ThePondguy RapidFlo 3000 User manual

RapidFlo®
Pump
Product Manual
TM
Important Information........................2
Technical Specs ..............................2-3
Package Contents.............................3
Installing Your RapidFlo Pump ............... 4-5
Maintaining Your RapidFlo Pump............. 6-7
Extended Maintenance..................... 8-14
Troubleshooting.............................16
Warranty Information........................16
Table of Contents:
For Models:
• RapidFlo®3000
(Item #120970)
• RapidFlo®4000
(Item #120971)
• RapidFlo®5000
(Item #120978)

IMPORTANT INFORMATION:
Please read these instructions thoroughly before use. Failure to follow instructions may
result in equipment damage or failure, losses, injury or death.
DANGER:
• ALWAYS use a properly grounded AC outlet. Do not immerse the
RapidFlo plug in water or attempt to use a wet plug.
• Provide a “drip loop” for the power cord. This is a loop in the cord
below the level of the receptacle or plug that prevents water
from traveling along the cord in the direction of the receptacle.
• Be sure that a ground fault circuit interrupter (GFCI) is installed
in the branch circuit supplying the pond equipment.
• NEVER remove the ground pin from the plug.
• The RapidFlo is not suitable for use in swimming pools,
swimming ponds, or other situations where humans may make bodily contact with the water.
• The power cable cannot be replaced. If the power cable becomes damaged, the RapidFlo
should be discarded.
• If an extension cord is necessary, a cord 14 gauge up to 100 ft. must be used. A cord may
overheat if the cord is rated for less amperes or watts then the unit rating.
WARNING:
For your protection, always unplug the unit from the power source before installing or servicing.
Should the unit appear to be not working, do not attempt to reach, remove, or disassemble
before disconnecting it from the power source.
To reduce the risk of electric shock:
• Do not remove cord and strain relief. Do not connect conduit to pump.
• This pump has been evaluated for use with water only.
• Properly ground the unit to reduce the risk of electric shock.
• This pump has not been investigated for use in swimming pool or marine areas.
• Do not connect to any voltage other than that shown on the pump.
• Always disconnect from electrical outlet before handling the pump.
• Operate pump completely submerged for proper cooling. Do not let the pump run dry.
IMPORTANT:
The Pond Guy is not responsible for equipment damage or failure, losses, injury
or death resulting from failure to follow safety precautions, misuse or abuse of
equipment.
TECHNICALSPECS :
MODEL POWER WATTAGE MAX FLOW
RATE
GPH @
5’ HEAD
GPH @
10’ HEAD
GPH @
15’ HEAD
MAX
HEAD OUTLET
RapidFlo
3000 120v 60Hz 321 Watts 3,300 GPH 2,600 GPH 1,400 GPH 900 GPH 20’ 2”FPT or MPT
RapidFlo
4000 120v 60Hz 414 Watts 4,300 GPH 3,900 GPH 3,100 GPH 2,500 GPH 28’ 2”FPT or MPT
RapidFlo
5000 120v 60Hz 528 Watts 5,300 GPH 4,900 GPH 4,200 GPH 3,300 GPH 32’ 2”FPT or MPT
Power Cord
Drip Loop
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2

A
B
C
Package Contents
RAPIDFLO PUMP
RapidFlo Pump
ARapidFlo Pump
BThreaded Nipple
CStep-Down Fitting w/Gasket
Tools Required:
(Not included)
Kink-Free Tubing
• Check Valve Assembly
• Hacksaw
• Hose Clamps to Secure
• Flathead Screwdriver or
Nut Driver
Flexible PVC Tubing
• Check Valve Assembly
• 2” MTP to Slip Fitting
• Rubber Coupler
• PVC Glue
• Primer
TECHNICALSPECS :(CONT)
RapidFlo 3000
RapidFlo 4000
RapidFlo 5000
15425 Chets Way | Armada, MI 48005 3

INSTALLING YOUR RAPIDFLO PUMP:
Step 1
Determine Tubing Type
Determine if you will be using Kink-Free tubing or
Flexible PVC tubing. If using Kink-Free tubing, please
see Step 2. If using Flexible PVC tubing, please see
Step 5 on Page 5.
Step 2 (Kink-FreeTubing)
Install Step-down Fitting
Install the barbed step-down tting. Ensure the gasket
is tucked into the step-down tting before screwing
on to the threaded nipple.
Step 3
Trim Fitting
Cut the step-down tting with the hacksaw to match
the tubing size being used for the installation.
Step 4
Secure Fitting
Slip tubing over the barbed tting, and secure with a
hose clamp.
Now move on to Step 7 on Page 5 to continue.
Flexible PVC
Kink-Free
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INSTALLING YOUR RAPIDFLO PUMP: (CONT)
Step 5 (Flexible PVCTubing)
Prepare PVC Tubing
Remove the pre-installed 2” threaded nipple. Install a 2”
MPT to slip tting (NOT INCLUDED) or kit components
for a check valve assembly (NOT INCLUDED).
Step 6
Glue Plumbing
Dry t your tubing before gluing permanently into
place with PVC Glue and Primer. Barbed step-down
tting will not be used for a Flexible PVC installation.
Step 7
DO NOT REMOVE FLANGE!
For either Kink-Free or Flexible PVC installation, the
ange held in with two screws does not need to be
removed!
Step 8
Submerge the Pump
Once tubing is secure, ensure pump is completely
submerged.
Step 9
Plug in the Pump
Plug the power cord into a standard 120v GFCI
protected outlet.
15425 Chets Way | Armada, MI 48005 5

