Flotec FP6121-01, FP6131, FPC6141, FPC6131 Owner's Manual

OWNER’S MANUAL

Above Ground Swimming Pool Pump

NOTICE D’UTILISATION

Pompe pour piscine hors sole

MANUAL DEL USUARIO

Bomba para piscinas de natación sobre el suelo

Installation/Operation/Parts

For further operating, installation, or maintenance assistance:

Call 1-800-365-6832

English . . . . . . . . . . . . . . Pages 2-12

Installation/Fonctionnement/Pièces

Pour plus de renseignements concernant l’utilisation, l’installation ou l’entretien,

Composer le

1 (800) 365-6832

Français . . . . . . . . . . . Pages 13-23

Instalación/Operación/Piezas

Para mayor información sobre el funcionamiento, instalación o mantenimiento de la bomba:

Llame al 1-800-365-6832

Español . . . . . . . . . . .Paginas 24-34

Mod. FP6121-01, FP6131,

FPC6131, FPC6141

P.O. Box 342, Delavan, WI 53115

Phone:

1-800-365-6832

Fax:

1-800-526-3757

E-Mail:

info@flotecwater.com

Web Site:

http://www.flotecwater.com

OVER TIGHTEN DO NOT

Safety 2

For parts or assistance, call Flotec Customer Service at 1-800-365-6832

FLOTEC SWIMMING POOL PUMP

To avoid unneeded service calls, prevent possible injuries, and get the most out of your pump, READ THIS MANUAL CAREFULLY!

The Flotec Above Ground Pool Pump:

• Is designed to circulate water in above ground swimming pools (not for use in spas or inground pools).

• Is an excellent performer; durable, reliable.

IMPORTANT SAFETY INSTRUCTIONS

Always follow basic safety precautions with this equipment, including the following.

To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at all times.

SAVE THESE INSTRUCTIONS

READ AND FOLLOW SAFETY INSTRUCTIONS!

This is the safety alert symbol. When you see this

symbol on your pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury.

warns about hazards that will cause serious

personal injury, death or major property damage if ignored.

warns about hazards that can cause serious

personal injury, death or major property damage if ignored.

warns about hazards that will or can cause

minor personal injury or property damage if ignored. The label NOTICE indicates special instructions which

are important but not related to hazards.

Carefully read and follow all safety instructions in this manual and on equipment. Keep safety labels in good

condition; replace if missing or damaged.

Incorrectly installed or tested equipment may fail, causing severe injury or property damage.

Read and follow instructions in owner's manual when installing and operating equipment. Have a trained pool professional perform all pressure tests.

1. Do not connect system to a high pressure or city

water system.

2. Use equipment only in a pool installation.

3. Trapped air in system can cause explosion. BE SURE

all air is out of system before operating or testing

equipment. Tighten Flotec trap lids to hand tight only. Water pressure must be less than 25 PSI (7.5 kg/cm

Water Temperature must be less than 104° F (40° C).

Fire and burn hazard. Modern motors run

at high temperatures. To reduce the risk of fire, do not allow leaves, debris, or foreign matter to collect around the pump motor. To avoid burns when handling the motor, let it cool for 20 minutes before trying to work on it. An automatic internal cutoff switch protects the motor from heat damage during operation.

For parts or assistance, call Flotec Customer Service at 1-800-365-6832

Table of Contents 3

Thank you for purchasing a top quality, factory tested pump.

Page

General Safety .....................................................................................................2

Installation ...........................................................................................................4

Electrical..............................................................................................................5

Operation ........................................................................................................6, 7

Pump Service...................................................................................................7, 8

Troubleshooting ...................................................................................................9

Repair Parts .................................................................................................10, 11

Warranty............................................................................................................12

Installation 4

For parts or assistance, call Flotec Customer Service at 1-800-365-6832

For ease of pump/motor removal, install pipe unions on the suction and discharge pipes close to pump.

Pump mount must:

Be located away from corrosive or flammable liquids. Have enough ventilation to maintain air temperature at

less than the maximum ambient temperature rating (Max. Amb.) listed on the motor model plate. If this pump is installed in an enclosure/pump house, the enclosure must have adequate ventilation and air circulation to keep the temperature in the enclosure at or below the motor’s rated ambient temperature whenever the pump is running.

Be solid - Level - Rigid - Vibration free. (To reduce vibration and pipe stress, bolt pump to mount.)

Allow pump suction inlet height to be at or below water level in pool.

