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Installation and Operating Data Jandy. Installation and Operation Manual FloPro Series Pumps Model FHPM A WARNING FOR YOUR SAFETY- This product must be installed and serviced by a contractor who is licensed and qualified in pool equipment by the jurisdiction in which the product will be installed where such state or local requirements exist. In the event no such state or local requirement exists, the maintainer must be a professional with sufficient experience in pool equipment installation and maintenance so that all of the instructions in this manual can be followed exactly. Improper installation and/or operation can create dangerous electrical hazards, which can cause high voltages to run through the electrical system. Before installing this product, read and follow all warning notices and instructions that accompany this product. Failure to follow warning notices and instructions may result in property damage, personal injury, or death. Improper installation and/or operation will void the warranty. ATTENTION INSTALLER: This manual contains important information about the w installation, operation and safe use of this product. This information should be given to the owner/operator of this equipment. M O jandy® FloPro Series Pumps Installation and Operation Manual Page 3 Table of Contents Section 1. Important Safety Instructions........... 4 Section 5. Service and Maintenance ................. 13 1.1 Safety Instructions.......................... 4 5.1 Routine Maintenance...................... 13 1.2 Pool Pump Suction Entrapment 5.2 Winterizing the Pump..................... 13 Prevention Guidelines..................... 6 Section 6. Troubleshooting and Repair............. 14 Section 2. General Description.......................... 8 6.1 Troubleshooting 2.1 Introduction..................................... 8 6.2 Service Technician Maintenance.... 15 2.2 Description...................................... 8 6.2.1 Blocked Impeller............................. 15 Section 3. Installation........................................ 8 6.2.2 Impeller Removal ........................... 15 3.1 Plumbing......................................... 8 6.2.3 Impeller Replacement..................... 16 3.1.1 Preparation...................................... 8 6.2.4 Mechanical Seal Replacement........ 17 3.1.2 Pump Location................................ 8 6.2.5 Motor Replacement......................... 18 3.1.3 Replacement of Existing Pump....... 8 Section 7. Product Specifications and 3.1.4 Pipe Sizing 9 Technical Data.................................. 19 3.2 Electrical Installation...................... 10 7.1 Replacement Parts List................... 19 3.2.1 Voltage Checks................................ 10 7.2 Exploded View................................ 20 3.2.2 Bonding and Grounding.................. 10 7.3 FHPM Pump Curves....................... 21 3.2.3 Electrical Wiring............................. 11 7.4 Physical and Operational 3.3 Pressure Testing.............................. I 1 Specifications.................................. 22 Section 4. Operation.......................................... 12 7.5 Replacement Motor Guide.............. 23 4.1 Start-up............................................ 12 EQUIPMENT INFORMATION RECORD DATE OF INSTALLATION INSTALLER INFORMATION INITIAL PRESSURE GAUGE READING (WITH CLEAN FILTER) PUMP MODEL HORSEPOWER NOTES: Page 4 FloPro Series Pumps Installation and Operation Manual 75;., Section 1 . Important Safety Instructions READ AND FOLLOW ALL INSTRUCTIONS 1.1 Safety Instructions All electrical work must be performed by a licensed electrician and conform to all national, state, and local codes. When installing and using this electrical equipment,basic safety precautions should always be followed, including the following: WARNING RISK OF SUCTION ENTRAPMENT HAZARD, WHICH, IF NOT AVOIDED, CAN RESULT IN SERIOUS INJURY AND/OR DEATH. Do not block pump suction, as this can cause severe injury and/or death. Do not use this pump for wading pools, shallow pools, or spas containing bottom drains, unless the pump is connected to at least two (2) functioning suction outlets. Suction outlet (drain) covers must be certified to the latest published version of ANSI/ASME All 12.19.8. A WARNING To reduce the risk of injury, do not permit children to use this product. A WARNING To reduce the risk of property damage and/or injury, do not attempt to change the backwash (multiport, slide, or full flow) valve position with the pump running. A WARNING Jandy Pumps are powered by a high voltage electric motor and must be installed by a licensed or certified electrician or a qualified swimming pool service technician. A WARNING Due to the potential risk of fire, electric shock, or injuries to persons, Jandy Pumps must be installed in accordance with the National Electrical Code (NEC), all local electrical and safety codes, and the Occupational Safety and Health Act (OSHA). Copies of the NEC may be ordered from the National Fire Protection Association online at www.nfpa.org or call 617-770-3000, or contact your local government inspection agency. WARNING Incorrectly installed equipment may fail, causing severe injury and/or property damage. A WARNING • Do not connect the system to an unregulated city water system or other external source of pressurized water producing pressures greater than 35 PSI. • Trapped air in the system can cause the pump and/or filter lid to be blown off. This can result in death, serious personal injury, and/or property damage. Be sure all air is out of the system before operating. Jandy FloPro Series Pumps Installation and Operation Manual Page 5 WARNING To minimize the risk of severe injury or death, the filter and/or pump should not be subjected to the piping system pressurization test. Local codes may require the pool piping system to be subjected to a pressure test. These requirements are generally not intended to apply to the pool equipment, such as filters or pumps. Jandy pool equipment is pressure tested at the factory. However, if the WARNING cannot be followed and pressure testing of the piping system must include the filter and/or pump, BE SURE TO COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS: • Check all clamps, bolts, lids, lock rings, and system accessories to make sure they are properly installed and secured before testing. • RELEASE ALL AIR in the system