relay logic control panels installation and service manual
Contents
1. voltage and control circuit voltage c Check overload relay to see if it is tripped Reset relay if tripped and check pump current with amp meter d With the power off check motor heat sensor continuity e Check wiring of pump to control panel It should agree with the schematic f Check contactor coil resistance 2 Pump does not run in Auto position a Check items above in 1 Floats may be miswired to control panel Check float type N O or N C and hook up by referring to the schematic If the start and stop floats are hooked in reverse pump will short cycle and will not pump the level down Check if the water level in the system is high enough to activate the floats 2 If there is enough water in the system with the power turned off mark and disconnect the off and on floats Next install jumper wires in the terminal blocks for off and on floats Turn power back on put H O A switch in Auto and see if pump runs 3 1f pump runs with jumper problem is with floats Remove jumpers and troubleshoot floats with ohmmeter 4 If pump does not run in Auto mode with jumpers check Auto circuit wiring in panel Pump runs but run light does not energize a Remove light and check with an ohmmeter b Check run light wiring Pump runs but does not pump down the wet well a On three phase only pump rotation may be wrong Wiring of pump to control panel may be r2. gt PENTAIR HYDROMATIC RELAY LOGIC CONTROL PANELS INSTALLATION AND SERVICE MANUAL ps NOTE To the installer Please make sure you provide this manual to the owner of the equipment or to the responsible party who maintains the system Item H 03 481 Part 4 5625 481 1 2014 Pentair Ltd 12 11 14 General Information This manual contains important information for the safe use of this product Read this manual completely before using this product and refer to it often for continued safe product use Do not throw away or lose this manual Reasonable care and safe methods should be practiced Check local codes and requirements before installation Unpacking Panel When unpacking unit check for concealed damage Claims for damage must be made at the receiving end through the delivery carrier Damage cannot be processed from the factory CALIFORNIA PROPOSITION 65 WARNING 44 WARNING This product and related accessories contain chemicals known to the State of California to cause cancer birth defects or other reproductive harm Power Supply WARNING Do not attempt to wire this control box unless you have a good working knowledge of electricity and are familiar with the state and local codes If you are in doubt about anything contact a qualified el
3. phase systems WARNING Before handling these pumps and controls always disconnect the power first Do not smoke or use sparkable electrical devices or flames in a septic gaseous or possible septic sump Electrical Connections The contractor must conform to the latest requirements of the National Electrical Code All conduit and cables shall be in accordance with NEC Code NFPA 70 To maintain UL and CSA ENCL rating use the same type UL and CSA weatherproof conduit hubs when connecting to this enclosure Prior to conducting any installation repair or service with regard to the control panel refer to the schematic appropriate for that panel The schematic will provide guidance with regard to the terminal block connections CAUTION A nonmetallic enclosure does not provide grounding conduit connections Use grounding bushing and jumper wires Make the Following Electrical Connections a Connect the pump leads to the control panel If pump is single phase and the panel has start capacitor start relay and run capacitor it is critical that the pump leads be connected properly The White Black and Red pump leads must be connected to the appropriate terminals as directed by the panel schematic and the label on the back panel below the terminals b Connect the pump heat sensor and seal failure leads if available on the pump to the appropriate terminal blocks in the control panel c Connect al
