Flotec FP5712-02 Bedienungsanleitung

OWNER’S MANUAL

Serviceable High Pressure

Booster Pump

NOTICE D’UTILISATION

Pompe de surpression

réparable

MANUAL DEL USUARIO

Bomba auxiliar de alta presión

de buen funcionamiento

Installation/Operation/Parts

For further operating, installation,

or maintenance assistance:

Call 1-800-365-6832

English . . . . . . . . . . . . . . Pages 2-10

Installation/Fonctionnement/Pièces

Pour plus de renseignements

concernant l’utilisation,

l’installation ou l’entretien,

Composer le

1 (800) 365-6832

Français . . . . . . . . . . . Pages 11-19

Instalación/Operación/Piezas

Para mayor información sobre el

funcionamiento, instalación o

mantenimiento de la bomba:

Llame al 1-800-365-6832

Español . . . . . . . . . . .Paginas 20-28

MOD. FP5712-02,

FP5722-02, FP5732-02

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

Safety 2

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

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.

ELECTRICAL SAFETY

Some models of pump

are supplied with 3-con-

nector grounding type cord.

Connect only to properly

grounded, GFCI protected

outlet. Do not lift pump by

electrical cord.

Pump is non-sub-

mersible. Keep motor

dry at all times. Do not wash

motor. Do not immerse.

Protect motor from wet

weather.

If using extension cord,

use only UL approved

indoor/outdoor, 3-wire,

grounding type cord. Do not

allow any part of cord or

receptacle ends to sit in water or damp locations.

Unplug pump before servicing.

Burn Hazard. Do not touch an oper-ating

motor. Modern motors can operate at high temperatures.

To avoid burns when servicing pump, allow it to cool for

20 minutes after shut-down before handling.

Follow local and/or national plumbing and electrical codes

when installing.

Hazardous Pressure. DO NOT run the pump

with discharge shutoff, as hose may burst or pump may be

damaged due to high temperatures.

GENERAL SAFETY

To avoid risk of serious bodily injury and property damage,

read safety instructions carefully before installing pump.

Do not allow pump or any system component to freeze. To

do so may damage system and will void warranty.

Risk of electric shock. To avoid fatal shocks,

proceed as follows if pump needs servicing.

A. Disconnect power to pump outlet box before pulling

pump cord plug. After plug is pulled, let pump cool for

20 minutes before attempting to work on it.

B. Take extreme care when changing fuses. To re-duced

chance of fatal electrical shocks, DO NOT stand in

water or put your finger in the fuse socket.

C. Ground electrical outlet box.

D. Use only Ground Fault Circuit Interrupter (GFCI) pro-

tected grounded outlet for cord plug.

Never run pump dry. Running pump dry can damage inter-

nal parts, overheat pump (which can cause burns to people

handling or servicing pump), and will void warranty.

Do not pump chemicals or corrosive liquids with pump.

Hazardous Pressure.

A. Use high pressure reinforced type discharge hose

ONLY. See parts list for available hose, nozzle and fit-

tings. A high pressure relief valve is recommended.

B. DO NOT use garden hose with High Pressure Booster

pump. Garden hose will not stand the discharge pres-

sure produced and will fail.

C. High pressure discharge stream is dangerous. To avoid

injury, DO NOT aim the discharge stream at any per-

son or animal.

D. BE SURE that the pump suction pipe pressure plus the

pump discharge pressure does not exceed the pressure

rating of hose and fittings. See Table I for pump dis-

charge pressure ratings.

WARNING

Hazardous voltage.

Can shock, burn, or

cause death.

Ground pump before

connecting to power

supply.

Table of Contents 3

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

Page

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

Warranty..............................................................................................................3

Installation........................................................................................................4-5

Operation .........................................................................................................5-6

Electrical...........................................................................................................6-7

Maintenance.....................................................................................................8-9

Repair Parts .......................................................................................................10

ATTACH ORIGINAL RECEIPT HERE FOR WARRANTY CONSIDERATION.

FLOTEC warrants to the original consumer purchaser (“Purchaser”) of its products that they are free from defects in material or workmanship.

If within twelve (12) months from the date of the original consumer purchase any such product shall prove to be defective, it shall be repaired or

replaced at FLOTEC’s option, subject to the terms and conditions set forth below.Your original receipt of purchase is required to determine war-

ranty eligibility.

