Pentair Flotec FP5200 Series User manual

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FP30 (11/21/19) ©2019 Pentair. All Rights Reserved.
INSTALLATION AND
OPERATION MANUAL
FP5200 SERIES SELF-PRIMING
CENTRIFUGAL PUMP
FLOTECH

SECTION.................................................................................................................................................................................................. PAGE
Safety Infomation.............................................................................................................................................................................3
Installation.................................................................................................................................................................................... 4-5
Electrical Installation....................................................................................................................................................................... 6
Operations....................................................................................................................................................................................... 7
Maintenance................................................................................................................................................................................. 8-9
Repair Parts................................................................................................................................................................................ 10-11
Troubleshooting.............................................................................................................................................................................. 12
Warrenty......................................................................................................................................................................................... 13
TABLE OF CONTENTS:

3
FP30 (11-21-19)
SAFETY INFORMATION
Carefully read and follow all safety instructions in this manual
or on pump.Keep safety labels in good condition. Replace
missing or damaged safety labels.
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.
NOTICE indicates special instructions which are important but
not related to hazards.
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
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.
Hazardous voltage. Can shock, burn, or cause
death.
Ground pump before connecting to power
supply.
GENERAL SAFETY
Hazardous pressure! Install pressure relief
valve in discharge pipe.
Release all pressure on system before
working on any component.
Do not touch an operating 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.
• Pump is designed as a lawn sprinkler only. To avoid heat
buildup, over-pressure hazard, and possible injury, do not
use in a pressure tank (domestic water) system. Do not use
as a booster pump; pressurized suction may cause pump
body to explode.
• Do not allow pump or piping system to freeze. Freezing can
damage pump and pipe, may lead to injury from equipment
failure, and will void warranty.
• Pump only water with this unit.
• Periodically inspect pump and system components.
• Wear safety glasses at all times when working on pumps.
• Keep work area clean, uncluttered and properly lighted;
properly store all unused tools and equipment.
• Keep visitors at a safe distance from the work areas.
• Make workshops childproof; use padlocks and master
switches; remove starter keys.
WARNING
WARNING
WARNING

4FP30 (11-21-19)
INSTALLATION
PRIOR TO PUMP INSTALLATION
• The well must not be more than 20 foot depth to water.
• Long runs and many fittings increase friction and reduce
flow. Locate pump as close to the well as possible, using
use as few elbows and fittings as possible.
• Ensure the well is clear of sand. Sand will clog the pump
and void the warranty.
• Protect pump and all piping from freezing. Freezing will
split pipe, damage pump and void the warranty. Check local
frost protection requirement. Usually piping must be 12"
below frost line and the pump must be insulated.
• Be sure all pipes and the foot valve are clean and in good
shape.
• Ensure there are no air pockets or leaks in suction pipe.
Use PTEE pipe thread sealant tape to seal pipe joints.
• Unions installed near the well and pump aid in servicing.
Make sure to leave room for use of wrenches.
Pump body may explode if used as a booster
pump. DO NOT use in a booster application.
WELL PIPE INSTALLATION
Use the installation method below that matches your well type.
CASED WELL INSTALLATION
1. Inspect foot valve to be sure it works freely. Inspect
strainer to be sure it is clean.
2. Connect foot valve and strainer to the first length of
suction pipe and lower pipe into well. Add sections of pipe
as needed, using PTFE pipe thread sealant tape on male
threads. Be sure that all suction pipe is leakproof or pump
will lose prime and fail to pump.
3. Install foot valve 10 to 20 feet below the lowest level to
which water will drop while pump is operating (pumping
water level). Your well driller can furnish this information.
• To prevent sand and sediment from entering the
pumping system, the foot valve/strainer should be at
least 5 feet above the bottom of the well.
4. When the proper depth is reached, install a sanitary well
seal over the pipe and in the well casing. Tighten the bolts
to seal the casing.
5. When using a foot valve, a priming tee and plug are
recommended (Figure 1).
DUG WELL INSTALLATION
Follow the same instructions as outlined in Cased Well
Installation.
DRIVEN WELL POINT INSTALLATION
1. Connect the suction pipe to the drive point (Figure 2). Keep
horizontal pipe run as short as possible. Use PTFE pipe
thread sealant tape on male pipe threads. Multiple well
points may be necessary to provide sufficient water to
pump.
2. Install a check valve in horizontal pipe. Ensure the check
valve's flow arrow point toward the pump.
HORIZONTAL PIPING FROM WELL TO PUMP INSTALLATION
1. Never install a suction pipe that is smaller than the suction
port of the pump.
2. To aid priming with well point installations, install a check
valve as shown in Figure 2.Ensure the check valve's flow
arrow point toward the pump.
DISCHARGE PIPE SIZES
1. If increasing discharge pipe size, install reducer in pump
discharge port. Do not increase pipe size by stages.
2. When the pump is set away from the points of water use,
the discharge pipe size should be increased to reduce
pressure losses caused by friction.
• Up to 100’ run: Same size as pump discharge port.
• Up to 100’ run: Same size as pump discharge port.
• 100’ to 300’ run: Increase one pipe size.
• 300’ to 600’ run: Increase two pipe sizes.
Suction
pipe
Foot
Valve
Priming plug
Priming tee
Drawdown water
level (pump on)
10-20' (3-6 m)
20' (6 m)
max.
At least 5 feet
(1.5 m)
828 1011
Standing water
level (pump off)
Figure 1 – Cased/Dug Well Installation
Check valve
Steel drive pipe
Drive coupling
Driven point
745 0993
Figure 2 – Driven Point Installation
WARNING

