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APPROVED Jandy PHPM Pump- 2.0 SPECS
and " INSTALLATION AND _ �Pro�eries® OPERATION MANUAL byZODIAC ENGLISH 2HP , JandyO Pro Series PlusHP Pump PHPF & PHPM 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.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. 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. Improper installation and/or operation can create unwanted electrical hazard which can cause serious injury, property damage, or death. ATTENTION INSTALLER-This manual contains important information about the installation, operation and safe use of this product. This information should be given to the owner/ operator of this equipment. 0 0 N O E2ZODIAC@ Jandy°Pro Series,PlusHP Pump I Installation&Operation Manual Page 3 Table of Contents Section 1. Important Safety Instructions...... 4 Section 5. Service and Maintenance ..................12 1.1 Safety Instructions..................... 4 5.1 Routine Maintenance........................12 1.2 Pool Pump Suction Entrapment 5.2 Winterizing the Pump .......................12 Prevention Guidelines ............... 6 Section 6. Troubleshooting and Repair...............13 Section 2. General Description .................... 8 6.1 Troubleshooting 13 2.1 Introduction................................ 8 6.2 Service Technician Maintenance......14 2.2 Description................................. 8 6.2.1 Blocked Impeller...............................14 Section 3. Installation................................... 8 6.2.2 Impeller Removal..............................14 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..........................17 3.1.3 Pipe Sizing................................. 9 Section 7. Product Specifications and 3.2 Electrical Installation........................10 Technical Data ...................................18 3.2.1 Voltage Checks................................10 7.1 Replacement Parts List ....................18 3.2.2 Bonding and Grounding...................10 7.2 Exploded View..................................19 3.2.3 Electrical Wiring...............................10 7.3 PHPF and PHPM Pump Curves.......20 3.3 Pressure Testing........................ 11 7.4 Physical and Operational Section 4. Operation .................................... 11 Specifications ...................................21 4.1 Start-up11 7.5 PHP Pumps Replacement ...................................... Motor Guide......................................22 EQUIPMENT INFORMATION RECORD DATE OF INSTALLATION INSTALLER INFORMATION INITIAL PRESSURE GAUGE READING (WITH CLEAN FILTER) PUMP MODEL HORSEPOWER NOTES: Page 4 Jandy'Pro Series,PlusHP Pump I Installation&Operation Manual 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: A WARNING RISK OF SUCTION ENTRAPMENT HAZARD, WHICH, IF NOT AVOIDED, CAN RESULT IN SERI- OUS INJURY OR DEATH. Do not block pump suction, as this can cause severe 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. Suction outlet (drain) covers must be certi- fied to the latest published version of ANSI/ASME All 2.19.8. 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 or injury, do not attempt to change the backwash (multiport, slide, or full flow) valve position with the pump running. A WARNING Jandy Pro Series 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 RISK OF ELECTRIC SHOCK, FIRE, PERSONAL INJURY, OR DEATH. Connect only to a branch circuit that is protected by a ground-fault circuit-interrupter (GFCI). Contact a qualified electrician if you cannot verify that the circuit is protected by a GFCI. Make sure 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 electrical shock. Do not use the pump. Disconnect the pump and have the problem corrected by a qualified service representative before using. Due to the potential risk of fire, electric shock, or injuries to persons, Jandy Pro Series Pumps must be installed in accordance with the National Electric 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 lo- cal government inspection agency. A WARNING Incorrectly installed equipment may fail, causing severe injury or property damage. Jandy°Pro Series,PlusHP Pump I Installation&Operation Manual Page 5 8 WARNING • Do not connect system to an unregulated city water system or other external source of pressurized water producing pressures greater than 35 PSI. • Trapped air in system can cause the pump and/or filter lid to be blown off which can result in death, serious personal injury, or property damage. Be sure all air is out of system before operating. A WARNING To minimize 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 require- ments are generally not intended to apply to the pool equipment, such as filters or pumps. Zodiac 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 ensure 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 system to be sure it is ready for operation. Notice: These parameters apply to Zodiac equipment only. For non-Zodiac equipment, consult the equipment manufacturer. A WARNING Chemical spills and fumes can weaken pool/spa equipment. Corrosion can cause filters and other equipment to fail, resulting