Pentair FREEFLO User manual

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INSTALLATION GUIDE / INSTALLATIEHANDLEIDING
BEDIENUNGSANTLEITUNG / GUIDE DE L’INSTALLATION
GUIA DE INSTALACION / GUIDE ALL’INSTALLAZIONE
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PUMPS   2
EUROPE
Pentair Water Belgium B.V.B.A
Toekomstlaan, 30 Herentals,
Belgium B-2200
www.pentairpooleurope.com
AUSTRALIA
Pentair Water Australia
1-21 Monash Drive
Dandenong South
Victoria Australia 3175
www.pentairwater.com.au
SOUTH AFRICA
Pentair Water South Africa
24 Vuurslag Street
Spartan Ext7
Gauteng, South Africa
www.kreepykrauly.co.za
© 2013 Pentair, Inc. All rights reserved. This document is subject to change without notice.
Trademarks and disclaimers: All Pentair trademarks and logos are owned by Pentair, Inc. FreeFlo™ and Cam and Ramp™
are trademarks of Pentair Water Pool and Spa, Inc. and/or its affiliated companies in the United States and/ or other countries.
Unless expressly noted, names and brands of third parties that may be used in this document are not used to indicate an
affiliation or endorsement between the owners of these names and brands and Pentair Water Pool and Spa, Inc. Those names
and brands may be the trademarks or registered trademarks of those third parties. Because we are continuously improving our
products and services, Pentair reserves the right to change specifications without prior notice. Pentair is an equal opportunity
employer.
Contents
Warnings and Safety Instructions………………………………………………. 2
Section 1: Introduction………………………………………………………........ 4
Section 2: Electrical Requirements and Wiring………………………………. 5
Section 3: Pump Installation……………………………………………………... 5
Section 4: Start / Operation………………………………………………………. 6
Section 5: Maintenance…………………………………………………………… 6
Section 6: Troubleshooting………………………………………………………. 7
Section 7: Technical Data………………………………………………………… 8
READ AND FOLLOW ALL WARNING AND SAFETY INSTRUCTIONS!
This is the safety alert symbol. When you see this symbol on your system 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 can cause death, serious personal injury, or major
property damage if ignored
Warns about hazards that may cause death, serious personal injury, or major
property damage if ignored.
Warns about hazards that may or can cause minor personal injury or property
damage if ignored.
Carefully read and follow all safety instructions in this manual and on equipment. Keep safety
labels in good condition; replace if missing or damaged.
FAILURE TO FOLLOW ALL INSTRUCTIONS AND WARNINGS CAN RESULT IN
SERIOUS BODILY INJURY OR DEATH. THIS PUMP SHOULD BE INSTALLED AND
SERVICED ONLY BY A QUALIFIED SERVICE PROFESSIONAL. INSTALLERS,
OPERATORS AND OWNERS MUST READ THESE WARNINGS AND ALL
INSTRUCTIONS IN THE OWNER'S MANUAL BEFORE USING THIS PUMP. THESE
WARNINGS AND THE OWNER'S MANUAL MUST BE LEFT WITH THE HOME OWNER.
SUCTION ENTRAPMENT HAZARD: STAY OFF THE MAIN DRAIN AND AWAY FROM ALL
SUCTION OUTLETS!
THIS PUMP PRODUCES HIGH LEVELS OF SUCTION AND CREATES A STRONG
VACUUM AT THE MAIN DRAIN AT THE BOTTOM OF YOUR POOL AND SPA. THIS
SUCTION IS SO STRONG THAT IT CAN TRAP ADULTS OR CHILDREN UNDER WATER
IF THEY COME IN CLOSE PROXIMITY TO A POOL OR SPA DRAIN, OR A LOOSE OR
BROKEN DRAIN COVER OR GRATE.
IMPORTANT PUMP WARNING AND SAFETY INSTRUCTIONS

