Sta-Rite Industries

Basic Training Manual

THIRD EDITION

Hydraulics
Pumps
Motors
Filtration

AUX
2

SPEED
LOW

PUMP

BOOSTER
SPEED
HIGH

AUX
1

FILTER
PUMP

Heaters
2668 0397NF

1915 0895

2003 Sta-Rite Industries, Inc.

Printed in USA

S4247 (Rev. 9/03)

Table of Contents
SECTION

SECTION

Hydraulics
Circulation System ...........................................................................................1
Hydraulics Water Flow ....................................................................................2
Friction Head Loss, Static Suction Lift,
Elevation Atmospheric Pressure .................................................................3
Fittings and Valves Friction Head Loss ....................................................4
Pipe Sizing, Pipe, Friction Head Loss ............................................................5
Exit Loss, System Head Loss ..........................................................................6
Swimming Pool Gallons,
Turnover Rate Gallons Per Minute (GPM)....................................................7
Spa-Gallons Per Minute
Spa-Turnover Rate
Spa Jets-Gallons Per Minute
Calculate System Head Loss............................................................................8
Procedures for Calculating the Head Loss Suction Side ........................9
Procedures for Calculating the Head Loss Return Side .......................10
Spa Circulation System
Plumbing, Spa Jet System Plumbing ...........................................................11
Plumbing & Safety Tips .................................................................................12
Friction/Flow Chart for Schedule 30 PVC Pipe ........................................13
Exit Loss Charts ........................................................................................14, 15
Friction Loss Created by Pipe Fittings ..................................................16, 17
Calculating Turn Over Rates ........................................................................18

SECTION

Pumps
Swimming Pool and Spa Pumps .................................................................19
Impellers ..........................................................................................................20
Water Flow .......................................................................................................21
Head vs. Capacity ..........................................................................................22
Semi Open Impeller Pump Test ....................................................................23
Closed Impeller Pump Test............................................................................24
Pump Curves Sizing Pumps ......................................................................25
Plumbing and Safety Tips ..............................................................................26

SECTION

Motors
Swimming Pool and Spa Motors Principles of Operation ......................27
Basic Component Parts ..................................................................................28
Motor Name Plate ....................................................................................29, 30
Motor Test ........................................................................................................31
Electrical and Safety Tips ...............................................................................32
Approximate Cost of Operating Electric Motors .......................................33
Single Phase Wire Size Selection Charts......................................................34
Pump Curve Graph.........................................................................................35
Plumbing Tips ..................................................................................................36

Pool & Spa Basic Training

Filtration
Swimming Pool, Spa and Water Feature Filtration ..................................37
Diatomaceous Earth Filters ...........................................................................38
D.E. Filter Basic Operation
D.E. Substitues ..........................................................................................39
Pre-Coating D.E. Filters
Velocity and its Effects on D.E. Filtration ............................................40
Sizing a D.E. Filter...........................................................................................41
Sand Filtration..................................................................................................42
Sand Filter and Backwash Cycle...................................................................43
Sand Filter Sizing.............................................................................................44
Velocity and Sand Filtration ..........................................................................45
Cartridge Filtration .........................................................................................46
Basic Operation of a Sand Filter
Velocity and the Cartridge Filter
Velocity and the Mega Cartridge Filter .................................................47
Cleaning the Cartridge Element
Dual Filter Systems
Sizing a Standard Cartridge Filter .........................................................48
Sizing a Mega Cartridge Filter ......................................................................49
Backwash Valves..............................................................................................50
Filtration and Safety Tips ...............................................................................51

38

100

SECTION

Heaters

Swimming Pool and Spa Heaters ................................................................52

Heat Loss .........................................................................................................53
Natural Gas/Propane Heaters
Heater Efficiencies
Basic Operations .......................................................................................54
Basic Heater Components..............................................................................55
Gas Flow and Air Flow Through the Heater..............................................56
Heater Sizing ....................................................................................................57
Plumbing and Safety Tips ..............................................................................58

SECTION

Reference
Basic Spa Equipment and Piping Specifications .......................................59
Spa Jet Hydraulics ..........................................................................................60
Basic Swimming Pool Worksheet ................................................................61

S4247

Pool & Spa Basic Training

Maintenance and
Safety Equipment

Safety Signs

KEEP
GATE
CLOSED

10

.
DO NOT
SWIM
ALONE

EMERGENCY
SHUT OFF

11

12

8
8

14

4
3

RESIDENTIAL
SWIMMING POOL

1. Hydrostatic
Relief Valve
2. Dual Main Drains
3. Automatic
Cleaner
4. Underwater Light
5. Depth Marker

6. Skimmer
7. Emergency
Shutoff Switch
8. Pump
9. Backwash Valve
10. Filter
11. Heater

15
16

12. Chlorinator
13. Safety Check
Valve
14. Return
Fitting
15. Cup Anchor
16. Recessed Steps

S4247

Figure 1

Circulation System

2
1

13

1 SECTION

Hydraulics

RESISTANCE

Figure 2

Hydraulics
Hydraulics, as used in this text, deals with the physical
movement of water for the many purposes associated with
swimming pools, spas, and water features.

In order to move water for the above purposes, we must

examine how we make it flow efficiently. We need to know
what restricts flow and how to calculate the resistance.
Once we understand flow and resistance, we can overcome
these obstacles to deliver the desired results. This is the
purpose of the section on hydraulics.

These purposes include the following:

Passing the water through a filter to remove the suspended particles.

Water Flow

Moving the water through a heater, solar system or

other device for the purpose of raising or lowering the
water temperature. (1)

Supplying water flow to sanitizing devices such as chlorinators, brominators, and ozone generators.

Water flows naturally downhill. Unfortunately, we cant

design a swimming pool, spa, or water feature so that the
water is always following gravity. To provide water flow
for all the different tasks associated with a pool, spa, or
water feature, we use a pump. The pump, which will be
discussed in Section II, draws and pushes the water
through pipes, fittings, filters, heaters, etc., used in the
operation of a pool, spa, or water feature. These objects
create resistance to flow that the pump must overcome.

Providing the right flow for the many types of fountains, water falls, water slides, wave pools, and other
specialty applications used with pools and spas.

Examine the basic pool plumbing layouts in Figures 1 and

2. List the objects that cause the resistance the pump must
overcome to deliver the proper amount of flow.

Providing enough flow of water with the right amount

of force to operate a pool cleaner or cleaning system.
Delivering the right amount of water flow to operate
several therapy jets for spas.

____________________________________________________
(1)

In many very hot areas of the world, solar systems are used at
night to lower the temperature of the water.

Pool & Spa Basic Training

____________________________________________________
____________________________________________________

S4247

1 SECTION

Hydraulics
HEAD LOSS

STATIC SUCTION LIFT

40 GPM

The water is below

centerline of pump

SKIMMER
2 FT.

See Charts & Tables

Page 17 for
Head Loss Charts for
other equipment.

5'
5

75 GPM

FILTER
7 FT.
Head Loss

Figure 3

Figure 4

Friction Head Loss

Elevation - Atmospheric Pressure

The resistance to flow (Friction Head Loss) is expressed in

FEET OF HEAD. For example, see Figure 3: Water flowing
at 40 GPM (gallons per minute) through a 2 skimmer will
result in 2 ft. of head loss. 75 GPM through a 53 sq. ft. D.E.
will result in 7.0 ft of head loss.

Atmospheric pressure on the surface of the water helps a

self-priming centrifugal pump to perform. The higher the
elevation that the pump is installed, the pressure on the
surface of the water decreases. This decrease reduces the
amount of work a given pump can do.

Static Suction Lift

Example:

The vertical distance between the center line of the pump

impeller and the surface level of the water is called the
static suction lift. This distance can be expressed as Positive
Suction Head or Negative Suction Head. Both are
expressed as Feet of Head.

The ability of a pump to lift water is reduced by

1.155 ft. of head for every 1,000 ft. of elevation.
A pump that lifts water 10 ft. at sea level will only
be able to lift water 8.845 ft. at an elevation of
1,000 ft. At 5,000 ft. of elevation, that same pump
will only be able to lift water 4.225 ft., or in other
words, a reduction of over 50% in the pumps
capacity to lift.

1. Positive Suction Head Pump is located below the surface of the water. This can be a standard centrifugal or a
self-priming centrifugal pump.
2. Negative Suction Head Pump is located above the surface of the water. This type of pump is usually considered a Self Priming Pump.

Example:
A pump located 5 above the surface of the water
will add 5 ft. of head loss to the system. (Figure 4)
A pump located 5 ft. below the surface of the
water will reduce system head loss by 5 feet. This is
due to the weight of the water assisting the pump.

Pool & Spa Basic Training

S4247

1 SECTION

Hydraulics

FITTINGS & VALVES

FRICTION HEAD LOSS

EQUIVALENT LENGTH
OF STRAIGHT PIPE
Line Flow
Branch Flow

= 5.6
= 9.9

90
ELBOW
1-1/2
TEE

2 90

GLOBE
VALVE

Short Radius
Long Radius

Figure 5

= 8.5
= 3.6

Figure 6

Using the Charts and Tables Manual, Pages 36 & 37, complete the following chart. (Use the Screwed/Steel numbers.
They are equivalent to PVC pipe.)

Fittings And Valves - Friction Head Loss

When water flows through fittings and valves, turbulence
is created in the water, which can result in cavitation. These
two phenomena produce a significant amount of friction
head loss. (See Figure 5).

What is the equivalent length of pipe?

1 - 112 90 elbow_____________________________________

Important Note: Unlike filters, heaters, skimmers, etc., we

do not express the resistance in fittings and valves as head
in feet. Instead, it is stated as EQUIVALENT LENGTH
OF STRAIGHT PIPE.

1 - 3 branch flow tee _________________________________

1 - 112 globe valve ___________________________________
2 - 2 45 elbows _____________________________________
4 - 112 gate valves____________________________________

Example:
One 2 90 PVC elbow is expressed as 8.5 ft. of 2
pipe. A sweep 2 PVC 90 is expressed as 3.6 ft. of
2 pipe. (See Figure 6)

1 - 3 line flow tee____________________________________

How much less equivalent length of pipe are 2 45 elbows
than 1 90 elbow?

Why is a sweep 90 equivalent to a shorter length

of pipe than a 90 elbow?

______________________________________________________

Now compare one sweep 112 90 with two 112 45 elbows.

____________________________________________

______________________________________________________

____________________________________________

Calculate the equivalent length of pipe savings in a plumbing layout that was designed with ten 2 regular 90 ells
that will be replaced with twenty 2 45 ells.

What is the difference in friction head loss between

a Branch Flow Tee and a Line Flow Tee?
____________________________________________

Ten 2 90 regular ells = __________ft.

____________________________________________

-Twenty 2 45 ells = __________ft.

Equivalent Length of Pipe Savings =__________ft.

Pool & Spa Basic Training

S4247

1 SECTION

Hydraulics

FRICTION LOSS - PIPE

FRICTION FLOW CHART

1-1/2 PVC Pipe (100 ft. lengh)

VELOCITY
7 FPS

GPM
20

VELOCITY
(FPS)
3.15

FRICTION
HEAD
(FT.)
2.47

40

6.30

8.90

80

12.60

35.00

160

25.20

140.00

Figure 7

Figure 8

Pipe Sizing

Pipe - Friction Head Loss

There are other factors that can cause resistance in the

plumbing system. The major factor affecting the efficiency
of water flow is VELOCITY.

As you see in the Friction Flow Chart for 112 schedule 40

PVC pipe (Figure 8), 40 GPM travels at a speed of 6.30 FPS
through the 112 pipe. At this speed, the amount of friction
loss will be 8.9 ft. of head for each 100 ft. Length of pipe.

Velocity is a term used to express the speed at which the

flow of water travels through a pipe and fittings. The
velocity of the water is measured and expressed in feet per
second (FPS).

If the flow were doubled to 80 GPM through the same 112

pipe, the speed of the water doubles to 12.60 FPS.
However, and more important, the friction head loss
increases almost 4 times to 35 feet of head.

The velocity of water flowing through a pipe and fittings is

determined by two factors:

Due to the rapid increase in friction head loss as the flow

increases in a given pipe, we follow the recommendations
of the Hydraulic Institute for suction pipe sizing.

1. The volume or quantity of flow (GPM).

2. The size of the pipe through which the water is moving.

Schedule 40 PVC pipe .................................velocity is 7 FPS

As water flows through the pipe (Figure 7), it encounters

friction from the pipe walls. The faster the water moves,
the more friction it encounters. In fact, if we double the
flow in a given pipe, the velocity will double, and friction
loss will increase approximately 4 times.

Copper Pipes ..................................................velocity is 6 FPS

Polyethylene Coil Pipe ................................velocity is 5 FPS
Using the Charts and Tables, Page 29, determine as closely
as possible the flow (GPM) at or near 7 FPS for each of the
following Sched. 40 PVC pipe.
3/4 _____________ 1 ______________ 114 _____________
112 _____________ 2 ______________ 212 _____________
3 __________ 4 __________ 6 __________ 8__________

Pool & Spa Basic Training

S4247

1 SECTION

Hydraulics
EXIT LOSS

5 - 3/4 RETURNS
@ 15 GPM EACH

FROM JET PUMP

FROM
CIRCULATION SYSTEM

Note:
Only use
Loss
One time

2 - 3/8 RETURNS
@ 10 GPM EACH

Exit Loss

Figure 9

System Head Loss or

Total Dynamic Head Loss (TDH)

Exit loss occurs on the discharge side of the pool, spa, or

water features circulation system, also know as the return
side. This loss occurs as a result of the water being discharged from the orifices in the return inlets fittings into
the large body of water.

As we have read in previous pages, many things contribute

to the resistance to flow that the pump must overcome.
Skimmers, main drains, fittings, pipe size, velocity, heaters,
filters, automatic cleaning systems, and elevations are some
of these obstacles. We know that these factors have resistance values that can be calculated. Once calculated and
combined they are known as the Total System Head Loss
or TDH (Total Dynamic Head).

The resistance created by the exit loss is calculated as

Velocity Head Loss in Feet. This exit head loss is part of the
total head loss on the discharge side of the pump. Exit Loss
Charts are provided in the Charts and Tables, Page 18.

We now can begin calculating the System Head Loss. The

steps necessary are as follows:

NOTE: An important thing to remember is that this resistance is not cumulative. You only add the head loss one
time, regardless of the number of return fittings.

1. DETERMINE THE REQUIRED FLOW RATE

There are several steps we must follow to calculate the
flow rate. Two factors are necessary for any body of water.

Example:

A. How many gallons are we dealing with?

A pool with three 1 return lines, each moving 20

GPM, will add 1.04 ft. of head to the discharge
head loss. (The head for one fitting only)

B. What is the desired turnover rate?

A. SWIMMING POOL GALLONS
It is a simple matter to calculate the gallonage of a square
or rectangle swimming pool. Free formed pools, such as
ovals and kidney shapes are much more difficult. Page 40
of the Charts and Tables shows some additional formulas
for free formed pool.

Using the chart on Page 18 of the Charts and Tables, fill in

the following Exit Head Losses.
Five 3/4 return lines flowing 15 GPM each will
add________ft. of head to the discharge head loss.
Two 3/8 return lines flowing 10 GPM each will
add________ft. of head to the discharge head loss.
(See Figure 9).
Pool & Spa Basic Training

S4247

1 SECTION

Hydraulics
SWIMMING POOL GALLONS
36
36'

18
18'
3
3'
8
8'

Gallons = L x 2963
W 0697
x AD x 7.48

Figure 10

A. Swimming Pool Gallons

[Link] Rate

Figure 10 is a rectangle shaped swimming pool. To calculate the amount of water in the swimming pool, the first
step is to determine the square feet of surface area.

Each time the total volume of water in a swimming pool,

spa or water feature is passed through the filter, it is said to
have turned over once. Although the turnover rate
should be the number times that a complete turnover
occurs in 24 hours, we usually talk about the number of
hours it takes to turn over the water once.

Length x Width = surface area square footage.

The second step is to find the average depth. (AD) This is
accomplished by taking at least 2 measurements. One at
the shallow end and the other at the deepest point of the
pool.

Example:
A body of water passing through a filter 3 times in
24 hours is considered to have an 8-hour turnover.

3 feet + 7 feet = 10 feet/ 2 = a AD of 5 feet.

The Third step is to multiply the square footage times the
average depth to get cubic feet.

If 4 turns are required in 24 hours, then a

6-hour turnover is required.
If a 12-hour turnover is needed, then all the
water will pass through the filter twice in 24 hours.

sq. ft. x AD = cubic feet

The final step is to multiply the cubic feet by 7.48 ( The
number of gallons in a cubic foot)

Gallons Per Minute (GPM)

Cubic Feet x 7.48 = gallons

To determine the GPM, we divide the total body of water

by the number of minutes in the turnover hours.

Example:
Calculate the gallons for the swimming pool in
Figure 10.

Example:
A 30,000 gallon pool with an 8 hour turnover:

Length_____x ____Width_____x AD_____x 7.48

30,000 / 480 (8 X 60) = 62.5 GPM

Equals______Gallons.

Pool & Spa Basic Training

What is the GPM for a 30,000 gallon pool with a

6-hour turnover?__________

S4247

1 SECTION

Hydraulics

Discharge Side
100 of 2 PVC pipe
with 10 regular
2 90 ells

75 GPM

50 ft.
in Head

Suction Side
Vacuum
=
10
10 x 1.13 = 11.3

7 FPS

1.
2.
3.
4.