5
FP30 (11-21-19)
INSTALLATION
LAWN SPRINKLING APPLICATION
This pump is designed for a pond, cistern or well points. Pump
discharge can be divided to supply two (2) or more sprinkler
systems. A suggested multiple discharge to service is shown in
Figure 3.
.
PUMP/PIPING INSTALLATION
Use only PTFE pipe thread sealant tape 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
the 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.
1. Bolt pump to solid, level foundation.
2. Support all piping connected to the pump.
• Install pump as close to well head as possible. Long
piping runs and many fittings create friction and
reduce flow.
3. Wrap 1-1/2 to 2 layers of PTFE pipe thread sealant tape
clockwise (as you face end of pipe) on all male threads
being attached to pump.
4. Tighten joints hand tight plus 1-1/2 turns. Do not
overtighten.
5. If long, horizontal pipe runs have to be used, install a
priming tee between the check valve and the well head
(Figure 1). Use schedule 80 or iron pipe.
20 100
80
60
40
1909 0997
Figure 3 – Multiple Discharge
Figure 4 – Bolt Pump Down
3023 0997
20 100
80
60
40
3024 0997
1102 0697
No Air Leaks
in Suction Pipe.
Pipe Joint
Compound Will
Damage Plastic.
If Air Flows
Water Won’t
Use PTFE Tape
748 0993
Don’t Hit
Thread Stops
Don’t
Overtighten
From
Well
Pump
Body
Hand Tight Plus 1-1/2 Tu rns With Wrench.
Figure 5 – Independently Support All Piping Attached to Pump

6FP30 (11-21-19)
ELECTRICAL INSTALLATION
DISTANCE IN FEET (METERS) FROM MOTOR TO SUPPLY
Pump Model HP Max. Load
Amps Phase, Volts Hz Branch Fuse* Rating* Amps
0' - 50' 51' - 100' 101' - 200' 201' - 300'
AWG WIRE SIZE - 115V/230V (mm2)
FP5242 1-1/2 19.2/9.6 1ph, 115/230 60 25/15 10/14 (5.5/2) 10/14 (5.5/2) 8/14 (8.4/2) 6/12 (9/3)
FP5252 212 1ph, 115/230 60 15 14 (2) 14 (2) 14 (2) 12 (3)
WIRING CHART RECOMMENDED WIRE AND FUSE SIZES
(*) Dual element or Fusetron time delay fuses recommended for all motor circuits.
WIRING
Install, ground, wire and maintain this pump in accordance
with electrical code requirements. Consult your local building
inspector for information about codes. Read and follow all
warnings below.
WARNING Hazardous voltage. Can shock, burn, or cause
death. Disconnect power to motor before working on pump or
motor. Ground motor before connecting to power supply.
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 damage motor and voids
warranty. If in doubt consult a licensed electrician.
Use wire size specified in this manual's Wiring Chart.
Wire motor according to diagram on motor nameplate. If
nameplate diagram differs from this manual's diagrams, follow
nameplate diagram.
1. Provide a correctly fused disconnect switch for protection
while working on motor. Consult local or national electrical
codes for switch requirements*.
2. Disconnect power before servicing motor or pump. If the
disconnect switch is out of sight of pump, lock it open and
tag it to prevent unexpected power application.
3. Ground the pump permanently using a wire of the same
size as specified in this manual's Wiring Chart. Make
ground connection to green grounding terminal under
motor canopy marked GRD. or .
4. Connect ground wire to a grounded lead in the service
panel or to a metal underground water pipe or well casing
at least 10 feet long. Do not connect to plastic pipe or
insulated fittings.
Do not ground to a gas supply line
5. Protect current carrying and grounding conductors from
cuts, grease, heat, oil, and chemicals.
6. Motor has automatic internal thermal overload protection.
If motor has stopped for unknown reasons, thermal
overload may restart it unexpectedly, which could cause
injury or property damage. Disconnect power before
servicing motor.
7. If this procedure or the wiring diagram are confusing,
consult a licensed electrician
• Refer to Figure 9 for wiring configuration.
• Connect current-carrying conductors to terminals
L1 and L2. When replacing the motor, check wiring
diagram on the motor nameplate. For 3-phase motors
or motor's whose wiring diagram does not match
Figure 9, follow the diagram on the motor.
115 VOLT USAGE CONFIGURATION
115/230 volt, single phase models are configured at the factory
for 230 volt usage.
If power supply will be 115 volts:
1. Ensure power is off.
2. Remove motor cover.
3. Using a screwdriver or 1/2" wrench, turn the voltage
selector dial counter-clockwise to the 115 volt setting.
4. Replace motor cover.
Figure 9 : Voltage set to 230 volt current. Rotary selector
Power Lead Terminals
L1 and L2

