Flotec FP4200 Series User manual

OWNER’S MANUAL
Convertible Deep Well Jet Pumps
Installation/Operation/Parts
®
2760 0197
Series FP4200
®
1543 0195
Series FP4300

Safety
Important Safety Instructions
SAVE THESE INSTRUCTIONS - This manual contains
important instructions that should be followed during
installation, operation, and maintenance of the product.
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!
indicates a hazard which, if not avoided, will
result in death or serious injury.
indicates a hazard which, if not avoided,
could result in death or serious injury.
indicates a hazard which, if not avoided,
could result in minor or moderate injury.
NOTICE addresses practices not related to
personalinjury.
Carefully read and follow all safety instructions in this
manual and on pump.
Keep safety labels in good condition. Replace missing or
damaged safety labels.
California Proposition 65 Warning
This product and related accessories contain
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
Electrical Safety
Risk of electric shock. Can shock, burn or
kill. Capacitor voltage may be hazardous. To discharge
motor capacitor, hold insulated handle screwdriver BY
THE HANDLE and short capacitor terminals together. Do
not touch metal screwdriver blade or capacitor terminals.
If in doubt, consult a qualified electrician.
General Safety
Risk of burns. Do not touch an operating
motor. Motors are designed to operate at high
temperatures. To avoid burns when servicing pump,
allow it to cool for 20minutes after shut-down
beforehandling.
Do not allow pump or any system component to freeze.
To do so will void warranty.
Pump water only with this pump.
Periodically inspect pump and system components.
Wear safety glasses at all times when working on pumps.
Keep work area clean, uncluttered and properly lighted;
store properly all unused tools and equipment.
Keep visitors at a safe distance from the work areas.
Risk of explosion. Pump body may explode
if used as a booster pump unless relief valve capable of
passing full pump flow at 75 psi is installed.
WARNING
Hazardous pressure!
Install pressure relief
valve in discharge pipe.
Release all pressure on
system before working on
any component.
WARNING
Hazardous voltage.
Can shock, burn, or cause
death.
Ground pump before
connecting to power
supply. Disconnect power
before working on pump,
motor or tank.
Wire motor for correct
voltage. See “Electrical”
section of this manual
and motor nameplate.
Ground motor before
connecting to power
supply.
Meet National Electrical
Code, Canadian
Electrical Code, and
local codes for all
wiring.
Follow wiring
instructions in this
manual when
connecting motor to
power lines.

Replacing an Existing Pump
Deep Well
Risk of electric shock. Can shock, burn or kill. Disconnect
power to pump before working on pump or motor.
1. Drain and remove the old pump. Check pipe for scale, lime, rust, etc.,
and replace it if necessary.
2. Install the control valve and pressure gauge in the pump body.
3. If your old pump has the suction pipe (the larger port – see Figure2)
below the drive port, you will need to install flexible pipe between the
well head and the pump so that the connection will be correct.
NOTICE Your old ejector (in the well) may not be properly matched
to your new pump. If the pump does not perform properly, we
recommend that you install Flotec ejector kit FP4800.
4. Install the pump in the system. Make sure that all pipe joints in the
suction pipe are air-tight as well as water tight. If the suction pipe can
suck air, the pump will not be able to pull water from the well.
5. Adjust the pump mounting height so that the plumbing connections do
not put a strain on the pump body. Support the pipe so that the pump
body does not take the weight of piping or fittings.
You have just completed the well plumbing for your new deep well jet
pump. Please go to Page 8 for discharge pipe and tank connections.
Shallow Well
Risk of electric shock. Can shock, burn or kill. Disconnect
power to pump before working on pump or motor.
1. Drain and remove the old pump. Check the old pipe for scale, lime,
rust, etc., and replace it if necessary.
2. Install the control valve and pressure gauge in the pump body.
3. Install ejector kit FP4855 with a Series 4200, or kit FP4875 with a
Series 4300 pump (kits are sold separately). Follow the instructions
provided with the kit. Be sure to align the venturi with the top hole on
the front of the pump.