before testing. • Water pressure for test must NOT EXCEED 35 PSI. • Water temperature for test must NOT EXCEED 100°F (38°C). • Limit test to 24 hours. After test, visually check the system to make sure it is ready for operation. Notice: These parameters apply to Jandy equipment only. For non-Jandy equipment, consult the equipment manufacturer. WARNING Chemical spills and fumes can weaken pool/spa equipment. Corrosion can cause filters and other equipment to fail, resulting in severe personal injury or property damage. Do not store pool chemicals near your equipment. CAUTION Do not start pump dry! Running the pump dry for any length of time will cause severe damage and will void the warranty. CAUTION 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 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. CAUTION Do not install within an outdoor enclosure or beneath the skirt of a hot tub or portable spa. The pump requires adequate ventilation to maintain air temperature at less than the maximum ambient temperature rating listed on the motor rating plate. SAVE THESE INSTRUCTIONS Page 6 FloPro Series Pumps Installation and Operation Manual andy 1.2 Pool Pump Suction Entrapment Prevention Guidelines A WARNING SUCTION HAZARD. Can cause serious injury or death. Do not use this pump for wading pools, shallow pools, or spas containing bottom drains, unless the pump is connected to at least two (2) functioning suction outlets. WARNING Pump suction is hazardous and can trap and drown or disembowel bathers. Do not use or operate swimming pools, spas, or hot tubs if a suction outlet cover is missing, broken, or loose. The following guidelines provide information for pump installation that minimizes the risk of injury to users of pools, spas, and hot tubs: Entrapment Protection -The pump suction system must provide protection against the hazards of suction entrapment. Suction Outlet Covers -All suction outlets must have correctly installed, screw-fastened covers in place.All suction outlet (drain) covers must be maintained. Drain covers must be listed/certified to the latest version of ANSI/ASME All 2.19.8. They must be replaced if cracked, broken, or missing. Number of Suction Outlets Per Pump - Provide at least two (2) main drains, with covers, as suction outlets for each circulating pump suction line. The centers of the main drains (suction outlets) on any one (1) suction line must be at least 3 feet apart, center to center. See Figure 1 on page 7. For additional details and guidelines, refer to ANSI/APSP 7, the standard for Suction Entrapment Avoidance in Swimming Pools, Wading Pools, Spas, Hot Tubs, and Catch Basins. The system must be built to include at least two (2) suction outlets (drains) connected to the pump whenever the pump is running. However, if two (2) main drains run into a single suction line, the single suction line may be equipped with a valve that will shut off both main drains from the pump. The system shall be constructed such that it shall not allow for separate or independent shutoff or isolation of each drain. See Figure 1 on page 7. More than one (1) pump can be connected to a single suction line as long as the requirements above are met. Water Velocity -The maximum water velocity through the suction fitting or cover for any suction outlet must be 1.5 feet per second, unless the outlet complies with the latest published version of ANSI/ASME All 2.19.8, the standard for Suction Fittings For Use in Swimming Pools, Wading Pools, Spas, and Hot Tubs. In any case, do not exceed the suction fitting's maximum 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 6 feet per second or less, even if one (1) main drain (suction outlet) is completely blocked. The flow through the remaining main drain(s) must comply with the latest published version of ANSI/ASME All 2.19.8, the standard for Suction Fittings For Use in Swimming Pools, Wading Pools, Spas, and Hot Tubs. Testing and Certification - Suction outlet covers must have been tested by a nationally recognized testing laboratory and found to comply with the latest published version of ANSI/ASME A112.19.8, the standard for Suction Fittings For Use in Swimming Pools, Wading Pools, Spas, and Hot Tubs. Fittings - Fittings restrict flow; for best efficiency use the fewest possible fittings (but at least two (2) suction outlets). Avoid fittings that could cause an air trap. Pool cleaner suction fittings must conform to applicable International Association of Plumbing and Mechanical Officials (IAPMO) standards. j4a,ndy FloPro Series Pumps Installation and Operation Manual Page 7 At Least 3 Feet Listed/certified to the latest Listed/certified to the latest published version of published version of ANSI/ASME A112.19.8 ANSI/ASME A112.19.8 Anti-entrapment Anti-entrapment Cover/Grate or Suction Cover/Grate or Suction Fitting, screw-fastened to No valves between Fitting, screw-fastened to Main Drain Sump Tee and Main Drains V/ Main Drain Sump Suction Outlet 0 E ► E < Suction Outlet (Main Drain) (Main Drain) Valves OK between- Pump pump and Tee Figure 1. Number of Suction Outlets Per Pump Page 8 FloPro Series Pumps Installation and Operation Manual ja 7gdy® Section 2. General Description NOTE Better self-priming will be achieved if the pump is installed as close as possible to the water level of the pool. 2.1 Introduction 2. If the pump is located below water level,isolation This manual contains information for the proper valves must be installed on both the suction and installation, operation, and maintenance of Jandy F1oPro return lines to prevent the back flow of pool water (FHP) Series Pumps,Model FHPM. Procedures in this during any routine or required servicing. manual must be followed exactly. To obtain additional A&WARNING copies of this manual, contact Jandy Customer Service Some Safety Vacuum Release System (SVRS) at 1.800.822.7933. For address information, see the devices are not compatible with installation of check back cover of this manual. valves. If the pool has an SVRS device, be sure to confirm that that it will continue to safely operate when 2.2 Description any check valves are installed. Jandy FHP Pumps are designed to meet the needs of today's more hydraulically demanding pool 3. Zodiac Pool Systems, Inc. recommends that the equipment. The pump housing,backplate, diffuser, pump and other circulation equipment be located impeller, and hair-and-lint pot(pump debris filter more than 5 feet