(10) 2 90 ells
=
85
85 + 100
=
185
Divided by 100
=
1.85
Friction Loss @ 75 GPM
through 2 PVC
=
7.2
5. Total Loss = 1.85 x 7.2 =
13.32 feet of friction head loss

Figure 11

If the jet is rated at 15 GPM and there are 6 of them, we

simply multiply the two together to get the gallons per
minute (15 GPM x 6 = 90 GPM)

Spa - Gallons Per Minute

And Turnover Rates
Since we usually deal with a small volume of water, the
gallons per minute for the turnover rate is not normally
calculated. However, commercial installations may require
15 minute turnovers. The calculation is the same as for a
swimming pool.

Because of the many different types of jets available on the

market today, it is a good idea to consult with the jet manufacturer before calculating the necessary GPM required
for the system.

Gallons/15 minutes = GPM.

Calculate Friction Head Loss

Example:

Figure 11 shows a short plumbing section on the discharge

side of the pump.

A 30 minute turnover for a 400 gallon spa is

13.4 GPM. A 1 hour turnover for a 600 gallon spa
is 10 GPM. Calculate the GPM for the following
spas:

There is 100 ft. of 2 PVC pipe with 10 - 2 regular 90 ells,

flowing 75 gallons per minute.
The procedure for calculating the head loss in the above
plumbing layout is as follows: (Refer to Pages 29, 36, and
37 for conversion charts in the (Charts and Tables).

1,000 gallons with a 30 minute turnover rate:

________GPM.
800 Gallons with a 112 hour turnover rate:

1. Convert the 2 90 ells to equivalent length of pipe.

________GPM.

2. Add the equivalent length of pipe to the existing length

of pipe.
3. Divide the total equivalent length of pipe by 100.

Spa Jets - Gallons Per Minute

4. Find the friction loss for 75 GPM through 2pipe.

Spa jets are the main factor in calculating the necessary gallons per minute. In the old days, we could figure 1/4 HP
per jet. At that time, most jets required 20 GPM each. With
improvements in jet design and pump performance, we
must know the jets required GPM.

Pool & Spa Basic Training

5. Multiply the friction head loss times the equivalent

length of pipe to get the total friction head loss.

S4247

1 SECTION

Hydraulics

SUCTION SIDE PLUMBING

Skimmer Line
40 2 PVC Pipe
3 2 90 Ells
1 2 Gate Valve
1

5'
5

2 Skimmer

Main Drain Line

65 2 PVC Pipe
3 2 90 Ells
1 2 Gate Valve
2

2 Main Drains

2 Branch Flow Tee

;;

75 GPM

Static
Suction Lift

37.5 GPM
EACH
LINE

Manifold Line
4 2 PVC Pipe
1 2 90 Ell
1

2 Branch Flow Tee

Figure 12

Figure 12 is a typical plumbing layout for the suction side of the circulation system. In this example the
Skimmer and Main Drain have separate lines manifolded together into the suction side of the pump.

Procedures for Calculating the Head Loss:

(Refer to Charts on Pages 29, 36, and 37 of the Charts and Tables).

Skimmer Line:

Main Drain Line:

Manifold Line:

1. Convert the fittings to equivalent

length of pipe.
3 - 2 Reg. 90 Ells = 3 x 8.5 = 25.5
1 - 2 Gate Valve
= 1.5
Total equivalent length
of pipe
= 27.0

1. Convert the fittings to equivalent

length of pipe.
1 - 2 Branch Flow Tee
= 12.00
3 - 2 Reg. 90 Ell = 3 x 8.5 = 25.50
1 - 2 Gate Valve
= 1.50
Total equivalent length
of pipe
= 39.00

1. Convert the fittings to equivalent

length of pipe.
1 - 2 Regular 90 Ell
= 8.50
1 - 2 Branch Flow Tee
= 12.00
Total equivalent length
of pipe
= 20.50

2. Add equivalent length of pipe

actual pipe length.
Equivalent length of pipe
Length of 2 pipe
Total pipe length

= 27.0
= 40.0
= 67.0

2. Add equivalent length of pipe to

actual pipe length.
Equivalent length of pipe
= 39.00
Length of 2 pipe
= 65.00
Total pipe length
= 104.00

2. Add equivalent length of pipe

to the actual pipe length.
Equivalent length of pipe
= 20.50
Length of 2 pipe
= 4.00
Total pipe length
= 24.50

3. Convert total pipe length to 100

length.
67.0 / 100
= .67

3. Convert total pipe length to 100

length.
104.00 / 100
= 1.04

3. Convert total pipe length to 100

length.
24.50 / 100
= .25

4. Calculate the Friction Head Loss in the

Skimmer Line
.67 pipe length x 2.35
= 1.57
1 - 2 Skimmer @ 37.5 GPM = 1.75
Total Friction Head Loss
= 3.32

4. Calculate the Friction Head Loss in the

Main Drain Line.
1.04 pipe length x 2.35
= 2.44
2 - 2 M.D. @ 37.5 GPM
= 2.00
Total Friction Head Loss
= 4.44

4. Calculate the Friction Head Loss

in the Manifold Line.
.25 pipe length x 7.17
= 1.79
Total Friction Head Loss
= 1.79

to the

Suction Side Head Loss:

Skimmer Line
Main Drain Line
Manifold Line
Static Suction Lift
Total Suction Head Loss

Pool & Spa Basic Training

= 3.32
= 4.44
= 1.79
= 5.00
= 14.55

S4247

1 SECTION

Hydraulics

FRICTION HEAD LOSS - RETURN SIDE OF PUMP

;;;;
;;;;

2,
75 GPM

1 2
35
3
1
2
20
2
1

50 GPM Line
112 PVC Pipe
112 Reg. 90 Ells
112 Branch Flow Tee
3/4 Eye Ball Fittings
1 PVC Pipe
1 Reg. 90 Ells

1 2
15
2
1
1

25 GPM Line
112 PVC Pipe
112 Reg.2966
900697
Ells
3/4 Eye Ball Fittings

Equipment Pad
32 2 PVC Pipe
6 2 90 Ells
1 2 Branch Flow Tee
300 Sq. Ft. Cart. Filter
400,000 BTU Heater

112,
50 GPM

1 Friction
Head Loss = 9
3

112,
25GPM

Figure 13

Figure 13 is a typical plumbing layout for multiple return lines. One 2 line Teed into two 112 lines, one
with a single return fitting, the other with two return fittings.

Procedures for Calculating the Head Loss:

(Refer to Charts on Pages 29, 36, and 37 of the Charts and Tables).

Equipment Pad:

112 50 GPM Line:

112 25 GPM Line:

1. Convert the fittings to equivalent

length of pipe.
6 - 2 Reg. 90 Ells = 6 x ____ = ____
1 - 2 Branch Flow Tee
= ____
Total equivalent length
of pipe
= ____

1. Convert the fittings to equivalent

length of pipe.
1 - 112 Reg. 90 Ell
= ____
1 - 112 Branch Flow Tee
= ____
Total equivalent length
of pipe
= ____

1. Convert the fittings to equivalent

length of pipe.
2 - 112 Reg. 90 Ells = 2 x ___ = ____

2. Add equivalent length of pipe

actual pipe length.
Equivalent length of pipe
Length of 2 pipe
Total pipe length

2. Add equivalent length of pipe

actual pipe length.
Equivalent length of pipe
Length of 112 pipe
Total pipe length

2. Add equivalent length of pipe to the

actual pipe length.
Equivalent length of pipe
= ____
Length of 112 pipe
= ____

to the
= ____
= ____
= ____

to the
= ____
= ____
= ____

3. Convert total pipe length to 100

length.
Total pipe length ____ / 100 = ____

3. Convert total pipe length to 100

length.
Total pipe length ____ / 100 = ____

3. Convert total pipe length to 100

length.
Total pipe length ____ / 100 = ____

4. Calculate the Friction Head Loss in the

equipment pad plumbing.
100 pipe length ____ x ____ = ____

4. Calculate the Friction Head Loss in the

112 50 GPM line.
100 pipe length ____ x ____ = ____

4. Calculate the Friction Head Loss in the

112 25 GPM Line.
100 pipe length ____ x ____ = ____

5. Filter Head Loss

= ____

6. Heater Head Loss

= ____

5. Friction Head Loss in 1 line

= 9.0
(Including the Branch Flow Tee)

7. Total Equipment Pad

Head Loss

Pool & Spa Basic Training

= ____

6. Exit Loss 3/4 @ 25 GPM

= ____

Return Side Head Loss:

7. Total Friction Head Loss

= ____

Equipment Pad Head Loss

50 GPM Line Head Loss
25 GPM Line Head Loss
Total Return Side Head Loss
Total Suction Side Head Loss
Total Circulation System
Head Loss

10

=
=
=
=
=

____
____
____
____
____

= ____
S4247

1 SECTION

Hydraulics

TWO PUMP SPA SYSTEM

CIRCULATION SYSTEM
11
22

4
4

33
TO CIRCULATION
PUMP
FROM
CIRCULATION SYSTEM

JET SYSTEM
77

8
8

66
55

FROM JET PUMP

TO JET PUMP

Figure 14

Circulation System Plumbing:

Jet System Plumbing:

1. Surface Skimmer - Normal flow is a minimum of 25

gpm. The maximum flow is 50 gpm. Some skimmers are
designed so that the Hair Lint Basket can be removed
through the throat of the skimmer. Others are designed
with a built in Cartridge Filter. These are usually
portable units that have a built in pumping, filtering
and heating system.

5. Dual Main Drains - Designed for safety. By drawing the

water from two separate sources, the spa is safer from
possible entrapment and entanglement. Dual Main
Drains also cut down on the possibility of eddies forming.
6. Spa Jets - Designed to add velocity to the water flow
and draw air from the atmosphere or a Mechanical
Blower. The addition of air can add as much as 50% to
the volume of the jet stream. There are some specialized
jets on the market that give a messaging action. The
plumbing should be Looped for equal jet pressure.

2. Auxiliary Suction - Designed to offer a separate source

of water for the pump in case the flow through the Main
Drain or Skimmer become restricted. Auxiliary Suction
Fitting should be IAPMO approved.
3. Main Drain - Located at the lowest point of the spa. It is
designed to collect the heavier dirt particles that are
passed on to the filter system. The Main Drain Cover
should be IAPMO approved. Always secure the cover
with a screw.

7. Air Line - Usually a Flex type pipe. This line should be

Looped for equal pressure and better distribution of
the air.
8. Air Intake - Source for air for the spa jets. Can be connected to a Mechanical Blower for even better action.
Some spas have a separate air line for each jet for individual adjustments.

4. Deep Heat Return - By injecting heated water at the

lowest point possible, you get a better distribution of
the heat. This will make the heat up time more efficient
and less costly.

Pool & Spa Basic Training

11

S4247

1 SECTION

Hydraulics
PLUMBING AND SAFETY TIPS
Equivalent Length of Pipe

Pipe Sizing Per

Horsepower of Pump
(Self Priming @ 60)

Regular 2
90 Ell = 8.5

1
1"

25 Run
50 Run
Over 50
H.P. Suc. Ret. Suc. Ret. Suc. Ret.

1
1"

2
2"

2 -2 45
Ells - 5.4

Multiple Lines vs.

One Line
2 - 1 pipes can only
handle 1/2 the volume
of a 2 pipe.

Sweep 2
90 Ell = 3.6

1/2
3/4
1
1.5
2
3
5
7.5
10
15
20

1.5
2
2
2.5
2.5
3
4
6
6
6
8

1.5
1.5
2
2.5
2.5
3
3
6
6
6
8

1.5
2
2.5
3
3
3
4
6
6
8
8

1.5
2
2
2.5
3
3
4
6
6
6
8

2
2
2.5
3
3
4
4
6
6
8
8

1.5
2
2.5
3
3
3
4
6
6
8
8

Figure 15

Plumbing & Safety Tips:

1. Long Plumbing Runs - Always use the correct size
pump and compensate for extended pipe runs with
larger pipe sizes. Increasing pump H.P. to try to overcome long plumbing runs will make the system less efficient.

3. Suction Connections for Suction Side Cleaners - Side

wall connections for the Suction Side Cleaners should
have a solid connection or Self Closing Sealing Covers
should be used on designated Suction Cleaner connection, for safety. Friction connections may come loose
exposing a single suction source that could trap someone.

2. Dual Suctions - Dual suctions should be plumbed into

all pools and spas to prevent body or hair entrapment.
Use only IAPMO approved fittings for suction use.

4. Pressure Testing Systems - Make sure to evacuate all of

the air out of the system as the pressure builds. Trapped
air will compress and powerfully propel a filter lid that
has an improperly installed clamp. Never pressure test
with pressures above 25 psi.

Areas to also consider for dual suctions are any shallow

body of water, such as a spa, fountain, or a wading pool.
Dual suctions in shallow bodies of water will cut down
on the possibility of Eddies forming. Eddies can cause
damage to the pump and make the system less efficient.

5. If you cant LOOP your return fittings, tie into a center point with an equal number on each side of tee. Then
use a tee on the last return instead of a 90ell. Extend
each line about 6 to a foot past the tee and cap the
ends. The back pressure from the capped end will help
the last fittings in the line to work better. Its not as good
a looping, but it helps.

In commercial Skimmer applications it is a good idea to

use Dual Auxiliary Suction Fittings to cut down on the
velocity of the water when the Auxiliary line is open.

Pool & Spa Basic Training

12

S4247

1 SECTION

Hydraulics

Friction/Flow Chart For Schedule 40 Rigid PVC Pipe

Friction Loss of Water in Feet per 100 Feet Length of Pipe
Based on Williams & Hazen Formula Using Constant 150. Sizes of Standard Pipe in Inches.
3
4 Pipe
U.S.
Gals.
Vel.
Loss
per Ft. per
in
Min.
Sec.
Feet

1
2
3
4
5
6
8
10
15
20
25
30
35
40
45
50
60
70
80
90
100
125
150
175
200
225
250
275
300
325

.60
1.20
1.80
2.41
3.01
3.61
4.81
6.02
9.02
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....

.25
.90
1.92
3.28
5.8
7.0
11.8
17.9
37.8
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....

1 Pipe
114 Pipe
112 Pipe
2 Pipe
212 Pipe
Vel.
Loss
Vel.
Loss
Vel.
Loss
Vel.
Loss
Vel.
Loss
Ft. per
in
Ft. per
in
Ft. per
in
Ft. per
in
Ft. per
in
Sec.
Feet
Sec.
Feet
Sec.
Feet
Sec.
Feet
Sec.
Feet
.37
.74
1.11
1.48
1.86
2.33
2.97
3.71
5.57
7.42
9.28
11.14
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....

.07
.28
.60
1.02
1.52
2.15
3.6
5.5
11.7
19.9
30.0
42.0
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....

....
.43
.64
.86
1.07
1.29
1.72
2.15
3.22
4.29
5.36
6.43
7.51
8.58
9.65
10.72
....
....
....
....
....
....
....
....
....
....
....
....
....
....

....
.07
.16
.25
.39
.55
.97
1.46
3.07
4.2
7.9
11.1
14.7
18.9
23.5
28.5
....
....
....
....
....
....
....
....
....
....
....
....
....
....

....
....
.47
.63
.79
.95
1.25
1.58
2.36
3.15
3.94
4.73
5.52
6.30
7.09
7.88
9.46
11.03
....
....
....
....
....
....
....
....
....
....
....
....

....
....
.07
.12
.18
.25
.46
.69
1.45
2.47
3.8
5.2
7.0
8.9
11.1
13.5
18.9
25.1
....
....
....
....
....
....
....
....
....
....
....
....

.
.
.
.
.

...
...
...
...
...
.57
.76
.96
1.43
1.91
2.39
2.87
3.35
3.82
4.30
4.78
5.74
6.69
7.65
8.60
9.56
11.95
....
....
....
....
....
....
....
....

.
.
.
.
.

...
...
...
...
...
.07
.14
.21
.44
.74
1.11
1.55
2.06
2.63
3.28
4.0
5.6
7.4
9.5
11.8
14.4
21.8
....
....
....
....
....
....
....
....

.
.
.
.
.
.

...
...
...
...
...
...
.54
.67
1.01
1.34
1.67
2.01
2.35
2.64
3.01
3.35
4.02
4.69
5.35
6.03
6.70
8.38
10.05
....
....
....
....
....
....
....

.
.
.
.
.
.

...
...
...
...
...
...
.05
.09
.18
.30
.46
.65
.88
1.11
1.39
1.69
2.36
3.14
4.0
5.0
6.1
9.2
12.8
....
....
....
....
....
....
....

3 Pipe
Vel.
Loss
Ft. per
in
Sec.
Feet
.
.
.
.
.
.
.
.

...
...
...
...
...
...
...
...
.65
.87
1.08
1.30
1.52
1.73
1.95
2.17
2.60
3.04
3.47
3.91
4.34
5.42
6.51
7.59
8.68
9.76
10.85
....
....
....

.
.
.
.
.
.
.
.

...
...
...
...
...
...
...
...
.07
.12
.16
.23
.30
.39
.48
.58
.81
1.09
1.39
1.73
2.10
3.19
4.5
5.9
7.9
9.4
11.5
....
....
....

U.S.
Gals.
per
Min.
1
2
3
4
5
6
8
10
15
20
25
30
35
40
45
50
60
70
80
90
100
125
150
175
200
225
250
275
300
325

Normal safe operating selection; Suction piping; Discharge or pressure piping.

Note: Where long pipe runs are encountered, make selection in minimum head loss range.

Pool & Spa Basic Training

13

S4247

1 SECTION

Hydraulics
Head Loss Charts

Component

GPM

Main drain
1-1/2
Outlet

20
30
40
50
60

Main drain
2
Outlet

Heater

Head Loss (Ft.)

Component

GPM

Head Loss (Ft.)