NOTICE Always replace the ejector when replacing the pump in a
shallow well installation.
4. Install the pump in the system. Make sure that all pipe joints in the
suction pipe are air-tight as well as water tight. If the suction pipe can
suck air, the pump will not be able to pull water from the well.
5. Adjust the pump mounting height so that the plumbing connections do
not put a strain on the pump body. Support the pipe so that the pump
body does not take the weight of piping or fittings.
You have just completed the well plumbing for your new shallow well jet
pump. Please go to Page 8 for discharge pipe and tank connections.
4182 0502
Figure 1 - Install Control Valve and Gauge
Drive
(Smaller
)
Port
Suction
Port
Suction
(Larger)
Port
2755 0197
Piping omitted
for clarity
Discharge
Drive
Port
Drive Pipe
sends water
down the well
to drive water
up through the
Suction Pipe
to Pump Suction
Figure 2 - Drive and Suction Functions
Suction
Pipe Drive
Pipe
Well
Head
If well head and pump
don't match, twist
reinforced flexible pipe
to connect drive
and suction pipes.
2759 0197
Figure 3 - Reversed Connections to Well
Tap clamp
to seat it
4183 0502
Figure 4 - Mount Ejector – Shallow Well

New Shallow Well Installation
Well Point Installation
1. Install the control valve and pressure gauge in the pump body.
2. Install ejector kit FP4855 with a Series 4200 pump, or kit FP4875 with
a Series 4300 pump (kits are sold separately). Follow the instructions
provided with the kit. Align the venturi with the top hole on the front of
the pump.
3. Drive the well, using “drive couplings” and a “drive cap”. “Drive
fittings” are threaded all the way through and allow the pipe ends to
butt against each other so that the driving force of the maul is carried
by the pipe and not by the threads. The ordinary fittings found in
hardware stores are not threaded all the way through the fitting and can
collapse under impact. “Drive fittings” are also smoother than standard
plumbing fittings, making ground penetration easier.
4. Mount the pump as close to the well as possible.
5. Use the fewest possible fittings (especially elbows) when connecting
the pipe from the well point to the pump suction port. The suction pipe
should be at least as large as the suction port on the pump (include a
check valve – see Figure 5). Support the pipe so that there are no dips
or sags in the pipe, so it doesn’t strain the pump body, and so that
it slopes slightly upward from the well to the pump (high spots can
cause air pockets which can air lock the pump). Seal the suction pipe
joints with PTFE pipe thread sealant tape or a PTFE-based pipe joint
compound approved for use on PVC. Joints must be air- and water-
tight. If the suction pipe can suck air, the pump cannot pull water from
the well. If one well point does not supply enough water, consider
connecting two or three well points to one suction pipe.
You have just completed the suction piping for your new shallow well jet
pump. Please go to Page 8 for discharge pipe and tank connections.
Cased Well Installation, 2” or Larger Casing
1. Install the control valve and pressure gauge in the pump body.
2. Install ejector kit FP4855 with a Series 4200 pump, or kit FP4875 with
a Series 4300 pump (kits are sold separately). Follow the instructions
provided with the kit. Align the venturi with the top hole on the front of
the pump.
3. Mount the pump as close to the well as possible.
4. Assemble the foot valve, strainer, and well pipe. Make sure that the foot
valve works freely.
5. Lower the pipe into the well until the strainer is five feet above the
bottom of the well. It should also be at least 10 feet below the well’s
water level while the pump is running in order to prevent the pump
from sucking air. Install a sanitary well seal.
