Figure 2 Ne A wanNING THIS SYSTEM OPERATES UNDER HIGH PRESSURE When any part of the circulating system e g Lock Ring Pump Filter Valves etc is serviced air can enter the system and become pressurized Pressurized air can cause the lid to separate off which can result in serious injury death or property damage To avoid this potential hazard follow these instructions 12 Open the manual air relief valve on top of the filter 13 Stand clear of the filter Start the pump 14 Bleed air from the filter until a steady stream of water comes out Close the manual air relief valve CHALLENGER Centrifugal Pump Installation and User s Guide Winterizing You are responsible for determining when freezing conditions may occur If freezing conditions are expected take the following steps to reduce the risk of freeze damage Freeze damage is not covered under warranty In mild climates when temporary freezing conditions may occur run your filtering equipment all night to prevent freezing To prevent freeze damage follow the procedures below 1 Shut off electrical powe
14. der to avoid the possibility of personal injury make sure the suction and discharge valves are open and strainer pot temperature is cool to touch then Pump Disassembly All moving parts are located in the rear sub assembly of this pump Refer to Figure 4 on page 9 for an illustrated parts view Tools required Adjustable wrench e 1 4 inch flat blade screwdriver 9 16 inch open end wrench e Rubber Mallet To remove and repair the motor sub assembly perform the following procedures T Turn off the pump circuit breaker at the main panel Close suction and discharge valves to relieve system pressure Drain the pump by removing the drain plugs The drain plugs can be removed by hand No tools are needed Loosen the band clamp by turning the band clamp knob counter clockwise The band clamp holds the rear subassembly to the housing strainer pot volute Remove the rear sub assembly from the housing strainer pot volute and place the band clamp to the side Note If the band clamp does not separate from the pump housing and seal plate when loose lightly tap the top of the band clamp with a rubber mallet This will free the clamp from the housing Place the rear sub assembly upright and on a flat surface Use a 1 4 inch flat blade screwdriver to remove the three 3 holding screws located on the diffuser Remove the diffuser and diffuser spacer from the rear sub assembly Use the 1 4 inch flat blade screwdriver to remove
15. e and advanced weathering e Ifa cover becomes loose cracked damaged broken or is missing replace with an appropriate certified cover e Replace drain covers as necessary Drain covers deteriorate over time due to exposure to sunlight and weather e Avoid getting hair limbs or body in close proximity to any suction cover pool drain or outlet e Disable suction outlets or reconfigure into return inlets The Virginia Graeme Baker VGB Pool and Spa Safety Act creates new requirements for owners and operators of commercial swimming pools and spas Commercial pools or spas constructed on or after December 19 2008 shall utilize A Amultiple main drain system without isolation capability with suction outlet covers that meet ASME ANSI A112 19 8a Suction Fittings for Use in Swimming Pools Wading Pools Spas and Hot Tubs and either i A safety vacuum release system SVRS meeting ASME ANSI A112 19 17 Manufactured Safety Vacuum Release systems SVRS for Residential and Commercial Swimming Pool Spa Hot Tub and Wading Pool Suction Systems and or ASTM F2387 Standard Specification for Manufactured Safety Vacuum Release Systems SVRS for Swimming pools Spas and Hot Tubs or ii A properly designed and tested suction limiting vent system or iii An automatic pump shut off system Commercial pools and spas constructed prior to December 19 2008 with a single submerged suction outlet shall use a suction outlet cover that meets ASME ANSI A112 19
16. i 1 friction loss and improve efficiency ne igure use short direct suction piping CLEARANCE returns 5x SUCTION PIPE DIAM 2 Install a minimum of 5 feet 1 5 meters from the inside wall of the pool or spa Canadian installations i require a minimum of 9 8 feet 3 meters from pool water 3 Install the pump a minimum of 3 feet 0 9 meters from the heater outlet 8IN 7 6 CM MINIMUM 4 Do not install the pump more than 10 feet 3 meters above the water level 5 Install the pump in a well ventilated location protected from excessive moisture i e rain gutter downspouts sprinklers etc 6 Install the pump with a rear clearance of at least 3 inches 7 6 cm so that the motor can be removed easily for maintenance and repair A vertical clearance of 12 inches 30 5 cm is required for strainer basket removal See Figure 1 Piping Fittings and Valves 1 Use thread seal tape or pipe sealants on all male connections of pipes and fittings Use only pipe sealant compounds suited for plastic pipe DO NOT USE PETROLEUM BASED PRODUCTS 2 Support pipe to prevent strains on the systems filter pump and valves 3 When connecting fitting to the pump apply a pipe sealant to the threads and then hand tighten plus 17 turns DO NOT OVERTIGHTEN 4 Long piping runs and elbows restr