0.5
1.0
1.5
2.0
2.5

Skimmer
1-1/2

20
30
40
50
60

1.0
2.0
3.0
4.0
5.5

40
50
60
70
80

1.0
1.5
2.0
3.0
4.0

Skimmer
2
Outlet

7.0 Average

20
30
40
50
60
70
80

0.5
1.0
2.0
3.0
4.0
5.0
6.0

Backwash Valves
1-1/2 Push/Pull

50
75

6.0
13.5

1-1/2 Multiport

50
75

5.0
10.0

2 Push/Pull

75
120

7.0
17.6

2 Multiport

75
100
120

3.5
6.0
8.5

Cartridge Filters

GPM (.75)

Head Loss (Ft.)

GPM (.375)

Head Loss (Ft.)

25 sq. ft.
35 sq. ft.
50 sq. ft.
70 sq. ft.
75 sq. ft.
100 sq. ft.
135 sq. ft.

18.75
26.25
37.50
52.50
56.25
75.00
101.25

1.1
2.0
4.3
7.5
8.0
17.5
28.0

9.38
13.13
18.75
26.25
28.13
37.50
50.63

7.0 Average
7.0 Average
7.0 Average
7.0 Average
7.0 Average
7.0 Average
7.0 Average

Sand Filters

GPM (20)

Head Loss (Ft.)

GPM (15)

Head Loss (Ft.)

14 1.05 sq. ft.

16 1.41 sq. ft.
18 1.80 sq. ft.
20 2.20 sq. ft.
22 2.66 sq. ft.
24 3.10 sq. ft.
30 4.90 sq. ft.
36 7.10 sq. ft.

21.0
28.2
36.0
44.0
53.2
63.0
98.0
142.0

10 (est.)
12 (est.)
14 (est.)
16
18 (est.)
25
17
24 (est.)

15.8
21.2
27.0
33.0
39.9
46.5
73.5
106.5

7.0 Average
7.0 Average
7.0 Average
7.0 Average
7.0 Average
7.0 Average
7.0 Average
7.0 Average

Modular Media Filters

GPM

Head Loss (Ft.)

GPM (.375)

Head Loss (Ft.)

100 sq. ft. Mini Mods.

125 sq. ft. Mini Mods.
150 sq. ft. Mini Mods.
175 sq. ft. Mini Mods.
200 sq. ft. Mini Mods.
300 sq. ft. Mini Mods.

75
94
113
131
150
150

6.0
9.0
12.0
16.0
20.0
20.0

38
47
56
66
75
113

1.5
2.5
3.5
4.5
6.0
13.0

Modular Media Filters

GPM (NSF)

Head Loss (Ft.)

300 sq. ft. - System3

400 sq. ft. - System3
450 sq. ft. - System3
500 sq. ft. - System3

100
115
124
130

3.0
4.6
5.5
6.3

Modular D.E. Filters

GPM (1.5)

Head Loss (Ft.)

GPM (NSF)

Head Loss (Ft.)

30 sq. ft.
36 sq. ft.
60 sq. ft.
72 sq. ft.

45
54
90
108

3.8
5.5
7.0
10.0

60
70
120
144

6.5
9.0
13.0
18.0

Pool & Spa Basic Training

14

S4247

1 SECTION

Hydraulics
Exit Loss Charts

3/8 (.375 ID)

GPM
1
2
3
4
5
6
7
8
9
10

3/4 (.75 ID)

Velocity
FPS

Exit Head
(Ft.)

2.91
5.81
8.71
11.62
14.53
17.43
20.34
23.24
26.15
29.05

.13
.53
1.18
2.10
3.28
4.72
6.43
8.40
10.63
13.12

1/2 (.50 ID)

GPM
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Velocity
FPS

Exit Head
(Ft.)

8.17
9.80
11.44
13.07
14.71
16.34
17.98
19.61
21.24
22.88
24.51
26.15
27.78
29.41
31.05
32.68

1.04
1.49
2.03
2.66
3.36
4.15
5.02
5.98
7.02
8.14
9.34
10.63
12.00
13.45
14.99
16.61

GPM
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Velocity
FPS
3.63
4.36
5.08
5.81
6.54
7.27
7.99
8.72
9.44
10.17
10.89
11.62
12.35
13.07
13.80
14.53
15.25
15.98
16.70
17.43
18.16
18.88
19.60
20.34
21.06
21.79

7/8 (.875 ID)

Exit Head
(Ft.)
.21
.30
.41
.53
.67
.82
.99
1.18
1.39
1.61
1.85
2.10
2.37
2.66
2.96
3.28
3.62
3.97
4.34
4.72
5.13
5.54
5.98
6.43
6.90
7.38

GPM
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Velocity
FPS
5.34
5.87
6.40
6.94
7.47
8.00
8.54
9.07
9.60
10.14
10.67
11.21
11.74
12.27
12.81
13.34
13.87
14.41
14.94
15.47
16.01
16.54
17.08
17.61
18.14
18.68
19.21
19.74
20.28
20.81
21.34

Exit Head
(Ft.)
.44
.54
.64
.75
.87
1.00
1.13
1.28
1.43
1.60
1.77
1.95
2.14
2.34
2.55
2.77
2.99
3.23
3.47
3.72
3.98
4.25
4.53
4.82
5.11
5.42
5.74
6.06
6.39
6.73
7.08

1.0 (1.0 ID)

GPM

Velocity
FPS

15
16
17
18
19
20
21
22
23
24
25
26

6.13
6.54
6.95
7.35
7.76
8.17
8.58
8.99
9.40
9.81
10.21
10.62

Pool & Spa Basic Training

Exit Head
(Ft.)
.58
.66
.75
.84
.94
1.04
1.14
1.26
1.37
1.50
1.62
1.75

GPM

Velocity
FPS

27
28
29
30
31
32
33
34
35
36
37
38

11.03
11.44
11.85
12.26
12.66
13.07
13.48
13.89
14.30
14.71
15.12
15.52

15

Exit Head
(Ft.)
1.89
2.03
2.18
2.34
2.49
2.66
2.83
3.00
3.18
3.36
3.55
3.75

GPM

Velocity
FPS

39
40
41
42
43
44
45
46
47
48
49
50

15.93
16.34
16.75
17.16
17.57
17.98
18.38
18.79
19.20
19.61
20.02
20.43

Exit Head
(Ft.)
3.95
4.15
4.36
4.58
4.80
5.02
5.25
5.49
5.73
5.98
6.23
6.49

S4247

1 SECTION

Hydraulics

Friction Loss Created by Pipe Fittings

The friction created by fittings is expressed as the equivalent length of straight pipe. For example, the loss
through a 1 regular 90 Ell is equal to that created by 5.2 feet of straight 1 steel pipe. Determine total friction
by combining fitting loss with pipe loss.
Equivalent Length of Straight Pipe for Various [Link] Flow Only.
Pipe Size
Fittings
Screwed
Regular
90 Ell

Steel

2.3

3.1

3.6

1 4

1 2

212

4.4

5.2

6.6

7.4

8.5

9.3

11.0

13.0

9.0

11.0
5.9

C.I.
Flanged

Steel

.92

1.2

1.6

2.1

2.4

3.1

3.6

4.4
3.6

4.8

2.2

2.3

2.7

3.2

3.4

3.6

3.6

4.0

4.6

3.3

3.7
4.2

C.I.
Long

Screwed

Radius
90 Ell

Steel

1.5

2.0

C.I.
Flanged

Steel

1.1

1.3

1.6

2.0

2.3

2.7

2.9

3.4
2.8

3.4

.71

.92

1.3

1.7

2.1

2.7

3.2

4.0

5.5

3.3

4.5
3.5

C.I.
Screwed
Regular
45 Ell

Steel

.34

.52

C.I.
Flanged

Steel

.45

.59

.81

1.1

1.3

1.7

2.0

2.6
2.1

2.9

1.7

2.4

3.2

4.6

5.6

7.7

9.3

12.0

17.0

9.9

14.0

2.2

2.8

C.I.
Screwed
Tee-Line
Flow

Steel

.79

1.2

C.I.
Flanged

Steel

1.9

Screwed

Branch
Flow

Steel

2.4

3.5

Steel

Screwed
180
Return
Bend

2.3

3.1

Steel

Flanged

C.I.

Long. Rad. Steel

Flanged

7.2

9.8

12.0 15.0

5.7

7.0

8.0

9.0

4.7

5.7

6.8

7.8

5.6

7.7

9.0

11.0

4.5

6.3

8.1

9.7

3.8

4.7

5.2

6.0

2.1

3.9

4.6

5.2

1.5

1.8

1.9

2.2

4.2

5.3

6.6

8.7

9.9

12.0 13.0 17.0

21.0

14.0

17.0
12.0 15.0 18.0 24.0 30.0 34.0

2.0

2.6

3.3

4.4

5.2

6.6

7.5

9.4
7.7

10.0

3.6

4.4

5.2

6.6

7.4

8.5

9.3

11.0

13.0

9.0

11.0
5.9

.92

1.2

1.6

2.1

2.4

3.1

3.6

4.4
3.6

4.8

1.1

1.3

1.6

2.0

2.3

2.7

2.9

3.4

4.2

2.8

3.4

C.I.

Pool & Spa Basic Training

12.0 14.0 17.0

16

3.3

12

1.3

C.I.
Regular

8.9

4.5

10

1.0

C.I.
Steel

7.3

5.0

.82

C.I.
Flanged

.69

C.I.
Tee-

15.0 20.0 25.0 30.0

7.3

8.9

12.0 14.0 17.0

7.2

9.8

12.0 15.0

5.0

5.7

7.0

8.0

9.0

4.7

5.7

6.8

7.8

S4247

1 SECTION

Hydraulics

Friction Loss Created by Pipe Fittings

The friction created by fittings is expressed as the equivalent length of straight pipe. For example, the loss
through a 1 regular 90 Ell is equal to that created by 5.2 feet of straight 1 steel pipe. Determine total friction
by combining fitting loss with pipe loss.
Equivalent Length of Straight Pipe for Various [Link] Flow Only.
Pipe Size
Fittings
Screwed
Globe

Steel

21.0

22.0

22.0

1 4

1 2

24.0

29.0

37.0

42.0

212

54.0 62.0

C.I.

Valve

Flanged

65.0

Steel

38.0

40.0

45.0

54.0

59.0

70.0 77.0

.56

.67

.84

1.1

1.2

1.5

C.I.
Screwed
Gate

Steel

.32

.45

Flanged

Steel

Screwed
Angle

12.8

15.0

15.0

15.0

17.0

18.0

18.0

2.5

1.6

2.0

2.7

2.8

2.9

2.3

2.4

18.0 18.0

18.0

18.0

15.0

15.0
38.0

C.I.

Valve

Flanged

Steel

15.0

15.0

17.0

18.0

18.0

21.0 22.0

28.0
23.0

31.0

8.0

8.8

11.0

13.0

15.0

19.0 22.0

27.0

38.0

22.0

31.0

27.0

38.0

22.0

31.0

.53

.65

.44

.52
.95

C.I.
Swing

Screwed

Check

Steel

7.2

7.3

C.I.

Valve

Flanged

Steel

3.8

5.3

7.2

10.0

12.0

17.0 21.0

.21

.24

.29

.36

.39

.45

C.I.
Coupling

Screwed

or Union

Steel

.14

.18

.47

C.I.
Bell Mouth Steel
Inlet

C.I.

Square

Steel

Mouth Inlet

C.I.

Re-Entrapment

Steel

Pipe

C.I.

Sudden
Enlargement

Pool & Spa Basic Training

.04

.07

.10

.13

.18

.26

.31

.43

.52

.67
.55

.77

.44

.68

.96

1.3

1.8

2.6

3.1

4.3

5.2

6.7

9.5

5.5

7.7

13.0

19.0

11.0

15.0

.88

1.4

1.9

2.6

3.6

5.1

8.5

10.0

10

12

150.0 210.0 270.0 330.0

3.1

3.2

3.2

3.2

3.2

2.6

2.7

2.8

.29

63.0

90.0 120.0 140.0

52.0

74.0

63.0

90.0 120.0 140.0

52.0

74.0

98.0 120.0

1.3

1.6

2.3

2.9

1.3

1.9

2.4

3.0

13.0

16.0

23.0

29.0

35.0

13.0

19.0

24.0

30.0

32.0

45.0

58.0

70.0

26.0

37.0

49.0

61.0

50.0

50.0

25.0

98.0 120.0

3.5

(V1 - V2)
V1
Feet of Fluid; if V2 = 0 b =
Feet of Fluid
2g
2g
2

b=

6.2

94.0 120.0 150.0 190.0 260.0 310.0 390.0

99.0

2.6

86.0

1.9

C.I.
Steel

77.0
1.7

C.I.

Valve

79.0 110.0

17

S4247

1 SECTION

Hydraulics

Calculating Turn Over Rates

Pipe Sizing Chart - Schedule 40 PVC

New Pool or Spa Divide the Pool or Spa gallons by the

number of minutes the filter system is designed to operate
in a single day.

Example:
A 6 hour turn over is equal to 360 minutes.
A 8 hour turn over is equal to 480 minutes.
A 30 minute turn over is the divider.
50,000 gallon pool with a 6 hour turn over rate
50,000 / 360 = 139 gpm
25,000 gallon pool with an 8 hour turn over rate

Pipe Size

7 fps

8 fps

10 fps

3/4
1
1-1/4
1-1/2
2
2-1/2
3
4
6

12 gpm
18 gpm
33 gpm
44 gpm
75 gpm
110 gpm
160 gpm
275 gpm
540 gpm

14 gpm
22 gpm
37 gpm
52 gpm
85 gpm
118 gpm
185 gpm
310 gpm
725 gpm

17 gpm
28 gpm
47 gpm
62 gpm
110 gpm
125 gpm
235 gpm
395 gpm
850 gpm

25,000 / 480 = 52 gpm

Calculating Head Loss for

an Existing Pool or Spa

1,000 gallon spa with a 30 minute turn over rate

1,000 / 30 = 33 gpm

Pressure Gauge x 2.31 = Head Loss plus

Vacuum Gauge x 1.13 = Head Loss equals

Existing Pool or Spa Determine the maximum flow rate

from the existing pipe sizes (See Pipe Sizing Chart in the
next column).

Total System Loss

Example:

Example:

Pressure Gauge Reading = 20 lbs.

Vacuum Gauge Reading = 10

1-1/2 pipe = 44 gpm, 2 = 75 gpm

25,000 gallon pool with 1-1/2 pipe
25,000 / 1-1/2 Flow Rate x 60 = Turn Over Rate

20 lbs. x 2.31 = 46 foot of head

10 x 1.13 = 11 foot of head

25,000 / 44 x 60 = 9.5 hours

Total System Loss = 57 foot of head

Filter Sizing

Modular Media Sizing

Pool or Spa Divide the pump gallons per minute by the

recommended flow rate for the filter.

Size filters based on maximum design flow

Example:
Example:

S8M150 - 450 sq. ft. = 125 gpm

D.E. = 1.5 gpm per sq. ft. of filter area.

500 gpm / 125 = 4 filters

80 gpm / 1.5 = 53

500 gpm / 1800 sq. ft. = .28 flow rate

Sand = 15 gpm per sq. ft. of filter area.

74 gpm / 15 = 4.9

Calculating Filter Flow Rates

Cartridge = .375 gpm per sq. ft. of filter area.

Divide the gallons per minute by the sq. footage

of the filter.

50 gpm / .375 = 133

Examples:
125 gpm w/83 DE
125 gpm / 83 = 1.5 gpm per sq. ft. of filter area
50 gpm w/ 3.4 Sand
50 gpm / 3.4 = 15 gpm per sq. ft. of filter area

Pool & Spa Basic Training

18

S4247

2 SECTION

Pumps
A

CENTRIFUGAL FORCE
WATER FLOW

;;;
;;;
;;;

IMPELLER EYE

Figure 1
DISCHARGE

ATMOSPHERIC
PRESSURE

IMPELLER

Figure 2

FLOW UNDER
PRESSURE

14.7 LBS.

Figure 3

ROTATION

Swimming Pool and Spa

Pumps

Pumps used for swimming pools, spas, and water features

are classified as centrifugal pumps. A centrifugal pump
derives its name from the principal known as centrifugal
force. A centrifugal pump, in its most simplified form, consists of two components. One component is stationary and
serves as the housing. It is known as a volute. Inside the
volute is the rotating component known as the impeller. If
the motor is the work horse of the pump, the impeller is
the cartwheel that moves the water along.

Figure 4

vanes generates centrifugal force, propelling the water at a

greater velocity (Figure 3)
This action imparts kinetic or velocity energy into the
water. As the water is propelled to the outer edge of the
impeller, there is a reduction in pressure at the eye of the
impeller, creating a partial vacuum. (See Figure 4)
As we learned in the Hydraulic Section, atmospheric pressure is necessary for the pump to perform. The combination of the atmospheric pressure on the surface of the water
and the vacuum at the eye of the impeller, causes the water
to flow in the suction pipe to the pump. (Figure 4)

The principal of operation can be demonstrated by

whirling a bucket full of water. In Figure 1, as the bucket is
rotated, the water is held in the bucket by centrifugal force.
(A) If we were to punch a hole in the bottom of the bucket,
the water would be forced out, again by centrifugal force.
(B) If we were to speed up the rotation of the bucket, the
water would exit with greater pressure. (C)
This same principal is performed by the impeller of the
pump. As water enters the center or eye of the impeller,
it is forced through the impeller vanes toward the outside
edge (Figure 2). The spinning, impelling action of these
Pool & Spa Basic Training

19

S4247

2 SECTION

Pumps
CLOSED IMPELLER

SEMI-OPEN
IMPELLER

EYE
GPM
GPM

IMPELLER

HEADPRODUCED
PRODUCED
HEAD

60
60

60
60

45
45

45
45

30
30

30
30

15
15

15
15

Flow

SET
SCREWS

00

3450
3450
RPM

RPM

1725
1725
RPM

RPM

00

3450
3450
RPM
RPM

1725
1725
RPM
RPM

Figure 5

CLEARANCE

The amount of pressure energy imparted into the water by

the impeller is determined in part by the size and design of
the impeller. Figure 5 shows there are two types of
impellers used in swimming pool, spa, and the water feature pumps: semi-open impeller and closed impellers.