PUMPS  
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READ AND KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE
THE USE OF UNAPPROVED DRAIN COVERS OR ALLOWING USE OF THE POOL OR
SPA WHEN COVERS ARE MISSING, CRACKED OR BROKEN CAN RESULT IN BODY
OR LIMB ENTRAPMENT, HAIR ENTANGLEMENT, BODY ENTRAPMENT,
EVISCERATION AND/OR DEATH.
The suction at a pool or spa drain or outlet can cause:
Limb Entrapment: When a limb is sucked or inserted into an opening resulting in a mechanical bind or swelling.
This hazard is present when a drain cover is missing, broken, loose, cracked or not properly secured.
Hair Entanglement: When the hair tangles or knots in the drain cover, trapping the swimmer underwater. This
hazard is present when the flow rating of the cover is too small for the pump or pumps.
Body Entrapment: When a portion of the body is held against the drain cover trapping the swimmer underwater.
This hazard is present when the drain cover is missing, broken or the cover flow rating is not high enough for the
pump or pumps.
Evisceration/Disembowelment: When a person sits on an open pool (particularly a child wading pool) or spa
outlet and suction is applied directly to the intestines, causing severe intestinal damage. This hazard is present
when the drain cover is missing, loose, cracked, or not properly secured.
Mechanical Entrapment: When jewelry, swimsuit, hair decorations, finger, toe or knuckle is caught in an opening
of an outlet or drain cover. This hazard is present when the drain cover is missing, broken, loose, cracked, or not
properly secured.
NOTE: ALL SUCTION PLUMBING MUST BE INSTALLED IN ACCORDANCE WITH THE LATEST NATIONAL
AND LOCAL CODES FOR SWIMMING POOLS, SPAS AND HOT TUBS.
TO MINIMIZE THE RISK OF INJURY DUE TO SUCTION ENTRAPMENT HAZARD:
• Pools and spas should utilize a minimum of two drains per pump.
• A properly installed and secured anti-entrapment suction cover must be used for each drain.
• Each suction cover must be installed at least thirty six (36”) inches apart, as measured from
the nearest point to nearest point.
• Regularly inspect all covers for cracks, damage and advanced weathering.
• If a cover becomes loose, cracked, damaged, broken or is missing, close the pool or spa
immediately, shut off the pump, post a notice and keep the pool or spa closed until an
appropriate certified cover is properly installed and approved.
• Replace drain covers as necessary. Drain covers deteriorate over time due to exposure to
sunlight, pool chemicals and weather.
• Avoid getting hair, limbs or body in close proximity to any suction cover, pool drain or outlet.
• Use a safety vacuum release system ("SVRS"), suction limiting system or automatic pump
shut-off system.
A clearly labeled emergency shut-off switch for the pool pump and spa jet pump must be in
an easily accessible, obvious place near the pool or spa. Make sure bathers know where it
is and how to use it in case of emergency.
• The appliance is not intended for use by persons (including children) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction
concerning use of the appliance by a person responsible for their safety.
• Children should be supervised to ensure that they do not play with the appliance.
• A means for disconnection from the supply mains, having a contact separation in all poles, must be included
in the fixed wiring in accordance with the wiring rules.
• The pump must be supplied through a residual current device (RCD) having a rated residual operating current
not exceeding 30mA.
• If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified
persons in order to avoid a hazard.
IMPORTANT PUMP WARNING AND SAFETY INSTRUCTIONS