17. ict flow For best efficiency use the fewest possible fittings large diameter pipe at least 1 5 inches and locate equipment as close to the pool as possible The pump suctions line should not be smaller than the pipe size on the inlet of the pump 5 Suction fittings must conform to ASME ANSI A 112 19 8 M Standards Use double suction fittings Wiring Installation A WARNING RISK OF ELECTRICAL SHOCK OR ELECTROCUTION This pool pump must be installed by a licensed or certified electrician or a qualified pool serviceman in accordance with the all National Electrical Code and all applicable local codes and ordinances Improper installation will create an electrical hazard which could result in death or serious injury to pool users installers or others due to electrical shock and may also cause damage to property sj Always disconnect power to the pool pump at the circuit breaker before servicing the pump Failure to do so could result in death or serious injury to serviceman pool users or others due to electric shock 1 Make sure all electrical breakers and switches are turned off before wiring motor 2 Make sure that the wiring voltage matches the motor voltage If they do not match permanent damage to the motor will occur CHALLENGER Centrifugal Pump Installation and User s Guide Wiring Installation continued 3 For wiring sizes and general guidelines for proper electrical installation please follow the
18. igned to operate for years with proper maintenance The pump housing seal plate diffuser hair and lint pot and impeller are made from high quality thermoplastic materials These materials have been selected for their corrosion resistant nature When installed operated and maintained in accordance with these instructions your pump will provide years of service Strainer Basket LU l Challenger Centrifugal Pump Your centrifugal pump is driven by an electric motor The motor is directly attached to the pump impeller As the electric motor turns it causes the impeller to turn and this causes the water to flow The water flows into the hair and lint pot inlet and through the basket assembly to pre strain large particles The flow then enters the center of the pump housing If the pump does not contain the hair and lint pot assembly the flow simply enters the center of the pump housing The flow goes through the impeller and out the pump discharge port Two Speed Pump Models The performance of this pump will be the same at high speed as the same model single speed pump both hydraulically and prime wise At low speed the pump will produce one half the flow and 1 4 the pressure of high speed However the pressure required by the filter and pool plumbing at half flow will also be greatly reduced due to much lower system friction These lower friction losses result in great energy savings At one half flow low speed the e
19. is in Off mode on a timer controlled circuit HR Motor terminal connections are incorrect 5 Motor shaft is locked by bad bearing 6 Impeller is locked by debris Electrical supply connections are incorrect Po Wiring to pump is undersized Power Company supply voltage is low Ventilation is inadequate for motor Remedy Add water to pot Tighten lid Replace o ring Adjust pool water level Clear basket Check all valves and open all necessary valves Adjust to high speed Find amp fix leak Clean filter Open return line restriction Clean basket Clean obstruction Find amp fix leak Find and open restriction Check power switch amp reset Check circuit breaker amp reset if re trips contact electrician Check timer mode Have terminal connections checked by electrician Have motor bearings replaced or replace pump Clean impeller Have terminal connections checked by electrician Consult electrician to rewire pump Notify Power Company Remove any restrictions to air flow CHALLENGER Centrifugal Pump Installation and User s Guide 12 REPLACEMENT PARTS Illustrated Parts View High Pressure Pump Parts List tems P N Description 6 55004 o spas ef mms me s esasass sm CHALLENGER Centrifugal Pump Installation and User s Guide Motor Table Single 3 Phase ver aaa 3650019 3