from the water. Choose a location basket) are all made from high quality thermoplastic that will minimize turns in the piping. materials. These materials were chosen for their strength NOTE In Canada, the pump must be located a and corrosion resistance. minimum of 3 meters (approximately 10 feet) from the water(CSA C22.1). The pump is driven by an electric motor directly 4. The pump must be placed on a solid foundation attached to the pump impeller.As the electric motor that will not vibrate. To further reduce the turns, it causes the impeller to turn,which forces water possibility of vibration noise,bolt the pump to the to flow through the pump. The water flows through the foundation, or place it on a rubber mat. pump inlet and then into the filter basket.The basket assembly pre-strains/traps large particles. The water NOTE Zodiac Pool Systems, Inc. recommends bolting then enters the center of the pump housing, flows the pump directly to the foundation. through the impeller into the diffuser, and then flows 5. The pump foundation must have adequate drainage out the pump discharge port. to prevent the motor from getting wet. Protect the pump from the rain and sun. Section 3. Installation 6. Proper ventilation is required for the pump to operate normally.All motors generate heat that must be removed by providing proper ventilation. 3.1 Plumbing 7. Provide access for future service by leaving a 3.1.1 Preparation clear area around the pump.Allow plenty of space above the pump to remove the lid and basket for 1. Upon receipt of the pump, check the carton for cleaning. damage. Open the carton and check the pump for concealed damage, such as cracks, dents, or a bent 8. If the equipment is under cover, provide adequate base. If you find damage, contact the shipper or lighting. the distributor where the pump was purchased. 2. Inspect the contents of the carton and verify that all parts are included. See Section 7.1, Replacement Parts List. 3.1.2 Pump Location 1. Zodiac Pool Systems,Inc. recommends installing the pump within 1 foot above water level. The pump should not be elevated more than a few feet above the water level of the pool.A check valve is recommended on the suction line to the pump. Jandy FloPro Series Pumps Installation and Operation Manual Page 9 3.1.3 Replacement of Existing Pump 3.1.3.3 Pentair°WhisperFlo°Pump Jandy FHP pumps can easily replace several To replace a Pentair®WhisperFlo®pump with a other pumps: the Hayward®Super Pump®,Pentair® Jandy FHP,place the FHP base with spacers on the SuperFlo®,Pentair®WhisperFlo®,Jandy P1usHP(PHP), equipment pad and place the FHP on the base, as shown and Jandy MaxHP(MHP). in Figure 6. To replace the Pentair®WhisperFlo®,Jandy PHP, 1. Using a hand cutter tool, cut the plastic bars or Jandy MHP,use the FHP's adjustable base. The FHP connecting the top and bottom sets of spacers, as base(and its spacers)increase the total height of the shown in Figure 4. pump and the height of the suction side of the pump. 2. Push the two(2)top spacers and two(2)bottom See Table 1. spacers out of the base. Table 1. FHP Dimensions 3. Align the pins in the four(4) spacers with the Base Configuration Suction Side Pump holes in the base and snap the spacers into place, Height Height as shown in Figure 5. Pump without Base 7 W 123/4" Pump with Base 8Y8' 13%" Pump with Base and Spacers 9'/8' 14'/8" 02 . ° EO 3.1.3.1 Hayward° Super Pump°and I Pentair° SuperFlo° Cut spacers ° ° The Jandy FHP can replace a Hayward'Super at X. ° ° Pump®or a Pentairl SuperFlo without using the FHP base. See Figure 2. ° ° 12 3/4" Figure 4. Cut Sets of Spacers Out of Base 0 7 3/4" o 0 Figure 2. Place FHP Directly Equipment Pad - - 9 Y on 3.1.3.2 Jandy PlusHP (PHP) and Jandy MaxHP (MHP) To replace a Jandy PHP or Jandy MHP pump with a Jandy FHP,use the FHP base as shown in Figure 3. Figure 5. Snap Spacers into Place 141/8" 13 7/8" 0 91/' o 0 0 8 7/8" o 0 LLUAI Figure 6. Place FHP with Base and Spacers on Figure 3. Place FHP with Base on Equipment Pad Equipment Pad Hayward®and Super Pump®are registered trademarks of Hayward Industries, Inc. Pentair is a registered trademark of Pentair, Inc. SuperFlo®and WhisperFloo are registered trademarks of Pentair Water Pool and Spa,Inc. Page 10 FloPro Series Pumps Installation and Operation Manual �dy 4. Place the FHP on the base assembly. See Figure 6. it eliminates the possibility of leaks at threaded adapters. 3.1.4 Pipe Sizing 4. The FHP Pump must be connected to at least two 3.1.3.1 Suction Pipe (2)main drains (suction outlets) for each pool pump suction line. Each drain must be provided When the pump is located up to 50 feet from the with covers that are listed or certified to the latest pool, the recommended Schedule 40 minimum pipe size published version ofANSI/ASME A112.19.8. for the suction side of the pump is 1/z" for .75 HP and The suction outlets of the main drains must be at 2" for 1 to 2 HP. For 2.5 HP pumps,the recommended least 3 feet apart or at different planes. The suction pipe size is 2'/z". outlets can be a drain and skimmer, two (2) drains, 3.1.3.2 Discharge Pipe two (2) skimmers, or a skimmer with an equalizer line installed. For additional details and guidelines, When the pump is located up to 50 feet from the refer to ANSI/APSP 7,the standard for Suction pool, the recommended Schedule 40 minimum pipe size Entrapment Avoidance in Swimming Pools, for the discharge side of the pump is P/z" for.75 HP and Wading Pools, Spas, Hot Tubs, and Catch Basins. 2" for 1 to 2 HP. For 2.5 HP pumps, the recommended Check the local codes for proper installation pipe size is 2'/2". requirements.Applicable local codes will take NOTE All pipe sizes (Schedule 40) are able to precedence over other codes. withstand the pressures the pump will deliver, but not necessarily the flow. If the pipe is too NOTE To prevent entrapment, the system must be small for the pump, or if the pump is elevated built so that it cannot operate with the pump above water, the maximum gallons per minute drawing water from only one (1) main drain.At (GPM) may not be delivered. If this happens, least two (2) main drains must be connected the pump will develop an air pocket(cavitation) to the pump when it is in operation. However, that will make noise, and the life of the pump if two (2) main drains run into a single suction may be shortened. line, the single suction line may be equipped with a valve that will shut off both main drains 3.1.3.3 Installation Recommendations from the pump. 1. If the pump is located below water level,isolation 5. The piping must be well supported and not forced valves must be installed on both sides of the pump together in places where constant stress will be to prevent the back flow of pool water during any experienced. routine or required servicing. 