6. Install a priming tee, priming plug, and suction pipe to the drop pipe.
If the distance from the well to the pump is substantial, add a priming
tee at the pump. Connect the pipe from the well to the pump suction
port, using the fewest possible fittings – especially elbows – as fittings
increase friction in the pipe. The suction pipe should be at least as large
as the suction port on the pump. Support the pipe so that there are no
dips or sags in the pipe, so it doesn’t strain the pump body, and so that
it slopes slightly upward from the well to the pump (high spots can
cause air pockets which can air lock the pump). Seal the suction pipe
P
222 0395
To Household
Water System
Suction Pipe
From Well
Priming
Tee and
Plug
Pressure Gauge
and Priming Port
Drive
Coupling
Drive
Point
Check
Valve
Built-in
Check
Valve
Not
to
Scale
Relief Valve
Figure 5 - Driven Point Installation
Figure 6 - Cased Well Installation
P
256 0395
To Household
Water System
Suction Pipe
From Well
Pressure Gauge
and Priming Port
Priming
Tee and
Plug
Built-in
Check Valve
Not
to
Scale
Well
Casing
Foot
Valve
Sanitary
Well Seal
Strainer
5-10'
At least
10'
Relief Valve

New Shallow Well Installation
joints with PTFE pipe thread sealant tape or a PTFE-based pipe joint
compound. Joints must be air- and water-tight. If the suction pipe can
suck air, the pump cannot pull water from the well.
You have just completed the suction piping for your new shallow well jet
pump. Please go to Page 8 for discharge pipe and tank connections.
Installation for Surface Water
Possible contamination. Do not use surface water for drinking.
The installation shown could be used for sprinkler applications.
1. Install the control valve and pressure gauge in the pump body.
2. Install ejector kit FP4855 with a Series 4200 pump, or kit FP4875 with
a Series 4300 pump (kits are sold separately). Follow the instructions
provided with the kit. Align the venturi with the top hole on the front of
the pump.
3. The pump should be installed as close to the water as possible, with
the fewest possible fittings (especially elbows) in the suction pipe. The
suction pipe should be at least as large as the suction port on thepump.
4. Assemble a foot valve and suction pipe. Make sure that the foot valve
works freely. Use PTFE pipe thread sealant tape or a PTFE-based pipe
joint compound on threaded pipe joints. Protect the foot valve assembly
from fish, trash, etc, by installing a screen around it.
5. Lower the pipe into the water until the strainer is five feet above the
bottom. It should also be at least 10 feet below the water level in order
to prevent the pump from sucking air.
6. Install a priming tee, priming plug, and suction pipe to the pump.
Support the pipe so that there are no dips or sags in the pipe, so it
doesn’t strain the pump body, and so that it slopes slightly upward
from the well to the pump (high spots can cause air pockets which can
air lock the pump). Seal the suction pipe joints with PTFE pipe thread
sealant tape or a PTFE-based pipe joint compound. Joints must be air-
and water-tight. If the suction pipe can suck air, the pump cannot pull
water from thewell.
You have just completed the plumbing for your new shallow well jet pump.
Please go to Page 8 for discharge pipe and tank connections.
4182 0502
Figure 7 - Install Control Valve and
Pressure Gauge
Tap clamp
to seat it
4183 0502
Figure 8 - Install Ejector
P
257 0395
To Household
Water System
Suction Pipe
From Well
Foot
Valve
Screen
Pressure Gauge
and Priming Port
Built-in
Check
Valve
Not
to
Scale
At least
10'
5 to 10'
Relief Valve
Figure 9 - Surface Water Installation

New Deep Well Installation
4” Or Larger Well
1. Install the control valve and pressure gauge in the pump body.
2. Assemble ejector kit FP4800 (sold separately). Follow the instructions
included with the kit in order to match the nozzle and venturi to your
well conditions.
3. Mount the pump as close to the well as possible.
4. Connect two pipes (1”drive, 1-1/4”suction) to the ejector and lower
the ejector into the well until it is five feet from the bottom. It should
also be at least 10 feet below the well’s water level while the pump is
running in order to prevent the pump from sucking air.