in severe 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 above the ground or in a building such that it cannot be readily disassembled for storage. A storable pool is con- structed 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 tempera- ture rating listed on the motor rating plate. SAVE THESE INSTRUCTIONS Page 6 Jandy'Pro Series,PlusHP Pump Installation&Operation Manual 1.2 Pool Pump Suction Entrapment Prevention Guidelines 8 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. A WARNING Pump suction is hazardous and can trap and drown or disembowel bathers. Do not use or operate swimming pools, spa, or hot tubs if a suction outlet cover is missing, broken, or loose. The following guidelines provide information for pump installation that minimizes 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 published version of ANSI/ASME All 2.19.8. They must be replaced if cracked, broken, or miss- ing. Number of Suction Outlets Per Pump - Provide at least two (2) hydraulically balanced 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. 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 sys- tem 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 out- let 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 (suc- tion 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 Swim- ming 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 Al12.19.8, 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: for example, IAPMO SPS-4. Jandy°Pro Series,PlusHP Pump I Installation&Operation Manual Page 7 E 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 tq No valves between Fitting, screw-fastened to Main Drain Sump y Tee and Main Drains Main Drain Sump Suction Outlet Suction Outlet (Main Drain) Ll (Main Drain) Valves OK between-- / Pump pump and Tee Figure 1. Number of Suction Outlets Per Pump Page 8 Jandy"Pro Series,PlusHP Pump I Installation&Operation Manual Section 2. General Description 3.1.2 Pump Location 2.1 Introduction 1. Zodiac recommends installing the pump within 1 foot above water level. The pump should not This manual contains information for the proper be elevated more than a few feet above the water installation, operation and maintenance of Jandy Pro level of the pool.A check valve is recommended Series P1usHP(PHP) Series Pumps. Procedures in this on the suction line to the pump. manual must be followed exactly. To obtain additional copies of this manual, contact Zodiac Pool Systems,Inc. NOTE Better self-priming will be achieved if the pump ("Zodiac") at 1.800.822.7933. For address information, is installed as close as possible to the water level of the pool. see the back cover of this manual. 2. If the pump is located below water level, isolation 2.2 Description valves must be installed on both the suction and Jandy Pro Series PHP Series Pumps are designed return lines to prevent back flow of pool water to meet the needs of today's more hydraulically during any routine or required servicing. demanding pool equipment.The pump housing, A WARNING backplate,diffuser,hair and lint pot(pump debris filter Some Safety Vacuum Release System (SVRS) basket), and impeller are all made from high quality devices are not compatible with installation of thermoplastic materials. These materials were chosen check valves. If the pool has an SVRS device, be for their strength and corrosion resistance. sure to confirm that that it will continue to safely operate when any check valves are installed. The pump is driven by an electric motor directly attached to the pump impeller.As the electric motor 3. The pump and other circulation equipment must turns, it causes the impeller to turn,which forces water be located more than 5 feet from the water. Choose to flow through the pump. The water flows through the a location that will minimize turns in the piping. pump inlet and then into the filter basket.The basket assembly pre-strains/traps large particles. The water NOTE In Canada, the pump must be located a then enters the center of the pump housing, flows minimum 3 meters (approximately 10 feet) from the water(CSA C22.1). through the impeller into the diffuser and then flows out the pump discharge port. 4. The pump must be placed on a solid foundation that will not vibrate. To further reduce the possibility of vibration noise,bolt the pump to the Section 3. Installation foundation, or place it on a rubber mat. 3.1 Plumbing NOTE Zodiac recommends bolting the pump directly to the foundation. 3.1.1 Preparation 5. The pump foundation must have adequate drainage 1. Upon receipt of the pump, check the carton for to prevent the motor from getting wet.The pump damage. Open the carton and check the pump for needs to be protected from the rain and sun. concealed damage, such as cracks, dents or a bent 6. Proper ventilation is required for the pump to base. If damage is found, contact the shipper or operate normally.All motors generate heat that distributor where the pump was purchased. must be removed by providing proper ventilation. 