Example:
The capacity of an impeller is 60 GPM at a rotating
speed of 3450 RPM. Its capacity would drop to 30
GPM if the speed of rotation was reduced to 1725
RPM. (Lower right Figure 5)

The semi-open impeller has the vanes exposed on the front

or receiving side. The back side of the vanes are closed by a
shroud. (Top left of Figure 5)

The head or pressure produced by an impeller varies to the

square of the change in its speed of rotation.

The inner surface of the pump volute serves as the front

shroud of the impeller. The efficiency of this design is
determined by the clearance between the front of the
impeller and the face of the volute surface. (Lower left of
Figure 5)

Example:
If the speed of rotation of an impeller is reduced
from 3450 RPM to 1725 RPM, or 50%, the head
produced by the impeller would change to the
square of that percentage, or a 75% reduction.

The clearance for a semi-open impeller can usually be

adjusted by the set screws on the motor shaft or by the use
of shims. This is considered a non-clogging impeller.

If the head produced by an impeller is 60 ft., at a

speed of 3450 RPM, the head would drop to 15 ft.,
if the rotating speed was reduced to 1725 RPM.

A closed impeller is designed to have two shrouds that

completely enclose the area of the impeller vane (Upper
left of Figure 5) These are called the front and rear shroud.
The impeller design requires no adjustment, since the
space between the two shrouds is fixed.

Note: The charts in Figure 5, Lower Right, are the basic

principals of a 2 speed pump.

The performance of an impeller is affected by another factor. This factor is the speed of its rotation. The speed at
which the impeller rotates affects its head and capacity
characteristics. The GPM of pump impeller varies in direct
proportion to the change in its speed of rotation.

Pool & Spa Basic Training

20

S4247

2 SECTION

Pumps
WATER
FROM
POOL

Figure 6A

2978 0697

HAIR &
LINT TRAP

WATER
FROM
FILTER

Figure 6B

WATER
FROM
MAIN
PUMP

IMPELLER
VELOCITY
ENERGY

TRAP
BASKET
COLLECTS
DEBRIS

IMPELLER
DIFFUSER

Figure 6C

PRESSURE
ENERGY

Figure 6D

A diffuser consists of a number of vanes which are set

around the impeller. As the water is discharged from the
impeller, its velocity is very high. As it flows through the
diffuser, the vanes help to reduce the speed of flow. As a
result, the priming capabilities and the hydraulic efficiencies of a pump are improved.

Water flowing from a swimming pool, spa, or water feature

usually will enter the pump through the hair and lint trap.
(Figure 6 - A)
Inside the hair and lint trap is a strainer called the hair lint
basket. It is designed to collect trash and debris that could
clog the impeller. (Figure 6 - C)

Other types of centrifugal pumps are designed to permit

the volute casing to fully encompass the impeller and flare
out into the discharge opening. This allows a gradual
reduction in the velocity of the water as it moves from the
impeller to the discharge port.

Pumps that are installed with the filter on the suction side
usually do not need to have a hair lint trap. The filter acts
as the trap, catching the trash and debris. This type of
installation is called a Vacuum Systems and is usually
found on portable spas, and some commercial pools.
However, it is not uncommon to find a pump installed
without the hair lint trap when used as a booster pump.
When used in this manner, its source of water usually
comes from another pump. (Figure 6 - B)
Water flows from the hair and lint trap to the impeller. The
impeller discharges it directly in a vaned diffuser or into a
volute, depending on the design of the pump.
(Figure 6 - D)

Pool & Spa Basic Training

21

S4247

2 SECTION

Pumps
1 lb. = 2.31 ft. of head

Pump B Looses 45 GPM or 69%

Pump A Looses 10 GPM or 15%

120
110
100

T 80
D 60
H
40
20
10

A
10

20

30

40 50

60 70

80

B
90 100 110 120 130 140 150

GPM
Both pumps are rated at 60 GPM at 60 Ft. of Head

Note: When comparing diffuser pumps and volute pumps,

remember that each pump was designed with different
goals. The diffuser pump can generally prime faster. The
volute pump, on the other hand, works well where smaller
pump bodies are needed such as portable spas and jetted
bathtubs. The volute pump, designed with a semi-open
impeller can handle bodies of water that have debris problems, such as pine needles, much better.

Figure 7

Performance curve A in Figure 7 represents a typical high

head pump. At a total system head of 60 ft., the capacity of
this pump is 75 GPM. At a total system head loss of 83 ft.,
which represents a filter pressure increase of 10 psi, the
capacity of this pump declines to only 65 GPM, or a loss of
approximately 15% flow.
It is clear that if you have a choice you would use a high
head pump on your filtration systems. If a medium head
pump is used for a filtration system, it should be cleaned at
a 5 lb. increase on the pressure gauge. The best application
for a medium head is for systems that have a constant
pressure. Spa jets, water falls, fountains, etc. These applications are generally sized at approximately 40 ft. of head.
Pump B in Figure 7 will deliver over 90 GPM vs. Pump A,
which will give you a little less than 80 GPM.

Most centrifugal pumps used on filtration systems are classified as high head pumps. However, the real test of a centrifugal pump, is its head vs. capacity performance. Most
filter manufactures recommend that the pressure in the filter be allowed to rise as much as ten pounds per square
inch (psi) above the initial start-up pressure before the filter
is cleaned. This rise in pressure affects an increase in the
total system head which reduces the GPM of a centrifugal
pump. A pressure rise in the filter of ten pounds psi translates to an increase in total head of 23 ft.
1 lb. psi = 2.31 ft. of head
This rise in the resistance of the system affects the pumps
performance.
Performance curve B in Figure 7 represents a typical 1 HP
medium head pump. Assume the filter media is clean. The
total system head is 60 ft. The capacity of pump B at 60 ft.
of head is 75 GPM. An increase of 10 psi filter pressure
would raise the total system head to 83 ft. This increase of
23 ft. of head causes the capacity of the pump to be
reduced to 30 GPM, or a loss of approximately 60% flow.
Pool & Spa Basic Training

22

S4247

2 SECTION

Pumps

1
2

10
3

11

12
4
1898 0795

13

7
8
18

14

17
16

15

Figure 8
1. Match the numbers with the correct definition for each
of the component parts for the above pump.

2. Answer the following questions Yes or No.

A. This pump is considered a Closed-Face Impeller
Pump.

____________ Hair and Lint Basket

Yes

____________ Impeller
____________ Volute and Trap Body

No

B. The impeller used on this pump is considered a

Non-Clogging Impeller.

____________ Trap Handles

Yes

____________ Motor
____________ Trap Cover

No

C. Can an adjustment be made to the impeller setting?

____________ Stub Shaft Assembly

Yes

____________ Adapter Bracket and Seal Plate

____________ Trap O Ring

No

D. When used as a self priming pump can you put a 90

elbow directly on the discharge of the pump?

____________ Drain Plugs

Yes

____________ Ground Lug

No

____________ Shaft Seal

____________ Gasket
____________ Set Screws

Pool & Spa Basic Training

23

S4247

2 SECTION

Pumps
1
2 3
4

5
6
9A

21
9

7
8
10
18

20

19

11

15

14

17

13

12

1831 0695

16

Figure 9
1. Match the numbers with the correct definition for each
of the component parts.

2. Answer the following questions Yes or No.

A. The impeller for this kind of pump can be adjusted.

Yes

__________ Clamp
__________ Seal Plate

No

B. This pump is designed with shaft seal heat protection.

__________ Diffuser O Ring

Yes

__________ Motor
__________ Volute or Tank Body

No

C. The pump, as shown, is a self-priming pump.

Yes

__________ Ground Lug

__________ Impeller

No

__________ Water Slinger

__________ Shaft Seal
__________ Base
__________ Drain Plug
__________ Heat Sink
__________ Motor Pad
__________ Diffuser
__________ Pump O Ring

Pool & Spa Basic Training

24

S4247

2 SECTION
T
D
H

Pumps

160
140
120
100
80
60
40
20
0

T
D
H

160
140
120
100
80
60
40
20
0
10 20 30 40 50 60 70 80 90 100 110 120

10 20 30 40 50 60 70 80 90 100 110 120

GPM

GPM

Figure 10A

T
D
H

160
140
120
100
80
60
40
20
0

Figure 10B

T
D
H

10 20 30 40 50 60 70 80 90 100 110 120

GPM

Figure 10C

160
140
120
100
80
60
40
20
0
10 20 30 40 50 60 70 80 90 100 110 120

GPM

Figure 10D

Pump Curves - Sizing Pumps

The four pumps in Figure 10 are typical high and medium
head pumps. Answer the following questions based on
these pump curves:

4. If the filter is clean and the pressure gauge is reading 15

lbs., and the vacuum gauge is reading 13 inches of mercury, how many GPM is pump C delivering?

1. Starting at 50 ft.. of head, which pump looses the most

flow during the 10 lb. rise in filter pressure?
A

5. If you had 7 spa jets, each delivering 15 GPM, at a head

loss of 40 ft. Which pump would you select?

2. Starting at 50 ft. of head, which pump looses the least

flow during the 10 lb. rise in filter pressure?
A

6. On a filtration system, you need 75 GPM. Which pump

would you choose?

3. At 60 ft. of head, which pump delivers the most GPM?

A

Pool & Spa Basic Training

25

S4247

2 SECTION

Pumps
PLUMBING AND SAFETY TIPS

AIR IN
SYSTEM

FITTING TOO
CLOSE TO
SUCTION OF
PUMP

ALLOW 4 TIMES THE PIPE

DIAMETER BETWEEN THE
SUCTION PORT AND THE
FIRST FITTING

AIR LOCK

KEEP SUCTION PIPES

BELOW THE SUCTION
PORT OF THE PUMP

Figure 11

Figure 12

Plumbing and Safety Tips:

5. Some motors use the motor case to dissipate the heat
from the inside of the motor. A pump that is improperly
sized, or installed with the incorrect wire size, or not
ventilated properly, and installed in direct sunlight can
cause a burn if the hand is rested on the motor. Rule of
Thumb: If you can leave your hand on the motor for a
few seconds, its probably O.K. If you cant leave your
hand on it for any period of time, you may have one of
the above problems. However, placing your hand on the
motor to determine if it is too hot is not a judgement of
whether or not the motor is operating properly. It is an
indication that something may be wrong.

1. Dont rely on the time clock being off when installing a

new or replacement pump. Time clock may kick on and
electrocute you.
2. When installing a pump more than 3 feet above water
level and more than 10 feet from the waters edge, try to
trench below the water level to a position directly below
the suction of the pump. The vertical lift is still just 3
feet. Most self priming pumps should not have a difficult time priming at that lift.
3. Locating a pump in a low area can be dangerous. Make
sure that it is in an area that has good drainage.
Standing water can cause an electrical shock.
4. A loud pump does not always indicate a bearing problem. Restrict the discharge of the pump and listen to see
if the pump quiets down. If it does, its cavitation, not a
bearing. Also, pushing down on the back of the motor,
and/or lifting upon the back of the motor with a slight
pressure may quiet the pump. If the noise diminishes,
there is a possibility that the pump is hanging on the
plumbing. Sometimes the pad may settle causing a level
installation to be out of plumb. With one end of the
pump rigidly attached to the plumbing and the other
end a heavy motor, the motor shaft can can be binding
on the front bearing and/or seal.

Pool & Spa Basic Training

26

S4247

3 SECTION

Motors
Rotor

A.C. Power Supply

Stator

Figure 1

Swimming Pool and Spa

Motors
Motors used with swimming pool, spa, and water feature
pumps are designed to cover a wide range of applications,
from fractional horsepowers to 50 HP or more. Some
applications call for multiple speed or even variable
speeds. The applications often require the motor to operate
continuously in the direct sunlight at air temperatures of
120 F or higher, and in all types of weather.

There are several different types of motor designs used for

pool, spa, and water feature pumps, listed in ascending
cost and efficiency:
1. Split Phase - Usually used in smaller circulation pumps
which have very low starting torque requirements.
Generally used in spa, jetted tub, above ground pools
and small water feature pumps. Some are used on the
lower end of in-ground pool and jet pumps. This design
has a start winding and start switch, but no capacitors.

The motor is one of the most important components of a

centrifugal pump, yet, it is probably one of the most
abused. Improper wiring, ventilation, and environmental
factors are just a few enemies of good motor operations.

2. Capacitor Start - (Figure 2) - The most common type of

single phase pump motor. A starting capacitor is in the
start winding circuit to add faster, stronger starting
torque with the high current surge. (150 - 175% of the
full load).

PRINCIPLES OF OPERATION
The electric motor is a device for converting electrical energy into mechanical energy. The motor, in general, has a set
of insulated wire windings: starting and running. Located
on the stator, they are connected to an external power
source. The rotor consists of an iron bar and continuous
wire loops. The magnetic field is established when currents
flow in these conductors in a narrow air gap between the
stator and the rotor. The current flow in the windings produces a rotating field that interacts with the rotor, causing
the rotor to move, thus converting electrical energy into
mechanical energy (Fig.l).

Pool & Spa Basic Training

27

S4247

3 SECTION
B

K C

Motors

D N

J G
Figure 2

2. Capacitor Start. (Cont.) - This gives the motor a starting

current lower than the split phase equivalent. The operation is similar to the split phase in that there is a start
switch to take the start winding and capacitor out of the
circuit once the motor reaches 2/3 to 3/4 of full speed
(Figure 2).

3. Capacitor Start/Capacitor Run (CSR)

These are known as energy-efficient motors. They
have a starting capacitor as in Figure 2 above but have
an additional capacitor The running capacitor helps to
smooth out the AC current flow and minimizes internal
heat buildup, which is lost energy and higher energy
costs. The running capacitor is combined with more
metal in the rotor and stator, CSR motors more effectively convert electrical energy to mechanical energy resulting in less loss to heat. This is why CSR motors can
operate in higher ambient temperatures with less thermal overloading problems and deliver a longer service
life in the windings of the stator, bearings, etc.

BASIC COMPONENT PARTS (Figure 2)

(a)

Main Frame (stator and coils)

(b) Rotor & Shaft Assembly

(c)

Front and Rear Bearings

(d) Fan
(e)

End Frames

(f)

Capacitors (where used)

4. 3 PHASE
This is the simplest, most efficient design. Its use is limited to commercial and industrial applications since
three phase power is not available in residential areas.
There are 6 motor lead wires and no operating capacitors. They operate much more efficiently at lower amps
and watts. However, they require costly external relays
or magnetic contactors to be installed in the wiring to
the motor.

(g) Terminal Board

(h) Thermal Overload Protector
(i)

Start Switch or Centrifugal Contactor

(j ) Governor
(k) Ground Terminal
(l)

End Cover

(m) Stator
(n) Stator Windings or C

Pool & Spa Basic Training

28

S4247

3 SECTION
BLACK
TRACER

Motors
BLACK
TRACER

L2

BLACK

L2
B

115V
LINE

L1

BLACK

220V
LINE

HIGH SERVICE
LOW SERVICE
FACTOR MOTOR FACTOR MOTOR

L1

U
SP C
B
SER. A89D E
MOTOR MOD. C48J2DB11 D
HP 1/2 G
VOLTS 115/230 F
8.4/4.2 H
I PH 1 CODE L T
RPM
3450 J
FR 56C K
HZ 60 L
AMPS 10.8/5.4 M
SF 1.9 N
B O AMB 50 C P
Q CONT.
TYPE C R A. O. SMITH CORP. S
LL

THERMALLY
PROTECTED

MET38ABN

MAX
LOAD

INSUL.
CLASS

TIME
RATING

616231

CAUTION

HP

SF

MAX.
HP

HP

SF

MAX.
HP

1/3

1.95

.65

1/2

1.30

.65

1/2

1.90

.95

3/4

1.27

.95

3/4

1.65

1.25

1.25

1.25

1.65

1.65

1.5

1.10

1.65

1.5

1.47

2.20

1.10

2.20

1.30

2.60

2.5

1.04

2.60

DO NOT OPERATE MOTOR WITHOUT CONNECTING GROUND WIRE TO

GREEN GROUNDING SCREW. DO NOT CONNECT TO A POWER
SOURCE OTHER THAN THAT SPECIFIED ON NAME PLATE. COVER
MUST BE REPLACED. FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN RESULT IN SERIOUS OR FATAL INJURY.
616230-2

Figure 3

Figure 4

Motor Nameplate
C The Canadian Standard Association (CSA) emblem
indicates that the motor is constructed in accordance
with the standards established by CSA and therefore is
satisfactory for installation in Canada. UL is the
emblem for Underwriters Laboratory. UR is the UL
recognized component of a system, such as a component in a spa pac.

Everything that you need to know about swimming pool,

spa, and water feature pumps is on the nameplate. (See
Figure 3). It is important that the pump specifier, dealer
and installer understand each marking on a conventional
pump motor nameplate for safety, proper installation and
servicing.
A Most pump motors are dual voltage and therefore can
be run on either 115 or 220 volts. If 230 volts where
applied to the motor when it is connected for 115 volts,
chances are high that the motor will burn out immediately. If 115 volts are applied to the motor when it is
connected to 220 volts, chances are the motor may run
or not run, but will not come up to speed.

D The motor model number identifies the motor type

parts that need to be obtained and determines the
exact electrical characteristics, if there is a question on
electrical performance. It is vital to provide this number whenever seeking a replacement motor or parts for
a motor
E Serial number - This code tells the month, year, and
day the motor was manufactured.