Exceptions to the Twelve (12) Month Warranty

Product Warranty Period

Drill Pump, Pitcher Pump, In-line Water Filter Cartridge 90 days

1/3 HP Submersible Sump Pumps, INTELLIPUMP (Model FP0S1775A) 2 Years

Back-up Sump Pump System (Model FP2800DCC)

4" Submersible Well Pumps, 1/2 HP Submersible Sump Pumps 3 Years

Models FPSC2200A-10 and FPSC2250A-10

Pre-Charge Water System Tank, Models FPSC3200A-10 and FPSC3250A-10 5 Years

Floodmate®7000 (Model FP0S6000A), Ironmate®(Model FPSC4550A)

Sewage Ejector (Model FPSE3601A), Pedestal Sump Pump (Model FPPSS5000) Lifetime

Utility Pump (Model FPSC1725X), Submersible Sump Pump (Model FPSC4550A-10)

General Terms and Conditions

Purchaser must pay all labor and shipping charges necessary to replace product covered by this warranty. This warranty shall not apply to

acts of God, nor shall it apply to products which, in the sole judgement of FLOTEC, have been subject to negligence, abuse, accident, mis-

application, tampering, alteration; nor due to improper installation, operation, maintenance or storage; nor to other than normal application,

use or service, including but not limited to, operational failures caused by corrosion, rust or other foreign materials in the system, or opera-

tion at pressures in excess of recommended maximums.

Requests for service under this warranty shall be made by returning the defective product to the Retail outlet or to FLOTEC as soon as pos-

sible after the discovery of any alleged defect. FLOTEC will subsequently take corrective action as promptly as reasonably possible. No

requests for service under this warranty will be accepted if received more than 30 days after the term of the warranty.

This warranty sets forth FLOTEC’s sole obligation and purchaser’s exclusive remedy for defective products.

FLOTEC SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT DAMAGES WHATSOEVER.

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES,

INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PUR-

POSE, SHALL NOT EXTEND BEYOND THE DURATION OF THE APPLICABLE EXPRESS WARRANTIES PROVIDED HEREIN.

Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty

lasts, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other

rights which vary from state to state.

FLOTEC • P.O. Box 342 • Delavan, WI U.S.A. 53115

Phone: 1-800-365-6832 • Fax: 1-800-526-3757

E-Mail: info@flotecwater.com • Web Site: http://www.flotecwater.com

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

Installation 4

INSPECT THE SHIPMENT

The high pressure booster pump has been carefully

inspected and packaged to assure safe delivery. Inspect the

pump and fittings and report to the carrier any items

which are damaged or missing.

INSTALLATION

The pump is designed to boost city water pressure or

water pressure from a private water system. Use this high

pressure stream to wash down milk parlors, barns, garages

and driveways, or for fire protection.

The pump is portable with a convenient carrying handle. If

an existing pressure water system is to be used as a water

supply, it can be connected with available fittings and 3/4"

or 1" high pressure hose to the pump inlet. A special heavy

duty 3/4" or 1" suction hose with fittings is available as an

accessory. If pump is permanently mounted on wall, use a

3/4" or 1" pipe or heavy-duty hose for suction line. This

pump can be disassembled for service without removing

installation piping.

Hazardous pressure. Pump body may

explode if pressures exceed rated limits. Maximum inlet

pressure is 80 PSI. Maximum discharge pressure is 315

PSI. Warranty is void if these pressure limits are exceeded.

HIGH PRESSURE BOOSTER PUMP

INSTALLATION INSTRUCTIONS

These instructions cover high pressure booster pump

installations as shown below:

Discharge Discharge

No. of Pressure at Pressure at

Model HP Stages Rated Flow No Flow

FP5712-02 1/2 6 75 113

FP5722-02 3/4 8 97 147

FP5732-02 1 10 134 188

TABLE I - DISCHARGE PRESSURE

NOTE: For total discharge pressure, add this pressure to

suction pipe pressure. For example, an FP5712-01 pump

taking suction from a 100 psi water service line will pro-

duce 75 + 100 = 175 psi total discharge pressure at 0

GPM flow. If suction pressure drops to 50 psi, discharge

pressure will drop to 125 psi.

Figure 1 – Connection to house service.

1208 0505

From pressurized

house service

Suction Discharge

Figure 2 – Connection to water reservoir.

1207 0505

Water tank

or reservoir

Suction Discharge

Installation / Operation 5

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

To reduce friction losses to a minimum, inlet (suction) line

should be short and have as few elbows as possible.