2. Inspect the contents of the carton and verify 7. Provide access for future service by leaving a that all the parts are included. See Section 7.1, clear area around the pump.Allow plenty of space Replacement Parts List. above the pump to remove the lid and basket for cleaning. 8. If the equipment is under cover,provide adequate lighting. Jandy"Pro Series,PlusHP Pump I Installation&Operation Manual M Page 9 3.1.3 Pipe Sizing water,refer to the pipe sizing chart,Table 1. For installations of equipment more than 100 feet from NOTE All HP ratings given in this section apply to full-rated pumps. For help with max-rated the water,the recommended pipe size must be pumps, contact Zodiac Customer service at increased to the next size. 1.800.822.7933. Table 1. Pipe Sizing Chart for Schedule 40 PVC 3.1.3.1 Suction Pipe Pipe Maximum Flow Maximum Flow Size Suction Discharge When the pump is located up to 50 feet from the (8 feet per second) (10 feet per second) pool,the recommended Schedule 40 minimum pipe size 1'/2" 50 GPM (189 LPM) 65 GPM (246 LPM) for the suction side of the pump is 2" for .75 to 1.5 HP*, 2" 85 GPM (322 LPM) 105 GPM (397 LPM) I V2" for.50 HP*. For 2.0 HP* pumps, the recommended 2'/2" 120 GPM (454 LPM) 149 GPM (564 LPM) pipe size is 2'V2". 3. PHP Pumps come equipped with unions on both * HP refers to full-rated pumps the suction and discharge ports. This feature 3.1.3.2 Discharge Pipe simplifies installation and service, and eliminates the possibility of leaks at threaded adapters. When the pump is located up to 50 feet 4. The PHP Pump must be connected to at least from the pool, the recommended two (2)hydraulically-balanced main drains for Schedule 40 minimum pipe size each pool-pump suction line. Each drain must be for the discharge side of the provided with covers that are listed or certified pump is 2" for .75 to 1.5 HP*,11/2" to the latest published version of ANSI/ASME for .50 HP*. For 2.0 HP* pumps, A112.19.8. The suction fittings of the main drains the recommended pipe size is must be at least 3 feet apart or at different planes. 21/2". The suction fittings can be a drain and skimmer, * HP refers to full-rated pumps two (2) drains, two (2) skimmers, or a skimmer with an equalizer line installed. Check the local NOTE All pipe sizes (Schedule 40) are able to codes for proper installation. withstand the pressures the pump will deliver, but not the flow. If the pipe is too small for NOTE To prevent entrapment, the system must be the pump, or it is elevated above water, the built so that it cannot operate with the pump maximum gallons per minute (GPM) may not drawing water from only one (1) main drain.At be delivered. If this happens, the pump will least two (2) main drains must be connected make noise (cavitate) and the pump life will be to the pump when it is in operation. However, shortened. if two (2) main drains run into a single suction 3.1.3.3 Installation Recommendations line, the single suction line may be equipped with a valve that will shut off both main drains 1. If the pump is located below water level,isolation from the pump. valves must be installed on both sides of the pump 5. The piping must be well supported and not forced to prevent back flow of pool water during any together where constant stress will be experienced. routine or required servicing. 6. Always use properly sized valves. Zodiac Jandy 2. To help prevent difficulty in priming, install the Diverter Valves and Zodiac Jandy Ball Valves suction pipe without high points (above the inlet typically have the best flow capabilities. of a pump, inverted"U"s in plumbing, commonly referred to as airlocks), which can trap air. For 7. Use the fewest fittings possible. Every additional installations of equipment up to 100 feet from the fitting has the effect of moving the equipment farther away from the water. NOTE If more than 10 suction fittings are needed, the pipe size must be increased. Page 10 4M Jandy®Pro Series,PIusHP Pump I Installation&Operation Manual 8. If this is a new installation,pressure test according 2. Bond the motor using the provided external lug. to local codes. See Section 3.3, Pressure Testing. A WARNING 3.2 Electrical Installation Always disconnect the power source before 3.2.1 Voltage Checks working on a motor or its connected load. The correct voltage, as specified on the pump data plate, is necessary for proper performance and long A WARNING motor life. Incorrect voltage will decrease the pump's Ensure that the control switch or time clock is installed in an accessible location, so that in the ability to perform and could cause overheating,reduce event of an equipment failure or a loose plumb- the motor life, and result in higher electric bills. ing fitting, the equipment can be turned off. This It is the responsibility of the electrical installer to location must not be in the same area as thepool pump, filter, and other equipment. provide data plate operating voltage to the pump by ensuring proper circuit sizes and wire sizes for this specific application. CAUTION The pump must be permanently connected to a CAUTION dedicated electrical circuit. No other equipment, Failure to provide data plate voltage (within 10%) lights, appliances or outlets may be connected to during operation will cause the motor to overheat the pump circuit. and will void the warranty. 