B Thermal Overload Protector. This device is sensitive to

heat and current flow. It acts as a breaker. This protector automatically shuts off the motor if the internal
temperature becomes too hot.
The motor will restart automatically when the motor
cools. The motor will continue to shut itself off until
the problem is corrected or until the protector fails.
Always replace the Thermal Protector with the same
number stamped on the block. If there is a break in the
current flow the motor will not start or restart until the
problem is corrected.

Pool & Spa Basic Training

29

S4247

3 SECTION
BLACK
TRACER

Motors
BLACK
TRACER

L2

BLACK

L2
B

115V
LINE

L1

BLACK

220V
LINE

HIGH SERVICE
LOW SERVICE
FACTOR MOTOR FACTOR MOTOR

L1

U
SP C
B
C48J2DB11
MOTOR MOD.
D SER. A89D E
HP 1/2 G
VOLTS 115/230 F
8.4/4.2 H
I PH 1 CODE L T
RPM
3450 J
FR 56C K
HZ 60 L
AMPS 10.8/5.4 M
SF 1.9 N
B O AMB 50 C P
Q CONT.
TYPE C R A. O. SMITH CORP. S
LL

THERMALLY
PROTECTED

MET38ABN

MAX
LOAD

INSUL.
CLASS

TIME
RATING

616231

CAUTION

HP

SF

MAX.
HP

HP

SF

MAX.
HP

1/3

1.95

.65

1/2

1.30

.65

1/2

1.90

.95

3/4

1.27

.95

3/4

1.65

1.25

1.25

1.25

1.65

1.65

1.5

1.10

1.65

1.5

1.47

2.20

1.10

2.20

1.30

2.60

2.5

1.04

2.60

DO NOT OPERATE MOTOR WITHOUT CONNECTING GROUND WIRE TO

GREEN GROUNDING SCREW. DO NOT CONNECT TO A POWER
SOURCE OTHER THAN THAT SPECIFIED ON NAME PLATE. COVER
MUST BE REPLACED. FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN RESULT IN SERIOUS OR FATAL INJURY.
616230-2

Figure 3

F Voltage rating for the motor - Either 115 or 230 volts.

Note the wiring terminal diagram for correct connections for either voltage.

Figure 4

load amperage is IMPORTANT. It is the value to

which all circuit breakers, fuses, heaters and wire must
be sized. Never size any of these components to an
amperage value that is less than the maximum load
amperage drawn by the motor as designated on the
data plate. Any amperage measurement drawn by the
motor above its max. load amps would be considered
an overload, which can have a variety of causes or
effects.

G Nominal or Advertised HP of the motor.

H The amps listed are for nominal HP and should not be
used for sizing the wire or setting the circuit breakers.
(See M, Max Load Amps).
I Almost all residential installations are single phase
(normal house current). Commercial pumps are often
3-phase, with six wire leads coming out of the motor.
J 3450 RPM is the standard speed for pump motors.
1750 RPM is used in larger commercial pumps and in
2 speed pumps for the slower speed and energy conservation.

N The service factor of an alternating current electric

motor, as defined by (NEMA) National Electrical
Manufactures Association, is a multiplier which, when
applied to the name plate HP rating, indicates the
maximum safe operating HP at which the motor can
be loaded for continuous duty operation.

K Motor frame size - This is important when a motor is

being replaced. For example, a 48J frame is of a different dimension than a 56J. Frame size is determined by
measuring the distance from the center of the motor
shaft to the base of the motor mount, times 16.
i.e. 3 x 16 = a 48 Frame.

High and Low Service Factor (Figure 4) - An electric motor

may be rated as either a 1 or a 1-1/2 HP. However, when
the motor is rated as a 1-1/2 HP, its service factor would
change from 1.65 to 1.1. Both motors have the same full
load HP capacity, and the maximum load amperage for
both motors would be the same.

L Hertz (HZ) is the term for cycle frequency of alternating current (AC). 60HZ (cycles) is the only frequency
used in the United States. 50HZ is found in many
other countries.
M Maximum load amps designates the maximum
amount of amperage drawn by a motor when it is
operating at its full load horsepower rating. Maximum
Pool & Spa Basic Training

30

S4247

3 SECTION
BLACK
TRACER

Motors
BLACK
TRACER

L2

BLACK

L2
B

115V
LINE

L1

BLACK

220V
LINE

L1

LL

SP C
B
SER. A89D E
MOTOR MOD. C48J2DB11 D
HP 1/2 G
VOLTS 115/230 F
8.4/4.2 H
I PH 1 CODE L T
RPM
3450 J
FR 56C K
HZ 60 L
AMPS 10.8/5.4 M
SF 1.9 N
B O AMB 50 C P
Q CONT.
TYPE C R A. O. SMITH CORP. S
THERMALLY
PROTECTED

MET38ABN

White lead
w/black
tracer to
terminal "A"

MAX
LOAD

INSUL.
CLASS

Black lead
to terminal
L1

L1

TIME
RATING

616231

CAUTION

DO NOT OPERATE MOTOR WITHOUT CONNECTING GROUND WIRE TO

GREEN GROUNDING SCREW. DO NOT CONNECT TO A POWER
SOURCE OTHER THAN THAT SPECIFIED ON NAME PLATE. COVER
MUST BE REPLACED. FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN RESULT IN SERIOUS OR FATAL INJURY.
616230-2

Figure 3

O This is the insulation class as designated by NEMA. It

designates the temperature it can withstand with out
being damaged.

Figure 5

Exercise:
Answer the next 3 questions using the sample Data
Plate in Figure 3.

P This is the maximum ambient temperature of the surroundings that the motor should be subjected to.
40 C = 104 F
50 C = 124 F

1. What size circuit breaker would you use if this

pump was connected to 115 volts?________
2. What is the Max Load HP of this
pump?________

Q This means the motor is suitable for operation on a

continuous basis at its rated load without a break.

3. Using the Charts and Tables, pages 58 & 59,

what size wire would you use for a 200 ft.
distance?

R This is the electrical type, with most motors being

capacitor start.
S Identifies the manufacturer. Consult their instruction
manual for proper installation and operation.

115 volt________ , 230 volt________ ,

230 volt 3-phase________.

T The code is a letter designation for locked rotor kVA

per HP as measured at full voltage and rated
frequency.

4. Is the pump in Figure 5 wired for 115 volt or

230 volts?________
5. Using the Charts and Tables, Page 57, complete
the following chart.

U This symbol designates UL component recognition. UL

standard 1081 covers swimming pool/spa pumps.

Note: cost of electricity is 15 cents per kilowatt

hour.

Motor
HP
1/2
3/4
1
1-1/2
2
3
Pool & Spa Basic Training

31

Cost
Per
Hour

8
Hour
Day

Week

Month

Year

S4247

3 SECTION

Motors
ELECTRICAL AND SAFETY TIPS

Figure 6

Electrical & Safety Tips:

1. Figure 6 - Never assume that the power is off. A time
clock could CLICK ON and electrocute you. Always
shut off the main power at the master breaker before
working on motor.

4. Dont use the pool while electrical devices are in the

water. Pool drainers may have a frayed electrical cord.
As an extra precaution, plug the electrical device into an
outlet that has a GFCI protector.

2. Ventilation - Motors need air circulating to keep the

temperature down. A rule of thumb is to provide at least
1 square foot of vent space at the top of an equipment
room and the bottom of the equipment room for each
horsepower of the motor for adequate ventilation. This
is in addition to other types of equipment that require
ventilation, such as a heater.

5. Chemical Storage - Keeping chlorine, acid and other

chemicals in close proximity to the pool equipment will
shorten the life of almost everything metal in the area.

3. Use a ventilated motor cover to protect the motor from

the elements, such as rain and the sun.

7. Refer to the motor wiring diagram before making any

electrical connections. Always connect the ground wire
first.

Pool & Spa Basic Training

6. Improperly sized and/or wired pumps may have very

hot motor casings. Over-loaded, under-wired, and poorly-ventilated motors can have very hot casings. Hot
enough to burn your hand.

32

S4247

3 SECTION

Motors

Approximate Cost of Operating Electric Motors

Motor
HP

*Average Kilowatts Input

or Cost per Hour Based on
1 Cent per Kilowatt Hr.

4
3
1
2
3
4
1
112
2
3
5
712
10
1
1

1-Phase

3-Phase

.305
.408
.535
.760
1.00
1.500
2.000
2.95
4.65
6.90
9.30

.520
.768
.960
1.41
1.82
2.70
4.50
6.75
9.00

Motor
HP

*Average Kilowatts Input

or Cost per Hour Based on
1 Cent per Kilowatt Hr.
3-Phase

15
20
25
30
40
50
60
75
100
125
150
200

12.8
16.9
20.8
25.0
33.2
41.3
49.5
61.5
81.5
102
122
162

*For any other rate multiply by the rate:

Example: To determine cost of operating a 3/4 HP single phase motor at 3 cents per kilowatt hour
multiply .760 X 3 = 2.280 cents or approximately 214 cents per hour.

ELECTRIC POWER

HORSEPOWER

AC = Alternating current power

1 HP equals. . .
.746 kilowatts or 746 watts
33,000 ft . lbs. per minute
550 ft. lbs. per second

DC = Direct current
E = Volts = Electrical pressure (similar to head)
I = Amperes = Electrical current (similar to rate of flow)

WATER HORSEPOWER

W = Watts = Electrical power (similar to head capacity)

kW = Kilowatts = 1000 watts

Apparent Power = Volts x amperes = Voltamperes

33,000

GPM x Head
3960

GPM = Gallon per Minute

8.33 = Pounds of Water per Gallon
33,000 = Ft.-lb. per Minute in one HP

Apparent Power - EI
Useful Power W = EI x P.F.
Power factor = ratio of useful power to apparent power
Power factor = PF =

GPM x 8.33 x Head

LABORATORY BHP

W
=

EI
kW Hr. = Kilowatt hour

Head x GPM x Sp. Gr.

3960 x Eff.

GPM = Gallon per Minute

Head = Laboratory Head (inc. column loss)
Eff. = Pump Only Efficiency

Single phase power W = E x I x PF

3 Phase Power W = 1.73 x I x PF

MOTOR INPUT HP

Where E = Average voltage between phases

I = Average current in each phase

Laboratory BHP
Motor Eff.

Total BHP from above

Motor Eff. from Manufacturer
UNIT EFFICIENCY
=

Water Horsepower
Motor Input Horsepower

Water Horsepower from above

Input Horsepower from above

Pool & Spa Basic Training

33

S4247

3 SECTION

Motors

Single Phase Wire Size Selection Charts

115 Volts 1 Phase
AWG Wire Size
Amps

14

12

10

2
3
4
5
6
7
8
9
10
12
14
16
18
20
22
24

595
397
298
238
198
170
149
132
119
99

946
630
470
378
315
270
236
210
189
158
135
118

1479
986
740
592
493
423
370
329
296
247
211
185
164
148
134
123

1161
926
774
663
581
516
464
387
332
290
258
232
211
194

1808
1447
1206
1033
904
804
723
603
517
452
402
362

1842
1579
1381
1228
1105
921
789
691
614
553

1871
1684
1403
1203
1052
935
842

1622
1420
1201
1136

Maximum Distance of Wire Run.

200 Volts 1 Phase

230 Volts 1 Phase

AWG Wire Size

AWG Wire Size

Amps

14

12

2
3
4
5
6
7
8
9
10
12
14
16
18
20
22
24
26
28
30
35
40
45
50
55
60

1035
690
518
414
345
296
259
230
207
173

1644
1096
822
658
548
470
411
365
329
274
235
206

10
1715
1287
1029
858
735
643
572
515
429
368
322
286
257
234
214

1615
1346
1154
1010
897
808
673
577
505
449
404
367
337
311
288
269
231

2097
1797
1573
1398
1258
1048
899
786
699
629
572
524
484
449
419
359
315
280
252

2403
2136
1922
1602
1373
1201
1068
961
874
801
739
686
641
549
481
427
384
349
320

2928
2440
2091
1830
1627
1464
1331
1220
1126
1046
976
837
732
651
586
532
488

2821
2469
2194
1975
1795
1646
1519
1411
1317
1129
988
878
790
718
658

Amps

14

12

2
3
4
5
6
7
8
9
10
12
14
16
18
20
22
24
26
28
30
35
40
45
50

1190
794
595
476
397
340
293
265
238
198

1891
1261
946
756
630
540
473
420
376
315
270
236

10

1479
1184
986
845
740
658
592
493
423
370
329
296
269
247

1858
1548
1327
1161
1032
929
774
663
581
516
464
422
387
357
332
310
265

2411
2067
1808
1607
1447
1206
1033
904
804
723
658
603
556
517
482
413
362
321
239

2763
2456
2210
1842
1579
1381
1228
1105
1005
921
850
789
737
632
553
491
442

3367
2806
2405
2105
1871
1684
1531
1403
1295
1203
1122
962
842
748
673

3245
2839
2524
2271
2065
1893
1747
1622
1514
1298
1136
1009
909

Maximum Distance of Wire Run.

Maximum Distance of Wire Run.

Pool & Spa Basic Training

34

S4247

3 SECTION

Motors
Pump Curve Graph

100
90
80
70

T
D
H

60
50
40
30
20
10
0

10

20

30

40

50

60

70

80

90

100

GPM

PLUMBING
Pipe
Suction

Pipe
Discharge

Vacuum
x 1.13

SYSTEM READINGS
Filter
Energy
Pressure
Used
x 2.31
AMPS

Pump
Pressure
x 2.31

Flow
Meter
GPM

System
Head Loss

FPS

FPS

HL

HL

HL

TDH

FPS

FPS

HL

HL

HL

TDH

FPS

FPS

HL

HL

HL

TDH

FPS

FPS

HL

HL

HL

TDH

FPS

FPS

HL

HL

HL

TDH

FPS

FPS

HL

HL

HL

TDH

FPS

FPS

HL

HL

HL

TDH

FPS

FPS

HL

HL

HL

TDH

FPS

FPS

HL

HL

HL

TDH

FPS

FPS

HL

HL

HL

TDH

FPS = Feet Per Second

HL = Head Loss
TDH = Total Dynamic Head

Pool & Spa Basic Training

35

S4247

3 SECTION

Motors
Plumbing Tips
AIR LOCK

FITTING TOO CLOSE TO

SUCTION OF PUMP
AIR IN
SYSTEM

ALLOW 4 TIMES THE PIPE DIAMETER

BETWEEN THE SUCTION PORT AND THE
FIRST FITTING

KEEP SUCTION PIPES BELOW THE

SUCTION PORT OF THE PUMP

ATMOSPHERIC PRESSURE

TYPE OF PIPE
STAINLESS STEEL
OR PVC

COMPARED TO
PVC

PUMP CAN
LIFT WATER
5'

20% MORE
RESTRICTIVE

2,000'

30% MORE
RESTRICTIVE

PUMP CAN
LIFT WATER
10'

40% MORE
RESTRICTIVE

SEA LEVEL

MULTIPLE PIPES

REDUCE RESISTANCE
90 ELL

1,000'

1-1/2"

2 - 45 ELLS

1/4 th

50% LESS
RESISTANCE

A SELF PRIMING
PUMP WILL
LOOSE 10% OF
ITS ABILITY TO
LIFT WATER FOR
EVERY 1,000'
OF ELEVATION

ATMOSPHERIC PRESSURE AT SEA LEVEL = 14.7 lbs.

ATMOSPHERIC PRESSURE AT 5,000 FEET = 12.0 lbs.

FLEX PIPE

SWEEP
90 ELL

4,000'
3,000'

COPPER

GALVANIZED

5,000'

A 1-1/2" PIPE
CAN ONLY
3" HANDLE 1/4
THE FLOW OF
A 3" PIPE

USE THE PIPE SIZING CHARTS TO SIZE

MULTIPLE PIPES TO REPLACE A SINGLE PIPE

40% LESS
RESISTANCE

1-1/2" = 44 GPM

3" = 160 GPM

Long plumbing runs Increase pipe size, dont increase pump horsepower.
Restrict flow at the top of a waterfall, not at the pump.
Balance the flow by looping the plumbing or tying in at the center and branching an equal distance in each direction.
Pool & Spa Basic Training

36

S4247

4 SECTION

Filtration

DIATOMATEOUS
EARTH

SAND

CARTRIDGE
FILTERED

FILTERED

UNFILTERED

FILTERED

UNFILTERED
UNFILTERED

Figure 1

Figure 2

Figure 3

Swimming Pool, Spa, &

Water Feature Filtration:
Which Filter is Best

Filters used for swimming pools, spas and water features

are designed to physically remove suspended particles
from the water. The water containing the solid dirt particles passes through a filter medium. The medium retains
the particles while the filtered water passes through.

This is an often asked question. All three of the filters are

used in almost every kind of application. Filter selection is
usually made because of the preferences of the specifier, or
designer. They specify what they like and have experience
with. The best advice is to leave your options open and
look at other types of filtration. Another type of filter may
do the job better than what you normally use.

Filter Media:
Generally, three types of filter media are used for removing
the suspended dirt particles from water in a swimming
pool, spa, or water feature.

Exercise:

1. Diatomaceous Earth (D.E.)

Complete the left side of the chart below.

2. Silica Sand

C Re
os pl
t ( ac
In em
te e
rn nt
al
s)

M
ai
n
Ti ten
m an
e c
e
M
ai
n
C ten
os an
t ce

C
Ti ycl
m e
e

C
N os
ew t

Lo D
ad irt
in
g

Re Mic
m ro
ov n
al

3. Cartridge or Fiber

Applications

Pool

Spa

Water
Feature

Ponds

Fish
Ponds

D.E.

SAND

CARTRIDGE

MEGA. CART.