6. Always use properly sized valves. Jandy Diverter 2. To help prevent difficulty in priming,install the Valves and Jandy Ball Valves typically have the suction pipe without high points, which can trap best flow capabilities. air. (High points are inverted`U's above the inlet 7 Use the fewest fittings possible. Every additional of a pump. In plumbing,they are commonly fitting has the effect of moving the equipment referred to as airlocks.)For installations of equipment up to 100 feet from the water, refer to farther away from the water. the pipe sizing chart in Table 2. For installations of NOTE If more than 10 suction fittings are needed, the equipment more than 100 feet from the water, the pipe size must be increased. recommended pipe size must be increased to the next size. 8. Every new installation must be pressure tested according to local codes. See Section 3.3, Pressure Table 2. Pipe Sizing Chart for Schedule 40 PVC Testing. Pipe Maximum Flow Maximum Flow Size Suction Discharge 3.2 Electrical Installation (8 feet per second) (10 feet per second) 1'/z" 50 GPM (189 LPM) 65 GPM (246 LPM) 3.2.1 Voltage Checks 2" 85 GPM (322 LPM) 105 GPM (397 LPM) 2'/2' 120 GPM (454 LPM) 149 GPM (564 LPM) The correct voltage, as specified on the pump data plate, is necessary for proper performance and long 3. FHP Pumps come equipped with unions on motor life. The incorrect voltage will decrease the both the suction and discharge ports. This pump's ability to perform and can cause overheating, feature simplifies installation and service, and reduce the motor life, and result in higher electric bills. dy® FloPro Series Pumps Installation and Operation Manual Page 11 It is the responsibility of the electrical installer to provide data plate operating voltage to the pump WARNING by ensuring proper circuit sizes and wire sizes for the To avoid the risk of property damage, severe specific application. personal injury, and/or death, make sure that the control switch or time clock is installed in an easily CAUTION accessible location, so that in the event of an Failure to provide data plate voltage (within 10%) equipment failure or a loose plumbing fitting, the during operation will cause the motor to overheat equipment can be easily turned off. and will void the warranty. CAUTION 3.2.2 Bonding and Grounding The pump must be permanently connected to a 1. The motor frame must be grounded to a reliable dedicated electrical circuit. No other equipment, grounding point using a solid copper conductor, lights, appliances, or outlets may be connected to No. 8 AWG or larger. In Canada,No. 6 AWG or the pump circuit, with the exception of devices that larger must be used. If the pump is installed within may be required to operate simultaneously with the 5 feet of the inside walls of the swimming pool, pump, such as a chlorinating device or heater. spa, or hot tub, the motor frame must be bonded to all metal parts of the swimming pool, spa, or hot 3.2.3 Electrical Wiring tub structure and to all electrical equipment,metal conduit, and metal piping within 5 feet of the WARNING inside walls of the swimming pool, spa, or hot tub. To avoid risk of property damage, severe personal 2. Bond the motor using the provided external lug. injury, or death, always ground before connecting to an electrical power suppy. �WARNING 1. The pump motor must be securely and adequately To avoid the risk of property damage, severe grounded using the green screw provided. Ground personal injury, and/or death, always disconnect before attempting to connect to an electrical power the power source before working on a motor or its supply.Do not ground to a gas supply line. connected load. 2. Wire size must be adequate to minimize a voltage drop during the start-up and operation of the pump. See Table 3 for suggested wire sizes. 3. Insulate all connections carefully to prevent grounding or short-circuits. Provide extra protection for sharp edges on terminals. To prevent wire nuts from loosening,tape them Table 3. Recommended Minimum Wire Size for FHP Pumps RECOMMENDED MINIMUM WIRE SIZE AWG FOR FHP PUMPS* Distance from Sub-Panel 0-50 Feet 50-100 Feet 100-150 Feet 150 Feet-200 Feet Branch Fuse AMPS Voltage Voltage Voltage Voltage Class:CC,G,H,J,K, Model RK,or T 230 VAC 115 VAC 230 VAC 115 VAC 230 VAC 115 VAC 230 VAC 115 VAC 230 VAC 115 VAC FHPM 0.75HP 15A 15A 14 12 12 8 10 6 8 6 FHPM 1.OHP 15A 20A 14 10 10 8 8 6 8 4 FHPM 1.5HP 15A 20A 12 10 10 6 1 8 6 1 6 4 FHPM 2.OHP 15A 20A 12 8 8 6 6 4 6 3 FHPM 2.5HP 15A N/A 12 N/A 8 N/A 6 N/A 6 N/A FHPM 1.OHP-2-Speed 15A N/A 14 N/A 10 N/A 8 N/A 8 N/A FHPM 1.5HP-2-Speed 15A N/A 12 N/A 10 N/A 8 N/A 6 N/A FHPM 2.OHP-2-Speed 15A N/A 12 N/A 8 N/A 6 N/A 6 N/A *Assumes three(3)copper conductors in a buried conduit and 3%maximum voltage loss in branch circuit.All National Electrical Code(NEC)and local codes must be followed.Table shows minimum wire size and branch fuse recommendations for a typical installation per NEC. Page 12 FloPro Series Pumps Installation and Operation Manual Jandy using a suitable, listed(UL, ETL, CSA) electrical Section 4. Operation insulating tape. For safety, and to prevent entry of contaminants,reinstall all conduit and terminal box covers.Do notforce connections into the 4.1 Start-up conduit box. 4. To configure the internal wiring of the pump motor CAUTION for the correct voltage,refer to the diagram on the Never run the pump without water. Running the motor data plate. pump "dry"for any length of time can cause severe 3.3 Pressure Testing damage to both the pump and motor and will void the warranty. WARNING If this is a new pool installation, make sure all When pressure testing a system with water, air piping is clear of construction debris and has been is often trapped in the system during the filling properly pressure tested. Check the filter for proper process. This air will compress when the system installation, verifying that all connections and is pressurized. Should the system fail, this trapped clamps are secure according to the manufacturer's air can propel debris at a high speed and cause recommendations. property