4. balance on three phase power sources can cause motor current to become unbalanced and excessive heating will result Tripping of the overload protectors and premature motor failures can be expected if the current unbalance exceeds five percent Maximum Current Percent i Difference from x 100 Current Average Current Unbalance Average Current To determine if motor current unbalance is a function of the motor or the power supply 1 Label the leads and the terminals 1 2 and 3 respectively 2 Record the amperage for each lead 3 Move each lead to the next terminal 1to2 2to3 3to1 4 Read the amperage of each lead 5 Move each lead to the next terminal 1 to3 2to 1 3to2 6 Read the amperage of each lead 7 1f the unbalance moves with the motor leads the unbalance is caused by the motor If the unbalance remains with the terminals the unbalance is in the power supply 8 If the current unbalance exceeds five percent nuisance tripping or excessive heating will result 9 Connect leads for the lowest percent of current unbalance f Check connections and start components on single phase units 1 Disconnect all power from the panel before making these checks 2 Motor winding resistance readings a Disconnect all three motor leads from panel terminal blocks b Using a volt ohmmeter with the scale set on RX1 measure the resistance between the leads with the chart T
5. d Start Line Voltage Black to Red Run 1DE Ling Start Winding Voltage THIS PAGE INTENTIONALLY LEFT BLANK STANDARD LIMITED WARRANTY Pentair Hydromatic warrants its products against defects in material and workmanship for a period of 12 months from the date of shipment from Pentair Hydromatic or 18 months from the manufacturing date whichever occurs first provided that such products are used in compliance with the requirements of the Pentair Hydromatic catalog and technical manuals for use in pumping raw sewage municipal wastewater or similar abrasive free noncorrosive liquids During the warranty period and subject to the conditions set forth Pentair Hydromatic at its discretion will repair or replace to the origina reserves the right a change or improvemen Start up reports and elec user the parts that prove defective in materials and workmanship Pentair Hydromatic o change or improve its products or any portions thereof without being obligated to provide such for prior sold and or shipped units rical schematics may be required to support warranty claims Submit at the time of start up through the Pentair Hydromatic website http forms pentairliterature com startupform startupform asp type h Warranty is effective on devices must be hooked only the lower seal and responsible for the cos y if Pentair Hydromatic authorized control panels are used All seal fail and heat sensing up f
6. e power check to see if each pump has proper rotation Wrong rotation will give low flow 8 Check full load current with amp probe and compare it with the nameplate rating On three phase pumps check all three phases On single phase pumps check black pump lead 9 Check operation of start relay if supplied on single phase panels 10 With H O A switch in Auto check float operation and response to control panel to the float operation For sequence of operation refer to design specification 11 Make sure H O A switch is left in the Auto position after start up is completed Pump Start Up Refer to pump Installation and Service Manual Pump Maintenance The maintenance schedule will vary with operating and environmental conditions It will also vary with the specific type of control supplied 1 Exercise breaker through one cycle Be careful not to over exercise as the breaker is not a switching device Excessive operations tend to affect the trip curve of the breaker 2 Check contactors and relays for excessive humming This can be accomplished by turning pumps on and off in the Hand mode with the H O A switch 3 Check pump run light s by running pump s in Hand mode Check bulb s in any other light s 4 With the power off check continuity of all control fuses 5 Check voltage at primary and secondary of control transformer 6 Check the pump full load amps 7 For single
7. ectrician Do not attempt to operate this unit on any other voltage or power distribution other than for which it was originally designed check nameplate Failure to comply with this will result in the immediate cancellation of all watranties and claims It is advisable to put the panel on its own circuit using a circuit breaker adequately sized to protect the pump s Check state 2 and local codes for the correct wire size and circuit protection to use The wire should be sized large enough to handle the full load current of the pump s you are operating and any voltage drop that might occur due to long service runs Run power supply lines to the control box and secure Select a convenient location on the bottom to enter the box with the power supply Cut a hole with a chassis punch Avoid getting metal chips in the components while cutting hole After the hole is cut any metal particles must be removed from the box Failure to do so may result in premature component failure Connect incoming power to the terminal blocks labeled L1 L2 L3 and all necessary ground wires to the ground lug at the bottom of the box The ground lug should be fastened to a good driven earth ground by one of the methods described in the National Electric Code NEC does not permit using ground as a current carrying conductor therefore a neutral must be provided for 115 volt 1 phase 208 volt 1 phase 230 volt 1 phase or 208 volt 3