The pump has a 3/4" NPT inlet opening. The inlet and

outlet lines should be 1".

An inlet strainer will prevent suspended debris from clog-

ging pump.

The internal running surfaces of the pump and seals

require water lubrication for good, consistent operation.

Allowing pump to run dry will severely damage pump

and seals.

Install a pressure gauge in pump inlet line. Keep at least

two pounds per square inch pressure (2 PSI) in inlet line

whenever pump is operating. If this is not possible, consult

customer service representative.

LUBRICATION

It is not necessary to lubricate pump or motor. The motor

is equipped with sealed ball bearings, lubricated for the

life of the bearing. The mechanical shaft seal in the pump

is self-lubricating and requires no adjustment. Disassemble

pump to replace seal (See “Maintenance”, Pages 8 to 9).

OPERATION

If the pump is not connected to a pressurized source, it

must first be primed. Prime the pump by filling the suction

pipe and pump body with water.

NOTICE: Observe the following precautions when operat-

ing the pump:

1. Keep the motor dry! Do not direct stream from pump

discharge onto the motor!

2. Hazardous pressure. Do not run the

pump with discharge shutoff, as hose may burst or

pump may be damaged due to high temperatures.

3. Do not use a standard trigger gun with this pump. Use

only trigger guns with an automatic weeping feature.

These are available as accessories and are provided

with three nozzles. The smallest nozzle restricts the

flow, allowing use of a smaller water source. The two

larger nozzles are used if the water source will supply

the pump’s full capacity.

4. Do not run pump dry; to do so may damage the seal.

5. To avoid internal damage to pump, Do not operate

with water temperature above 175 degrees F.

Figure 4 – Wall mounted to pressurized service line.

To Powe r

Gate Valve or Hose Bibb

Male Pipe to Male Hose Adapter

High Pressure Hose with two

Female Connections

Service Line

Male Pipe to Male Hose Adapter

(Suction)

(Discharge)

Female Hose Connection

High Pressure Hose

Gun Nozzle

Weeping Type ONLY

1209 0505

Figure 3 – Cistern or shallow well installation.

Male Pipe to Male Hose Adapter

Female Hose Connection

Male Hose

Connection

High Pressure

Hose

15 Feet

Maximum

Gun Nozzle

Weeping Type ONLY

Priming Plug Tee 90 Elbow

Water Supply

Foot Valve

1210 0505

Operation / Electrical 6

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

MOTOR SWITCH SETTINGS

Dual-voltage motors without cords (motors that can oper-

ate at either 115 or 230 volts), are set at the factory to 230

volts. Do not change motor voltage setting if line voltage

is 230 volts, or if you have a single voltage motor.

NOTE: Never wire a 115 volt motor to a 230 volt line.

Remove Motor End Cover

If you have a dual-voltage motor, and will connect it to

115 volts, follow the procedure below.

You will need to remove the motor end cover to change

the voltage setting.

Your motor terminal board (located under the motor end

cover) should look like the one below.

Dial Type Voltage Selector

To change to 115 volts:

1. Make sure power is off.

2. Turn the dial counter-clockwise until 115 shows in the

dial window.

3. Attach the power lead wires to the power lead termi-

nals. Make sure the wires are secure.

4. Attach the ground wire to the green ground screw

5. Reinstall the Motor end cover

Go to Wiring Connections below.

ELECTRICAL

Ground motor before connecting to electrical

power supply.

Failure to ground motor can cause severe or fatal

electrical shock hazard.

Explosion hazard. Do not ground to a gas supply

line.

To avoid dangerous or fatal electrical shock, turn

OFF power to motor before working on electrical

connections.

Supply voltage must be within ±10% of nameplate

voltage. Incorrect voltage can cause fire or serious

damage to motor and voids warranty. If in doubt consult

a licensed electrician.

Use wire size specified in Wiring Chart (Table II,

Page 7). If possible, connect pump to a separate

branch circuit with no other appliances on it.

Wire motor according to diagram on motor name-

plate. If nameplate diagram differs from diagrams

above, follow nameplate diagram.

Figure 5 – Removing end cover.

Motor

End Cover

End Cover Screws

Figure 6 – Voltage adjustment dial.