20. lectrical energy savings are 60 for equal amounts of circulated water Turn motor to low speed for quiet operation and electrical cost savings Since the pump should be operated mostly at low speed for cost saving minor adjustments may be required in the automatic chlorine dispenser the skimmers and the heater due to the lower flow See the equipment manufacturer s operation manuals Pool owners should use high speed for vacuuming the pool quick filtering action priming the system and to keep up with heavy bathing loads Spa and Tub owners will want to use high speed for good jet action Pump Strainer Basket The strainer basket sometimes referred to as the Hair and Lint Pot is located in front of the pump housing Inside the chamber is the basket which must be kept clean of leaves and debris at all times Regardless of the length of time between filter cleaning it is important to visually inspect the hair and lint pot basket at least once a week A dirty basket will reduce the efficiency of the filter and heater and also put an abnormal stress on the pump motor CHALLENGER Centrifugal Pump Installation and User s Guide 2 INSTALLATION Location Be sure the Challenger Centrifugal Pump location meets the following requirements Note Do not install this pump within an outer enclosure or beneath the skirt of a hot tub or spa unless marked accordingly 1 Install the pump as close to the pool or spa as possible To reduce F
21. ll be damaged and the pump will start leaking If this occurs the damaged seal must be replaced ALWAYS maintain proper water level in your pool half way up skimmer opening If the water level falls below the skimmer opening the pump will draw air through the skimmer losing the prime and causing the pump to run dry resulting in a damaged seal Continued operation in this matter could cause a loss of pressure resulting in damage to the pump case impeller and seal and may cause property damage and personal injury Priming the Pump The pump strainer pot must be filled with water before the pump is initially started Follow these steps to prime the pump 1 2a R oO LD Remove the pump lid Fill the pump strainer pot with water Reassemble the pump lid onto the strainer pot The pump is now ready to prime Open the air release valve on the filter and stand clear of the filter Turn on the switch or time clock When water comes out of the air release valve close the valve The system should now be free of air and recirculating water to and from the pool This pump will prime within thirty 30 minutes Do not allow your pump to run longer than this time without developing full flow If the pump does not prime see Troubleshooting on page 11 Two speed pumps should run on high speed for priming CHALLENGER Centrifugal Pump Installation and User s Guide 11 TROUBLESHOOTING Use the following troubleshooting infor
22. lled pool is constructed 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 is capable of being readily disassembled for storage and reassembled to its original integrity AWARNING For all permanently installed units intended for use on 15 or 20 ampere 125 through 240 volt single phase branch circuits RISK OF ELECTRICAL SHOCK Connect only to a branch circuit protected by a ground fault circuit interrupter GFCI Contact a qualified electrician if you cannot verify that the circuit is protected by a GFCI General Warnings Never open the inside of the drive motor enclosure There is a capacitor bank that holds a 230 VAC charge even when there is no power to the unit The pump is not submersible The pump is capable of high flow rates use caution when installing and programming to limit pumps performance potential with old or questionable equipment Code requirements for the electrical connection differ from state to state Install equipment in accordance with the National Electrical Code and all applicable local codes and ordinances Before servicing the pump switch OFF power to the pump by disconnecting the main circuit to the pump This appliance is not intended for use by persons including children of reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision o