5. Install a sanitary well seal and connect the ejector piping to the pump.
Use steel nipples through the well seal with flexible poly pipe to avoid
crushing the plastic pipe when tightening the seal.
6. Support the pipe so that there are no dips or sags in the pipe, so it
doesn’t strain the pump body, and so that it slopes slightly upward
from the well to the pump (high spots can cause air pockets which can
air lock the pump). Seal the suction pipe joints with PTFE pipe thread
sealant tape or a PTFE-based pipe joint compound. Joints must be air-
and water-tight. If the suction pipe can suck air, the pump cannot pull
water from thewell.
You have just completed the plumbing for your new double pipe deep well
jet pump. Please go to Page 8 for discharge pipe and tank connections.
2” Well
1. Install the control valve and pressure gauge in the pump body.
2. Mount the pump as close to the well as possible.
3. Assemble ejector kit FP4840 (sold separately), well piping, and well
head adapter according to the instructions provided with the ejector
package. Use galvanized drop pipe with turned couplings to allow
proper flow. Follow the instructions included with the kit in order to
match the nozzle and venturi to your well conditions.
4. Run two pipes (one smaller drive pipe, one larger suction pipe) from
the well to the pump. Support the pipe so that there are no dips or sags
in the pipe, so it doesn’t strain the pump body, and so that it slopes
slightly upward from the well to the pump (high spots can cause air
pockets which can air lock the pump). Seal the suction pipe joints with
PTFE pipe thread sealant tape or a PTFE-based pipe joint compound.
Joints must be air- and water-tight. If the suction pipe can suck air, the
pump cannot pull water from the well.
You have just completed the plumbing for your new single pipe deep well
jet pump. Please go to Page 8 for discharge pipe and tank connections.
P
Suction (Larger)
Pipe from Well
To Household
Water System
Pressure
Gauge and
Priming
Plug
Well
Head
Drive (Smaller)
Line to Well
Venturi
Nozzle
Ejector
Not
to
Scale
Foot Valve
Strainer
266 0395
Relief Valve
Figure 10 - 4” and Larger Deep Well
Figure 11 - 2” (Single Pipe) Deep Well
4
1
JET NO. J32P- 24
P
Suction (Larger)
Pipe from Well
To Household
Water System
Pressure Gauge
and Priming
Plug
Well
Head
Drive (Smaller)
Pipe to Well
Well Casing
serves as
Drive Pipe
Suction Pipe
Venturi
Nozzle
Ejector
Not
to
Scale
267 1111
Relief Valve
Foot Valve
Strainer

Discharge Pipe and Pressure Tank Connections
Pre-Charge Tank Connection
1. Install a close nipple and a tee in the pump discharge port. The
pipe size must be at least as large as the discharge port. Run a pipe or
reinforced hose from one arm of the tee to the port on the pre-charged tank.
2. Install a second close nipple and tee with a relief valve in the tee.
3. Connect the other end of the second discharge tee to your
plumbingsystem.
4. Check the pre-charge of air in the tank with an ordinary tire gauge. The
pre-charge should be 2 PSI less than the cut-in setting of the pump’s
pressure switch. The pre-charge is measured when there is no water
pressure in the tank. Your new pump has a 30/50 PSI switch, so adjust
the tank pre-charge pressure to 28 PSI.
You have just completed the tank connection for your jet pump. Please go
to Pages 9 and 10 for electrical hookup.
Standard Tank Connection
1. Install a close nipple and a tee in the pump discharge port. Mount a
relief valve in one arm of the tee.
2. Install a second close nipple and tee in the open arm of the first tee. Put
a priming plug in one arm of the second tee.
3. Run a pipe from the open arm of the second tee to the inlet port of your
tank. The pipe size must be at least as large as the pump dischargeport.
4. Remove the 1/8” NPT pipe plug from the pump Air Volume Control
(AVC) port. Run tubing from the pump’s AVC port to the port on the
AVC mounted on the tank. See instructions provided with tank and AVC
for details.