3.2.3 Electrical Wiring 3.2.2 Bonding and Grounding 1. The pump motor must be securely and adequately l. The motor frame must be bonded to a reliable grounded using the green screw provided. Ground grounding point using a solid copper conductor, before attempting to connect to an electrical power No. 8 AWG or larger. In Canada,No. 6 AWG or supply.Do not ground to a gas supply line. larger must be used. If the pump is installed within 2. Wire size must be adequate to minimize voltage five(5) feet of the inside walls of the swimming drop during the start-up and operation of the pool, spa,or hot tub,the motor frame must be pump. See Table 2 for suggested wire sizes. bonded to all metal parts of the swimming pool, spa, or hot tub structure and to all electrical 3. Insulate all connections carefully to prevent equipment,metal conduit, and metal piping within grounding or short-circuits. Provide extra protection for sharp edges on terminals. Tape five(5) feet of the inside walls of the swimming pool, spa, or hot tub. Table 2. Recommended Minimum Wire Size for PHP Pumps RECOMMENDED MINIMUM WIRE SIZE AWG FOR PHP PUMPS* Distance from Sub-Panel 0-50 Feet 50-100 Feet 100-150 Feet 150-200 Feet Pump Model BRANCH FUSE AMPS VOLTAGE VOLTAGE VULTAGEW VOLTAGE 230 VAC 115 VAC 230 VAC 115 VAC 230 VAC 115 VAC 230 VAC 115 VAC 230 VAC 115 VAC PHPF 0.5HP/PHPMO.75HP 15A 15A 14 12 12 8 10 6 8 6 PHPF 0.75HP/PHPM1.OHP 15A 20A 14 10 10 8 8 6 8 4 PHPF 1.OHP/PHPM1.5HP 15A 20A 12 10 10 6 8 6 6 4 PHPF 1.5HP/PHPM2.OHP 15A 20A 12 8 8 6 6 4 6 3 PHPF 2.OHP/PHPM2.5HP 15A N/A 12 N/A 8 N/A 6 N/A 6 N/A PHPF 1.OHP-2-SPD(1) 15A N/A 12 N/A 10 N/A 8 N/A 6 N/A PHPF 1.5HP-2-SPD(1) 15A N/A 12 N/A 8 N/A 6 N/A 6 N/A PHPF 2.0HP-2-SPD(1) 15A N/A 12 N/A 8 N/A 6 N/A 6 N/A PHPM 1.5HP-2-SPD(1) 15A N/A 12 N/A 10 N/A 8 N/A 6 N/A PHPM 2.OHP-2-SPD(1) 15A N/A 12 N/A 8 N/A 6 N/A 6 N/A PHPM 2.5HP-2-SPD(1) 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 Electric Code(NEC)and local codes must be followed.Table shows minimum wire size and branch fuse recommendations for typical installation per NEC. (1)Two-speed pumps are not rated for use with 208 VAC. Jandy°Pro Series,PlusHP Pump I Installation&Operation Manual Page 11 wire nuts to prevent loosening.For safety, and Section 4. Operation to prevent entry of contaminants, reinstall all conduit and terminal box covers.Do not force 4.1 Start-up connections into the conduit box. 4. To configure the pump motor's internal wiring WARNING 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 damage to both the pump and motor, and it will void 3.3 Pressure Testing 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. The filter should be checked process. This air will compress when the sys- for proper installation,verifying that all connections tem is pressurized. Should the system fail, this and clamps are secure, according to the manufacturer's trapped air can propel debris at a high speed and recommendations. cause 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 To avoid risk of damage or injury,verify that all power the pump. is turned off before starting this procedure. WARNING 1. Release all pressure from the system and open the Trapped air in the system can cause the pump lid filter pressure release valve. to be blown off, which can result in death, serious 2. If the pump is located below the water level of the injury, or property damage. Be sure all air is prop- pool, opening the filter pressure release valve will erly out of the system before operating. DO NOT USE COMPRESSED AIR TO PRESSURE TEST prime the pump with water. OR CHECK FOR LEAKS. 3. If the pump is located above the water level of the pool,remove the lid and fill the basket with water WARNING before starting the pump. Do not pressure test above 35 PSI. Pressure test- 4. Prior to replacing the lid, check for debris around ing must be done by a trained pool professional. the lid seal seat. Debris around the lid seal seat Circulation equipment that is not tested properly can fail, which could result in severe injury or prop- erty damage. difficult to prime the pump. 5. Hand-tighten the lid to make an air tight seal.Do WARNING not use any tools to tighten the lid: hand-tighten When pressure testing the system with water, only. Ensure that the lid is secure. Make sure all it is very important to make sure that the pump valves are open and the unions are tight. basket lid is completely secure. 6. Restore power to the pump,then turn on the pump. 7. Once all the air has left the filter, close the 1. Fill the system with water,using care to eliminate pressure release valve. trapped air. 8. 