Pump Replacement Made Easier

Manufacturers report that anywhere between 80 and 90 percent of pump and motor sales are for the replacement market — an unsurprising estimate given the ratio of existing to new pools at any given time.

With so many pumps replaced each year, and so many service companies relying on pump sales and labor for a large chunk of their annual revenue, it only makes sense to establish practices that both ease the replacement process and ensure the best results in terms of performance and longevity.{bglink 4725}

To a large extent, pump replacement — and by extension, motor replacement — is not an overly complicated or challenging process, especially if the existing components were installed with care. Nevertheless, commonsense measures, along with a bit of experience and forethought, will not only help with the job at hand, but will also make things easier for the next person who comes around.

With that in mind, here's a brief list of helpful ideas that can help streamline the pump/motor replacement chore.

AT THE SERVICE PANEL

Any list of pump-replacement procedures begins with this most basic safety measure: Make sure the power is off at the circuit breaker before you start!

For a variety of painfully obvious reasons, live electrical wires and pump/motor replacement work are a potentially disastrous combination.

And while you're at it, be sure the pump motor is wired to the correct type of power service. Always verify the voltage going to the pump and make sure you're replacing it with one that can cover the voltage.

For example, if you have a 208 application, make sure the motor on the new pump is suited to run at that voltage. But more importantly, make sure it can handle a plus/minus 10 percent factor for voltage drops, which always happen.

CHOOSE WISELY

In a very real sense, a big part of facilitating pump installation is simply ensuring you don't have to do the job more often than necessary. That means making sure you have the correct unit for the application.

To a large extent, servicers will simply replace like with like. While that works just fine most of the time, you may one day be confronted with a pump completely mismatched for the application — one that's oversized for the plumbing diameter, for example — and as a result, you'll better serve the client by changing pump models or horsepower.

With all that in mind, verify your application. Make sure you know the proper gallons per minute and total dynamic head in your system so you replace the pump with the right pump. With pump efficiency on the rise in recent years, you may find in some cases you'll be able to get away with installing a lower-horsepower pump — especially if you're replacing a unit more than 10 to 12 years old.

PARTS & PROCEDURES

Experienced service techs point out that when replacing a pump, it will typically be packaged with all of the requisite seals and hardware. Therefore, so long as you're sure you have the proper pump for the application, you'll have the parts you need for the pump itself.

(However, it's always a good idea to be sure you have a full compliment of PVC plumbing supplies on the truck, including fittings, hydraulic unions and adhesive.)

On the other hand, when it comes to replacing a motor, it can indeed be a challenge to be sure you have all the seals, O-rings, etc. Service techs and manufacturers recommend seal replacement even if the existing seals don't appear worn.

For route service accounts, keeping a log of the pumps and motors on each pool will enable you to accurately stock the truck with necessary parts for a majority, if not all of the pumps you'll need to replace.

Along the same lines, keep a folder, hardcopy or digital library of "exploded view" diagrams that depict how a pump/motor goes together. These can be revisited again and again as reminders of all the parts you'll need.

BREAK OUT THE CAMERA

If you service a pool and are familiar with the pump/motor and equipment pad layout, odds are you know what to expect and which parts and tools to have on hand. If it's a system you've never seen before, be it a new account or a repair-only customer, it can be tremendously helpful to have a look beforehand.

Planning a repair at an unfamiliar property once meant either traveling to the site or even having the homeowner describe what they have over the phone. These days, service techs sing the praises of smartphone camera, which homeowners can use to send a quick snapshot of the equipment set and plumbing, saving the tech from extra trips and relying on guesswork.

Likewise, keeping a set of photos of equipment pads on service can be a helpful reminder when planning a repair, or when sending out a new tech to the job site.

REPOSITION THE PUMP IF NECESSARY

Many late-model pumps are different sizes than older versions, and many units these days, including some variable-speed drive pumps, are longer than their predecessors.

If that's the case, and space looks tight, consider reorienting the pump at a 45-degree angle. Although that will require some re-plumbing, the time it could save next time around may be well worth the trouble.

While there's a tendency to think that all equipment has to be at 90-degree angles, truth be told, positioning equipment on an angle can be a great way to give yourself more working room in the future.

LUBE THE BOLTS

It's a simple step that only takes a dollop of silicon lube on the threads before replacing them. Doing so will help prevent corrosion, and when the time comes to remove the motor, the bolts will unscrew with ease.

THE REPLACEMENT GOLDEN RULE

Think about the next person who has to replace the pump and/or filter you're working on.

That's perhaps the most important measure to ensure a smooth replacement process — after all, it may be you who's doing the job the next time around.

For starters, always make sure to allow plenty of room to work on pump, but more importantly, make sure you allow enough clearance at the back of the motor to be able to remove it, should you need to replace it or have serviced in the future. After all, if don't have room to turn a wrench, a simple job can become a painful ordeal.

THINK IT THROUGH

Because pump/motor installation is not high on the difficulty scale, some techs say there can be a tendency to make assumptions about the process and more or less work by wrote.

Before you start, make at list or at least briefly think through each step. If you're doing plumbing work, think about where you'll cut the pipes and where new elbows or hydraulic unions will be located. And, of course, always think about what it will be like to come back and do the next installation.