7
FP30 (11-21-19)
PRIMING THE PUMP
Priming refers to the pump expelling all air in the system and
beginning to move water from its source out into the system.
It does not refer only to pouring water into the pump (although
pouring water in is usually the first step).
1. Make sure suction and discharge valves and any hoses on
discharge side of pump are open.
2. Remove priming plug. Fill pump and suction pipe with
water (Figure 10). NEVER run pump dry. Running pump
without water in it will damage seals and can melt impeller
and diffuser. Be sure discharge (valve, pistol grip hose
nozzle, etc.) is open whenever pump is running.
• If a priming tee and plug have been provided for a long
horizontal run, be sure to fill suction pipe through this
tee and replace plug. Remember to tape the plug.
• Replacing the existing priming plug with one that has a
pressure gauge and reducer bushing mounted in it will
make troubleshooting pump performance easier.
3. Start pump. Water should be produced in 10 minutes or
less. The time depends on the well's depth to water and
the length of horizontal run. If no water is produced within
10 mins., stop pump, release all pressure, remove priming
plug, refill, and try again.
WARNING Hazardous pressure and risk of explosion and
scalding. If pump is run continuously at no flow (that is, with
discharge shut off or without priming), water may boil in pump
and piping system. Under steam pressure, pipes may rupture,
blow off of fittings or blow out of pump ports and scald anyone
near.
20 100
80
60
40
3025 0997
Figure 10 – Remove Priming Plug and Fill Pump Before Starting
OPERATIONS
20 100
80
60
40
3026 0997
Figure 12 – Do Not Run Pump with Discharge Shut-off.

8FP30 (11-21-19)
The pump and piping do not need to be disconnected to repair
or replace the motor or seal.
If motor is replaced, a new shaft seal must be installed. Keep
an extra shaft seal on hand for future needs.
Check motor label for lubrication instructions. The
mechanical shaft seal in the pump is water lubricated and
self-adjusting.
PUMP DISASSEMBLY
Drain pump when disconnecting from service or when it might
freeze.
1. Disconnect power to motor.
2. Mark wires for correct assembly.
3. Release all water pressure from system.
4. Remove drain plug and drain pump.
5. Remove capscrews holding seal plate to pump body.
Motor assembly and seal plate can now be pulled away
from pump body (Figure 14).
6. CAREFULLY remove gasket.
CLEANING/REPLACING IMPELLER
1. Follow instructions under “Pump Disassembly”.
2. Remove screws fastening the diffuser to the seal plate.
3. Remove diffuser (Figure 15). The exposed impeller can
now be cleaned.
4. If impeller must be replaced, loosen two machine screws
and remove motor canopy (Figure 16).
5. Capacitor voltage may be hazardous. To
discharge capacitor, hold insulated handle screwdriver
BY THE HANDLE and short capacitor terminals together
(Figure 16). Do not touch metal screwdriver blade or
capacitor terminals. If in doubt, consult a qualified
electrician.
6. Unscrew capacitor clamp and remove capacitor. Do not
disconnect capacitor wires to motor.
7. Slide a 7/16" open-end wrench behind the spring-
loaded switch on the motor end of the shaft.
Hold motor shaft with wrench on shaft flats and unscrew
impeller screw (if used) by turning clockwise (left hand
thread) when looking into eye of impeller.
8. Unscrew impeller while holding shaft by turning
counterclockwise while looking into eye of impeller.
9. To reinstall, reverse steps 1 through 6 and follow
directions in the "Pump Reassembly" section below.
REMOVING OLD SEAL
1. Follow instructions under “Pump Disassembly”.
2. Follow steps 2 through 5 under “Cleaning/Replacing
Impeller”.
MAINTENANCE
3027 0997
Figure 14 – Slide Motor Back
3028 0997
Figure 15 – Remove Diffuser
739 0993
Figure 16 – Hold Shaft
To avoid electrical
shock hazard, use
insulated-handle
screwdriver to short
capacitor terminals
as shown.
3029 0997
Figure 17 – Remove Seal Plate
WARNING