damage, severe injury, or death. Every effort to remove trapped air must be taken, including opening the bleed valve on the filter WARNING and loosening the pump basket lid while filling the To avoid risk of property damage, severe personal pump. injury, or death, verify that all power is turned off before starting this procedure. A WARNING 1. Release all pressure from the system and open the Trapped air in system can cause the filter lid to filter pressure release valve. be blown off, which can result in death, serious 2. Take one of the following actions: personal injury, or property damage. Be sure all air is properly out of system before operating. DO NOT — If the pump is located below the water level USE COMPRESSED AIR TO PRESSURE TEST OR of the pool, open the filter pressure release CHECK FOR LEAKS. valve to prime the pump with water. — If the pump is located above the water level, A WARNING remove the lid and fill the basket with water Do not pressure test above 35 PSI. Pressure before starting the pump. testing must be done by a trained pool professional. 3. Prior to replacing the lid, check for debris around Circulation equipment that is not tested properly may the lid o-ring seat. Debris around the lid o-ring fail. This could result in severe personal injury or seat will cause air to leak into the system, and property damage. make it difficult to prime the pump. 4. Hand-tighten the lid to make an air tight seal.Do not use any tools to tighten the lid.hand-tighten WARNING only. Ensure that the lid is secure. Make sure all When pressure testing the system with water, it is valves are open and the unions are tight. very important to make sure that the pump basket 5. Restore power to the pump and then turn it on. lid is completely secure. 6. Once all the air has left the filter, close the filter 1. Fill the system with water,being careful to pressure release valve. eliminate trapped air. 7. The pump should prime. The time it takes to prime 2. Pressurize the system with water to no more than will depend on the elevation and length of pipe 35 PSI. used on the suction supply pipe. See Section 3.1.3.3, Installation Recommendations for 3. Close the valve to trap pressurized water in the proper elevation and pipe size. system. 8. If the pump does not prime and all the instructions 4. Carefully observe the system for leaks and/or to this point have been followed, check for a pressure decay. suction leak. If there is no leak,repeat Steps 2 through 7. 9. For technical assistance, call Jandy Technical Support at 1.800.822.7933. < dy FloPro Series Pumps Installation and Operation Manual Page 13 Section 5. Service and Maintenance 9. Turn on the power to the pump. Once all the air has been evacuated from the filter, close the filter pressure release valve. 5.1 Routine Maintenance WARNING 5.2 Winterizing the Pump To avoid the risk of property damage, severe personal CAUTION injury, and/or death, turn off the pump and switch off The pump must be protected when freezing the circuit breaker to the pump motor before servicing temperatures are expected.Allowing the pump the pump. to freeze will cause severe damage and void the Inspect the pump basket for debris by looking I warranty. through the clear pump lid. Remove any debris,because as debris accumulates,it will begin to block the flow CAUTION of water through the pump. Keep the basket clean to improve the performance of the pump. Do not use antifreeze solutions in the pool, spa, or hot tub systems!Antifreeze is highly toxic 1. Turn off the power to the pump. If the pump is and may damage the circulation system. The only located below the water level, close the isolation exception to this is Propylene Glycol. For more valves on the suction and discharge sides of the information, see your local pool/spa supply store or pump to prevent backflow of water. contact a qualified swimming pool service company. 2. Turn the lid's locking ring counter-clockwise until `START'aligns with the ports. Carefully remove 1. Drain all water from the pump, system equipment, the lid. and piping. 2. Remove the two (2) drain plugs. Store the drain CAUTION plugs in a safe location and reinstall them when A misaligned basket will cause the lid to be the cold weather season is over.Do not lose the improperly seated, allowing an air leak, which could o-rings. result in pump damage. 3. Keep the motor covered and dry. Do not cover it with plastic, as this will create condensation and 3. Lift the basket out of the pump. Dispose of all this moisture will damage the pump. debris and thoroughly clean the basket, making sure all the holes are open. Using a garden hose, NOTE To protect your pump, Zodiac Pool Systems, spray the basket from the outside to help clear the Inc. recommends having a qualified service holes. Remove any remaining debris by hand. technician or electrician properly disconnect the electrical wiring at the switch or junction 4. Replace the basket in the pump by aligning the box. Once the power is removed, the two (2) open section of the basket with the inlet pipe. If unions can be loosened and the pump stored aligned properly, the basket will drop easily into indoors. For safety, and to prevent entry of place.Do not force it into place. contaminants, reinstall all conduit and terminal box covers. 5. Remove the lid o-ring and remove debris around 4. When the system is reopened for operation,make the lid o-ring seat, as this will cause air leaks into sure all piping, valves, wiring, and equipment the system. Clean the lid o-ring and replace it. are in accordance with the manufacturer's 6. Replace the lid with locking ring on the pump recommendations. Pay close attention to the filter housing.Align `START'with the ports and turn and electrical connections. the lid's locking ring clockwise until `LOCKED' 5. The pump must be primed prior to starting;refer aligns with the ports.Hand-tighten the lid to make to Section 4.1, Start-up. an air tight seal.Do not use any tools to tighten the lid. 7. Verify that all valves have been returned to the proper position for normal operation. 8. Open the pressure release valve on the filter, and make sure it is clean and ready for operation. Page 14 FloPro Series Pumps Installation and Operation Manual Jandy Section 6. Troubleshooting and Repair Zodiac Pool Systems, Inc. strongly recommends that you call a qualified service technician to perform any repairs on the filter/pump system. To locate a qualified technician, check your local yellow pages or visit wwwjandy.com and click on"Product Support." 