Pump Installation
Contents
1. Lightning In some areas where considerable lightning occurs it is recommended that a lightning arrestor be installed at the control panel Complete data on lightning arrestors and cost is available from the factory Lightning arrestors are good insurance against damage to an expensive motor Servicing Instructions IMPORTANT Read all instructions before replacing any parts 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 Field Service On Motor All submersible motors can be serviced out of warranty in the field by any reliable motor service shop Any pump in warranty must be returned to the factory for service or repaired in an authorized HYDROMATIC service center Charges will not be allowed if in warranty pump is not taken to a motor repair shop that is not an authorized HYDROMATIC service center When field service is performed on a pump these instructions should be carefully followed Replacing Stator If motor winding is burned or shorted it can be rewound or replaced with new factory wound stator Refer to sectional drawing of pump and motor and use following steps to remove and replace stator 1 If stator only is damaged it may not be necessary to completely dismantle pump as stator and housing can be lifted from pump without disturbing s2. seal parts Replace with all new seals 8 Thoroughly clean all castings before replacing seals One grain of dirt between the seal faces can cause failure Examine all O rings for nicks before reusing 9 Use Locktite on socket head locking screw in end of shaft 10 Before refilling chamber with oil air test as described above 11 Refill chamber with oil as described above 12 Always check all leads with high voltage or with megger for grounds before operating the pump CONNECTION DIAGRAM FOR LEADS IN MOTOR AND CONNECTION BOX Y WYE MOTOR CONNECTIONS 230 VOLTS 5 4 8 460 VOLTS 11 2 19 tb 15 GREEN Pump Troubleshooting Below is a list of common problems and the probable causes Pump will not start 1 No power to the motor Check for blown fuse or tripped circuit 2 Hand off auto switch may be in the off position 3 Control circuit transformer fuse may be blown 4 Overload relay on starter may be tripped Push to reset Pump will not start and overload heaters trip 1 Turn off power and check motor leads with megger or ohmmeter for possible ground 2 Check resistance of motor windings All 3 phases should show close to the same reading 3 If no grounds exist and the motor windings check O K remove pump from sump Oand check for clogged or blocked impeller Pump operates with selector switch in hand position but will not operate in auto position 1 Thi
3. Pump Installation and Service Manual HYDROMATIC Sas Submersible Sewage Pump E NOTE To the installer Please make sure you provide H HYD ROMATIC e this manual to the owner of the pumping equipment or to the responsible party who maintains the system Pentair Pump Group General Information Thank you for purchasing your HYDROMATIC Pump To help insure years of trouble free operation please read the following manual carefully Before Operation Read the following instructions carefully Reasonable care and safe methods should be practiced Check local codes and requirements before installation Attention 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 Keep it in a safe place so that you may refer to it often Unpacking Pump Remove pump from carton 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 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 Pumps Not In Storage Operating or Pumps with carbon ceramic seals must have impellers manuall
4. Upper Bearing R 25 10922 024 5 Rotor w Shaft 3HP 19 6461 0245 Cord Cap Assy 30 Single 10 4 9 00065 018 Lower Bearing R 01329 025 5 Rotor w Shaft All 30 6461 002 5 Cord Cap Assy 15 Single 12 4 10 04916 000 Shaft Seal 5 2750 023 5 Rotor w Shaft 5HP 12 6461 014 5 Cord Cap Assy 30 Single 12 4 04916 001 Shaft Seal Carbide Opt C 26 4698 003 Stator 3HP 19 230V R 0418 000 5 Cord Cap Assy 15 Single 8 4 1 00239 016 Capscrew 4 4699 003 Stator 3HP 39 230 460V R 0418 002 5 Cord Cap Assy 30 Single 8 4 2 01130 003 Machine Screw Flat Head 4 4699 203 Stator 3HP 39 200V R 29 9978 007 2 Impeller 3HP 3 09995 000 2 Volute Case 4699 603 Stator 3HP 39 575V R 9978 008 2 Impeller 5HP 4 10108 000 1 Impeller Washer 4711 003 Stator 5HP 19 230V R 9978 009 2 Impeller 712HP 5 00238 001 1 Impeller Capscrew 4712 003 Stator 5HP 39 230 460V R 51700 061 7 Seal Kit R 6 08908 002 1 Key 4712 203 Stator 5HP 39 200V R 51700 361 7 Carbide Seal Kit 7 09996 002 2 Seal Plate 4712 603 Stator 5HP 39 575V R Rebuild Kit Notes S Parts in Seal Kit C Parts in Carbide Seal Kit I Parts in Impeller Kit R Parts in Rebuild Kit Consult Factory OJ LL 28 24 a Ff N e 6 Not Shown 23 22 10 12 13 7 KhhIISQEEX SSI 14 29 15 16 WARRANTY Hydromatic Pumps Inc warrants to the original purchaser of e