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 3. Close the valve to trap pressurized water in the Section 3.1.3.3, Installation Recommendations, for system. proper elevation and pipe size. 4. Carefully observe the system for leaks and/or 9. If the pump does not prime and all the instructions pressure decay. to this point have been followed, check for a suction leak and then repeat Steps 2 through 7. Page 12 Jandy"Pro Series,PIusHP Pump I Installation&Operation Manual Section 5. Service and Maintenance lid's locking ring clockwise until the 'LOCKED' marking aligns with the ports. Hand-tighten the lid 5.1 Routine Maintenance to make an air tight seal.Do not use any tools to tighten the lid. Inspect the pump basket for debris by looking through the clear pump lid. Remove any debris,because 8. Verify that all valves have been returned to the as debris accumulates, it will begin to block the flow proper position for normal operation. of water through the pump. Keep the basket clean to 9. Open the pressure release valve on the filter, and improve the performance of the pump. make sure it is clean and ready for operation. 1. Turn off the power to the pump. If the pump is 10. Turn on the power to the pump. Once all the located below the water level, close the isolation air has been evacuated from the filter, close the valves on the suction and discharge sides of the pressure release valve. pump to prevent backflow of water. 2. Turn the lid's locking ring counter-clockwise until 5.2 Winterizing the Pump 'START' aligns with the ports. Carefully remove the lid. CAUTION You must protect the pump when freezing temper- CAUTION atures are expected.Allowing the pump to freeze will cause severe damage and void the warranty. A misaligned basket will cause the lid to be im- properly seated, allowing an air leak. This could result in pump damage. CAUTION 3. Lift the basket out of the pump. Dispose of all Do not use antifreeze solutions in pool, spa, debris and thoroughly clean the basket,making or hot tub systems!Antifreeze is highly toxic sure all the holes are open. Using a garden hose, and may damage the circulation system. The only exception to this is Propylene Glycol. For spray the basket from the outside to help clear the more information, see your local pool/spa supply holes. Remove any remaining debris by hand. store or contact a qualified swimming pool service 4. Replace the basket in the pump by aligning the company. open section of the basket with the inlet pipe. If 1. Drain all water from the pump, system equipment, aligned properly,the basket will drop easily into and piping. place.Do not force it into place. 2. Remove the two (2)drain plugs. Store the drain 5. Remove the lid seal and remove debris around plugs in a safe location and reinstall them when the lid groove, as this will cause air leaks in the the cold weather season is over.Do not lose system. Clean the lid groove and the lid seal. the o-rings. 6. Note that one (1) side of the lid seal has two(2) 3. Keep the motor covered and dry. But do not cover ribs and the other has one(1). Place the side with the pump with plastic. This creates condensation two(2)ribs into the lid groove. See Figure 2. that will damage the pump. 7. Replace the lid on the pump housing.Align the NOTE Zodiac recommends having a qualified service 'START'marking with the ports and turn the technician or electrician properly disconnect the electrical wiring at the switch or junction box. Once the power is removed, loosen the two (2) unions and store the pump indoors. For safety, and to prevent entry of contaminants, reinstall all conduit and terminal box covers. 4. When the system is reopened for operation, have a qualified technician or electrician make sure all piping,valves,wiring, and equipment are in accordance with the manufacturer's recommendations. Pay close attention to the filter Place side with two ribs into lid groove. and electrical connections. 5. The pump must be primed prior to starting. Refer Figure 2. Cross Section of Lid Seal to Section 4.1, Start-up. Jandy°Pro Series,PlusHP Pump I Installation&Operation Manual Page 13 Section 6. Troubleshooting and Repair Zodiac 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 www.jandy.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 manually to ensure that the system is adjusted according to the manufacturer's recommendations. Bubbles present in the pump Air in system. Check pool or spa water level to ensure that it is at the proper level and that basket. air is not being drawn into suction piping. If water is at normal level,turn off pump.Turn lid's locking ring counter-clockwise until'START'aligns with ports. Remove lid and check for debris around lid seal seat OR improper installation of lid seal, as either of these conditions will cause air leaks in the system. Clean lid seal and lid groove. Note that one(1)side of lid seal has two(2)ribs and the other has one(1). See Figure 2. Place the side with two(2) ribs into lid groove. Replace the lid on the pump housing.Align'START'with the ports and turn the 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. Page 14 Jandy°Pro Series,PlusHP Pump I Installation&Operation Manual 6.2 Service Technician Maintenance 6.2.2 Impeller Removal A WARNING A WARNING This pump must be serviced by a professional While servicing the pump, switch off the circuit service technician, qualified in pool/spa installa- breakers at the power source. Severe personal tion. The following procedures must be followed injury or death may occur if the pump starts while exactly. Improper installation and/or operation your