1. Best
Pool & Spa Basic Training

2. Very Good

3. Good

4. O.K.

37

S4247

4 SECTION

Filtration
DIATOMACEOUS EARTH FILTERS
0

10

50

20 25

55 6
0

15
3

0
35

40

45

Cartridge D.E. Element

NOT TO SCALE

2804 0497

Grid support
Internal air bleed
Grids

Drive hub
assembly

Spacer

Connector
rods

Manifold

End
hub

Collection
manifold

Grids
Grid support

Figure 4

cept. A seal between the two halves is achieved with an

O ring or gasket. The tank is supported by a base or legs.
The tank support is designed to keep the filter elevated to
provide clearance between the tank and the pad so that
there is access to a tank drain. The tank support also has
mounting holes so that the filter can be secured to the
pad.

Diatomaceous Earth Filters:

Diatomaceous earth filters use, as a medium, the tiny skeleton remains of an animal called a diatom. Each tiny fossil
is porous and contains many minute passages and channels. These channels and passages are so small that a layer
of diatomite measuring 1/8 inch in thickness will provide a
filters bed equivalent to 2 ft. of sand. Diatomite has the
capability of retaining particulate matter so minute that
even some bacteria can be filtered from the water.

An inlet and an outlet fitting, usually 1-1/2 or larger,

depending on the size of the filter, are located on the bottom half of vertical tank filters, and on the back half of horizontal filters. Having the inlet and outlet fittings on one
half of the filter tank allows the other half to be removed
for servicing and repair. At the top of the filter is a manual
air relief, which usually is in conjunction with a pressure
gauge. (See Figures 6 & 7).

Basic Design of a D.E. Filter:

D.E. filters generally are of the pressure type and are
designed to operate at pressures up to 50 psi. There are
some D.E. systems that are designed as vacuum type filters. These are usually found on large commercial swimming pools. The filter is located on the suction side of the
pump (vacuum side). The water is pulled through the filter
rather than pushed through, as in the case of the pressure
type. The vacuum filter will be discussed in more detail in
the Commercial Section ( 7 ) of this Manual. Tank construction is of various materials or a combination of materials.
Stainless steel, plastic, and fiberglass are the main materials. These tanks are constructed in many different configurations, depending on the concepts of the designer.

The internal grid assembly of the filter is of various sizes

and shapes, depending on the designers concept. The
grids are usually made of a moderate temperature, high
impact resistant plastic. The grids are covered by a grid
cloth that is the support base for the D.E. cake. The individual grids are held together by the collection manifold
and in some cases a support bracket. A collection manifold
is located at the other end of the grids. The grids are held
together by connecting rods between the support bracket
and the manifold.

Most tanks are two parts, a top, or lid, and a bottom, or in

the case of a horizontal filter, a front and a back. Tank
halves are held together with clamps, bolts, other type
locking devices, again depending on the designers conPool & Spa Basic Training

38

S4247

4 SECTION

Filtration

D.E. GRID

FILTER CYCLE

BACKWASH CYCLE

Filtered Water to
the Manifold
Handle
down

Handle
up

D.E.
Cake

Water Flow

Effluent

Filter Grid
Filter Cloth

Influent
(supply)

Figure 5

Figure 6

To waste or sep. tank

Backwash (supply)

Figure 7

the pressure rises 10 psi higher than the original starting

pressure, it is time to clean the filter. Cleaning the filter can
be done manually by removing the grid assembly or element and hosing it off. The easiest way to clean the filter is
to backwash it. By the use of gate valves or a backwash
valve, the flow in the filter is reversed. (Figure 7) This
action breaks off the cake of D.E. containing the dirt particles. The dirty water is directed out of the filter to waste.

Basic Operation of a D.E. Filter:

Diatomaceous earth is fed into the suction side of the
pump, either through the skimmer or a slurry pot, which is
sent to the filter where it forms a cake on each of the filter
grids or element. The water, under pressure, containing the
suspended dirt particles, passes through the D.E. cake and
the grid cloth, or element. The dirt particles become
trapped in the tiny cracks and crevices of the diatoms. The
filtered water passes through the grids/element and
plumbing back to the swimming pool, spa, or water feature. (Figures 5 and 6).

D. E. Substitutes:
There are several D.E. substitutes on the market. They offer
some advantages and disadvantages as compared to D.E.
The biggest advantage is that it does not require as much
material as D.E., thus less cost. However, there are a number of disadvantages. Some do not backwash as well as the
D.E. This results in a shorter 2nd cycle, 3rd cycle, etc.
Others take longer than D.E. to fall off of the filter grid
when the pump shuts off, making the maintenance of the
filter a longer project.

Filter Cycle:
Water from the pump enters the filter through a series of
valves or a backwash valve. As it enters the filter, it
encounters a baffle designed to deflect the water away
from the grids and toward the bottom of the tank. This
action sweeps the D.E. from the bottom of the tank and
deposits it on the grids. The water, containing the suspended dirt particles, passes through the D.E. cake, where the
particles are removed. The filtered water then enters the
supporting grid/element and proceeds to the outlet port of
the filter where it returns to the original body of water.
(Figure 6).

These substitutes are continually improving. In time, they

will probably perform as well as D.E., or even better.

Backwash Cycle:
As the D.E. filter collects the dirt particles in the D.E. cake,
the passageways for the water to flow become restricted.
This resistance to flow causes the pressure to rise. When
Pool & Spa Basic Training

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QQQ

D.E. media

PRE-COATING

D.E. Grid Surfacer

D.E. Cake

1 LB
D.E. media

Suspended
dirt particles
Unfiltered
water

@@


;;
QQ
@@


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QQ

Skimmer deck
opening

Unfiltered
water Suspended
dirt particles

Figure 8

Pre-Coating the D.E. Filter Grids or

Elements

Element grid cover

Filtered
water

Filtered
water

Figure 9

Velocity and its effects on D.E. filtration:

When designing a filtration system using D.E. filters, it is
important to keep the velocity of the water as slow as possible. If the speed of the water is too great, the D.E. will be
impacted into the grid cloth or element cloth and will not
be released during the backwash cycle. The filter will have
to be cleaned manually. In some cases, the filter grids or
elements will need to be cleaned with special cleaners to
remove the dirt particles that have imbedded themselves
into the filter cloth. The filters are designed to hold the D.E.
cake at low pressure. At 0 pressure, when the pump is
shut off, the D.E. will fall off of the grids to the bottom of
the tank. When the pump is restarted, the D.E. will re-coat
to the grids or the elements. Slower water velocities will
also provide longer filter cycles since the water passes filter
the area through more of the grid or element, rather than
being driven through at points closest to the outlet of the
grid or element.

On initial start-up or after the filter is cleaned, it is necessary to pre-coat the grids or elements with diatomaceous
earth or a D.E. substitute. The rule of thumb for the
amount of D.E. required is 1 lb. of D.E. per 10 sq. ft. of filter
area. (A 2 lb. coffee can will hold approximately 1 lb. of
D.E. (Figure 8).

Exercise:
A 50 sq. ft. filter requires how much D.E. to
pre-coat the grids or element?
1 Ib. of D.E. per 10 sq. ft. equals? _______ Ibs.
How many 2 Ib. coffee cans will it take? _______
The amount of a D.E. substitute that is required
ranges from 1/2 Ib. to 3/4 Ib. per sq. ft. of _______

High velocities and high heat applications, such as spas,

hot tubs, and therapy tanks, will wear down the plastic
internals of the filter, causing sagging and warping, and
eventually breaking down the grids. The filter media will
pass through the grids and back to the original body of
water. This can happen in just a few months, depending on
how high the velocity and temperatures are.

Exercise:
A 50 sq. ft. filter requires how much D.E. substitute
to pre-coat the grids or element _______ Ibs.

Pool & Spa Basic Training

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Filtration

40

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4 SECTION

Filtration
FILTER SIZING

1.5 ft
Dia.

Total Head In Feet

140

1.5 ft

120
100
80
60
3/4 hp

40
20
1/2 hp

1.5 ft

10

20

30

40

50

60

70

80

90 100 110

Capacity (U.S. G.P.M.)

Total Head In Feet

140
120
100
80
1 hp
60
40
20

1/2 hp
3/4 hp
0

10

20

30

40

50

60

70

80

90 100 110

Capacity (U.S. G.P.M.)

Figure 10

Figure 11

NOTE: D.E. sizing charts are located on Pages 5 through 10 in the Charts and Tables.

Sizing a D.E. Filter:

With just the above information available, many filters are undersized. The problem is that the pump
selected to do the job may be delivering a lot more
flow than is required. The pump curve for a 3/4 HP
pump, shown in Figure 11, top, is pump selected
for the above pool. The resistance in the system is
60 ft. of head. The 3/4 HP pump will deliver 70
GPM, or 27 GPM more than is needed. The filter
selected based on 43 GPM would probably be too
small, causing short cycles and possibly excessive
pressure in the system.

The size or sq. ft. area of a D.E. filter is determined by the

surface area of the filter grid, minus the plastic grid structure of the grid itself. The sq. ft. of a D.E. element is determined by the actual sq. ft. of the cloth elements. (Figure 10)
Spin Grid = area of a circle, minus the 2 hub, times both
sides, minus the percent the grid network takes up. ( 1 to
5% depending on the type. )

Formula: (Figure 10)

Filter Sizing Procedures:

(.75 x .75) x 3.14 = 1.77 minus .262 (hub) = 150 x 2 (both

sides) = 3 sq. ft. minus the plastic grid percentage, 5% =
2.85 sq. ft.

The desired flow for most pressure D.E. filters is between

1.5 and 2 GPM per sq. ft. of filter area. It should be sized so
that the flow is not below the 1.5 GPM nor above the 2
GPM range. In certain filter designs, flows below 1.5 GPM,
there is not enough flow to adequately backwash the filter.
Other designs have poor filter cycles if the flow is over 2
GPM. 1.5 GPM is the ideal flow rate. It allows for longer
filter cycles and enough flow for backwashing.

Square or Curved Grid = area of the grid, times both sides,

minus the plastic grid percentage = sq. ft.
1.5 x 1.5 x 2 (both sides) = 4.5, minus the plastic grid percentage, 5% (. 11 ) = 4.39 sq. ft.

Selecting the Correct D.E. Filter:

It is important that the filter be sized to the pump rather
than the gallons per minute calculated to turn the body of
water over in the desired number of hours.

Exercise:
Using the pump curves in Figure 11, bottom, what
size D.E. filter would you select for a 18,000 gallon
pool requiring a 6 hr turnover. The resistance of the
system is 50 ft. of head.

Example: (Figure 11, top)

20,000 gallon pool that requires an 8 hour
turnover.

6 hr. turnover ______GPM, Pump Selected

20,000 / 480 (minutes) = 42 GPM

Filter Selected ______sq. ft.

Pool & Spa Basic Training

______HP, Pump Delivers ______GPM,

41

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4 SECTION

Filtration

SAND
0

Distributor

10

55 6
0
50

20 25
3

FILTERED
WATER

15
0
35

40

45

SAND
PARTICLES

FILTER DESIGN

;;
;;
Underdrain

2804 0497

2 PIECE FIBERGLASS TANK

Aquatools
.WATERFORD, WI.
53185
USA

A
S
W
K

B
A
C

TE
IR
CR
IL
C
ULAT
F
RE
E

Freeboard

UNFILTERED
WATER

SYSTEM 3

Figure 12

Figure 13

Figure 14

The filter is supported by legs or a base. There is an air

bleed located at the top of the filter along with a pressure
gauge. A drain is located at or near the bottom of the filter
tank to allow for draining and servicing of the filter.

Sand Filter:
Sand filtration is the oldest form of filtration known to
man. It is believed that the caveman dug holes near a river
bank allowing the water to seep through the sandy soil and
fill up the holes with filtered water. The Roman Baths
were filtered by water flowing by gravity through a sand
bed in an urn, or other vessel, exiting the bottom and
returning to the Baths, by gravity, through water falls,
fountains, and statuary.

The internal components of the sand filter are very simple.

At the top of the filter is a distributor. Its purpose is to
spread the unfiltered water evenly over the surface of the
sand bed. The sand bed is generally one to two feet below
the distributor. The upper area is called the freeboard.
This area is necessary for the proper distribution of the
incoming water. At the bottom of the tank is the underdrain assembly designed to collect the filtered water after
it has passed through the sand bed. The underdrain assembly has a series of laterals that have very small slots that
are large enough for the water to flow through, but small
enough that the sand grains can not pass.

Basic Operation of a Sand Filter: (Figure 12)

Water, containing the suspended dirt particles passes
through the sand grains, either by gravity or pressure. The
dirt particles are trapped in the tiny openings, cracks, and
crevices. Over time, the sand grains become round smooth,
becoming less effective as a filter media. This process may
take as little as a year or it can take many years, depending
on the velocity of the water.

Sand filters have a valve attached to the filter tank to direct

the flow of water through the tank. The main purpose of
the valve is to reverse the flow of water in the tank to
Backwash the dirt out. Filter tanks that separate at the
middle usually have the valve attached to the inlet and
outlet on the lower half of the tank. One piece tanks may
have the valve attached to either the inlet and outlet on the
side of the tank or on the top. Filters that have the valve on
the top of the tank require the valve assembly to be
removed to service the tank. Many of these valves have
multiple purposes and are called Multiport Valves. These
valves will be discussed at the end of this section.

Basic Design of a Sand Filter: (Figs. 13 & 14)

Like the D.E. filters, sand filters are generally of the pressure type and are designed to operate at pressures up to 50
lbs. Tank construction is of various materials or combination of materials. Stainless steel, plastic, and fiberglass are
the most common materials used. These tanks are constructed in many different configurations, depending on
the concepts of the designer. One piece tanks with a lid to
access the internal parts and two piece tanks that are held
together with clamps or bolts are the most common.
Pool & Spa Basic Training

CRISTAL FLO

42

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;; ;;
;;

4 SECTION

Filtration

FILTER CYCLE

BACKWASH CYCLE

Effluent

To waste

Influent
(supply)

Backwash
supply

Figure 15

observe the water being ejected to waste. When the water

appears to be clean the backwash cycle is complete. This
backwash cycle can take as little as a couple of minutes to
as much as 7 or 8 minutes, depending on how deep the
dirt particles were embedded and the type of dirt particles
the filter was removing. Heavy clays and oils will take
longer to remove than dust or insects.

Filter Cycle:
Water from the pump enters the filter through a series of
gate valves or a backwash valve. The backwash valve
can be on top of the tank or installed at the inlet and outlet
on the side of the tank, depending on the designers concept of how the filter should perform. The water, containing the dirt particles, is directed to the distributor where it
is evenly spread over the sand bed. The water is driven
into and through the sand bed, trapping the dirt particles.
The filtered water enters the underdrain lateral assembly
and is directed out of the tank and back to the original
body of water. (Figure 15)

When the filter is clean, the sand bed has been rejuvenated
and the filter can be placed back in the filter mode. (Figure
16).

Filter Square Footage:

Sand filters are rated in square feet. The surface area of the
sand bed is the square footage of the filter.

Backwash Cycle:
As the dirt particles are trapped in the sand bed, the passageways become restricted. It becomes difficult for the
pump to push the water through the sand, causing the
pressure to rise. When the pressure rises a predetermined
amount, usually 5 to 10 pounds over the original starting
pressure, it is time to clean the filter. By opening and closing a series of gate valves, or changing the position of a
backwash valve, the flow in the filter is reversed. The
water now enters the tank through the tank outlet to the
bottom of the lateral assembly. It proceeds through the
sand bed causing the sand bed to expand, freeing the
trapped dirt particles. The dirt particles, being lighter than
the sand grains, proceed to the top of the tank, through the
distributor through the tank inlet and exit to waste. There
is usually a clear sight glass installed in the waste line to
Pool & Spa Basic Training

Figure 16

Examples:
I. A round tank - 24 in diameter
Formula - Area = R2
Area = 3.14 x (1 x 1) = 3.1 sq. ft.
II. A square tank - 3 long by 2 wide
Formula - Area = length x width
Area = 3 x 2 = 6 sq. ft.

43

S4247

4 SECTION

Filtration

140

140

120

120

Total Head In Feet

Total Head In Feet

SAND FILTER SIZING

100
80
2 hp

60
40
20
1 hp
0

10

20

30

40

50

60

70

80

90 100 110

Capacity (U.S. G.P.M.)

100
80
60
40
1 hp

20
0

10

20

30

40

1/2 hp
50 60

3/4 hp
70

80

90 100 110

Capacity (U.S. G.P.M.)

Figure 17

Figure 18

NOTE: Sand sizing charts are located on Pages 11 through 15 in the Charts and Tables.
To size a sand filter, the procedure is as follows:

Selecting the Correct Size Filter for a

Swimming Pool, Spa, or Water Feature:

Divide the recommended flow rate for the filter into the
GPM produced by the pump

Like all filters, it is important that the filter be sized to the

GPM the pump is delivering, rather than the gallons per
minute that has been calculated for the correct turnover
rate.

Example: (Figure 18)

A pump is delivering 73 GPM. We want to size the
filter at the recommended flow rate of 15 GPM per
sq. ft. of filter area.
73 / 15 = 4.9 sq. ft. filter.

Example: (Figure 17)

2,000 gallon commercial spa with a 30 minute
turnover at 40 ft. of head loss.
2,000 / 30 min. = 67 GPM

What size sand filter would you use for a 22,500

gallon pool that requires an 8 hour turnover? Use
the pump curve in figure 18 at 60 foot of head
loss. The best flow rate for the sand filter is 15
GPM, per sq. ft.

The 2 H.P. pump in Figure 17 is delivering almost

90 GPM. If we sized the filter for 67 GPM and
pump is delivering 90 GPM, the filter would be
undersized causing short cycling, possibly channeling, and do a poor job of filtering the spa.