9
FP30 (11-21-19)
3. Remove rotating half of seal by placing two screwdrivers
under seal ring and carefully prying up (Figure 17).
4. Remove nuts from studs holding seal plate to motor.
Carefully slide seal plate off of shaft.
NOTICE: Be sure you do not scratch or mar shaft. If shaft
is marred, it must be dressed smooth with fine emery or
crocus cloth before installing new seal. DO NOT reduce
shaft diameter!
5. Place seal plate half face down on flat surface and tap out
stationary half of seal (Figure 18).
INSTALLING NEW SEAL
Gaskets and o-rings are not interchangeable per models.
Make sure to install the type of gasket or o-ring you removed.
1. Clean seal cavity in seal plate.
2. Sparingly wet outer edge of rubber cup on ceramic seat
with liquid soap.
3. Put clean cardboard washer on seal face. The ceramic
seal's polished face should be facing up. Firmly and
squarely, press ceramic seal into cavity using only hand
pressure.
4. If seal will not seat correctly:
• Remove seal, placing polished side up on bench. Re-
clean cavity and install as outlined in previous step.
• If seal still does not seat properly after re-cleaning
the cavity, place a cardboard washer over polished
seal face and carefully press into place using a piece
of standard 3/4 inch pipe as a press being careful not
to scratch seal face."
5. Dispose of cardboard washer and recheck seal face to
be sure it is free of dirt, foreign particles, scratches and
grease.
6. Inspect shaft to be sure it is free of nicks and scratches.
7. Reassemble pump body half to motor flange. BE SURE it
is right side up.
8. Apply liquid soap sparingly (one drop is sufficient) to
inside diameter of rotating seal member.
9. Slide rotating seal member (carbon face first) onto shaft
until rubber drive ring hits shaft shoulder.
NOTICE: Be sure not to nick or scratch carbon face of seal
when passing it over threaded shaft end or shaft shoulder.
The carbon surface must remain clean or short seal life will
result.
10. Hold motor shaft with 7/16” open end wrench on shaft
flats and screw impeller onto shaft. Be sure you do
not touch capacitor terminals with body or any metal
object. Tightening impeller will automatically locate seal
in correct position.
11. Replace impeller screw (if used) by turning
counterclockwise (left-hand thread) into end of shaft.
12. Remount diffuser on seal plate with two screws.
13. Follow instructions under “Pump Reassembly”.
PUMP REASSEMBLY
1. Install new gasket or O-ring. Note to replace with using
the same as the pump was originally manufactured with.
2. Slide motor/seal plate assembly into pump body. Secure
with capscrews.
3. Replace base mounting bolts.
4. Replace motor wiring; close draincock.
5. Prime pump according to instructions. See “Operation.”
6. Check for leaks.
3030 0997
Figure 18 – Tap Out Seal
3031 0997
Figure 19 – Press in New Seal
1072 0697
Ceramic
Face Carbon
Face
Be Careful That
Motor Shaft Shoulder...
...Does Not Damage
Seal Face
Figure 20 – Protect Seal Faces
MAINTENANCE

10 FP30 (11-21-19)
REPAIR PARTS
2419A 0605
1
2
3
14
13
6
7B
10
12
11
5
6
7
8
6A
4a
9
4