8. everse sequenced b Impeller may be dragging in volute due to solids High amperage draw would identify this c Refer to the pump manual for other possibilities Severe humming chattering of contactors and control relays a There may be low voltage Check voltage at primary and secondary of control transformer using a voltmeter This low voltage condition may cause severe chattering and burnout of contactors and relays b Contactor may have dust around magnet of coil structure Dry or clean as required c Check voltage to the control panel Contactors require a minimum of 85 of full voltage to pull in without chatter If the problem is a recurring one measure voltage with recorder on a 24 hour basis d Make sure the floats are located away from any turbulence e Dry out the junction box if furnished moisture in the junction box may cause relays to energize intermittently 6 Short cycling pump a Check float controls 7 Run light stays on a Selector switch may be in the Hand position 8 Nuisance tripping of overload on motor starters or circuit breakers a Check pump amp draw with amp probe and compare to nameplate amps on pump b The impeller may be locked up due to excessive debris or solids c Possible motor failure fault in windings d Pump may be miswired to terminal block e Check for possible voltage and current unbalance Three phase only Voltage un
9. hould exercise judgment in defining specific requirements based on this guide 1 Fuses for control transformer primary and secondary If required 2 Contactor 3 Bulbs for any light requiring a bulb 4 Control transformer If required 5 Alternator relay If required Float Controls Optional The low water redundant off float should be installed just above where the pump begins to ingest air normally this is about the top of the volute The off float should be installed about halfway down the pump If a low water redundant off float is used then the off float should be installed a minimum of 4 inches above the low water redundant off float Install the on lead floats a minimum of 4 inches above the off float If additional volume is to be pumped on each cycle or if the pump running time for each cycle needs to be increased then increase the distance from the on lead float to the off float as needed Install the high water float 4 inches above the on lead float For duplex systems install the lag override float 4 inches above the high water float On duplex systems where both pumps have to run on a daily basis to keep up with the incoming flow then the high water and the lag override float position should be reversed Troubleshooting 1 Pump does not run in Hand position a Check pump circuit breaker and control fuse for tripping or blown condition b Check incoming power
10. l the float control leads or 4 20mA leads to the appropriate panel terminals Contractor must be very careful in locating the floats at the proper elevations The maximum distance from the control panel to the floats is the lesser of 100 feet or the maximum distance recommended for the pump d Before connecting power to the control panel make sure all control switches e g H O A switch and protective devices e g breakers are in the Off position Now connect power to the terminal block or the circuit breaker as directed by the schematic e Control panel must be grounded properly per NEC and or local codes To facilitate this a ground lug is provided on the control panel Start Up Operation 1 Check junction box for moisture Moisture may cause chattering of relays contactors 2 If pump is single phase with start capacitor start relay and run capacitor in panel Check that pump White Black and Red power wires are connected to panel correctly 3 Check incoming power voltage to make sure that it is correct for panel and pump model 4 Turn on power to panel 5 Check overload relay and verify reset mode if overload is supplied 6 Check voltage to the panel and at secondary of control transformer using a voltmeter If no transformer is supplied check voltage at the circuit breakers 7 With H O A switch in hand check discharge to verify the pump is running Check for flow On three phas