Allow use of short, direct suction pipe (To reduce friction losses).

Allow for gate valves in suction and discharge piping. Have adequate floor drainage to prevent flooding. Be protected from flooding. Allow adequate access for servicing pump and piping. NOTICE: Use Teflon tape or Plasto-Joint Stik1for making

all threaded connections to the pump. Do not use pipe dope; pipe dope will cause stress cracking in the pump.

NOTICE: Pump suction and discharge connections have molded in thread stops. DO NOT try to screw pipe in beyond these stops. Tighten the pump/trap fittings only as much as required to insure a tight connection (1-1/2 turns past hand tight is sufficient). Overtightening may damage the pump trap. Use care when using teflon tape as friction is reduced considerably; do not overtighten connections or damage may occur.

Teflon Taping Instructions:

Use only new or clean PVC pipe fittings. Wrap male pipe threads with one to two layers of Teflon

tape. Cover entire threaded portion of pipe. Do not overtighten or tighten past thread stop in pump

port! If leaks occur, remove pipe, clean off old tape, rewrap

with one to two additional layers of tape and remake the connection.

NOTICE: Support all piping connected with pump!

Lake Chemical Co., Chicago, Illinois

Piping:

To avoid strains on the pump, support both suction and discharge pipes or hoses independently. Place these supports near the pump.

To avoid airlocking, slope suction pipe slightly upward toward the pump.

NOTICE: To prevent flooding when removing pump for service, all flooded suction systems must have gate valves in suction and discharge pipes.

Union available for pump discharge port (Part number WC198-105). Use as follows for leak-free connection to pump:

1. O-Ring and sealing surfaces must be clean.

2. Assemble handtight only! (NO WRENCHES!)

3. NO pipe compound or teflon tape on union.

4. Bond pipe to union with PVC cement.

Fire hazard. Use PVC cement only in a well ventilated area away from flame; follow manufacturer’s instructions.

Fittings:

Fittings restrict flow; for best efficiency use fewest possible fittings.

Avoid fittings which could cause an air trap.

Figure 1

/2" NPT Discharge Port

Strainer Basket Cover

E N

11/2" NPT Suction Por

V E R

I G

Drain Plug

Electrical 5

For parts or assistance, call Flotec Customer Service at 1-800-365-6832

Hazardous voltage. Can shock, burn or

cause death. Plug pump into a grounded power supply.

Do not alter cord or plug. Disconnect power to motor before working on electrical connections.

Ground Fault Circuit Interrupter (GFCI) tripping

indicates an electrical problem. If GFCI trips and will not reset, have a qualified electrician inspect and repair electrical system.

Exactly match supply voltage to nameplate voltage.

Incorrect voltage can cause fire or seriously damage motor and voids warranty. If in doubt consult a licensed electrician.

Plug cord of pump directly into a GFCI protected

receptacle. Do not use an extension cord.

Voltage:

Voltage at motor must be not more than 10% above or below motor nameplate rated voltage or motor may overheat, causing overload tripping and reduced component life. If voltage is less than 90% or more than 110% of rated voltage when motor is running at full load, consult power company.

Wiring:

Do not alter cord or plug on cord-connected units. Plug in to a GFCI protected, grounded outlet only. If plug and outlet do not match, consult a licensed electrician.

Table I, gives correct circuit breaker sizes for the pump alone. If other lights or appliances are also on the same circuit, be sure to add their amp loads to pump amp load before figuring circuit breaker sizes. (If unsure how to do this or if this is confusing, consult a licensed electrician.) Use the load circuit breaker as the master on-off switch.

Install a Ground Fault Circuit Interrupter (GFCI) in circuit; it will sense a short-circuit to ground and disconnect power before it becomes dangerous to pool users. For size of GFCI required and test procedures for GFCI, see manufacturer’s instruction.

In case of power outage, check GFCI for tripping (which will prevent normal pump operation). Reset if necessary.

Model Number Motor H.P. Branch Fuse Rating Amps* Max Load Amps Voltage/Hz/Phase

FP6121-01 3/4 15 9.0 115/60/1

FP6131 1 15 12.0 115/60/1 FPC6131 1 15 11.9 115/60/1 FPC6141 1-1/2 15 11.9 115/60/1

TABLE I - RECOMMENDED FUSING DATA

Values given in table below are for PUMP MOTOR ONLY. If additional accessories are installed on

pump motor circuit (heater, blower, etc.), include their amperage draw when figuring wire and circuit breaker sizes.