6.1 Troubleshooting Symptom Possible Problem/Solution The cleaning/circulating system is Verify that skimmer baskets, pump basket and other screens are clean. Clean as not operating correctly. necessary. Check filter and clean as necessary. Check valve positions.Adjust as necessary. NOTE Multiple pieces of equipment operating at one time (for example,waterfalls, spa jets, and surface returns) may affect the cleaning system and prevent it from working properly. Check the cleaning system manual to ensure that the system is adjusted according to the manufacturer's recommendations. Bubbles present in the pump Air in system. Check the pool or spa water level to ensure that it is at the proper level and basket. that air is not being drawn into the suction piping. If the water is at the normal level, turn off the pump.Turn the lid's locking ring counter-clockwise until 'START'aligns with the ports. Carefully remove the lid and check for debris around the lid o-ring seat, as debris will cause air to leak into the system. Clean the lid o-ring and place on the lid. Replace the lid with locking ring on the pump housing.Align 'START'with the ports and turn the lid's locking ring clockwise until `LOCKED'aligns with the ports. Hand-tighten the lid to make an air tight seal. Do not use any tools to tighten the lid.Turn the pump back on. Air leaks are still present. Check the suction side piping union.While the pump is running, try to tighten the union. If this does not stop the air leak,turn off the pump. Loosen both unions and slide the pump out of the way. Remove, clean and re-install both union o-rings. Reposition the pump next to the piping and secure the union nuts to the pump.With clean union o-rings, hand-tightening of the unions should create a seal. If the unions still do not seal, gently tighten with a large pair of tongue-and-groove pliers. Do not over-tighten. There is no air in the system, but It is possible that debris is caught in the pump impeller.The pump impeller moves the the pressure is still low. water, and the vanes in the impeller can become blocked with debris. See Section 6.2, Service Technician Maintenance, 6.2.1, Blocked Impeller, for more information. There is no debris blocking the The pump impeller and diffuser are showing signs of normal wear. Have a qualified service impeller and the pressure is still technician check the impeller and diffuser and replace as necessary. low. If the pump is part of a relatively new installation, it could be an electrical problem. Contact a qualified service technician. Have the technician check for loose electrical connections and check the voltage at the pump motor while it is in operation.The voltage must be within 10%of the motor's data plate rating. If the voltage is not within 10%, contact a qualified electrician and/or the local power service provider. The pump seal is leaking air. Have a qualified service technician replace the seal. The pump is leaking water between This is caused by a damaged or failed mechanical seal. Replace the seal. See Section 6.2, the motor and pump body. Service Technician Maintenance, 6.2.4, Mechanical Seal Replacement. The pump gets hot and shuts off Ensure that there is adequate room around the motor to circulate air and keep the motor periodically. cool. Have a qualified electrician check for loose connections and check the voltage at the pump motor while it is in operation.The voltage must be within 10%of the motor's data plate rating. If the voltage is not within 10%, contact a qualified electrician and/or the local power service provider. 7:, FloPro Series Pumps Installation and Operation Manual Page 15 6.2 Service Technician Maintenance NOTE If you are replacing the motor, Zodiac Pool Systems, Inc. strongly recommends that a WARNING qualified service technician or electrician properly disconnect the electrical wiring at the This pump must be serviced by a professional pump motor. service technician, qualified in pool/spa installation. The following procedures must be followed exactly. 2. Turn off any valves to prevent pool water from Improper installation and/or operation can create reaching the pump. Drain the water from the pump dangerous electrical hazards, which can cause high by loosening the unions or removing the voltages to run through the electrical system. This drain plugs. can cause property damage, serious injury, and/ 3. Using a 9/16" wrench, loosen the bolts connecting or death. Improper installation and/or operation will the pump body to the motor backplate. See void the warranty. Figure 7. 6.2.1 Blocked Impeller m �$ WARNING Bolts (6) Before servicing the pump, turn off the pump and switch off the circuit breaker to the pump motor. Severe personal injury, death, or property damage Pump may occur if the pump starts while your hand is Body inside the pump. 1. Turn off the pump. Switch off the circuit breaker to the pump motor. Motor Backplate 2. Remove the lid and basket. 3. Look inside the pump for any debris. Remove any Motor Shaft Cover debris found inside. 4. Replace the basket and lid. Figure 7. Remove the Pump Housing 5. Switch on the circuit breaker to the pump motor. 4. Pull the motor and backplate out of the pump body. Remove the pump body o-ring. The impeller 6. Turn on the pump, and see if the problem is is connected to the motor shaft. solved. 5. Using a No. 1 Phillips screwdriver, remove the 7. If the impeller is still blocked with debris and it two (2) screws holding the diffuser. (The diffuser is not possible to remove the debris using Steps 2 is the cover over the impeller). Then remove the through 4,the pump will need to be disassembled diffuser. (See Figure 8.) in order to access the inlet and outlet of the impeller. Motor 6.2.2 Impeller Removal 8 WARNING ser Before servicing the pump, turn off the pump and switch off the circuit breaker to the pump motor. Severe personal injury, death, or property damage may occur if the pump starts while your hand is 1)04 inside the pump.1. Turn off the pump. Switch off the circuit breaker 0 to the pump motor. If you are not replacing the / motor, do not disconnect the electrical wiring. Backplate Screws(2) Diffuser 0-ring Figure 8. Remove the Diffuser Page 16 FloPro Series Pumps Installation and Operation Manual Jandy 6. If necessary,remove any debris in the inlet and 6.2.3 Impeller Replacement outlet of the impeller. 