23. mation to resolve possible Challenger Centrifugal Pump problems RISK OF ELECTRICAL SHOCK OR ELECTROCUTION Improper installation will create an electrical hazard which could result in death or serious injury to pool users installers or others due to electrical shock and may also cause damage to property 1 If you are not familiar with your pool filtering system and or heater DO NOT attempt to adjust or service without consulting your dealer or a qualified pool professional b Read the entire Installation amp User s Guide before attempting to use service or adjust the pool filtering system or heater 2 SWITCH OFF power to the pump at the breaker before attempting service or repair Problems and Corrective Actions Problem Pump will not prime Low Flow High Filter Pressure Low Flow Low Filter Pressure Motor does not turn Motor Over Heating Too Cause No water in strainer pot Strainer pot lid is not tight Damaged lid o ring Water level is below skimmer Strainer basket or skimmer basket is clogged Closed valve in piping system SHARON m Pump is on low speed two speed units only Air leak in suction line co Filter is dirty Restriction in return line m Strainer basket or skimmer basket is clogged Clogged impeller Air leak in suction line Restriction in suction line Boe Power switch is off Circuit breaker has tripped Po 3 Pump
24. minal provided under motor canopy or access plate use size and type wire required by code Connect motor ground terminal to electrical service ground On cord connected circuits check for proper grounding Bonding The National Electrical Code Article 680 22 requires that the motor be electrically bonded to appropriate permanently installed pool or spa hot tub structure by a solid copper conductor no smaller than No 8 AWG no smaller than No 6 AWG for Canadian installations Bonding wire should be connected from the accessible wire connector on the motor shell to all metal parts of the swimming pool spa or hot tub structure and to all electrical equipment metal conduit and metal piping within five 5 feet of the inside walls of a swimming pool spa or hot tub A grounding lug is provided on the exterior of the motor shell for this purpose FOR CORD AND PLUG CONNECTED UNITS Do not bury cord Locate cord to minimize abuse from lawn mowers hedge trimmers and other equipment WARNING To reduce the risk or electric shock replace damaged cord immediately To reduce the risk of electric shock do not use extension cord to connect unit to electric supply provide a properly located outlet AWARNING RISK OF ELECTRIC SHOCK Connect only to a grounding type receptacle protected by a ground fault circuit interruptor GFCI Contact a qualified electrician if you cannot verify that the receptacle is protected by a GFCI ACAUTION This p
25. or expecting operation e When replacing the motor be certain that the motor support is correctly positioned to support the size of motor being installed CHALLENGER Centrifugal Pump Installation and User s Guide SERVICING This section describes how to service the Challenger Centrifugal Pump RISK OF ELECTRICAL AND ELECTROCUTION i vi fii open with extreme caution A CAUTION Be sure not to scratch or mar the polished shaft seal faces seal will leak if faces are damaged This pool pump must be installed by a licensed or certified electrician or a qualified pool serviceman in accordance with the National Electrical Code and all applicable local codes and ordinances Improper installation will create an electrical hazard which could result in death or serious injury to pool users installers or others due to electrical shock and may also cause damage to property Always disconnect power to the pool pump at the circuit breaker before servicing the pump Failure to do so could result in death or serious injury to serviceman pool users or others due to electric shock Read all servicing instructions before working on the pump DO NOT open the strainer pot if pump fails to prime or if pump has been operating without water in the strainer pot Pumps operated in these circumstances may experience a build up of vapor pressure and may contain scalding hot water Opening the pump may cause serious personal injury In or