hand is inside the pump. can create dangerous electrical hazards, which can cause high voltages to run through the elec- 1. Turn off the pump. Switch off the circuit breaker trical system. This can cause property damage, to the pump motor. If you are not replacing the serious injury, or death. Improper installation motor, do not disconnect the electrical wiring. and/or operation will void the warranty. NOTE If you are replacing the motor, Zodiac strongly 6.2.1 Blocked Impeller recommends that a qualified service technician or electrician properly disconnect the electrical A WARNING wiring at the pump motor. While servicing the pump, switch off the circuit 2. Turn off any valves to prevent pool water from breakers at the power source. Severe personal reaching the pump. Drain the water from the pump injury or death may occur if the pump starts while by loosening the unions or removing the your hand is inside the pump. drain plugs. 1. Turn off the pump. Switch off the circuit breaker 3. Using a 9/16" wrench, loosen the bolts connecting to the pump motor. the pump body to the motor backplate. See 2. Remove the lid and basket. Figure 3. 3. Look inside the pump for any debris. Remove any debris found inside. 4. Replace the basket and lid. �' e 5. Switch on the circuit breaker to the pump motor. Bolts(8) 6. Turn on the pump, and see if the problem is solved. Pump Body 7. If the impeller is still blocked with debris and it is not possible to remove the debris using Steps 2 through 4,the pump will need to be disassembled in order to access the inlet and outlet of the Motor Backplate impeller. Motor Shaft Cover Figure 3. Remove the Pump Housing 4. Pull the motor and backplate out of the pump body. Remove the pump body o-ring. The impeller is connected to the motor shaft. 5. Using a No. I Phillips screwdriver,remove the two (2) screws holding the diffuser. (The diffuser is the cover over the impeller). Then remove the diffuser. (See Figure 4.) NOTE At this point you have access to the inlet and outlet of the impeller to remove any debris. Jandy°Pro Series,PlusHP Pump I Installation&Operation Manual M Page 15 Backplate Diffuser O-Ring 0 Diffuser Screws with Washers (2) ° Self Sealing Left Handed Screw Motor Diffuser 4 Backplate O-ring Screws with Diffuser ° Washers(2) Impeller ° Mechanical ° Seal ° o� o Motor 0 Backplate Figure 7. Diffuser and Impeller Exploded View Diffuser O-ring 6. Remove the motor shaft cover on the back of the Figure 4. Remove the Diffuser motor by twisting the hex-head screw with a 90' crescent wrench. (See Figure 3.)The motor shaft Pump Body will be exposed. � p Y p 7. Hold the exposed motor shaft with a''/z" wrench '- Diffuser while removing the impeller center screw using a O-ring No. 2 Phillips screwdriver. See Figure 6. ° Diffuser NOTE The impeller center screw is a left-hand threaded screw. Therefore, turn the screw clockwise to loosen it. ° ° 8. Hold the motor shaft with a'/z" wrench while ° ° °° unscrewing the impeller from the motor shaft with ° ° / your hand. O-ring Location NOTE The impeller is a right-handed thread. for SHP Only Therefore, turn the impeller counter-clockwise O-ring Location to unscrew it. for PHP/MHP Only 9. Inspect the impeller and diffuser for signs of Figure 5. Location of Diffuser 0-ring rubbing and/or damage. Self Sealing Left Handed Screw 00 � � 0 I peller Backplate Mechanical Seal Figure 6. Remove the Impeller Page 16 qm Jandy°Pro Series,PlusHP Pump Installation&Operation Manual 6.2.3 Impeller Replacement 1. Press the carbon face seal half(see Self Sealing Left Diffuser Figure 8) on the motor shaft using a twisting Handed Screw Screws and motion. Make sure the carbon surface is facing 0 Impeller washers (2) toward the ceramic ring in the backplate. ® I CAUTION Backplate VERY IMPORTANT! Grasp the lower portion of Bac p the seal (opposite the carbon face)when installing N, the seal or it will be damaged. Mechanical Seal NOTE To assist assembly, only use water or a soap Diffuser O-ringer solution as a lubricant.Any other lubricant will destroy the seal after a short period of time. Figure 9. Backplate, Impeller, Diffuser, and NOTE Great care must to exercised to keep the seal Mechanical Seal Exploded View and mating parts clean. 6. Make sure the diffuser o-ring, o-ring groove, and 2. While holding the motor shaft with a'/z"wrench, o-ring seal area are clean and free of debris,which thread the impeller onto the motor shaft. Hand- could cause a leak. If you removed the diffuser tighten the impeller until it is secure. Install o-ring,make sure you install it in the proper the impeller center screw into the center of the location. (See Figure 5.)If grease is used to retain impeller and tighten,using a No. 2 Phillips the o-ring, it must be silicone based.Do not use screwdriver. Do not overtighten. petroleum-based grease. It will destroy the o-ring. 7. Slide the diffuser into the mating hole in the pump NOTE The impeller center screw is a left-hand body.While supporting the motor, start two(2) threaded screw. Therefore, turn the screw screws on opposite sides. This will hold the motor counter-clockwise to tighten it. in position while you start the other six(6) screws. 