You have just completed the tank connection for your jet pump. Please go
to Pages 9 and 10 for electrical hookup.
P
268 0395
To Household
Water System
Pressure Gauge
and Priming
Plug
Pressure
Switch
From
Well
Relief
Valve
Figure 12 - Pre-charged Tank
Connections
To Household
Water System
Pressure
Switch
From
Well
Air Volume
Control
Air Volume
Control Tube
P
Priming Tee
and Plug
276 0395
Relief Valve
Figure 13 - Standard Tank Connections
Sealing Pipe Joints
Use only PTFE pipe thread sealant tape or PTFE-based joint
compounds for making all threaded connections to the pump
itself. Do not use pipe joint compounds on plastic pumps: they
can react with the plastic in pump components. Make sure that
all pipe joints in the suction pipe are air tight as well as water
tight. If the suction pipe can suck air, the pump will not be able
to pull water from the well.

Electrical
Plug Type Voltage Selector
Voltage is set to 230V To change to 115V:
1. Make sure power is off.
2. Pull the voltage change plug off of the tabs.
3. Move the voltage change plug to the 115V position.
The plug will now cover 2 metal tabs and the arrow
on the plug will line up with the 115V arrow on the
label.
4. Attach the incoming power leads to the two outer
screws on the pressure switch as shown in Figure14.
5. Attach the ground wire to one of the grounding
connections, shown in Figure 14.
6. If there are other wires, they should be capped.
7. Reinstall the motor end and pressure switch covers.
Dial Type Voltage Selector
Voltage is set to 230V To change to 115V:
1. Make sure power is off.
2. Turn the dial counter-clockwise until 115 shows in
the dial window as shown in Figure 17.
3. Attach the incoming power leads to the two outer
screws on the pressure switch as shown in Figure16.
4. Attach the ground wire to the grounding connections
as shown in Figure 16.
5. If there are other wires, they should be capped.
6. Reinstall the motor end and pressure switch covers.
Risk of electric shock. Can shock, burn or kill. Disconnect power before working on pump, motor,
pressure switch, or wiring.
Figure 14 - Voltage set to 230V, Plug Type
Ground Wire Connection
Voltage Change Plug
Pressure Switch
Power Connections
4530
Figure 15 - Voltage set to 115V, Plug Type
Figure 16 - Voltage set to 230V, Dial Type
Ground Wire Connection
Power Supply Connections
Voltage
Change
Dial
Pressure Switch
Figure 17 - Voltage set to 115V, Dial Type
Motor Switch Settings
NOTICE 1/2 HP motors are dual voltage and are factory set to 115V. 3/4 & 1 HP motors are also dual voltage, but are
factory set to 230V. Motor terminal boards (located under the motor end cover) should look like one of those below.
Use the instructions to set your motor to match your power source.
Risk of electric shock. Can shock, burn or kill. Never connect a motor set to 115V to a 230V power source.

Electrical
Risk of electric shock. Can shock, burn or kill. Connect ground
wire before connecting power supply wires. Use the wire size (including
the ground wire) specified in the wiring chart. If possible, connect the pump
to a dedicated branch circuit (one with no other appliances on it).
Risk of explosion. Do not ground to a gas supply line.
Wiring Connections
Risk of fire. Incorrect voltage can cause a fire or seriously
damage the motor and voids the warranty. The supply voltage must be
within ±10% of the motor nameplate voltage.
NOTICE Dual-voltage motors may be set for 115V or 230V. If necessary,
reset the motor to the desired voltage, as shown. Do not alter the wiring in
single voltage motors.
Install, ground, wire, and maintain your pump in compliance 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.
Connection Procedure:
1. Connect the ground wire first as shown in Figure 16. The ground wire
must be a solid copper wire the same or larger gauge as the power
supply wires.