5. ach Hydromatic product s that any part thereof which proves to be defective in material or workmanship within one year from date of installation or 18 months from manufacture date whichever comes first will be replaced at no charge with a new or remanufactured part F O B factory Purchaser shall assume all responsibility and expense from removal reinstallation and freight Any item s designated as manufactured by others shall be covered only by the express warranty of the manufacturer thereof This warranty does not apply to damage resulting from accident alteration design misuse or abuse The pump must be installed operated and maintained in accordance with the published instructions of the appropriate Installation amp Service Manual All dual seal non clogs and 3 5 HP grinders must have seal failure and heat sensors attached and functional for Warranty to be in effect If a seal failure should occur Hydromatic Pumps will cover only the lower seal and labor thereof Labor based on Authorized Service Center contract allowance If the heat sensor is not attached and functional Warranty is void If the seal failure sensor is not attached and functional Warranty is void If the material furnished to the Buyer shall fail to conform to this contract or to any of the terms of this written warranty Hydromatic Pumps Inc shall replace such nonconforming material at the original point of delivery and shall furnish instruction for its disposition An
6. eals or bearings 2 Drain all oil from upper housing If oil is clean and no water is present seals can be considered satisfactory to reuse 3 After chamber is drained remove hold down bolts and lift off Use care in lifting 4 Set assembly on bench and remove cord cap assembly When this is lifted off connection wires to motor will be exposed These wires will probably be burned but each wire is tagged with a metal marker giving wire number Cut the wires 5 If the leads to the cord cap assembly are burned the assembly must be replaced Pump Maintenance 6 After stator retaining ring is removed turn housing upright and bump on hardwood blocks This should jar the stator loose and allow it to drop out 7 Thoroughly clean housing before replacing new stator Replace stator and make all wire connections to cord cap assembly before replacing housing on pump This is important as leads must be tucked behind the windings by using hands up through rotor core IMPORTANT Use only compression type insulated connectors on the wires Do not tape leads as oil will deteriorate the tape and cause damage to stator and bearings 8 Check top bearing If clean and does not turn rough bearings can be reused and it is not necessary to completely dismantle pump to change bearings If bearings are damaged with dirt or heat they must be replaced See additional instructions on replacing seals and bearings R
7. emember to reinstall the upper bearing load spring 9 Replace stator housing onto seal chamber and bolt in place Be sure O ring seal has been replaced If O ring is nicked or cut replace the new rings This applies to all O rings used in assembly 10 After all leads are reconnected make a high voltage ground test on each wire The only wire that should show ground is the green power lead 11 Refill motor chamber with oil Use only high grade transformer oil or regular HYDROMATIC special submersible oil Fill chamber until oil covers top of windings Leave air space in top for expansion Use permatex on plug threads Replacing Seals And Bearings 1 Drain all oil from motor chamber as described Remove bolts that hold motor housing to pump housing Remove screws holding seal plate to motor housing Lift rotating assembly rotor shaft and impeller from pump case and place horizontally on bench With hardwood block tap end of impeller to loosen from shaft Shaft sleeves are not used Remove lower seal spring and pry out seal with screwdriver Fig 1 6 Use bearing puller to remove bearings Replace with new bearings Press only on inner race of bearing when replacing Pressing on outer race can damage the bearing Bearings are standard size that can be obtained from any bearing supply house or can be obtained from HYDROMATIC factory 7 IMPORTANT Do not use any of the old