3. Replace the motor shaft cover by inserting the cover tabs into the slots and rotating the cover 90° 8. Tighten the screws lightly in a crossing"X" clockwise. pattern using a 9/16"wrench. Start with the inner (middle) four(4) and then tighten the outer(top 4. Replace the diffuser over the impeller,using care and bottom) four(4)to draw the backplate to the to insert alignment pins into the correct holes.The body in an even manner. Once all the screws are molded-in arrow must point toward the handle of snug,torque in the same order to 18 foot-pounds. the backplate. 9. If the pump is located above water level of the 5. Replace the two(2) small Phillips-head screws. pool,remove the lid and fill the basket with water Tighten the screws to draw the diffuser against the before starting the pump. motor backplate. NOTE Prior to replacing the lid, check for debris Carbon Seal Surface around the lid seal seat, as this will cause air leaks in the system. 10. Hand-tighten the lid to make an air tight seal.Do not use any tools to tighten the lid. 11. Open the pressure release valve on the filter, and make sure it is clean and ready for operation. 12. Switch on the circuit breaker to the pump motor. • Ceramic Face Seal • Carbon Face/Spring 13. Turn on the pump and check the system for normal • Backplate Seal Side of Seal operation. • Impeller Side of the Mechanical Seal 14. Once all the air has left the filter, close the Figure 8. Replace the Mechanical Seal pressure release valve. Jandy®Pro Series,PIusHP Pump I Installation&Operation Manual Page 17 6.2.4 Mechanical Seal Replacement 2. To disassemble the pump housing from the motor, NOTE This is a two-part replacement process. The follow steps 1 through 8 in Section 6.2.2, mechanical seal must be replaced as a set. Impeller Removal. 3. Place the backplate motor assembly o-ring side NOTE Refer to Figure 9 for an illustration of the down and unscrew the four(4) 9/16" screws and location of the mechanical seal and impeller. remove the motor. A WARNING NOTE Before removing the backplate, note the Do not damage the ceramic or carbon surfaces alignment of the backplate to the motor. See of the seal. If surfaces are damaged, leaks will Figure 10. occur. Backplate 1. To access the mechanical seal,comply with the Bolts and warning and follow steps 1 through 8 of Section ° ° washers (4) 6.2.2, Impeller Removal. o 2. Remove the carbon face seal half from the motor shaft. (See Figure 8.)This is a spring loaded seal. Starting 0 0 o Capacitor Grasp the portion of the seal closest to the impeller body and pull the seal off using a twisting motion. ° 3. Remove the motor from the backplate by V�� complying with the caution and following the steps in Section 6.2.5, Motor Replacement. 4. Place the backplate o-ring side down and force the Motor ceramic seal out using a screwdriver or drift. Figure 10. Backplate Assembly 5. Turn the backplate o-ring side up and insert the 4. If installing a new motor,remove the protective new ceramic seal side into the backplate. Use plastic cap from the motor shaft. Place the motor great care to press the seal in squarely with your on the backplate so that the opening in the motor fingers. The ceramic is easily damaged and must faces the bottom of the backplate.The starting be pressed in using only your fingers or soft tools. capacitor on the motor should be at the Do not use any lubricant other than water and soap 12 o'clock position. solution. 6. Install the motor by complying with the caution 5. Replace the four(4)bolts and washers holding the and following the steps in Section 6.2.5, Motor backplate to the motor. Replacement. 6. To reassemble the pump after replacing the 7. Install the backplate by complying with the motor, comply with the caution and follow steps 1 through 14 of Section 6.2.3, Impeller Replacement. caution and following the steps in Section 6.2.3, Impeller Replacement. 7. Have a qualified service technician or electrician properly connect the electrical wiring at the pump 6.2.5 Motor Replacement motor. CAUTION NOTE Zodiac recommends that the mechanical seal To ensure continued safety and reliable operation, be replaced at the same time the motor is Zodiac requires that you replace the motor with a replaced. See Section 6.2.4, Mechanical Seal Jandy Pro Series motor that has the identical HP Replacement, for details. rating and service factor. 