11. ltered by anyone other than Pentair Hydromatic or an ce provider h to any unit that has been repaired using non factory specified Y ATI G rom abuse accident rade practices e if the unit is han for what it is designed and TIES THAT EXTEND PARTICULAR PURPOSE C BE LIABLE OR RESPONSIBLE FOR FROM OR RELATED IN ANY MANNER TO PARTS THEREOF PERSONAL INJURY AND OR PROPERTY DAMAGE MPROPER INSTALLAT ON PENTAIR HYDROMAT 0 C DISCLAIMS ALL LIABILITY INCLUDING PENTAIR HYDROMATIC RECOMMENDS Some states do not permit some or all of the above warranty limitations or the exclusion or limitation of incidental or consequential damages and therefore such limitations may not apply to you No warranties or representations at any time made by any representatives of Pentair Hydromatic shall vary or expand the provision hereof gt PENTAIR HYDROMATIC 740 EAST 9TH STREET ASHLAND OHIO USA 44805 419 289 1144 WWW HYDROMATIC COM Warranty Rev 12 13 490 PINEBUSH ROAD UNIT 4 CAMBRIDGE ONTARIO CANADA NIT 0A5 800 363 PUMP
12. phase panels with start circuit about 5 seconds after the pump starts check the voltage from terminal 1 to terminal 2 on the start relay to be sure that the relay has operated The voltage from terminal 1 to terminal 2 on the start relay must exceed 10 VAC For some pumps the voltage may exceed 400 VAC If after 5 seconds the voltage from terminal 1 to terminal 2 on the start relay does not exceed 10 VAC stop the pump as damage to the start capacitor may occur in about 15 seconds If the start relay is not operating check the pump and the system voltage to be sure that they match Check the power wiring to ensure that the pump is connected properly Start the pump once more and check that the voltage from the terminal for the black wire to the white wire is within system tolerance 8 Check junction boxes for moisture Moisture may cause chattering of relays and contactors 9 Check for moisture inside control panel enclosure Moisture can cause damage to electrical components Check door gasket for proper seal 10 Check labels to verify they have not been damaged 11 Lubricate enclosure hinges 12 Pull floats and check for proper operation and ensure there is no foreign buildup on them Spare Parts List The following is a list of recommended spare parts However conditions of service vary significantly and a general list may not in its entirety be applicable to a given installation The user s
13. unctional and monitored or this warranty will be void Pentair Hydromatic will cover labor thereof for all dual seal pumps Under no circumstance will Pentair Hydromatic be of field labor travel expenses rented equipment removal reinstallation costs or freight expenses to and from the factory or an authorized Pentair Hydromatic service facility This limited warranty will not apply la to defects or malfunctions resulting from failure to properly install operate or maintain the unit in accordance with or negligence c to normal maintenance services and parts used in connection with such service d to units that are not installed in accordance with moved from its original installation manufactured g to any uni authorized Pentair Hydromatic servi OEM parts Warranty Exclusions Liability Limitation PENTAIR HYDROMATIC MAKES NO EXPRESS OR IMPLIED WARRA FACE HEREOF PENTAIR HYDROMATIC SPECIFICALLY DISCLAIMS THE BILITY AND FITNESS FORA BEYOND THE DESCRIPTION ON THE MPLIED WARRANTIES OF MERCHANTA IN NO EVENT SHALL PENTAIR HYDROM CONSEQUENTIAL INCIDENTAL OR SPECIA ANY PENTAIR HYDROMATIC PRODUCT OR MAY RESULT FROM IMPROPER INSTALLATI LIABILITY UNDER THIS WARRANTY FOR NSTALLATION BY PROFESSIONALS L DAMAGES RESULT the printed instructions provided b to failures resulting applicable local codes ordinances and good location f if unit is used for purposes other t that has been repaired or a
14. ypical Resistance Winding Motor Leads Reading Main Black to Lowest White Start Black to Next Lowest Red Middle Both White to Highest Red Main amp Start 3 Check capacitor a Make sure the capacitor is discharged Use extreme caution as a spark might occur b Disconnect the capacitor leads and connect an analog type volt ohmmeter to the capacitor terminals c Set the meter on the RX1 000 scale to check the start capacitor Set the meter on the RX10 000 scale to check the run capacitor d The meter should indicate low ohms when it is first connected but as the capacitor becomes charged by the meter it will return to a reading of infinity open circuit 4 Check start relay a Check the coil resistance It should be 3 000 to 15 000 ohms b Install a clamp on amp meter around the start winding lead c Set the amp meter scale to at least 2 times the pump motor full load current d Place the H O A switch in the Hand position to start the pump e The meter should read approximately 2 times full load current during starting f After the motor has started within one second the current should drop to a value much less than full load current 5 Motor voltage check Typical Motor Voltage Component Lead Mode Reading Main Winding Black to White Start Line Voltage Main Winding Black to White Run Line Voltage Start Winding Black to Re
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