8. ires can be 14 16 or 18 gauge wire If power lines are for 460 or 575 volts insulation of control wires must be for this voltage if used in conduit with power lines Volts 230 460 575 230 460 575 230 460 575 230 460 575 230 460 575 230 460 575 230 460 575 230 460 575 230 460 575 Wire Motor Size HP 3 3 3 5 5 5 TV 72 Th 10 10 10 15 15 15 20 20 25 25 25 30 30 30 35 35 35 12 110 450 700 90 370 580 10 180 720 1120 140 550 370 90 360 560 50 220 340 8 270 1100 1650 220 900 1400 175 700 1100 105 420 650 320 500 230 360 180 280 6 400 1600 2500 350 1400 2200 220 900 1400 150 600 930 105 420 650 90 370 570 360 560 320 500 230 360 4 370 1500 2300 230 950 1450 175 700 1100 140 550 850 125 500 800 100 400 620 90 360 560 2 370 1500 230 270 1100 1700 220 900 1400 210 820 1250 200 800 1250 150 600 930 Special Junction Box required for wire sizes larger than 4 NUMBER OF CONDUCTORS REQUIRED BETWEEN CONTROL PANEL AND NEMA 4 JUNCTION BOX System Number of Number of Number of Type Control Wires Power Lines Ground Wires 8 Simplex 3 3 1 Simplex with Alarm 5 3 1 Duplex 5 6 1 Duplex With Alarm 7 6 1 Pump Operations Starting System 1 Turn H O A switch to off position then turn on main circuit breakers Open all discharge valves and allow water to rise in sump pump Turn H O A switch to Hand position on one pump and notice operation If pump is noisy and vibrates rota
9. k valve where it is desirable Q 1 2 3 4 5 6 Not Shown 29 15 16 to self drain the discharge line to prevent freezing This can be done only with short discharge lines Otherwise water will return to the sump and cause short cycling of the pump Nema 4 Junction Box Optional If electrical control panel is to be set remote from the pump sump a NEMA 4 junction box should be used to make power and control connections The HY DROMATIC NEMA 4 junction box is provided with compression connectors for sealing all wires No sealing compound is needed to make connections waterproof Wiring diagrams are provided with panel for making connections An extra set of diagrams are included so that one set can be used during installation when making connections The size of any additional wiring from the pump cord to the panel is based on the distance and pump 58 24 27 26 25 Pump Installation current Double check that all wiring is properly connected and tight NOTE On single phase pumps the white black and red pump wires must be connected properly to the panel Only the proper sequence will work Installing 3900 Switch Float The float cords are supported by a mounting bracket that is attached to sump wall or cover or to the NEMA 4 junction box Cord snubbers are used to hold the cord in place Float level can be changed at any time by loosening Mercury the snubbe
10. logged impeller 28 24 ORDERING REPLACEMENT PARTS Product improvements are made from time to time The latest part design will be furnished as long as it is interchangeable with the old part When ordering replacement parts always furnish the following information 1 pump serial number 2 pump model and size 3 part description 4 part number 5 impeller diameter if ordering impeller 6 quantity required and 7 shipping instructions Ref Part Part Ref Part Part Ref Part Part No No Description Qty No No Description Qty No No Description Qty 1 00589 002 Eyebolt 2 18 00150 021 O Ring SE wil 4713 003 Stator 71 2HP 39 230 460V R 1 2 00178 004 Capscrew 2 19 00517 007 Capscrew 4 4713 203 Stator 71 2HP 30 200V R 1 3 13425 023 Nameplate 1 20 00995 008 Lockwasher 4 4713 603 Stator 71 2HP 30 575V R 1 4 04580 001 Drive Screw 4 21 00299 002 Stator Retaining Ring 27 2577 000 Wire Connector As Recq 5 00087 004 Pipe Plug 1 22 05454 001 Roll Pin 0282 001 1 Wire Connector 14 amp 16 wire size As Recq 6 01032 003 Nut Hex 3 8 16 SST 2 23 13391 000 2 Motor Housing 1006 001 1 Wire Connector 10 amp 12 wire size As Recq 1 00064 003 Load Spring R 24 00834 015 1 O Ring sc 28 6461 023 5 Cord Cap Assy 15 Single 10 4 8 00065 021