Turnover Rate ________GPM

Pump Size

________HP

Filter Sizing Procedures:

Pump Delivers ________GPM

The desired flow for most pressure high-rate sand filters is

between 15 and 20 GPM per sq. ft. of filter area. Flow rates
below 15 GPM may not be sufficient in many cases to back
wash the filter properly. Flows over 20 GPM will drive the
dirt particles deep into the sand bed, which may not be
discharged during backwash. In many filters, flows of 20
GPM or more may channel the filter.

Filter Size

________sq.ft.

Channeling is when the sand bed is short circuited

allowing unfiltered water to be returned to the main body
of water.
Pool & Spa Basic Training

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Filtration

;;;; ;;
;; ;;
VELOCITY AND THE SAND FILTER

Water enters
tank

Unfiltered water
returned to pool

Water
exits
tank

Figure 19

Velocity and its Effect on Sand Filtration:

the 8 lateral filter twice as fast as the 16 lateral filter. As a result, the 16 lateral filter will trap more
and finer dirt particles than will the 8 lateral filter.
The same thing holds true for backwashing the filter. The fewer the laterals, the greater the distance
between them. During backwash, the sand directly
above each lateral is expanded while leaving dead
spots that dont get cleaned.

When water enters a sand filter, it heads directly to the easiest way out of the tank. In a typical sand filter, the easiest
way out is the underdrain laterals. The faster the water is
moving (high velocity), the faster it passes through the
sand bed on its way to the laterals. High velocity will drive
the dirt particles deeper into the sand bed than is necessary
for quality filtration. The higher the velocity the larger the
dirt particles that will be driven through the sand bed. This
results in poorer filtration than if the velocity is kept low.
Particles that are too deep in the sand bed will be difficult
to discharge during backwash. In some cases, the dirt particles are driven through the sand bed and back to the
main body of water. This is called channeling. Channeling
can occur at lower velocities in some filters than in others.
For that reason, we recommend that velocity inside the filter be kept down to 7 FPS. (Figure 19)

Sand Filters and Spas:

There are several possible problems that can occur when
using a sand filter with a spa:
1. When backwashing a sand filter, it may require as much
as 5 minutes to get the sand bed clean. If the spa is 400
gallons and the pump is flowing 90 GPM, there is not
enough water in the spa to backwash the filter.
2. High spa temperatures release body oils that tend to
seal the surface of the sand bed. This will cause the filter
to cycle very quickly. If not watched closely, resistance
can increase to the point that there is little or no flow
from the pump, possibly burning up the pump.

Some filters are designed with only a few laterals. This

type of filter can be channeled easier than a filter that has
more laterals

3. When it comes to Bacterial Sanitation, it is difficult to

ensure uniformity and effectiveness. This can cause
pseudomonas or legionella infections in bathers.

Example:
2 filters are both flowing 80 GPM. One has 8 laterals and the other has 16. The flow to each lateral in
the 8 lateral filter is 10 GPM per lateral. The filter
with 16 laterals has a flow to each lateral of 5
GPM. The water is passing through the sand bed in

Pool & Spa Basic Training

Figure 20

45

S4247

4 SECTION

Filtration
CARTRIDGE FILTRATION
450 SQ. FT.
REL
EAS
E

150 SQ. FT.

Modular
media

Dual flow
single
cartridge

Single
flow
cartridge

OU
TL
ET

Cartridge
with
adaptor for
stacking
Multiple element
cartridge

Figure 21

2641 0996

NOTE: Mega cartridge filter sizing charts are located on Page 16 in the Charts and Tables.
The internal components of a cartridge filter are the filter
elements, an internal air bleed, and in some cases, a top
and bottom holding bracket. One of these brackets acts as a
manifold for collecting the water from multiple filter elements. Many configurations of filter element designs are
used depending on the concept of the designer. There can
be one single element or groups of several elements.
(Figure 21). Some are stacked end to end to achieve the
square footage of the filter.

Cartridge Filter:
Cartridge filtration is the newest principle to be introduced
to the swimming pool, spa, and water feature industries.
The compact size gives the designer the option of sizing a
large square footage filter in a relatively small tank. As an
example; a 75 sq. ft. cartridge filter will occupy half the
area on the filter pad as would the same size D.E. or sand
filter. The spa industry utilizes the cartridge filter almost
exclusively for filtration of pre-plumbed portable spas.

Some of the newer filters are using one or two very large
filter elements in a larger tank. The square footage in these
filters is much higher, some as high as 450 square feet, and
more. These filters are known as Mega Cartridges, and
are designed to remove a very large amount of dirt from
the swimming pool/spa, or water feature before the filter
needs to be cleaned. As a result, the cycle time is much
longer, in most cases at least a year between cleanings.

Basic Design of a Cartridge Filter:

Cartridge filter tanks are usually smaller and lighter than
D.E. or sand filters. Consequently, more tanks are made of
plastic and fiberglass, although stainless steel is used for
many of the larger tanks.
The tanks are of various designs depending on the concepts used. There are one piece tanks with threaded or
clamped lids. Two piece tanks with clamps are generally
used in the larger tanks.
Since these filters are not backwashed, there is no need for
gate valves or a backwash valve. As a result the tanks
inlets and outlets can be located on different planes, front
and back, top and bottom, etc. Many of the filters can be
installed in the horizontal position or even upside down.
Some of smaller filters are suspended from the plumbing.
The larger filters are supported by a base or legs. At, or
near the top of the tank is located an air bleed and a pressure gauge.
Pool & Spa Basic Training

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Filtration

@


;
Q
@


;
Q


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;
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;
Q

CARTRIDGE FILTER - BASIC OPERATIONS

Cartridge Filtration

Suspended
dirt particles
Unfiltered
water

Unfiltered
water Collected
dirt particles

To pool
From pool

Cartridge Filtering Media

Paper or cloth

Filtered
water

Filtered
water

Figure 22

or more directions slowing down the velocity of the water

through the filter element. This allows the filter element to
remove finer dirt particles and use more of the element.
(Figure 24).

Basic Operation of a Cartridge Filter:

The water containing the suspended dirt particles enters
the filter at various points, again, depending on the designers concepts. The water then passes through the cartridge
material depositing the dirt particles on the element. The
filtered water exits the cartridge and filter and returns to
the main body of water. As more dirt particles accumulate
on the filter element, the passageways become restricted.
The dirtier the filter gets, the finer it filters, until it reaches
a point, usually a 10 PSI increase on the pressure gauge
above the original starting pressure, where the filter element is removed and cleaned. (Figure 22).

Velocity and the Mega Cartridge Filter:

The design of most Mega Cartridge Filters is a cluster of
smaller filter elements. As an example, 4 - 50 sq. ft. filter
elements are combined with a common manifold to provide 200 sq. ft. of filter area. By splitting the flow 4 ways,
the velocity is very slow as it passes through the filter element. As a result, the filtration will be much better than
with a single element. In some of the Mega Cartridges, the
velocity is so slow that some of the larger dirt particles
never make it to the filter element, they just drop to the
bottom of the tank.

Velocity and its Effects on Cartridge

Filtration:
Of the three types of filters, D.E., sand and cartridge, the
cartridge filter is the most sensitive to high velocity. Water
at high speed passing through the cartridge element will
drive the dirt particles through the filter element and back
to the main body of water. It is important to keep the flow
down to a minimum. Unlike the D.E. and sand filters, the
cartridge filter is not backwashed. There is no minimum
flow, so the slower the flow the better the filtration. We recommend that the velocity not exceed 7 FPS, or 1 GPM per
sq. ft. of filter area.

The results of the slow velocity through the Mega

Cartridges, is that finer filtration is achieved and very long
cycles occur as compared to the same size D.E. or sand filters. On a normal residential swimming pool is typical that
the filter may go an entire year before it needs to be
cleaned.

The design of the cartridge has a lot to do with the filter

cycles and the degree of filtration. A dual flow cartridge
element will filter finer and give longer filter cycles than
will a single filter flow element. By splitting the flow two
Pool & Spa Basic Training

47

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4 SECTION

Filtration

CLEANING

DUAL FLOW DESIGN

W
CLEAN Clean
WITHw
and noz
HOSE AND
NOZZLE

COLLECTION
Collection
COREcore

ele
WATER
FLOWS
b
ACROSS
ELEMENT
FROM
BOTH
SIDES

Figure 23

Figure 24

Cleaning the Cartridge Element:

Cartridge Filters and Spa Applications:

When the pressure gauge has increased 10 PSI over the

original starting pressure, it is time to clean the filter element. The element is removed from the filter and simply
hosed off. In cases where the velocity has been too high,
and the filter is loaded with calcium it should be soaked in
a solution of TSP or other filter cleaners. If the pool/spa or
water feature has a heavy bather load, there are probably
lots of oils and sun tan lotions in the water. We suggest that
the pool/spa or water feature use a daily treatment of
Enzymes. The Enzymes are safe to use and will
remove these oils. On heavy bather loads, we suggest that
the filter element be soaked for a minimum of 24 hrs. in a
solution of the Enzymes. About I cup of the enzymes in a
barrel of water will be enough to remove the oils. The
longer you soak the element the more of the oils that will
be removed. (Figure 23).

Of the three types of filters used to remove the suspended

particles out of spa water, the cartridge filter seems to hold
up the best. Because of its compact size, containing a large
filtration area, and the fact that it can be installed in tighter
areas, the cartridge filter is the most used filter on spas.
The D.E. and sand filters are more sensitive to heat and
body oils than is the cartridge type filter. The cartridge element is also easier to clean when the filter media is impacted with body oils and calcium.

After the filter is cleaned, the element is returned to the filter and the system is turned back on.

Sizing a Standard Cartridge Filter:

Dual Filter Systems:

Like the dual element design, installing 2 filters in parallel
instead of a single filter will split the flow, slowing down
the velocity through the filter element. Two filters installed
in parallel will remove more and finer dirt particles, plus
extending the filter cycles.

Like the D.E. and sand filter, the cartridge filter should be
sized to the GPM that the pump is delivering, rather than
what has been calculated as necessary for the turnover rate
desired. The recommended flow rate for a cartridge filter is
.75 GPM per sq. ft. of filter area for best residential performance.

Cleaning a Mega Cartridge Filter:

It takes longer to clean the larger filter elements because
these elements collect a lot of dirt over a long period of
time. On pools/spas, and water features that have heavy
bathing loads there will be large amounts of oils and
lotions in the filter element. It will take some soaking and
extra time to clean these very large elements.

Pool & Spa Basic Training

48

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Filtration

SIZING

MEGA. CARTRIDGE SIZING

73
GPM

Total Head In Feet

140
120

CALCULATING FLOW RATE

35,000 Gallon Residential Pool

100

8 Hour Turnover = 73 GPM

80
60

73 GPM 450 sq. ft. = .16 GPM

per sq. ft. Filter Area

40
20
0

10

20

30

40

50

60

70

80

90 100 110

.16
FLOW
RATE
MEGA CARTRIDGE
450 SQ. FT.

Figure 25

Sizing a Standard Cartridge Filter

Figure 26

Sizing a Mega Cartridge Filter:

Because of the large square footage of the Mega Cartridge
Filter, it can not be sized by a recommended flow rate, like
the D.E., sand, or standard cartridge filters. As an example;
if we size a 450 sq. ft. Mega Cartridge Filter at a flow rate
of 1 GPM per sq. ft. of filter area, as we do with a standard
cartridge filter, it would mean that we can flow 450 GPM
through the filter. This would require that the inlet, outlet,
and internal plumbing would need to be at least 6.

Example:
15,000 gallon swimming pool that requires an 8
hour turnover rate.
15,000 gal. 480 min. = 31 GPM
31 GPM .75 flow rate = 41 sq. ft. filter

Commercial Pools & Spas:

On residential swimming pools, spas, and water features

the filter should be sized at flows recommended by the filter manufacturer. The recommended flow rate is usually
dictated by the size of the inlet, outlet ports, and the internal plumbing. (Figure 26).

The recommended flow rate for a commercial application

is .375 GPM per sq ft of filter area This cuts the flow
through the filter in half. We recommend that the velocity
be cut even further by using a dual filter system

Exercise:
Using the pump curve in Figure 25, for a 2,000 gal.
commercial spa. We need 67 GPM for a 30 minute
turnover. What size dual cartridge filter would you
use?_______

Pool & Spa Basic Training

49

S4247

4 SECTION

Filtration
BACKWASH VALVES

STA-RITE

LO

SE

STA-RITE IND., INC.

WATERFORD, WI.
53185
USA

WINTER
IZE
W
A
S

IL

KWA
C
S
A
B

E
T

R IN S

RECIR
CU
LA
TE

2834 0597

MULTI PORT VALVE

2816 0497

PUSH PULL VALVE

4 - VALVE BACKWASH

Figure 27

Recirculate - Water enters the valve from the pump and

goes directly back to the main body of water, bypassing
the filter. Used to recirculate the water with the filter in
the plumbing line. In this position the filter can be
worked on without shutting off the pump.

Types of Backwash Valves:

Generally, there are 3 kinds of valves used to backwash a
D.E. or Sand System. They are the Multi Port Valve, Push
Pull Valve and the 2 way Valves. These valves change the
direction of flow in the filters, placing the filter in the
backwash mode.

Push Pull Valve:

This valve has only two directions. Filter and Backwash.
Generally works on a piston rod that moves up and down,
changing the position of 2 or more Cams. Fully extended
in one direction, you are in filter. Fully extended in the
other direction, you are in backwash.

Multi Port Valve:

The Multi Port Valve is generally used with sand filters.
The valve can be connected to the top of the filter or to the
side ports, depending on the designers concept of operation. Other than the Filter and Backwash positions, the
Multi Port Valve has 3 or 4 other settings.

2 Way Valves:
Usually a group of 4 or 5 valves, depending on the designers concept. By opening and closing the valves the direction of flow in the filter is changed.

Rinse - Water enters the valve from the pump - through

the valve and filter to waste.
Used for initial start-up and to clean and level the sand
bed after Back washing.

Exercise:

Closed - This position shuts off flow from the pump to

the filter. In this position the pump should be off
because the pump is dead headed.

Using the filter at the far right of Figure 27,

position the valves for the following chart:

Used mainly for servicing the system.

Valves

Waste - Water enters the valve from the pump and goes
directly to waste.

Filtration

Used for lowering the water level of the main body of

water. Also, used to vacuum the pool spa or water feature with out loading the filter bed.

Pool & Spa Basic Training

Backwash
X = Closed O = Open

50

S4247

4 SECTION

Filtration
FILTRATION AND SAFETY TIPS

I Told You, You

Didnt Know What
You Were Doing!!!!!!!

READ AND FOLLOW

ALL THE
INSTRUCTIONS IN
THE OWNERS
MANUAL - PLEASE!

Make sure the clamp is

secure before turning on
the pump!

FILTRATION AND SAFETY

TIPS:
1. Good filtration is a direct result of the velocity of the
water passing through the filter. High velocity will drive
larger dirt particles through the filter media. Higher
velocities will generally result in higher system pressures and a shorter life for the filter. Keep the velocity
through the filter at, or below 7 FPS.

4. Enzymes can help. The regular use of Enzymes in pools,

spas, and water features that have heavy loads and or
exposed to trees, plants, fields, etc. will remove the oils
and other unwanted oils from organic materials. This
will extend the filtration cycles and make the filters easier to clean.

2. Air, trapped in a filter can compress and cause an

improperly adjusted tank clamp to fail. Read the
Warning Labels and the Owners Manual for the proper
procedures to follow when removing and replacing the
filter lids. Filters equipped with internal air bleeds are
designed to remove the continuing build up of air in the
tank. The internal air bleed has a screen at the top. This
screen needs to be routinely cleaned for proper operation.

5. Separation Tanks - Where used, there should be an isolation valve placed between outlet of the Separation Tank
and the return line. After backwashing, the backwash
valve(s) are switched to the filter position and the isolation valve is turned to the off position. By doing this the
Separation Tank is isolated and not under pressure. If
the lid is removed while the system is running, the
Separation Tank is not under pressure, and the possibility of an injury is prevented.

3. Valves that are seldom used will take a set on the gasket
and the O rings. All valves should be taken apart at
least once a year and the gaskets and O rings inspected and lubricated, or replaced, if needed.
Note: Valves that are down stream of the filter should
not be shut off while the pump is running. This could
result in a surge of pressure which could cause an
improperly installed filter clamp to fail.

Pool & Spa Basic Training

51

S4247

5 SECTION

Heaters

HEAT
HEATERS
38

100

ELECTRIC HEATER
AUX
2

SPEED
LOW

R PUMP

BOOSTE
SPEED
HIGH

AUX
1

FILTER
PUMP

SOLAR HEATER - PANEL SYSTEM

C

SOLAR
HEATER PIPE
SYSTEM
2668 0397NF

Figure 1

NATURAL GAS / PROPANE

NOTE: Natural Gas/Propane Heater sizing charts are located on Page ## in the Charts and Tables.

Swimming Pool and Spa

Heating

Energy Efficiencies and the

Pool and Spa Heater
Since the majority of the heat loss is due to the exposed
surface of the water, it is good practice to keep the swimming pool and spa covered. A cover can save as much as
75% of the heat loss due to the lower temperature of the
surrounding air. It is particularly important with spas that
are kept at the desired temperature year round.

Heaters, as used with swimming pools and spas, offer the

extended enjoyment and therapeutic effects of swimming
and the heated Jet Action on the body. Most spas are
used all year long. The use of a heater can extend the normal swimming season to the entire year. In any case, the
heater is a necessity for a spa and a helpful addition to a
swimming pool.

Other variables are the wind, altitude, and sheltered or

shady areas

Types of Heating

Wind - A constant wind can remove heat from the swimming pool or spa at a greater rate. The higher the wind
velocity the more heat is removed. If there is a constant
wind that is greater than 10 miles per hour, you should
add at least 25% to the size of the heater. (Figure 2)

There are several types of heating devices in use for swimming pools and spas. We will cover 3 of these: (Figure 1)
Electric
Natural Gas or Propane

Example:

Solar

A swimming pool requires a heater that is rated at

300,000 BTUs. There is a consistent wind of 13
MPH. The heater size should be increased to at
least a 375,000 BTU heater, or larger.