Voltage

Change Dial

Ground

Screw

Power Lead

Terminals

Electrical 7

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

WIRING CONNECTIONS

1. Install, ground, wire and maintain this pump in com-

pliance with the National Electrical Code (NEC) or the

Canadian Electrical Code (CEC) and with all local

codes and ordinances that apply. Consult your local

building inspector for local information.

2. Make sure that the voltage, frequency and phase (sin-

gle phase or three phase) of the power supply agree

with that stamped on the motor nameplate. If in

doubt, check with the power company.

3. Some models are equipped with three phase motors.

Three phase motors require magnetic starters and can

run in either direction, depending on how they are

connected to the power supply.

NOTICE: Dual voltage motors without cords are factory

wired for 230 volts. If necessary, reconnect the motor for

115 volts, as shown. All cord connected motors are wired

for 115 volts (See Page 5). Do not alter the wiring in single

voltage motors.

Install, ground, wire, and maintain your pump in com-

liance with the National Electrical Code (NEC) or the

Canadian Electrical Code (CEC), as applicable, and with

all local codes and ordinances that apply. Consult your

local building inspector for code information.

NOTICE: Clamp the power cable to prevent strain on the

terminal screws.

NOTICE: Do not change motor wiring if line voltage is

230 volts. Connect power supply as shown for your sup-

ply voltage.

NOTICE: Some models are equipped with three phase

motors. Three phase motors require magnetic starters and

can run in either direction, depending on how they are

connected to the power supply.

To Check For Proper Rotation – 3 Phase Motors

Risk of electrical shock.

1. Be sure power is disconnected to motor when work-

ing on electrical connections.

2. Remove the motor end cover, exposing motor shaft.

Momentarily start pump. If hookup is correct, the shaft

will rotate clockwise.

3. If rotation is not clockwise, reverse any two leads to

the starter. The rotation will now be correct.

GROUNDING THE MOTOR

Ground the pump permanently using a wire of size and

type specified by local or National Electrical Code.

1. Connect ground wire first. Connect the ground first,

then to green grounding terminal provided under

motor canopy (see Figures 6 and 7) identified as GRD.

Make ground connection to this terminal. Do not con-

nect motor to electrical power supply until unit is per-

manently grounded; otherwise serious or fatal electri-

cal shock hazard may be caused.

2. For best ground connection, connect to a grounded

lead in the service panel or to a metal underground

water pipe or well casing at least 10 ft. long. If plastic

pipe or insulated fittings are used, run ground wire

directly to the metal well casing or use ground elec-

trode furnished by the power company.

TABLE II - RECOMMENDED FUSING AND WIRING

Branch

Max. Fuse Wire Length

Motor Volts/ Load Rating 0’-100’ 101-200’ 201-300’

H.P. Phase Amps Amps AWG Wire Size

1/2 115/230/1 12.4/ 6.2 20/15 12/14 10/14 8/14

3/4 115/230/1 14.8/7.4 20/15 12/14 8/14 6/14

1 115/230/1 19.9/9.95 25/15 10/14 8/14 6/12

NOTE: These instructions are specific to ODP (Open Drip

Proof) motors.

Disassembly

1. Disconnect the pump from the power supply.

2. Drain pressure from the system by opening a faucet.

3. Drain the pump.

4. Close the isolation valves on both sides of the pump.

5. Remove the motor bolts and slide the motor / stack

assembly backwards (or lift it, if the pump is mounted

on the wall) away from the pump body flange. The

seal plate, seal plate O-Ring, seal, spacer, and pump

stack are removed together.

6. Remove the motor end cover from the switch end of

the motor.

Hazardous voltage. Discharge the

capacitor before proceeding.

To discharge the capacitor, use a screwdriver with an

insulated handle. Hold the screwdriver by the handle

and move the metal part of the screwdriver to contact

both terminals of the capacitor at the same time. DO

NOT touch the metal part of the screwdriver blade or

the capacitor terminals with your hand.

7. Loosen the screw that holds the overload protector

and move it out of the way. Hold the end of the motor

shaft with a 7/16" open end wrench.

8. Use another 7/16" open end wrench on the motor

shaft. This can be accessed through the inner support

cage, or at the discharge end of the shaft. Unscrew the

stack and coupling from the motor. Remove the stack

and coupling as a unit.

Maintenance 8

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

Drain Pump

Disconnect Power

to Pump

Close Isolation

Valves to Pump

4Unbolt Motor;

Slide Motor/Stack

Assembly Back

Relieve

System Pressure

Remove Motor

Canopy

Unscrew Pump

Shaft from Motor

Shaft with 7/16"

Wrench

Hazardous

voltage.