11. ols can be supplied for alarm functions Triplex systems use four floats The fourth highest float brings on the second lag pump Three pumps operate together only if sump level rises to the fourth float second override This float also brings on the third pump in case of failure of either or both of the first two pumps Alarm Controls The alarm float is usually set above the override level so the alarm will signal only if the override level is exceeded However some engineers prefer to have the alarm float set below the override level as it is possible for one pump to fail and the other pump to operate on the override level with the sump level never reaching the alarm level This is particularly true in cases of low inflow capacity Electrical Control Panel It is recommended that the HYDROMATIC control panel be used with all pumps as proper start components and pump protection are furnished NOTE All single phase pumps require properly sized start capacitor start relay and run capacitor in the control panel IMPORTANT If HYDROMATIC control panel is not used and the motor fails because of improper components the motor guarantee is void HYDROMATIC equipment is installed in a weatherproof enclosure The electrical equipment includes a main circuit breaker for each pump a magnetic starter with overload protection for each pump a H O A switch and run light for each pump an electric alternator and a transf
12. omatic Ashland Ohio All Rights Reserved L HYD ROMATIC Your Authorized Local Distributor Pentair Pump Group 1840 Baney Road Ashland O hio 44805 Tel 419 289 3042 Fax 419 281 4087 www hydromatic com ISO 9001 Certified Part 5625 321 1 ltem E 03 321 5M 1 01
13. ormer to provide appropriate control for control circuit and alarms electrical Overload Heaters If a HYDROMATIC control panel is not used on three phase pumps all three phases must have over load protection The overload should be ambient compensated class 10 The heaters full load amps on the pump be sized in accordance with the nameplate amps on the motor housing The amp draw on these submersible motors is slightly higher than a corresponding horsepower surface motor so heaters must be sized by the nameplate full load amp rating Single phase pumps with capacitor start Circuit must have the overload protection on the black pump lead NOTE On single phase pumps the white black and red pump leads must be connected properly for the pump to run Pump Installation Installing Before installing pump in sump lay it on side and turn impeller with fingers Impeller may be slightly stuck due to factory test water so it must be broken loose with small bar or screw driver in edge of vanes The impeller should turn freely Clean all trash and sticks from sump and connect pump to piping A check valve must be installed on each pump A gate or plug valve in each pump discharge line is also recommended This valve should be installed on the discharge side of the check valve so if necessary to service the check valve the line pressure can be cut off Single pump systems are sometimes installed without a chec
14. r cord length and readjusting In either simplex or duplex system the lower or turn off float is set just above the top of volute so that the volute will always be submerged during the pumping cycle The second or lead on float higher is set at about 24 inches above the lower turn off control More distance between turn on and turn off controls can be used but sewage may become septic and excessive solids may collect for the pump to handle A frequent pumping cycle is recommended for best operation If an alarm system is used this control is usually set about 6 inches above the override control Some engineers as described previously prefer to have the WIRE SIZE TABLE alarm control set below the override control Making Electrical Connections All electrical wiring must be in accordance with local code and only competent electricians should make the installations A set of prints is included for use in making the installation All wires should be checked for grounds with an ohmmeter or Megger after the connections are made This is important as one grounded wire can cause considerable trouble IMPORTANT If equipment is not properly wired and protected as recommended the motor guarantee is void FOR REMOTE LOCATION OF CONTROL PANEL LENGTHS ARE BASED ON A VOLTAGE DROP OF TWO PERCENT Maximum length in feet from NEMA 4 junction box to control panel For 3 phase only and for power lines only All control w
15. s indicates trouble in the float level control or the alternator relay 2 To check for defective float control put selector switch in auto position and turn off main power Put a jumper wire on terminal strip Tum on power and if pump starts trouble is in float control Replace control Pump runs but will not shut off 1 Pump may be air locked Turn pump off and let set for several minutes then restart 2 Lower float control may be hung up in the closed position Check in sump to be sure control is free 3 Selector switch may be in the Hand position Pump does not deliver proper capacity 1 Discharge gate valve may be partially closed or partially clogged 2 Check valve may be partially clogged Raise level up and down to clear 3 Pump may be running in wrong direction Low speed pumps can operate in reverse a fF N 6 Not Shown 7 8 29 15 16 direction without much noise or vibration Discharge head may be too high Check total head with gauge when pump is operating Total head is discharge gauge pressure converted to feet plus vertical height from water level in sump to center line of pressure gauge installed in discharge line Gauge should be installed on pump side of all valves Multiply gauge pressure in pounds by 2 31 to get head in feet If pump has been in service for some time and capacity falls off remove pump and check for wear or c