The others are Heat Pumps and Oil Fired Heaters. These
types of heaters are effective, but not in great use.

Pool & Spa Basic Training

52

S4247

5 SECTION

Heaters

HEAT
HEAT LOSS
38

100

WIND

AERATION

Figure 2

SHADE

Shade - In pools or spas constructed in an area shaded

from the heat of sun, the heater size should be based on the
temperature of the shaded area. This temperature can be as
much as 20 below the sunny areas. (Figure 2)

Problem:
A spa that is installed outside of a penthouse on
top of a 60 story building. The altitude is 750 feet
and there is a constant 12 MPH wind blowing. The
spa is continually heated and has been sized for a
300,000 BTU Heater. Due to altitude and the wind
conditions.

Aeration - Waterfalls, fountains, and spa jets have an effect

of cooling the water faster than the normal cool down by
the surrounding ambient air temperature. When sizing a
heater, keep in mind that these features will extend the
time it takes to heat a pool or spa. Efforts should be taken
to turn off these features during the heat up time.
(Figure 2)

What is the size of the heater you will

recommend?
________________ BTU

Altitude - Due to the reduction in atmospheric pressure as

you gain altitude, it takes longer to heat the water. A rule
of thumb is to increase the size of the heater about 4% for
each 1,000 feet in elevation.

Pool and Spa Temperatures

Swimming Pools - The American Red Cross recommends
that the average temperature range be from 78 to 82
Fahrenheit (26 to 28 Centrigade).
Spas and Hot Tubs - The National Spa and Pool Institute
recommends that the temperature in a spa or hot tub
should not exceed 104 Fahrenheit (40 Centigrade).

Example:
A swimming pool that requires a 200,000 BTU
heater is located at an altitude of 5,000 ft. To compensate for the lower atmospheric pressure, the
heater size needs to be increased 4% for each
1,000 ft.
(4% x 200,000) x 5 = 40,000 BTU
Heater size needs to be 240,000 BTU or larger.

Pool & Spa Basic Training

53

S4247

5 SECTION

Heaters

HEAT
NATURAL GAS OR PROPANE
38

100

HEATER INPUT
400,000 BTUs

HEATER
EFFICIENCY
70% = 280,000 BTU

Inlet
(Cold Water)

75% = 300,000 BTU

F
Primary
Heating
Coils
Secondary
Heating
Coils

*HEATER
OUTPUT

80% = 320,000 BTU

85% = 340,000 BTU

*HEATER
OUTPUT

Outlet
(Warm/Mixed
Water)

Figure 3

Natural Gas or Propane Heaters

Basic Operation of a Natural Gas

or Propane Heater

These type of heaters are the most commonly used with

swimming pool and spas. They are called direct fired
heaters. A direct fired heater burns fossil fuels. Water flowing through the exchanger is heated by the heat produced
by the burning process. The exhaust must be vented to the
outside atmosphere or reburned.

Water, usually after it passes through the filter(s), enters the

heater through the inlet fitting. In some heaters the inlet
and outlet are plumbed with a heat sink. The heat sink is
made of metal, copper or stainless steel. The purpose of the
heat sink is to absorb the high temperature in the water
and cool it down enough so that the rest of the plumbing
can be PVC. Most heater manufacturers that require heat
sinks recommend at least a 3 foot run on the inlet and outlet side of the heater. In some cases they recommend a
check valve between the heater and the filter. When the
system shuts off, hot water cant backflow from the heater
to the filter causing distortion of the filters plastic parts.

Heater Ratings and Efficiencies

Most of the heaters used for swimming and spa systems
range from 100,000 BTU to 500,000 BTUs. A BTU is a unit
of measurement. A British Thermal Unit is how we size
these heaters. One BTU can raise one pound of water one
degree Fahrenheit.

Once inside the heater some of the water is by-passed.

Heaters are designed to operate at a predetermined flow
rate, normally not exceeding 100 GPM. Any excess flow is
diverted to the outlet side of the heater. The bypass valve is
a spring loaded valve that opens when the pressure indicates that there is too much flow.

The heater is rated by the input BTUs per hour. The output
BTUs are the amount of energy transferred to the water.
The ratio of the input to the output BTUs is shown as the
efficiency of the heater. (Figure 3)

The water now enters the heat exchanger. The heat

exchanger is a series of copper finned tubes that absorb the
heat from the combustion chamber and transfer it to the
water.
After passing through the heat exchanger, the water exits
the heater and returns to the pool or spa. (Figure 3)

Pool & Spa Basic Training

54

S4247

5 SECTION

Heaters

HEAT
BASIC HEATER COMPONENTS
38

100

AIR
BLOWER

CONTROLS

AIR FLOW SWITCH

EXHAUST
GAS
VALVE

GAS
CONNECTION

MANIFOLD

ELECTRICAL
CONNECTION
PRESSURE
HIGH LIMIT
SWITCH
AGS SWITCH
THERMISTOR
INLET & OUTLET
COMBUSTION
CHAMBER
Figure 4

10. If the burner does not ignite in seven seconds, the system shuts down and locks itself out. Power to the system must be turned off and turned back on again
before it will start.

Basic Heater Components

1. The Thermistor senses the inlet water temperature.
2. If the temperature sensed is lower than that set on the
Operating Control, power is supplied to the Ignition
Control Module through a series of safety interlocks.

11. The HSI element automatically switches from ignition

mode to a flame sensing mode to monitor the flame.

3. The Water Pressure Switch senses whether or not the

pump is running.

12. The Burner in the Combustion Chamber fires until the

desired water temperature is reached. Once reached,
the Burner shuts off and the Blower continues to run
for about 45 seconds (known as post purge).

4. The High Limit Switch monitors the outlet water temperature and will open if a malfunction causes the outlet
temperature to reach 135F.

13. If the flame is extinguished during operation, the

Combination Control Gas Valve closes and the ignition cycle reactivates.

5. The Automatic Gas Shutoff Switch (AGS) monitors the

outlet temperature from the Heat Exchanger and will
open if a malfunction causes the water outlet temperature to reach 150F.

14. If any safety interlocks open during Burner operation,

the Burner immediately shuts off, but the Blower continues to run for about 45 seconds.

6. If the High Limit Switch and the Water Pressure Switch

are OK, the Ignition Control Module starts the
Combustion Air Blower.
7. When the Blower comes up to speed the Air Flow
Switch (AFS) senses air flow across the Air Metering
Orifice.
8. If the airflow is sufficient, the AFS closes, completes the
ignition circuit, and supplies power to the Ignition
Control Module.
9. In 20 seconds the Hot Surface Ignition (HSI) element
heats to ignition temperature. The Combination Gas
Control Valve then opens and the burner flame ignites.

Pool & Spa Basic Training

55

S4247

5 SECTION

Heaters

HEAT
GAS AND AIR FLOW THROUGH THE HEATER
38

100
Gas

Exhaust

Air

Figure 5
Gas and Air Flow Through the Heater
1. The Blower draws ambient air into the Burner System
by negative pressure through the Air Orifice.
2. The Blower at the same time is drawing Natural or LP
Gas into the Burner System by negative pressure
through the Gas Orifice.
3. The air and gas are thoroughly mixed in the Mixing
Tube.
4. The Blower then forces the air/gas mixture into the
Combustion Chamber under a slight positive pressure.
5. The mixture is ignited in the Combustion Chamber,
around the circumference of the Flameholder.
Combustion continues until the pre-set water temperature is reached.
6. The Heat Exchanger tubes surrounding the Burner
extract heat from the hot flue gases and heat the water
flowing through the tubes.
7. The cooled exhaust is collected in a sealed Exhaust
Plenum, then is discharged out the flue.

Pool & Spa Basic Training

56

S4247

5 SECTION

Heaters

HEAT
HEATER SIZING
38

100

POOL HEATER SIZING CHART

(24 Hr. Period)

(Outdoors, 3.5 mph Wind)

Pool
Size
Sq. Ft. 10

Temperature
Rise
15
20
25

30

200
300
400
500
600
700
800
900
1,000

83,800
125,820
167,775
209,715
251,655
293,595
335,535
377,475
419,415

167,760
251,640
335,550
419,430
503,310
587,190
671,070
754,950
838,830

55,900
83,880
111,850
139,810
167,770
195,720
223,690
251,650
279,610

111,840
127,700
223,700
279,620
335,540
391,460
447,380
503,300
559,220

POOL MAINTENANCE HEATER

SIZING CHART

139,800
209,700
279,625
349,525
419,435
489,325
559,225
629,125
699,025

Heat Loss = Required Heater Output (BTUs/Hour)

Note: Chart prepared by the Commercial Water Heating Sub-committee of the
American Gas Association in Oct. 1995.

Figure 6

Initial Heat Up Time

Pool
Size
Sq. Ft. 10

Temperature
Rise
15
20
25

30

200
21,000 31,500 42,000 52,500
63,000
300
31,500 47,300 73,000 78,800
94,500
400
42,000 63,000 84,000 105,000 126,000
500
52,500 78,800 105,000 131,000 157,000
600
63,000 94,500 126,000 157,000 189,000
700
73,400 110,000 147,000 184,000 220,000
800
84,000 126,000 168,000 210,000 252,000
900
94,500 142,000 189,000 236,000 284,000
1,000
105,000 157,000 210,000 263,000 315,000
Heat Loss = Required Heater Output (BTUs/Hour)
Note: Chart prepared by the Commercial Water Heating Sub-committee of the
American Gas Association in Oct. 1995.

Figure 7

Example:

Figure 6 is an easy way to size a Heater for a swimming

pool. Simply determine the surface area square footage and
the desired temperature. Then refer to the chart for the
amount of BTUs required to heat up the swimming pool.

Using the previous example, the number of BTUs

required to heat up the swimming pool in 24 hours
is 3,332,000 BTUs. Divide this number by the
Output BTUs of the chosen Heater.
3,332,000 340,000 BTU = 9.8 hrs.

Example:

To maintain the heat in normal conditions, use the

chart in Figure 7 Using the above example, it would
take 84,000 BTUs per hour to maintain the desired
temperature.

A 400 sq. ft. pool with a Temperature rise of 20

degrees. The Heater Output per Hour needs to be
at least 223,700 BTUs to heat up the swimming
pool in 24 hours.
To calculate the heat up time, use the following
formula.
Pool Gallons x 8.33 (the weight of 1 gal of water) x
Temp. Rise = Output BTUs needed to achieve
desired water temp. in a 24 hour period.

Example:
20,000 gal. pool with a 20 temperature rise
20,000 x 8.33 x 20 = 3,332,000 Output BTUs
needed. 3,332,000 24 hours = 138,833 BTU
Heater.
If a heater has already been selected, the heat up
time can be determined using the same formula
and dividing the required BTUs to heat up the pool
or spa in 24 hours by the Output BTUs of the
heater.

Pool & Spa Basic Training

57

S4247

5 SECTION

Heaters

HEAT
PLUMBING AND SAFETY TIPS
38

100

FIRE

What do ya mean,
I cant put the heater near
a window and under the
eaves?

FUMES

Figure 8

Plumbing and Safety Tips

1. Leave access room around the heater for maintenance.
2. Comply with local codes when installing heaters. If
there are no local codes, install in accordance to the
National Fuel Gas Code, ANSI Z223.1 and the National
Electrical Code.
3. Install a check valve between the heater and any
Chlorinating Device that is down stream of the heater.
4. Heaters installed too close to combustible surfaces may
cause a fire. (Figure 8)
5. Check the Heater Owners Manual. The heater may
require a check valve between the heater and the filter.
6.

Heaters running on LP gas. LP gas is

heavier than air and can settle in low places. This is a
life hazard and a explosion hazard.

7. Flex gas connections can restrict the gas supply and

affect the performance of the heater.
8. Be careful when designing an external by-pass to divert
excess flow around the heater. It is possible to dead
head the flow on both sides of the heater. The pressure
switch may still sense pressure and allow the heater to
fire.

Pool & Spa Basic Training

58

S4247

6 SECTION

Reference
Equipment Pad

SPA
JET PUMP

CIRCULATION
SYSTEM

H
2 Way Valve

G
Check Valve
A

E
3 Way Valves
F

ABCDEFGH-

To the Spa Jets

From Spa Dual Main Drains for Safety
Return to Spa Deep Heat Return(s)
2 to Pool Returns
From Spa Dual Main Drains
From Pool Skimmer(s)
From Dual Main Drains
1-1/2 to Maintenance Drain

Basic Spa Equipment and Piping Specifications

CIRCULATION SYSTEM
Pool Pump
Gallons HP

JET PUMP

Mod
Filter

Sand
Filter

D.E.
Filter

Heater

No.
of
Jets

Pipe Sizing

Pump
HP

Pipe Sizing
A

20,000

1/2

150+

2.4+

37+

200,000+

1-1/2

1-1/2

1-1/2

1-1/2

1-1/2

3/4

1-1/2

1-1/2

27,000

3/4

150+

3.4+

53+

333,000+

1-1/2

1-1/2

1-1/2

4.9+

35,000

300+

53+

333,000+

1-1/2

1-3/4

2-1/2

44,000

1-3/4

300+

(2) 3.4+ 53+

400,000+

2-1/2

2-1/2

1-1/2

1-1/2

2-1/2

48,000

1-1/2

450

(2) 4.9+ 53+

400,000

2-1/2

2-1/2

1-1/2

2-1/2

2-1/2

56,000

450

(2) 4.9+

83

400,000

2-1/2

2-1/2

2-1/2

2-1/2

1-1/2

67,000

(2) 300+ (2) 4.9+

83

(2) 333,000+

1-1/2

10

Jet Pump Notes:

1. Pumps sized at 40 foot of head.
2. High Head or Medium Head pumps can be used. Pipe
runs of 35 feet or more, use High Head pump.
3. Spa jets calculated at 15 gpm each.

Circulation System Notes:

1. Pumps sized at 60 foot of head for an 8 hour turnover
rate.
2. Filters sized at best flow rates. + = O.K. to increase filter
size.
3. Pipe sizing based on 7 fps or better.
4. Multiple pump and filter systems can be substituted for
single systems.
5. If spa is elevated, place a check valve on line C.

Pool & Spa Basic Training

59

S4247

6 SECTION

Reference
B
C

G
D
A
E
H
F
C

C
B

1. Spa gallons 800 gallons

2. 30 minute turnover = 27 GPM
3. Pipe A From Spa Jet Pump - Full Flow
4. Pipe B Half Flow Manifold to Spa Jet Loops
5. Pipe C Spa Jet Loop
6. Pipe D Spa Jets
7. Pipe E Main Drain Manifold
8. Pipe F Suction Pipe from Dual Main Drain to Spa Jet Pump
9. Pipe G Suction Pipe to Circulation System
10. Pipe H Deep Heat Return(s) from Filter System
11. Skimmer 2 to the Pump

Spa Jet Hydraulics Balanced Hydraulic Design

Pipe Sizing

Spa Jet
Orifice

GPM Per
Jet

Total
GPM

1/4

56

1-1/2

1-1/2

1-1/2

1-1/2

1-1/2

5/16

11

88

1-1/2

1-1/2

1-1/2

2-1/2

1-1/2

1-1/2

3/8

15

120

1-1/2

1-1/2

1-1/2

7/16

19

152

1-1/2

1-1/2

1-1/2

1/2

25

200

2-1/2

2-1/2

1-1/2

2-1/2

1-1/2

1-1/2

Orifice Size for Gunite or Portable Spas.

All Jet Sizing at 15 gpm.
All Suction Piping sized at 6 fps or better.
All Return Piping sized at 8 fps or better.
Piping will need to be adjusted for runs of 50 or more.

Pool & Spa Basic Training

60

S4247

6 SECTION

Reference

Basic Swimming Pool Worksheet:

Pool Specifications:
Square Footage
Cubic Feet
Average Depth
Pool Gallons
8 Hr. Turnover Rate

Pipe, Fittings, Lights:

Number of Main Drains
Number of Skimmers
Number of Returns

System Head Loss:

Ft.
GPM

Main Drain Head Loss

Skimmer Head Loss
Return Piping Head Loss
Section I
Section II
Section III
Static Suction Lift
Filter/Heater
System Head Loss
Total System Head Loss

Ft.
Ft.

Circulation Pump

Ft.
Ft.
Ft.
Ft.

Max. Load Amps

Breaker Size
Wire Size
High Rate Sand Filter

Ft.
= 15.40

5' RADIUS
40'

8"

Other Equipment

AGW
Sq. Ft.

Amount of Sand

Lbs.
Sq. Ft.

Filter Flow Rate

fps

Amount of D.E.

Lbs.

Filter Flow Rate

Filter Flow Rate

5"

No.

fps

Modular Media Filter

3"

AMP

Filter Flow Rate

Cartridge Filter
20'

HP

Motor Voltage

Diatomaceous Earth Filter

Main Drain to Pump

Pipe Size
Skimmer to Pump
Pipe Size
Filter System to Returns
Pipe Size
Number of Lights

Filtration and Heating System:

Sq. Ft.
fps
Sq. Ft.
fps

Back Wash Valve Type

Heater Type

NA
LP

Heater Size

BTU

Gas Line Size

Inches

Equipment Pad

Pool & Spa Basic Training

61

S4247

6 SECTION

Pool & Spa Basic Training

Reference

62

S4247

Pool & Spa Basic Training

63

S4247

Simply Smarter.
Sta-Rite Pool/Spa Group
293 Wright Street, Delavan,WI 53115
North America: 800-752-0183, FAX 800-582-2217
International: 262-728-5551, FAX: 262-728-4461,TELEX: ITT 4970245

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