Tools Required: • #2 Phillips Screwdriver
• #3 Phillips Screwdriver
• Damp Cloth or Small Brush
• Clean Water
Step 1
Prepare the Pump
Unplug pump from outlet.
Pull pump out of water and conduct initial clearing
of the intake basket. Ensure there is no large debris
blocking suction intake.
Step 2
Remove Pump Base/Intake Screen
Using a #2 Phillips screwdriver, remove the three
screws from the pump base/intake screen (2a). Pull
intake screen away from base (2b). It is often a good
idea to set screws and small parts in a container or jar
to avoid lost parts before reassembly.
WARNING:
Before performing any maintenance, always unplug the RapidFlo pump from
the power source.
GENERALMAINTENANCE:
When a reduction in ow rate is noticed or if pump is making
loud noises, proceed with initial General Maintenance.
2a
2b
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MAINTAINING YOUR RAPIDFLO PUMP:

Step 4
Remove Ball Float
Remove the ball oat from the bottom side of the
pump motor mounting base and set aside.
Step 5
Clean Parts
Clear debris from impeller and underbelly of pump by
ushing with fresh water or wiping away with rag.
Step 6
Inspect Impeller
Using your hand, rotate the impeller clockwise to
determine if impeller is seized. If able to rotate impeller
with no hesitation, repeat steps in reverse order to
put pump back together. If impeller is locked, please
proceed to extended maintenance procedure on Page 8.
Step 3
Remove Inner Base
Using a #3 Phillips screwdriver, remove the four pump
base screws (3a). Next, remove the proper rubber
foot to gain access to the fth inner pump base screw
and remove it (3b). Once the inner pump base is free,
remove it and set it aside (3c). Some of the screws
thread directly into the acorn nuts that are seated in
the top trim ring; therefore, if the nuts drop out of the
trim ring, simply set them aside until reassembly.
3a
3b
3c
15425 Chets Way | Armada, MI 48005 7
MAINTAINING YOUR RAPIDFLO PUMP: (CONT)

Tools Required: • #2 Phillips Screwdriver
• #3 Phillips Screwdriver
• Rigid Wire or Small T-handle Wrench
• Airmax® D-Scale™ Equipment Cleaner
• Rag or Scouring Pad (Green Scotch-Brite®Pad)
Step 1
Continue Disassembly
Loosen the two pump cord strain relief screws (but
do not remove them) (1a). Next, remove the four top
housing screws (1b).
WARNING:
Before performing any maintenance, always unplug the RapidFlo pump from
the power source.
EXTENDEDMAINTENANCE:
If you’ve performed the General Maintenance and the unit
appears to have seized, proper function of the pump motor can
often be resolved by performing this Extended Maintenance
Procedure.
1a
1b
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EXTENDED MAINTENANCE RAPIDFLO PUMP:

Step 2
Remove Motor Housing
Lift the top housing from the unit (2a). Then with one
hand on the internal pump cord, slide the housing away
to allow room to work on the unit without interference
from the top housing (2b). Next, slide the stainless steel
body up and away from the lower trim ring (2c).
Step 3
Release Motor From Assembly
With the unit on its side (or upside down) remove
the position lock screw from the motor mount base
(3a). Then slide the trim ring up and away from the
base (3b). Next, rotate the motor mount base ¼ turn
counterclockwise to release it from the motor mount
locking tabs (3c).
2a
2b
2c
3a
3b
3c
Motor Locking Tabs
(Motor)
Motor Mount Base
Locking Slots
15425 Chets Way | Armada, MI 48005 9
EXTENDED MAINTENANCE RAPIDFLO PUMP:

Step 4
Remove Motor
Now that the motor is free, remove the rotor and
impeller assembly from the stator.
Step 5
Begin the Cleaning Process
At this point, you may want to use a pair of latex or other
rubber-based gloves to protect your skin during the
cleaning process.
Liberaly apply Airmax D-Scale to the rotor and stator
(5a). You may even want to remove the spray tip from
the bottle and pour 6–8 ounces directly into the stator
and let it foam for 5–10 minutes in order to break
down any scale and buildup (5b). Use a Scotch-Brite
pad or abrasive sponge to thoroughly clean debris and
buildup on the rotor and inside the stator. Repeat as
needed until all debris and scale buildup is removed.
NOTE: Be sure to rinse all components with clean
water after using the D-Scale.
5a
5b
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EXTENDED MAINTENANCE RAPIDFLO PUMP:

Step 6
Clean Rotor Shaft & Rotor Ports
Liberaly apply Airmax D-Scale to the rotor, and if
possible, use a rigid wire (6a) or small T-handle wrench
to clear any debris that may be plugging the rotor shaft
and rotor ports (6b). Clearing the rotor is important as
it assures proper water ow in and out of the motor for
cooling and lubrication (6c).
Step 7
Begin Reassembly
When ready to reassemble the unit, be sure that the
motor O-ring is seated properly (it can be cleaned
beforehand if necessary). At this stage, it is also helpful
to coat the O-ring, rotor, and stator with a light silicone
lubricant if possible. Coating with silicone lubricant is
more important when winterizing than it is when the
pump is going to be placed back in the pond within the
next 24 to 48 hours.
NOTE: Do not use lithium grease or other heavy
lubricants.
6a
6b
6c
15425 Chets Way | Armada, MI 48005 11
EXTENDED MAINTENANCE RAPIDFLO PUMP:

Step 8
Ensure Proper Alignment
Place the rotor and impeller assembly back inside the
stator, ensuring that the large and small holes (8a) on
the bearing holder seat properly on the corresponding
nubs on the motor; otherwise, the motor mounting
base will not t correctly (8b).
Step 9
Install Base
Reinstall the motor mounting base, making sure that,
when locking it in by turning ¼ turn clockwise, the
discharge and pump motor cord are opposite each
other.
Step 10
Install Trim Ring
Slide the trim ring back down against the motor
mounting base, and insert all four acorn nuts.
NOTE: Be sure to check that the impeller spins
freely by hand before completing the reassembly.
Step 11
Install Position Lock Screw
With the unit on its side (or upside down) reinstall the
position lock screw into the motor mounting base.
8a
8b
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EXTENDED MAINTENANCE RAPIDFLO PUMP:

If you nd any broken or damaged parts during the disassembly
or cleaning process or for additional help, please contact
The Pond Guy Technical Support at [phone].
Step 12
Reinstall Motor Housing
Slide the stainless steel body down and onto the lower
trim ring (12a). Holding the top housing with one hand
and the internal pump cord in the other, slide the top
housing back down the cord, onto the stainless steel
body (12b).
Step 13
Assemble Base
Reinstall the four top housing screws (13a).
Tighten the two pump cord strain relief screws (13b).
Set the ball oat back into the bottom side of the pump
motor mounting base (13c).
NOTE: Do not over-tighten any screws during
reassembly. Screws should be snug but not so tight
that they could cause the plastic to crack.
12a
12b
13a
13b
13c
15425 Chets Way | Armada, MI 48005 13
EXTENDED MAINTENANCE RAPIDFLO PUMP:

Step 14
Secure Inner Base
Align the inner pump base and the bottom of the
pump (14a). Using a #3 Phillips screwdriver, insert and
tighten the fth inner pump base screw under where
you removed the rubber footing in Step 3 on Page 7
(14b). Secure the rubber footing over the screw hole
(14c). Insert and tighten the four remaining pump
base screws.
Step 15
Reinstall Pump Base/Intake Screen
Align the pump base and intake screen (15a). Using
a #2 Phillips screwdriver, insert and tighten the three
screws for the pump base/intake screen (15b).
14a
14b
14c
15a
15b
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EXTENDED MAINTENANCE RAPIDFLO PUMP:

15425 Chets Way | Armada, MI 48005 15
NOTES:

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TROUBLESHOOTING:
Pump does not turn on.
• Power cord not connected.
• Circuit breaker tripped.
• Faulty GFI.
Pump turns on then shuts o.
• Pump is getting hot due to low water level or because intake is clogged.
• Pump is plugged into an extension cord resulting in low voltage.
Reduced water ow.
• Pump is plugged with debris.
• Intake is clogged with debris.
• Tubing is clogged with debris.
• Low water level.
PRODUCT WARRANTY:
The Pond Guy will repair or replace any RapidFlo found to be defective within 3 years of
the original purchase date. This limited warranty is extended exclusively to the original
purchaser beginning from the date of original receipt. Abuse or misuse of this product or
power cord alterations void all warranty. In case of warranty claims, the product must be
returned to place of purchase accompanied with the original receipt.
THANK YOU FOR CHOOSING:
The Pond Guy®Inc.
We Know Ponds™
15425 Chets Way
Armada, MI 48005
866-POND-HELP (766-3435)
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