*Time delay fuses are recommended instead of standard fuses in any motor circuit.

Operation 6

For parts or assistance, call Flotec Customer Service at 1-800-365-6832

NEVER run pump dry! Running pump dry may damage seals, causing leakage and flooding! Fill

pump with water before starting motor.

Before removing trap cover:

1. STOP PUMP before proceeding.

2. CLOSE GATE VALVES in suction and discharge pipes.

3. RELEASE ALL PRESSURE from pump and piping system.

Fire and burn hazard. Modern motors run

NOTICE: Do not block pool return. To do so may flood area causing damage to equipment and water damage to surrounding area.

Priming Pump:

Open valves before starting system. Release all pressure from filter, pump, and piping system;

see the filter owner’s manual. In a flooded suction system (water source higher than

pump), pump will prime itself when suction and discharge valves are opened.

Pool Water:

Keep water level at least two inches above bottom of skimmer opening when system is not in use. Failure to do so can allow air to enter system, causing pump to lose its prime.

Keep pool water “balanced”. Maintain the water pH between 7.2 and 7.6.

Do not use or allow the use of the pool by anyone

using alcohol or drugs. The effects of hot water, alcohol and/or drugs can cause dizziness and falling, loss of consciousness, or heart attack.

Storage/Winterizing:

Explosion hazard. Purging the system with compressed air can cause components to explode, with risk of severe injury or death to anyone nearby. Use only

a low pressure (below 5 PSI), high volume blower when air purging the pump, filter, or piping.

To prevent damage to components from fumes, store chemicals away from pump. If possible, store

chemicals in another room. NOTICE: Drain pump! Allowing pump to freeze will

damage pump and void warranty! NOTICE: Do not use anti-freeze solutions (except propy-

lene glycol) in your pool system. Propylene glycol is non-toxic and will not damage plastic system components; other anti-freezes are highly toxic and may damage plastic components in the system. Propylene glycol is widely used as antifreeze in recreational vehicles.

Drain all water from pump and piping when expecting freezing temperatures or when storing pump for a long time (see instructions below).

Keep motor dry and covered during storage. To avoid condensation/corrosion problems, do not cover

or wrap pump with plastic. For outdoor/unprotected installations:

1. Pump down water level below all inlets to pool.

2. Enclose entire system in a weatherproof enclosure.

3. To avoid condensation/corrosion damage, allow ven-

tilation; do not wrap system in plastic.

4. Use a 40% propylene glycol/60% water solution to

protect pump to -50°F.

5. Follow pool manufacturer’s directions for storage of

pool.

Draining Pump:

Hazardous voltage. Can shock, burn or cause death. Disconnect power before working on pump

or motor.

1. Close all valves on suction and return piping.

2. Remove drain plug in bottom of trap body.

3. Drain all piping and storage tanks exposed to freezing

temperatures.

4. Be sure no airlocks are holding water in the system.

5. To prevent pump from freezing, remove trap cover

and drain the tank body through the drain plug (Key No. 12, Page 10). Clean pump thoroughly. Replace trap cover.

6. Before restarting, replace all plugs and make sure all

pipe connections are tightly sealed.

Hazardous Suction. Can trap hair or body, causing severe injury or death.

• Do not block suction.

• Keep small children under close adult supervision at all times.

Operation / Pump Service 7

For parts or assistance, call Flotec Customer Service at 1-800-365-6832

Startup For Winterized Equipment:

1. Remove any temporary weather protection placed around system for shutdown.

2. Follow filter manufacturer’s instructions for reactivation of the filter.

3. Inspect all electrical wiring for damage or deterioration over the shutdown period. Have a qualified serviceman repair wiring as needed.

4. Inspect and tighten all watertight connections.

5. Open all valves in suction and return piping.

6. Remove any winterizing plugs in piping system.

7. Drain all propylene glycol (RV antifreeze) from the system.

8. Close all drain valves and replace all drain plugs in piping system.

9. Prime pump according to instructions on Page 6.

10.Refill pool to proper water level.

PUMP SERVICE

To avoid dangerous or fatal electrical shock hazard, disconnect power to motor before working on pump or motor.

Pump should only be serviced by qualified personnel. Be sure to prime pump (Page 6) before restarting.