7. Remove the motor shaft cover on the back of the Q WARNING motor by twisting the hex-head screw with a 90' To avoid the risk of property damage, severe personal crescent wrench. (See Figure 7.)The motor shaft injury, or death, turn off the pump and switch off the will be exposed. circuit breaker to the pump motor before beginning 8. Hold the exposed motor shaft with a 1/2" wrench this procedure. and remove the impeller center screw using a No. 1. Press the carbon face seal half(see 2 Phillips screwdriver. Turn the left-hand-threaded Figure 11) on the motor shaft using a twisting screw clockwise to loosen it. See Figure 9. motion. Make sure the carbon surface is facing toward the ceramic ring in the backplate. Backplate Carbon Seal Surface 0 Mechanical o Seal Impeller 0 • Ceramic Face Seal • Carbon Face/Spring • Backplate Seal Side of Seal Self Sealing Left Hand Screw • Impeller Side of the Mechanical Seal Figure 9. Remove the Impeller Figure 11. Mechanical Seal 9. Hold the motor shaft with a''/2" wrench while unscrewing the impeller from the motor shaft with CAUTION your hand. Turn the right-hand-threaded impeller VERY IMPORTANT! Grasp the lower portion of counter-clockwise to unscrew it. the seal (opposite the carbon face)when installing 10. Inspect the impeller and diffuser for signs of the seal or it will be damaged. rubbing and/or damage. See Figure 10. NOTE To assist assembly, only use water or a soap Diffuser O-Ring solution as a lubricant.Any other lubricant will destroy the seal after a short period of time. Screws(2) / NOTE Excercise great care to keep the seal and Self Sealing Left Hand Screw mating parts clean. 0 Mechanical Seal 2. While holding the motor shaft with a'/z" wrench, thread the impeller onto the motor shaft. Hand- tighten the impeller until it is secure. Install the impeller center screw into the center of the ® impeller and tighten,using a No. 2 Phillips screwdriver. Do not overtighten. Turn the left- Diffuser / hand-threaded impeller screw counter-clockwise Impeller ® o to tighten it. / 3. Replace the motor shaft cover by inserting the Backplate 0-ring cover tabs into the slots and rotating the cover 90' / clockwise. Backplate 4. Replace the diffuser over the impeller, using care to insert alignment pins into the correct holes. The Figure 10. Diffuser and Impeller Exploded View alignment pins in the diffuser allow the diffuser to be inserted only one (1)way. dy® FloPro Series Pumps Installation and Operation Manual Page 17 5. Replace the two(2) small Phillips-head screws. 12. Open the pressure release valve on the filter and Tighten the screws to draw the diffuser against the make sure it is clean and ready for operation. motor backplate. 13. Switch on the circuit breaker to the pump motor. 6. Make sure the diffuser o-ring, o-ring groove, and o-ring seal area are clean and free of debris,which 13. Turn on the pump and check the system for normal could cause a leak. If you removed the diffuser operation. o-ring during disassembly,re-install it on the 14. Once all the air has left the filter, close the filter diffuser, as shown in Figure 12. If grease is used pressure release valve. to retain the diffuser o-ring,it must be silicone based. Do not use petroleum-based grease. It will destroy the o-ring. 6.2.4 Mechanical Seal Replacement NOTE Refer to Figure 13 for an illustration of the location of the mechanical seal and impeller. wer- Pump Body tkMplate 0-ring .off' Diffuserechanical Seal 0-ring Self Sealing Left Hand Screw Diffuser Screws(2) 0 o Backplate o Impeller o Diffuser 0-ring Mounting Location Diffuser O-ring *O Figure 12. Pump Body and Diffuser Exploded View Figure 13. Backplate, Impeller, Diffuser, and 7. Slide the diffuser into the mating hole in the pump Mechanical Seal Exploded View body.While supporting the motor, start two (2) screws on opposite sides. (This will hold the motor NOTE This is a two-part replacement process. The in position while you start the other screws.) Start mechanical seal must be replaced as a set. the other four(4) screws. 8. Tighten all six(6) screws lightly in a crossing"X" WARNING pattern using a 9/16" wrench. Start with the inner Do not damage the ceramic or carbon surfaces of (middle)two (2),then tighten the outer(top and the seals. If surfaces are damaged, leaks will occur. bottom) four(4)to draw the backplate to the body in a even manner. Once all the screws are snug, 1. To access the mechanical seal, comply with the torque in the same order to 10 foot-pounds. warning and follow steps 1 through 8 of Section 9. If the pump is located above the water level of the 6.2.2, Impeller Removal. pool,remove the lid and fill the basket with water 2. Remove the carbon face seal half from the motor before starting the pump. shaft. (See Figure 11.)This is a spring-loaded seal. Grasp the portion of the seal closest to the impeller 10. Prior to replacing the lid,remove any debris body and pull the seal off using a twisting motion. around the lid o-ring seat, as debris will allow air to leak into the system. 3. Remove the motor from the backplate following steps 1 through 3 in Section 6.2.5, Motor 11. Place the lid with locking ring on the pump Replacement. housing.Align `START'with the ports and turn the lid's locking ring clockwise until `LOCKED' 4. Place the backplate o-ring side down and force the aligns with the ports.Hand-tighten the lid to make ceramic seal out using a screwdriver or drift. an air tight seal.Do not use any tools to tighten the lid. Page 18 FloPro Series Pumps Installation and Operation Manual Jandy, 5. Turn the backplate o-ring side up and insert the new ceramic seal side into the backplate. Use Backplate great care to press the seal in squarely with your fingers. The ceramic is easily damaged and must be pressed in using only your fingers or soft tools. ° Bolts and Do not use any lubricant other than water and soap Washers(4) solution. 6. Install the backplate following the steps in o ® o \ Section 6.2.3, Impeller Replacement. ° Starting 7. Install the motor following the steps in Section ° Capacitor 6.2.5, Motor Replacement. \ 6.2.5 Motor Replacement CAUTION To ensure continued safety and reliable operation, Zodiac Pool Systems, Inc. requires that you replace / the motor with a motor that has the identical HP rating and service factor(Zodiac Pool Systems, Inc. Motor approved only). WARNING Figure 14. Backplate Assembly To avoid the risk of property damage, severe personal injury, or death, turn off the pump and switch off the circuit breaker to the pump motor before beginning this procedure. 