26. present when the flow rating of the cover is too small for the pump or pumps Body Entrapment When a portion of the body is held against the drain cover trapping the swimmer underwater This hazard is present when the drain cover is missing broken or the cover flow rating is not high enough for the pump or pumps CHALLENGER Centrifugal Pump Installation and User s Guide IMPORTANT PUMP WARNING AND SAFETY INSTRUCTIONS Evisceration Disembowelment When a person sits on an open pool particularly a child wading pool or spa outlet and suction is applied directly to the intestines causing severe intestinal damage This hazard is present when the drain cover is missing loose cracked or not properly secured Mechanical Entrapment When jewelry swimsuit hair decorations finger toe or knuckle is caught in an opening of an outlet or drain cover This hazard is present when the drain cover is missing broken loose cracked or not properly secured NOTE ALL SUCTION PLUMBING MUST BE INSTALLED IN ACCORDANCE WITH THE LATEST NATIONAL AND LOCAL CODES STANDARDS AND GUIDELINES A WARNING TO MINIMIZE THE RISK OF INJURY DUE TO SUCTION ENTRAPMENT HAZARD e Aproperly installed and secured ANSI ASME A112 19 8 approved anti entrapment suction cover must be used for each drain e Each suction cover must be installed at least three 3 feet apart as measured from the nearest point to nearest point e Regularly inspect all covers for cracks damag
27. r for the pump at the circuit breaker 2 Drain the water out of the pump housing by removing the two thumb twist drain plugs from the housing Store the plugs in the pump basket 3 Cover the motor to protect it from severe rain snow and ice Note DO NOT wrap the motor with plastic or other air tight materials during winter storage The motor may be covered during a storm winter storage etc but never when operating or expecting operation Electric Motor Care Protect from heat 1 Shade the motor from the sun 2 Any enclosure must be well ventilated to prevent overheating 3 Provide ample cross ventilation Protect against dirt 1 Protect from any foreign matter Do not store or spill chemicals on or near the motor Avoid sweeping or stirring up dust near the motor while it is operating If a motor has been damaged by dirt it may void the motor warranty Clean the lid and clamp O ring and sealing surface of the pump pot IRON Protect against moisture 1 Protect from continuous splashing or continuous sprayed water 2 Protect from extreme weather such as flooding 3 If motor internals have become wet let it dry before operating Do not allow the pump to operate if it has been flooded 4 f a motor has been damaged by water it may void the motor warranty Note e DONOT wrap motor with plastic or other air tight materials The motor may be covered during a storm for winter storage etc but never when operating
28. r instruction concerning the use of the appliance by a person responsible for their safety FAILURE TO FOLLOW ALL INSTRUCTIONS AND WARNINGS CAN RESULT IN SERIOUS BODILY INJURY OR DEATH THIS PUMP SHOULD BE INSTALLED AND SERVICED ONLY BY A QUALIFIED POOL SERVICE PROFESSIONAL INSTALLERS POOL OPERATORS AND OWNERS MUST READ THESE WARNINGS AND ALL INSTRUCTIONS IN THE OWNER S MANUAL BEFORE USING THIS PUMP THESE WARNINGS AND THE OWNER S MANUAL MUST BE LEFT WITH THE POOL OWNER SUCTION ENTRAPMENT HAZARD STAY OFF A DANGER THE MAIN DRAIN AND AWAY FROM ALL SUCTION OUTLETS M YIA m THIS PUMP PRODUCES HIGH LEVELS OF SUCTION AND CREATES A STRONG VACUUM AT THE MAIN DRAIN AT THE BOTTOM OF THE BODY OF WATER THIS SUCTION IS SO STRONG THAT IT CAN TRAP ADULTS OR CHILDREN UNDER WATER IF THEY COME IN CLOSE PROXIMITY TO A DRAIN OR A LOOSE OR BROKEN DRAIN COVER OR GRATE THE USE OF UNAPPROVED COVERS OR ALLOWING USE OF THE POOLOR SPAWHEN COVERS ARE MISSING CRACKED OR BROKEN CAN RESULT IN BODY OR LIMB ENTRAPMENT HAIR ENTANGLE MENT BODY ENTRAPMENT EVISCERATION AND OR DEATH The suction at a drain or outlet can cause Limb Entrapment When a limb is sucked or inserted into an opening resulting in a mechanical bind or swelling This hazard is present when a drain cover is missing broken loose cracked or not properly secured Hair Entanglement When the hair tangles or knots in the drain cover trapping the swimmer underwater This hazard is
29. r than reasonable care however a Shaft Seal may occasionally become damaged and must be replaced ACAUTION The polished and lapped faces of the seal could be easily damaged if not handled with care ACAUTION In mild climate area when temporary freezing conditions may occur run your filtering equipment all night to prevent freezing To replace the pump seal 12 13 14 15 16 Follow steps 1 11 in the Pump Disassembly section Place the seal plate face down on a flat surface and tap out the old ceramic seal Press the new ceramic seal into the seal plate with your thumbs and wipe off the white ceramic with a clean cloth Using a 9 16 inch wrench remount the seal plate to the motor via the four 4 bolts that hold the motor to the seal plate Grease the motor shaft thread and continue with steps 2 10 from the Pump Reassembly section to reassemble the pump Spring Seal Ceramic Seal Figure 3 CHALLENGER Centrifugal Pump Installation and User s Guide Pump Reassembly 1 8 9 Use the 9 16 inch wrench to remount the seal plate to the motor via the four 4 bolts that hold the motor to the seal plate Reseat the spring seal on the white ceramic seal Ensure that the carbon face of the spring seal contacts the ceramic face of the stationary seat Grease the motor shaft thread and screw the impeller onto the motor shaft Note Use the 1 4 inch flat blade screwdriver