1. Have a qualified service technician or electrician properly disconnect the electrical wiring at the pump motor. Page 18 Jandy°Pro Series,PlusHP Pump I Installation&Operation Manual Section 7. Product Specifications and Technical Data 7.1 Replacement Parts List To order or purchase parts for Jandy Pro Series PHP pumps, contact your nearest Zodiac dealer. If a Zodiac dealer cannot supply you with what you need, contact Zodiac technical support at 1.800.822.7933, or send an e-mail message to techsupport.vista@zmp-zodiac.com. Key Model No. No. Description (HP) Order Part No. 1 Single-speed Motor&Hardware, PHPF 0.50 R0445108 1 Single-speed Motor&Hardware, PHPF 0.75 R0445109 1 Single-speed Motor&Hardware, PHPF 1.0 R0445110 1 Single-speed Motor&Hardware, PHPF 1.5 R0445111 1 Single-speed Motor&Hardware, PHPF 2.0 R0445112 1 Single-speed Motor&Hardware, PHPM 0.75 R0479310 1 Single-speed Motor&Hardware, PHPM 1.0 R0479311 1 Single-speed Motor&Hardware, PHPM 1.5 R0479312 1 Single-speed Motor&Hardware, PHPM 2.0 R0479313 1 Single-speed Motor&Hardware, PHPM 2.5 R0479314 1 Two-speed Motor&Hardware, PHPF 1.0 R0445113 1 Two-speed Motor&Hardware, PHPF 1.5 R0445106 1 Two-speed Motor&Hardware, PHPF 2.0 R0445107 1 Two-speed Motor&Hardware, PHPM 1.5 R0479307 1 Two-speed Motor&Hardware, PHPM 2.0 R0479308 1 Two-speed Motor&Hardware, PHPM 2.5 R0479309 1 Bolts and Washers All R0445106,08-13 2 Backplate Kit w/Hardware,0-ring&Mechanical Seal All R0445200 3 Impeller&Diffuser w/Screw w/O-ring, PHPF 0.50 R0445301 3 Impeller&Diffuser w/Screw w/O-ring, PHPF 0.75 R0445302 3 Impeller&Diffuser w/Screw w/O-ring, PHPF 1.0, 1.0-2 R0445303 3 Impeller&Diffuser w/Screw w/O-ring, PHPF 1.5, 1.5-2 R0445304 3 Impeller&Diffuser w/Screw w/O-ring, PHPF 2.0,2.0-2 R0445305 3 Impeller&Diffuser w/Screw w/O-ring, PHPM .75 R0445301 3 Impeller&Diffuser w/Screw w/O-ring, PHPM 1.0 R0445302 3 Impeller&Diffuser w/Screw w/O-ring, PHPM 1.5, 1.5-2 R0445303 3 Impeller&Diffuser w/Screw w/O-ring, PHPM 2.0,2.0-2 R0445304 3 Impeller&Diffuser w/Screw w/O-ring, PHPM 2.5 R0445305 3 Screw w/O-ring,Self-sealing All R0445301-05 4 Diffuser w/O-ring&Hardware All R0445400 5 Mechanical Seal(Carbon and Ceramic) All R0479400 6 Body,Pump, PHPF/PHPM All R0448700 7 Motor Mounting Foot Assembly w/Screws,PHPF/PHPM All R0445700 8 Locking Ring w/Lid&Seal All R0448800 9 Pump Debris Filter Basket All R0448900 10 Drain Plug w/O-ring All R0446000 11 Tail Piece(2"by 2'/2")w/O-ring&Coupling Nut(Set of 2) All R0449000 12 Lid Seal and Lid 0-ring(Lid 0-ring Not Shown) All R0449100 13 0-ring,Backplate All R0446300 14 0-ring,Tail Piece All R0449200 15 Diffuser/Impeller w/O-rings&Mounting Hardware All R0446500 16 Backplate Bolts&Washers All R0446600 17 Motor Bolts&Washers All R0446700 18 Screws,Motor Mounting Foot All R0446800 Jandy°Pro Series,PlusHP Pump Installation&Operation Manual Page 19 7.2 Exploded View 11 14 �11 14 3, 4 _ O 8 3 0 —12 � � � 2, 5 2 9 2 (qty 8) ' 16 (qty 8) 1 (qty 4) 17 (qty 4) 10 (qty 2) 4, 15 B 4 (qty 2) 3, 15 15 (qty 2) 2, 13 � 1 7 (qty 2) 7 18 (qty 2) Figure 11. PHPF and PHPM Exploded View Page 20 Jandy°Pro Series,PlusHP Pump I Installation&Operation Manual 7.3 PHPF and PHPM Pump Curves Jandy PlusHP Series High Head Pumps Full-Rated (PHPF) and Max-Rated (PHPM) Total Dynamic Head Pounds per Square (Feet of Water) Inch (PSI) 120.0 50 110.0 45 100.0 90.0 40 80.0 35 70.0 30 60.0 25 50.0 20 40.0 PHPF 2.0/ 15 PHPM 2.5 30.0 Low Speed 20.0 10 PH�151 10.0 PHPM 2'0 Low Speed PHPF 1..5 5 PHPM 1.5 0.0 1 Low Sp eed 0 0 20 40 60 80 100 120 140 160 180 200 220 240 Flow Rate-Gallons Per Minute(GPM) Jandy®Pro Series,PIusHP Pump I Installation&Operation Manual Page 21 7.4 Physical and Operational Specifications 7.4.1 PHPF Pump Specifications Model No. HP Voltage Amps Pipe Size Carton Weight Overall Length'A' PHPF .50 0.50 230/115 5.4/10.8 1'/2-2" 40.4 28'/" PHPF.75 0.75 230/115 7.1/14.2 2-2'/z" 41.8 28%" PHPF 1.0 1.00 230/115 8.0/16.0 2-2'/2" 43.3 29'/" PHPF 1.5 1.50 230/115 11.2/22.4 2-2'/z" 54.6 303/" PHPF 2.0 2.00 230 11.5 2-2'/2" 49.3 29Y8" PHPF 1.0-2SPD 1.00 230 7.2/3.0 2-2'/2" 48.7 293/" PHPF 1.5-2SPD 1.50 230 10.0/3.5 2-2'/z" 52.9 30'/" PHPF 2.0-2SPD 2.00 230 11.0/4.0 2-2'/2" 60.7 30%" 7.4.2 PHPM Pump Specifications Model No. HP Voltage Amps Pipe Size Carton Weight Overall Length 'A' PHPM .75 0.75 230/115 5.4/10.8 1'/-2" 40.4 28%" PHPM 1.0 1.00 230/115 7.1/14.2 2-2'/2" 41.8 283/" PHPM 1.5 1.50 230/115 8.0/16.0 2-2'/z" 43.3 29'/4" PHPM 2.0 2.00 230/115 11.2/22.4 2-2'/2" 54.6 303/" PHPM 2.5 2.50 230 11.50 2-2'/2" 49.3 29Ys" PHPM 1.5-2SPD 1.50 230 7.2/3.0 2-2'/z" 48.7 29%" PHPM 2.0-2SPD 2.00 230 10.0/3.5 2-2'/2" 52.9 30'/" PHPM 2.5-2SPD 2.50 230 11.0/4.0 2-2'/2" 60.7 303/" 7.4.3 PHP Pump Dimensions .A. 91/$„ _ a 137/8" 14'/8" 0 87/8-' 87/$1- o Bolt Holes, Front Edge of Union to Center Center to Center of Bolt Holes NOTE When installing the pump, leave a minimum of 2 feet of clearance above the pump for removal of strainer basket. Page 22 Jandy'Pro Series,PlusHP Pump Installation&Operation Manual 7.5 PHP Pumps Replacement Motor Guide PHPF Pumps PHPM Pumps Pump Model A.O Smith /Century Pump Model A.O Smith/Century PHPF 0.50 B846 PHPM 0.75 B852 PHPF 0.75 B847 PHPM 1.0 B853 PHPF 1.0 B848 PHPM 1.5 B854 PHPF 1.5 B858 PHPM 2.0 B859 PHPF 2.0 B748 PHPM 2.5 B840 PHPF 1.0-2SPD B982, B2982 PHPM 1.5-2SPD B982, B2982 PHPF 1.5-2SPD B983, B2983 PHPM 2.0-2SPD B983, B2983 PHPF 2.0-2SPD B984, B2984 PHPM 2.5-2SPD B984, B2984 Jandy®Pro Series,PlusHP Pump I Installation&Operation Manual Page 23 NOTES 0%, " NSF Intertek CONFORMS TO UL 1081 CERTIFIED TO CSA C22.2 NO 108 Zodiac Pool Systems,Inc. 2620 Commerce Way,Vista,CA 92081 1.800.822.7933 1 www.ZodiaePoolSystems.com ZODIAC®is a registered trademark of Zodiac International,S.A.S.U.,used under license. ZODIAC 0 All trademarks referenced herein are the property of their respective owners. ©2012 Zodiac Pool Systems,Inc.H0279500 Rev F 1206 r