1. To disassemble the pump housing from the motor, follow steps 1 through 8 in Section 6.2.2, Impeller Removal. 2. Remove the four(4) screws on the main cover and remove the main cover. 3. Place the backplate motor assembly o-ring side down and unscrew the four(4) 9/16" screws and remove the motor. NOTE Before removing the backplate, note the alignment of the backplate to the motor. See Figure 14. 4. If installing a new motor,remove the protective plastic cap from the motor shaft. Place the motor on the backplate so that the opening in the motor faces the bottom of the backplate. The starting capacitor on the motor should be at the 12 o'clock position. 5. Replace the four(4)bolts and washers holding the backplate to the motor. 6. To reassemble the pump after replacing the motor, follow steps 1 through 13 of Section 6.2.3, Impeller Replacement. NOTE Zodiac Pool Systems, Inc. recommends replacing the mechanical seal at the same time that you replace the motor. See Section 6.2.4, Mechanical Seal Replacement, for details. < dy FloPro Series Pumps Installation and Operation Manual Page 19 Section 7. Product Specifications and Technical Data 7.1 Replacement Parts List To order or purchase parts for Jandy pumps, contact your nearest Jandy dealer. If the Jandy dealer cannot supply you with what you need, contact Jandy customer service at 1.800.822.7933, or send an e-mail message to info@jandy.com. Key No. Description Model No. (HP) Order Part No. 1 Single-speed Motor&Hardware, FHP 0.75 R0479310 1 Single-speed Motor&Hardware,FHP 1.0 R0479311 1 Single-speed Motor&Hardware, FHP 1.5 R0479312 1 Single-speed Motor&Hardware, FHP 2.0 R0479313 1 Single-speed Motor&Hardware, FHP 2.5 R0479314 1 2-Speed Motor&Hardware, FHP 1.0 R0479306 1 2-Speed Motor&Hardware, FHP 1.5 R0479307 1 2-Speed Motor&Hardware, FHP 2.0 R0479308 2 Backplate, FHP(Backplate w/Hardware, Backplate O-ring&Mechanical Seal) All R0479500 3 Impeller, FHP(Impeller,Screw w/O-ring&Backplate O-ring) 0.75 R0479601 3 Impeller, FHP(Impeller,Screw w/O-ring&Backplate O-ring) 1.0, 1.0-2 R0479602 3 Impeller, FHP(Impeller,Screw w/O-ring&Backplate O-ring) 1.5, 1.5-2 R0479603 3 Impeller, FHP(Impeller,Screw w/O-ring&Backplate O-ring) 2.0,2.0-2 R0479604 3 Impeller, FHP(Impeller,Screw w/O-ring&Backplate O-ring) 2.5 R0479605 4 Diffuser, FHP(Diffuser w/O-ring, Hardware&Backplate O-ring) 0.75, 1.0, 1.0-2 R0479702 4 Diffuser, FHP(Diffuser w/O-ring, Hardware&Backplate O-ring) 1.5, 1.5-2,2.0,2.0-2,2.5 R0479701 5 Mechanical Seal,Carbon and Ceramic(1 Set) All R0479400 6 Pump Body,FHP(Body and Backplate O-ring) All R0479800 7 Motor Mounting Foot, FHP All R0479900 8 Lid w/Locking Ring, FHP(Lid w/Locking Ring&Lid O-ring) All R0480000 9 Pump Debris Filter Basket, FHP All R0480100 10 Drain Plug w/O-ring(Set of 2) All R0446000 11 Tail Piece,O-ring&Union Nut(Set of 2) All R0327301 12 Lid O-ring, FHP All R0480200 13 Backplate O-ring, FHP All R0480300 14 Diffuser/Impeller Hardware(Diffuser O-ring,Screws(2),Screw w/O-ring&Backplate All R0480400 O-ring) 15 Backplate Hardware, FHP(Backplate Hardware&Backplate O-ring) All R0480500 16 Motor Hardware Kit All R0446700 17 Tailpiece O-ring(Set of 2) All R0337601 18 Pump Base Kit All R0486700 Page 20 FloPro Series Pumps Installation and Operation Manual jandy 7.2 Exploded View -11 11 (qty 2) 6 4 —17 (qty 2) 3 y 2, 5 ° 2 ° 2 (qty 6) 8— 15 (qty 6) ° 1 (qty 4) °12 16 (qty 4) O 4,14- 10 (qty 2) 3,14 ° 9 4, 14 (qty 2) 2, 3, 4, 6, 13, 14, 15 7-/ 1 18-/ Figure 15. FHP Exploded View dy, FloPro Series Pumps Installation and Operation Manual Page 21 7.3 Performance Curves Jandy FloPro Series Pumps Total Dynamic Max-Rated (FHPM) Pounds Per Head Square Inch (Feet of Water) (PSI) 120 110 35 100 3 90 0 80 25 70 60 20 50 15 40 Flo Pro,F HPM. 5 HP 3460 RP 30 %, Flo ro,F PM 2.0 HP 3450 RPM 10 FI)Pro,IFHPM2.OH , 1725 RPM z 20 FI Pro,FHPM .5 HP 3450 RPM Fic Pro, HPM 1.0 HP,345 RPM 5 10 Flo Pro,F PM .0 HP 1715 RP Flo ro,F PM 1. HP, 725 PM 0 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 Flow Rate, Gallons Per Minute (GPM) Page 22 FloPro Series Pumps Installation and Operation Manual �dy. 7.4 Physical and Operational Specifications 7.4.1 Specifications Table 4. FHPM Pump Specifications Model No. HP Voltage Amps Pipe Size Carton Weight Overall Length 'A' FHPM .75 0.75 230/115 5.4/10.8 1'/z-2" 40.6 25 3/16" FHPM 1.0 1.00 230/115 7.1/14.2 2-2'/2' 41.2 25 3/16" FHPM 1.5 1.50 230/115 8.0/16 2-2'/2' 42.6 25'/2" FHPM 2.0 2.00 230/115 11.2/22.4 2-2Y2' 54.6 27 3/16" FHPM 2.5 2.50 230 11.5 2'/z-3" 48.6 26 3/16" FHPM 1.0-2-SPD 1.00 230 6.0/2.3 2%-3" 46.5 26 5/16" FHPM 1.5-2SPD 1.50 230 7.2/3.0 2'/z-3" 48.0 26 9/16" FHPM 2.0-2SPD 2.00 230 10.0/3.5 2'/z-3" 52.9 27 11/16" 7.4.2 Dimensions Table 5 shows the height of the FHP pump in the three(3)mounting configurations listed below. Figures 2, 3 and 6, on page 9, show drawings of these three(3) configurations. 1)Without the FHP base 2)With the FHP base 3)With the FHP base and spacers The width of the FHP base(with or without spacers) is 8%". Table 5. FHP Mounting Configurations FHP Mounting Configurations Suction Side Height Pump Height FHP Pump without Base 7 3/4' 123/4" FHP Pump with Base 87/8' 13%" FHP Pump with Base and Spacers 9'/s" 14'/8" Figure 16 shows the dimensions(height,width, and length)of the FHP pump without the FHP base and spacers. OR 10" 12 3/a' a/��7 - o a 7 3/" o 4 I -6%------------ I 107/e' �I Bolt Holes, Front Edge of Union, Center to Center to Center of Bolt Holes NOTE See Table 4, column 7 for the value of'A'. NOTE When installing the pump, leave a minimum of two feet(2 ft)of clearance above the pump for removal of the strainer basket. Figure 16. FHP Pump Dimensions (without Base or Spacers) Andy, FloPro Series Pumps Installation and Operation Manual Page 23 7.5 Replacement Motor Guide Table 6. FHPM Replacement Motor Guide Jandy FHPM Pump Model A.O. Smith Century Model Emerson Motor Technologies Model FHPM 0.75 B852 EB852 FHPM 1.0 B853 EB853 FHPM 1.5 B854 EB854 FHPM 2.0 B859 EB859 FHPM 2.5 B840 EB840 FHPM 1.0-2SPD B980, B2980 EB980 FHPM 1.5-2SPD B982, B2982 EB982 FHPM 2.0-2SPD B983, B2983 EB983 0%. us Intertek CONFORMS TO UL 1081 CERTIFIED TO CSA C22.2 NO 108 Lu an d R y C) jZodiac Pool Systems, Inc. 6000 Condor Drive•Moorpark,CA USA 93021 • 1.800.822.7933•Fax 1.877.327.1403 o © 2010 Zodiac Pool Systems,Inc.1007 2