16. tion 1s wrong To change rotation 3 phase interchange any two line leads to motor DO NOT INTERCHANGE MAIN INCOMING LINES If duplex system check second pump in same manner Now set both H O A switches to Auto position and allow water to rise in sump until one pump starts Allow pump to operate until level drops to turn off point Allow sump level to rise to start other pump Notice run lights on panel pumps should alternate on each successive cycle of operation Turn both H O A switches to off position and allow sump to fill to the override control level Turn both switches to Auto position and both pumps should start and operate together until level drops to turn off point Repeat this operation cycle several times before leaving job Check voltage when pumps are operating and check the amp draw of each pump On 3 phase pumps check amps on each wire as sometimes a high leg will exist One leg can be somewhat higher 5 to 10 without causing trouble For excessive voltage draw on one leg the Power Company should be consulted Pump Maintenance As the motors are oil filled no lubrication or other maintenance is required The pump should be lifted once every two years and the oil drained from the motor chamber to check for water Generally these pumps give very reliable service and can be expected to operate for years on normal sewage pumping without failure
17. y rotated 6 revolutions after setting non operational for 3 months or longer and prior to electrical start up Pump The S3S submersible pumps are supplied for 1 and 3 phase and for 200 230 460 or 575 volts Pump is supplied with 15 feet of power cord Longer cable lengths can be furnished but must be specified at time of order Power cable is 4 wire with the green wire for ground Be sure green wire is connected a ground lug in the control panel and the control panel must be connected to a ground rod or ground wire from supply service NOTE All single phase pumps require properly sized start capacitor start relay and run capacitor in the panel Sump Level Control Sump level is controlled by HYDROMATIC 3900 mercury switch level controls The 3900 level controls is a metal case mercury switch sealed in a solid polyurethane float The float is held in position by a weight attached to the power cord above the float The cord supports the float and is adjusted for height from the surface Typical duplex systems use three Floats the lowest float turns the pumps off the next higher float starts the lead pump the next higher float override starts the lag pump The pumps alternate on successive cycles Two pumps operate together only if sump level rises to the third or override float The override float also brings on the second pump in case of failure of the first pump Extra floats with appropriate contr
18. y transportation charges involved in such disposition shall be for the Buyer s account The Buyer s exclusive and sole remedy on account or in respect of the furnishing of material that does not conform to this contract or to this written warranty shall be to secure replacement thereof as aforesaid Hydromatic Pumps Inc shall not in any event be liable for the cost of any labor expended on any such material or for any incidental or consequential damages to anyone by reason of the fact that such material does not conform to this contract or to this written warranty ALL IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE ARE DISCLAIMED TO THE SAME EXTENT AS THE EXPRESS WARRANTY CONTAINED HEREIN Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you MANUFACTURER EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ARISING IN CONNECTION WITH THIS PRODUCT INCLUDING WITHOUT LIMITATION WHETHER IN TORT NEGLIGENCE STRICT LIABILITY CONTRACT OR OTHERWISE Some States do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from State to State 1999 Hydr
Download Pdf Manuals
Related Search