2. There must be a solid metal connection between the pressure switch
and the motor for motor grounding protection. If the pressure switch
is not connected to the motor, connect the green ground screw in the
switch to the green ground screw under the motor end cover. Use a
solid copper wire the same or larger gauge as the power supply wires.
3. Connect the ground wire to a grounded lead in a service panel, to a
metal underground water pipe, to a metal well casing at least ten feet
(3m) long, or to a ground electrode provided by the power company or
the hydro authority.
4. Connect the power supply wires to the pressure switch as shown in
Figure 16.
You have just completed the wiring for your pump.
Please go to Page 11 or 12 for startup preparations.
Wiring Chart – Recommended Wire and Fuse Sizes
Motor HP Volts
Max. Load
Amp
Branch Fuse
Rating Amp
DISTANCE IN FEET FROM MOTOR TO SUPPLY
0 - 50 51 - 100 101 - 200 201 - 300 301 - 400 401 - 500
AWG WIRE SIZE (mm2)
1/2 115/230 9.9/4.95 15/15 14/14 (2/2) 14/14 (2/2) 12/14 (3/2) 10/12 (5/3) 8/12 (7/3) 8/10 (7/5)
3/4 115/230 12.2/6.1 20/15 14/14 (2/2) 14/14 (2/2) 10/14 (5/2) 8/14 (7/2) 8/14 (7/2) 6/12 (9/3)
1 115/230 14.8/7.4 20/15 14/14 (2/2) 12/14 (3/2) 10/14(5/2) 8/12 (7/3) 8/12 (7/3) 6/12 (9/3)

Preparing to Start the Pump – Deep Well
Risk of burns. Never run pump dry. Running pump without
water may cause pump to overheat, damaging seal and possibly causing
burns to persons handling pump. Fill pump with water before starting.
Risk of explosion and scalding. Never run pump against closed
discharge. To do so can boil water inside pump, causing hazardous pressure
in unit, risk of explosion and possibly scalding persons handling pump.
1. Open the control valve as far as possible. Then remove the priming plug
from the pump and fill the pump, fill all piping between the pump and
the well, and make sure that all piping in the well is full. If you have
also installed a priming tee in the suction piping, remove the plug from
the tee and fill the suction piping.
2. Replace all fill plugs and close the control valve completely.
3. Power on! Start the pump and watch the pressure gauge. The pressure
should build rapidly to 50 PSI as the pump primes.
4. Open several faucets in the residence to permit water flow and to
release trapped air. After 2 or 3 minutes, the gauge should show
pressure. If not, stop the pump, remove the fill plugs, reopen the control
valve, and refill the pump and piping. You may have to repeat this two
or three times in order to get all the trapped air out of the piping. Don’t
forget to close the control valve each time before you start the pump.
5. When water pressure has built up and is maintained by the pump,
slowly open the control valve while watching the pressure gauge
needle. Continue opening the valve until the valve is fully open or
you see the pressure gauge needle start to flutter. If the needle starts to
flutter, slowly close the valve just enough to stop the flutter. Your pump
is now operating at peakefficiency.
6. Close all open faucets. After the pump has built up pressure in the
system and shut off, check the pressure switch operation by opening a
faucet or two and running enough water out to bleed off pressure until
the pump starts. The pump should start when pressure drops to 30 PSI
and stop when pressure reaches 50 PSI. Run the pump through one
or two complete cycles to verify correct operation. This will also help
clean the system of dirt and scale dislodged during installation.
Congratulations on a successful installation.
If you were unsuccessful, please refer to Troubleshooting or call our
customer service technical staff.
Figure 20 - Set Control Valve
P
P
C-Close Control Valve until Pressure
Stabilizes
281 0395
A-Open Control Valve
B-Watch for Pressure Gauge to Flutter
P
Open control valve
as far as possible
and fill pump and
piping through
priming port
or priming tee.
280 0395
Figure 18 - Fill Pump
Figure 19 - Prime Pump
Replace all
fill plugs and
close control
valve completely.
556 0395