30. se in swimming pool applications The pump will function correctly only if it is properly sized to the specific application and properly installed AWARNING Pumps improperly sized or installed or used in applications other than for which the pump was intended can result in severe personal injury or death These risks may include but not be limited to electric shock fire flooding suction entrapment or severe injury or property damage caused by a structural failure of the pump or other system component AWARNING The pump can produce high levels of suction within the suction side of the plumbing system These high levels of suction can pose a risk if a person comes within the close proximity of the suction openings A person can be seriously injured by this high level of vacuum or may become trapped and drown It is absolutely critical that the suction plumbing be installed in accordance with the latest national and local codes for swimming pools Warnings and safety instructions for Pentair Water Pool and Spa Inc pumps and other related products are available at http www pentairpool com pool owner safety warnings or call 800 831 7133 for additional free copies of these instructions Please refer to http www pentairpool com pool owner safetywarnings for warning and safety instructions related to this product SAVE THESE INSTRUCTIONS 1 INTRODUCTION Pump Overview The Challenger Centrifugal Pump is des
31. specifications defined in the National Electric Code and any local codes as required Make sure all electrical connections are clean and tight Cut wires to the appropriate length so they don t overlap or touch when connected to the terminal board on cds Never work on pump while it is running or power is still connected hazardous voltage can cause severe or fatal injury A suitable ground fault interrupter should always be installed at the power supply source of the unit 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 6 The Challenger Centrifugal Pump motor must be wired for the proper voltage in accordance with the wiring diagram supplied with the motor ACAUTION Wiring the motor with the incorrect supply voltage will cause damage to the motor and void the warranty 7 The wiring to the motor should be kept as short as possible and large enough NOT to cause an excessive voltage drop 8 Install ground and bond wire according to local or National Electrical Code requirements 9 Bond the motor to the pool structure in accordance with the National Electrical Code Use a solid No 8 AWG or larger copper conductor No 6 AWG for Canadian installations Run a wire from the external bonding Screw on the motor to the pool bonding structure Grounding Permanently ground motor Use green ter
32. ump is for use with permanently installed pools and may also be used with hot tubs and spas Do not use with storable pools unless pump is protected by a factory installed double insulated enclosure A permanently installed pool is constructed 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 disassembled for storage and reassembled to its original integrity and has a maximum dimension of 18 feet and a maximum wall height of 42 inches Do not install within an outer enclosure or beneath the skirt of a hot tub or spa unless so marked CHALLENGER Centrifugal Pump Installation and User s Guide 4 OPERATING THE PUMP Initial Start Up 1 Relieve all system pressure and open all air bleeders on entire hydraulic system prior to starting the Challenger Centrifugal Pump See filter owner s manual Ensure that all fittings clamps closures and couplings are tight and in accordance with equipment manufacturer s recommendations Open suction and discharge valve to allow free flow of water On flooded suction pumps with strainer pot the water source is higher than the pump The water will flow into the pump strainer pot and the pot will fill with water On pumps without strainer pot the water will fill the pump housing On non flooded suction systems the pump lid will have to be removed by rotating the lid counter clockwise and lifting The
Download Pdf Manuals
Related Search