PUMPS   4
HAZARDOUS PRESSURE: STAND CLEAR OF PUMP AND FILTER DURING START-UP
Pool and spa circulation systems operate under high pressure. When any part of the
circulating system (i.e. pump, filter, valves, etc.) is serviced, air can enter the system and
become pressurized. Pressurized air can cause the pump housing, cover, filter lid and valves
to violently separate which can result in severe personal injury or death. Filter tank lid and
strainer cover must be properly secured to prevent violent separation. Stand clear of all
circulation system equipment when turning on or starting pump.
Electrical controls such as on/off switches, timers, and control systems, etc. should be
properly installed to allow the operation (start-up, shut-down, or servicing) of any pump or filter
without requiring the user to place any portion of his/her body over or near the pump strainer
lid or filter lid. Such installation should allow the user to stand clear of the filter and pump
during system start-up, shut down or servicing of the system.
Before servicing pool and spa equipment, make note of the filter pressure. Be sure that all
controls are set to ensure the system cannot inadvertently start during service. Turn off all
power to the pump.
IMPORTANT: Before starting the system, fully open the manual air relief valve and place all
system valves in the "open" position to allow water to flow freely from the pool and spa back to
the pool or spa. Stand clear of all pool and spa equipment and start the pump.
IMPORTANT: Do not close filter manual air relief valve until all pressure has been discharged
from the valve and a steady stream of water appears. Observe filter pressure gauge and be
sure it is not higher than the pre-service condition.
Section 1
Introduction
Failure to follow the safety instructions may result in serious adverse health
effects, or even serious or fatal injury. Failure to follow the safety instructions will
in all cases invalidate all guarantees and liability on the part of the manufacturer.
DO NOT run the pump dry. If the pump is run dry, the mechanical seal will be damaged and the pump will
start leaking. If this occurs, the damaged seal must be replaced. ALWAYS maintain proper water level. If the
water level falls below the suction port, the pump will draw air through the suction port, losing the prime and
causing the pump to run dry, resulting in a damaged seal. Continued operation in this manner could cause a
loss of pressure, resulting in damage to the pump case, impeller and seal and may cause property damage
and personal injury.
FreeFlo™ High Performance Pump Overview
The perfect choice for all types of pools, the FreeFlo™ pump was specifically designed to be your best choice
for a variety of aboveground and inground pools. Thick walled body parts, a heavy duty motor, and highly
engineered hydraulics make this rugged and tested design perfect for any pool, spa, water feature, or fountain.
The silent running capability and small footprint allow FreeFlo pump to easily drop into a compact space.
General Features
• Extremely quiet operation
• Cam and Ramp™ Lid for easy cleaning access and maintenance
• Union fittings for simple replacement
• Heavy-duty, TEFC motor for long life
• See-through lid permits easy inspection of strainer basket
• 1/3 HP (250 Watts) to 1.5 HP (1100 Watts) configurations to accommodate a wide range of applications
• Self-priming for quick, easy start-up
• Cord included for ease of installation
• Large basket to hold debris
IMPORTANT PUMP WARNING AND SAFETY INSTRUCTIONS

PUMPS  
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Section 2
Electrical Requirements and Wiring
Electrical installation shall be in accordance with the local wiring codes taking into account its ratings. The pump is
supplied with 1.5 m (5 feet) of cord.
A GFCI (Ground Fault Circuit Interrupter) with maximum rated residual current of 30mA is
required for the power supply to the pump. Additionally, if a suitable socket outlet is not
available a weatherproof socket must be installed by an electrician in a suitable location.
GFCI tripping indicates an electrical problem. If GFCI trips and will not reset have a
qualified electrician inspect and repair electrical system.
Do not use extension leads as they are unsafe in and around the pool area.
Incorrect voltage can cause fire or seriously damage pump and voids warranty.
Voltage at pump must not be more than 6% above or 10% below motor nameplate rated
voltage or pump may overheat, causing overload tripping and reduced component life.
Wiring Installation
Note: Before installing this product, read and follow all warning notices and instructions.
Risk of electrical shock or electrocution.
The AC pump connection must be done by a service professional as described in this
manual and all applicable current local regulations. The service professional installer
should also be sure the pump motor has sufficient protection. All required pump wiring
and AC electrical information is shown on the pump's motor name plate.
BEFORE CONNECTING AC POWER WIRES TO THE PUMP, be sure to switch OFF
the main AC power supply.
PUMP GROUNDING: BE SURE TO PERMANENTLY GROUND THE PUMP MOTOR.
Be sure all electrical breakers and switches are turned off before wiring motor.
Choose a wire size from the chart below. When in doubt use a heavier gauge (larger diameter) wire.
Heavier gauge will allow the motor to run cooler and more efficient. Make sure all electrical connections are clean
and water tight. Cut wires to the appropriate length so they don’t overlap or touch when connected to the terminal
board. Connect the pump permanently to a separate circuit. Be sure no other lights or appliances are on the same
circuit.
SUPPLY WIRE SIZES (mm2)
(Size and length by Power)
WATTS 15 m (50 ft.) 30 m (100 ft.) 45 m (150 ft.)
250 2.5 2.5 4.0
370 2.5 4.0 6.0
550 4.0 4.0 6.0
750 4.0 6.0 10.0
1100 6.0 6.0 10.0
HP
1/3
1/2
3/4
1
1.5
This pump is not double insulated to the water circuit.
If equipotential bonding is required by the local codes, connect all metal parts of the swimming pool, spa, or hot
tub structure, metal conduit, and metal piping in accordance with the wiring rules (AS/NZS 3000). Run a wire from
the equipotential bonding terminal on the pump to the pool bonding structure. Please see diagram below for
location of equipotential bonding terminal.
Equipotential Bonding Connection
Equipotential Bonding Terminal