Before removing trap cover:

1. STOP PUMP before proceeding.

2. CLOSE GATE VALVES in suction and discharge pipes.

3. RELEASE ALL PRESSURE from pump and piping system.

No lubrication or regular maintenance is needed beyond reasonable care and periodic cleaning.

If shaft seal is worn or damaged, repair as follows:

Removing Old Seal:

1. Disconnect power to pump motor.

2. Drain pump; disconnect plumbing to allow access to

pump.

3. Remove four bolts holding trap body to seal plate;

remove trap body.

4. Remove shaft cover or motor canopy; using screw-

driver in slot on motor end of shaft or wrench on flats of shaft extension, hold pump shaft and unscrew impeller from shaft (turn counterclockwise). Rotating half of seal will come off with impeller.

5. Carefully remove rotating part of seal from impeller sleeve by pulling and turning on sealing washer and spring (Figure 2). Do not damage impeller surface where drive ring seats and seals.

6. Carefully remove four motor throughbolts from seal plate (Figure 3); remove seal plate and use a screwdriver to tap ceramic seat out from the rear (Figure 4). Do not damage seal cavity in seal plate.

7. Clean cavity from which seal was removed and clean motor shaft.

Figure 2

Figure 3

Figure 4

Pump Service 8

For parts or assistance, call Flotec Customer Service at 1-800-365-6832

Installing New Seal:

1. Ceramic seat must be clean and free of dirt, grease, dust, etc. Wet rubber cup gasket of ceramic seat with small amount of water; press into cavity firmly and squarely with finger pressure (Figure 5).

2. If ceramic seat will not locate properly, remove it, place face up on bench, and reclean cavity. Ceramic seat should now locate.

3. Seal must be free of dirt, grease, grit, scratches or chips; be sure impeller sleeve is clean. Slide seal assembly, rubber drive ring first, onto impeller sleeve until drive ring bottoms on impeller back shroud.

4. Slip slinger over shaft; remount seal plate. Torque throughbolts to 25 inch-lbs. (29 cm-kg).

5. Screw impeller onto shaft until it seats against shaft shoulder. Work slinger over end of impeller sleeve so it rides on sleeve (Figure 6).

6. Install wear ring on back of volute. NOTICE: Teeth on wear ring interlock with ribs on trap body.

7. Remount trap body.

8. Reconnect unions; tighten hand tight only.

Figure 5

Figure 6

Troubleshooting 9

For parts or assistance, call Flotec Customer Service at 1-800-365-6832

Read and understand safety and operating instructions in this manual before doing any work on

pump.

Only qualified personnel should electrically test pump motor.

FAILURE TO PUMP; REDUCED CAPACITY OR DISCHARGE PRESSURE

Suction leaks/lost prime:

1. Pump must be primed; make sure that pump volute and trap are full of water. See priming instructions, Page 6.

2. Make sure there are no leaks in suction piping.

3. Make sure suction pipe inlet is well below the water level to prevent pump from sucking air.

4. Suction lift of 1 to 2 feet (.3-.6M) will reduce performance. Suction lift of more than 2 feet (.6M) will prevent pumping and cause pump to lose prime. In either case, move pump closer (vertically) to water source. Make sure suction pipe is large enough.

Clogged pipe/trap/impeller, worn impeller:

1. Make sure suction trap is not clogged; if it is, clean trap and strainer.

2. Make sure impeller is not clogged (follow instructions under “Removing Old Seal”, Page 7; check impeller for clogging; follow instructions under “Installing New Seal”, Page 8, for reassembly).

3. Impeller and diffuser may be worn. If so, order replacement parts from Repair Parts List, Page 10.

Inadequate Circulation:

1. Check trap basket; if plugged, turn pump off and clean basket. Check and clean skimmer basket.

2. Check that gate valves are fully open.

3. Suction/discharge piping is too small.

4. Check and clean pool filter.

5. Check for clogged pipe/trap/impeller, Page 8.

6. Consult dealer/installer or service representative.

Circuit Breaker In Home Panel Trips Repeatedly:

1. Breaker must be of adequate capacity.

2. For GFCI breaker, test according to GFCI manufacturer’s instructions.

3. Be sure no other lights and appliances are on circuit.

4. Consult dealer/installer or service representative.

5. Voltage too high or too low. See “Voltage”, Page 5.

Electrical:

1. Pump may be running too slowly; check voltage at motor terminals and at meter while pump is running. If low, see wiring instructions or consult power company. Check for loose connections.