Discharge capacitor

before working under

motor canopy.

Move Overload

Aside and Hold Shaft

Flats with7/16" Wrench

Figure 7

Figure 8

Figure 9 – Capacitor location.

Capacitor

Terminals

Protective Cover

(Pulled back to show terminals)

Figure 10 – Wrench on end shaft.

7 / 16

Disconnect from

power source.

Motor end view with

canopy removed

Overload Protector

(Moved for access)

Overload screw

(remove)

7/16" Open

End Wrench

Maintenance 9

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

9. Slide the seal off the motor shaft. This can be done by

gently prying the seal plate away from the motor. This

will push the seal off the shaft.

10. Remove the seal plate from the motor shaft, turn it

face down, and push the ceramic stationary half of the

seal out of the seal plate.

Assembly

Refer to the exploded view on Page 10.

1. Install the new seal (stationary half) into the seal plate.

Lay the seal plate flat and lubricate the rubber side of

the seal with a small amount of soap. Set the seal into

the recess and press it in fully. Protect the face with

the cardboard disc (included). Use a tool such as a

3/4" socket with extension to press it in evenly.

Discard the cardboard disk.

2. Put the seal plate on the motor shaft.

3. Install the new rotating half of the seal on the motor

shaft. Polished surfaces face each other. Push the seal

on evenly. The seal will seat fully when the pump

shaft is tightened.

4. Install the spacer on the stack. It fits in grooves in both

the seal plate and stack and will stay in place once

the pump shaft is tightened.

5. Use a 7/16" open end wrench to hold the motor shaft

at the wiring end of the motor. Thread the coupling

end of the pump stack onto the threaded motor shaft.

Use SAF-T-LOK (provided with the new stack) on the

threads. Tighten with 7/16" wrenches on the motor

shaft and on the pump stack shaft. Tightening the shaft

will fully seat the seal.

6. Install the seal plate O-Ring into the recess on the

pump body.

7. Assemble the motor/pump stack assembly into the

pump body.

8. Attach the motor to the pump body with four cap-

screws. Tighten the capscrews firmly in a cross pat-

tern. Do not over-tighten the bolts. Torque the bolts to

25 foot-lbs torque.

9. Reinstall the motor end cover on the motor.

Figure 11 – Prying seal plate.

Seal Plate

Seal

Figure 12 – Installing seal.

Repair Parts 10

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

Hose 6’-3/4" w/Female Ends

(150 PSI Rating) PKG 83

Hose 25’-3/4" w/Male & Female Ends

(150 PSI Rating) PKG 84

Adapter 3/4" NPT x 3/4" Hose PKG 85

Nozzle - High Pressure PKG 86

Suction Vacuum Relief Valve PKG 96

THE FOLLOWING ACCESSORIES MAY

BE ORDERED FOR HIGH PRESSURE

BOOSTER PUMPS

Key FP5712-01 FP5722-01 FP5732-01

No. Description Qty. 1/2 HP 3/4 HP 1 HP

1 Motor, 1-phase 1 J218-590PKG J218-596PKG J218-601PKG

2 Handle 1 C54-21 __ __

3 Slinger 1 17351-0009 17351-0009 17351-0009

4 Seal Plate 1 C3-203 C3-203 C3-203

5 O-Ring, Seal Plate 1 U9-448 U9-448 U9-448

6 Shaft Seal 1 M13800 M13800 M13800

7 Plastic Spacer 1 P1-187P P1-187P P1-187P

8 Pump Stack 1 P325-771R P325-772R P325-773R

9 Shaft End Bearing 1 * * *

10 Drain Plug 1 U78-941ZPV U78-941ZPV U78-941ZPV

11 Pump Body 1 C2-90 C2-90 C2-90

12 Shell 1 P56-654SSL P56-656SSL P56-658SSL

13 O-Ring, Discharge 1 U9-430 U9-430 U9-430

14 Discharge 1 C52-8 C52-8 C52-8

15 Capscrew 4 U30-104ZP U30-104ZP U30-104ZP

• Pump Stack Replacement Kit† – P325-771KIT P325-772KIT P325-773KIT

REPAIR PARTS LIST

* Shaft end bearing is part of the discharge assembly.

† Includes pump stack, O-Ring, shaft end bearing, mechanical seal and adhesive for installation.

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