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Section 5
Maintenance
Risk of electrical shock or electrocution.
Always disconnect power to the pool pump at the circuit breaker before servicing the pump.
Failure to do so could result in death or serious injury to serviceman, pool users or others
due to electric shock. Read all servicing instructions before working on the pump.
DO NOT open the strainer pot lid if pump fails to prime or if pump has been operating
without water in the strainer pot.
Pumps operated in these circumstances may experience a build up of vapor pressure and
may contain scalding hot water. Opening the pump may cause serious personal injury. In
order to avoid the possibility of personal injury, make sure the suction and discharge valves
are open and strainer pot temperature is cool to touch, then open with extreme caution.
Section 3
Pump Installation
• Install the pump not closer than 1.5m (5 feet) from inside walls of the swimming pool or spa.
• Use a direct and short suction line with continuous slope in order to avoid long priming times.
• The pump should be placed on a flat, solid foundation, high enough to prevent flooding of the motor.
• Install the pump in a sheltered location, ensuring ventilation and adequate access for servicing.
• Do not mount electrical controls directly over pump. Read and fully understand all CAUTIONS on page 4.
• Provide adequate floor drainage to avoid equipment and property damage.
• Size all piping adequately and keep the number of elbows to a minimum.
• Independently support the pipe near the suction and discharge of the pump in order to reduce the strain.
• It is essential that the suction line is free of air leaks. The suction line should always be at least the same size
as the suction inlet of the pump.
Section 4
Start / Operation
Starting the pump
• Turn strainer pot lid in a counter-clockwise direction until it opens.
• Fill the strainer pot and volute up to the inlet port with water.
• Reinstall the strainer pot lid by placing the strainer pot lid on the strainer pot. Make sure the lid O-ring is
properly placed. Seat the strainer pot lid then turn clockwise until the handle locks. Hand Tighten only!
• Open the manual air relief valve on top of the filter. If no manual air relief valve is present, depress the
multiport valve handle to relieve the pressure.
• Stand clear of the system and filter. Energize the motor.
• Bleed air from the filter until a steady stream of water comes out.
• Close the manual air relief valve.
• Priming time depends on the suction lift and distance from the pool.
• Five minutes for priming is a reasonable time.
• Pump will not lift more than 1.8 m (6 ft.). If pump does not prime, see troubleshooting guide.

PUMPS   7
The Pump Strainer Basket
Pump strainer basket unit is in front of the pump housing. Inside the chamber is the basket which must be
kept clean of leaves and debris at all times. View basket through the ‘See through Lid’ to inspect for leaves
and debris.
Regardless of the length of time between filter cleaning, it is most important to visually inspect
the strainer pot basket at least once a week. A dirty basket will reduce the efficiency of the
pump and also put an abnormal stress on the pump motor which could result in a costly repair
bill.
1. Turn off motor and relieve pressure in the system.
2. Turn strainer pot lid in a counter-clockwise direction until it opens and then remove the strainer pot
lid from the strainer pot.
3. Put the debris from the strainer basket into the trash and rinse out the basket. If the strainer basket is
cracked, it should be replaced.
4. Replace the strainer basket. Make sure the strainer basket is properly seated in strainer pot.
5. Fill the strainer pot and volute with water up to the inlet port.
6. Clean the strainer pot lid, O-ring, and sealing surface of the strainer pot. Then grease the O-ring with
silicone based lubricant.
7. Reinstall the strainer pot lid by placing the strainer pot lid on the strainer pot. Make sure the lid O-
ring is properly placed. Seat the strainer pot lid then turn clockwise until the handle locks. Hand
Tighten only!
8. Turn the power “ON” at the house circuit breaker. Reset the pool time clock to the correct time.
THIS PUMP OPERATES UNDER HIGH PRESSURE
When any part of the circulating system (e.g., Strainer Pot Lid, Pump, Filter, Valves, etc.) is
serviced, air can enter the system and become pressurized. Pressurized air can cause the
lid to separate which can result in server injury, death, or property damage. To avoid this
potential hazard, follow these instructions.
9. Open the manual air relief valve on top of the filter. If no manual air relief valve is present, depress
the multiport valve handle to relieve the pressure.
10. Stand clear of the system and filter.
11. Start pump.
12. Bleed air from the filter until a steady stream of water comes out. Close the manual air relief valve.
Winterizing
1. If the air temperature drops below 2°C (35°F), the water in the pump can freeze and cause damage.
Freeze damage is not warrantable.
2. To prevent freeze damage follow the procedures listed below:
a. Shut off electrical power for the pump at the house circuit breaker.
b. Drain the water out of the pump by removing the two thumb-twist drain plugs and the O rings from
the pump housing and one from the strainer pot. Store the plugs and the O rings in the pump
basket.
c. Cover the motor to protect it from severe rain, snow and ice.
d. Do not wrap the motor in plastic. It will cause condensation and rust on the inside of the motor.

PUMPS  
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Problems and Corrective Actions
PROBLEM CORRECTIVE ACTIONS
Pump Will Not Prime — too much air
Check suction piping and valve glands on any suction gate valves.
Secure pot casing lid on pump strainer pot and make sure lid O-
ring is in place.
Make sure O-ring on union is OK and is in place.
Ensure O-ring on diffuser nose is OK and is in place.
Check water level to make sure skimmer is not drawing air.
Pump Will Not Prime — not enough
water
Make sure suction lines, pump strainer, and pump volute are full of
water.
Make sure valve on suction line is working and open, (some
systems do not have valves).
Check water level to make sure water is available through
skimmer.
Pump strainer basket clogged Clean pump strainer basket.
Pump strainer O - Ring defective Replace O – Ring.
REDUCED CAPACITY AND/OR HEAD
Air pockets or leaks in suction line Check suction piping and valve glands on any suction gate valves.
Clogged impeller Clean debris from impeller.
Section 6
Troubleshooting
Use the following troubleshooting information to resolve possible problems with your High Performance
FreeFlo™ Pump.
Risk of electrical shock or electrocution.
Turn off power to unit prior to attempting service or repair.
1. Protect from heat.
a. Shade the motor from direct sunlight.
b. Any enclosure must be well ventilated to prevent overheating.
c. Provide ample cross ventilation.
2. Protect against moisture or other elements.
a. Protect from any foreign matter or splashing water.
b. Do not store (or spill) pool chemicals near the motor.
c. If a motor has become wet - let it dry before operating. Do not operate if it has been flooded.
d. If a motor has been damaged by water it voids the motor warranty.
Care of Electric Motor

PUMPS   9
Max Working Pressure 260 kPa (37 PSI)
Water Temp. Range 5°C – 35°C (41°F-95°F)
Maximum Ambient
temperature
50°C (122°F)
IP Rating IP55
Electrical Rating 220-240V, 50Hz, Single Phase
Motor
Built in auto reset thermal
overload protection.
Section 7
Technical Data
OUTPUT POWER
DIMENSION "A"
WATTS HP
250W 1/3 540 mm (21.3 in)
370W 1/2 540 mm (21.3 in)
550W 3/4 562 mm (22.2 in)
750W 1562 mm (22.2 in)
1100W 1.5 600 mm (23.6 in)

PUMPS  
10
FFL-031
FFL-051
FFL-071
FFL-101
FFL-151
Pentair Water (Suzhou) Co., Ltd.
371 He Shan Rd
Suzhou, JiangSu
China
[phone] Direct
www.pentair.com
Jonah Shen
PLANT MANAGER
Suzhou (China), 17/07/2013

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   
              
        
            
      
         
  
        
  
             
    
SAVE THESE INSTRUCTIONS
SAVE THESE INSTRUCTIONSSAVE THESE INSTRUCTIONS
SAVE THESE INSTRUCTIONS
PUMPS  
11 Rev. A 7/13 P/N P-0041-CDR