2. Pump may be too hot. A. Check line voltage; if less than 90% or more than

110% of rated voltage consult a licensed electrician. B. Increase ventilation. C. Reduce ambient temperature. D. Tighten any loose wiring connections.

3. Motor internal thermal overload protector is open. Motor runs too hot. Turn power to motor off. Check for proper voltage. Check for proper impeller or impeller rubbing.

4. Consult dealer/installer or service representative.

Mechanical Troubles and Noise:

1. If suction and discharge piping are not adequately supported, pump assembly will be strained. See “Installation”, Page 4.

2. Do not mount pump on a wooden platform! Securely mount on concrete platform for quietest performance.

3. Air leak in suction line (bubbles in water returning to pool). Repair leak. Tighten trap lid.

4. Foreign matter (gravel, metal, etc.) in pump impeller. Disassemble pump, clean impeller, follow pump service instructions on Page 8 for reassembly.

5. Cavitation. Improve suction conditions. Increase pipe size. Decrease number of fittings. Increase discharge pressure. Reduce flow by throttling

discharge gate valve.

Repair Parts 10

For parts or assistance, call Flotec Customer Service at 1-800-365-6832

Key Part No. FP6121-01 FP6131 No. Description Used 3/4 HP 1 HP

1 Motor 1 AS920DLL AS920ELL 2 Slinger 1 17351-0009 17351-0009 3 Seal Plate 1 17500-0001 17500-0001 4 Seal Plate O-Ring 1 35505-1438 35505-1438 5 Shaft Seal 1 37400-0027S 37400-0027S 6 Impeller 1 17301-0113 17301-0112 7 Floating Wear Ring 1 17500-0004 17500-0004 8 Trap Body 1 17500-0002 17500-0002

9 Trap Lid 1 17500-0003 17500-0003 10 Trap Lid O-Ring 1 35505-1437 35505-1437 11 Trap Basket 1 17350-0100 17350-0100 12 Drain Plug 1 U178-920P U178-920P 13 Hex Head Bolt, 1/4-20x1-3/4" 4 30787-0005 30787-0005 14 Hex Nut 4 35402-0071 35402-0071 15 Cord 1 U117-1117 U117-1117

• Hardware Kit (2 Bolts, 2 Washers) 1 17290-0001 17290-0001

• Nameplate 1 U33-155 U33-155

• Warning Tag 1 61002-0013 61002-0013

• Caution Tag 1 C63-12 C63-12

• Decal - “GFCI Required” 1 U27-558 U27-558

Repair Parts List

• Not illustrated.

3345 1198

Repair Parts 11

For parts or assistance, call Flotec Customer Service at 1-800-365-6832

Key Part No. FPC6131 FP6141 No. Description Used 1 HP 1-1/2 HP

1 End Cap Screw 3 37337-0085 37337-0085

2 End Cap and Cord Assembly 1 17190-0026 17190-0026

3 Toggle Switch 1 16920-0511 16920-0511

4 Toggle Switch Boot 1 32800-0107 32800-0107

5 Baffle Ring 1 17290-0004 17290-0004

6 Motor 1 AS901EL AS901SFL

7 Motor Cover 1 17190-0021 17190-0021

8 Slinger 1 17351-0009 17351-0009

9 Seal Plate 1 17500-0001 17500-0001 10 Seal Plate O-Ring 1 35505-1438 35505-1438 11 Shaft Seal 1 37400-0027 37400-0027 12 Impeller 1 17301-0112 17301-0112 13 Floating Wear Ring 1 17500-0004 17500-0004 14 Trap Lid 1 17500-0003 17500-0003 15 Trap Lid O-Ring 1 35505-1437 35505-1437 16 Trap Basket 1 17350-0100 17350-0100 17 Trap Body 1 17500-0002 17500-0002 18 Drain Plug with O-Ring 1 U178-920P U178-920P 19 Hex Head Bolt, 1/4-20x1-3/4" 4 30787-0005 30787-0005 20 Hex Nut 4 35402-0071 35402-0071

• Hardware Kit (2 Bolts, 2 Washers) 1 17290-0001 17290-0001

• Warning Tag 1 61002-0013 61002-0013

• Caution Tag 1 C63-12 C63-12

• Decal - “GFCI Required” 1 U27-558 U27-558

Repair Parts List

• Not illustrated. For complete suction trap order Pkg. 115.

V E R

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3345 1198 CAN

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Flotec FP6121-01, FP6131, FPC6141, FPC6131 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual