Pentair Hydromatic Dry Pit Installation And Service Manual

MODEL DRY PIT

SOLIDS HANDLING DRY PIT PUMPS

INSTALLATION AND SERVICE MANUAL

NOTE! To the installer: Please make sure you provide this manual to the owner of the equip ment or to the responsible
party who maintains the system.

Item # E-03-458 | Part # 5625-458-1 | © 2013 Pentair Ltd. | 11/11/13

General
Information

Shipping:

When unpacking unit, check
for concealed damage. Claim
for damage must be made at the
receiving end through the delivering
carrier. Damage cannot be processed
from the factory.

CALIFORNIA PROPOSITION
65 WARNING:

This product
and related accessories contain
chemicals known to the State of
California to cause cancer, birth
defects or other reproductive harm.

Pumps Not Operating or in
Storage:

Pumps with carbon ceramic seals
must have impellers manually
rotated (6 revolutions) after setting
nonoperational for 3 months
or longer and prior to electrical
start-up.

Pumps with carbide seals must
have impellers manually rotated
(6 revolutions) after setting
nonoperational for 3 weeks
or longer and prior to electrical
start-up.

Seal Failure:

An electrode is installed in the
seal chamber so if water enters
the chamber through the first seal,
the electrode will be energized and
a signal will be transmitted to
the sensing unit at ground surface,
causing an alarm activation. The
electrode probe is installed in
all units, but the sensing unit is
supplied at an extra cost and must
be ordered.

In operation the seal failure unit
indicates only that there is some
water in the seal chamber. The pump
will continue to operate, but the
seal should be checked immediately
after failure is indicated.

2

The sensing unit is recommended on
all installations as good insurance
against motor failure.

Pump:

The dry pit submersible pump is
supplied for 1 or 3 phase and for
200, 230, 460 or 575 volts. Power
cable is supplied with green wire to
connect to a good ground such as
water pipe or ground stake.

Heat Sensors:

All motors have heat sensor units
embedded in the motor winding
to detect excessive heat. The heat
sensors are set to trip at 120ºC. The
sensors automatically reset when
the motor cools to safe temperature.

The sensors are connected in
series with the motor starter coil
so that the starter is tripped if heat
sensor opens. The motor starter is
equipped with overload heaters so
all normal overloads are protected
by the starter.

IMPORTANT: If Hydromatic
electrical starting equipment
is not supplied, the heat sensor
circuit must be connected in
series with the starter coil or
warranty is void.

Wet Well Level Control:

Sump level is controlled by
Hydromatic switch controls. The
float is held in position in the sump
by a weight attached to the power
cord above the float. The cord
supports the float and is adjusted
for height from the surface.

Duplex systems use three controls:
one set at turn-off, one set at turn­on for one pump, and one set at
turn-on for both pumps. Pumps
then alternate lead and lag on each
successive cycle. Two pumps
operate together only when the
sump level rises to the third or
override control. The override
control also brings on the second
pump in case of failure of the first
pump. Extra floats with appropriate

®

controls can be supplied for alarm
functions. Triplex systems use four
controls: One set at turn-off, one
set at turn-on for one pump, one
set at turn-on for two pumps, and
one set at turn-on for three pumps.
The pumps alternate with each
successive cycle.

Three pumps operate together only
if the sump level rises to the fourth
control (second override). This
control also brings on the third
pump in case of failure of either or
both of the first two pumps.

Alarm Controls:

The alarm level 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
level 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 starter
heaters and connections for heat
sensor wires are furnished.

Hydromatic electrical equipment
is installed in a weatherproof
NEMA 3R enclosure. The electrical
equipment includes a main circuit
breaker for each pump, a magnetic
starter with overload protection for
each pump, an H-O-A switch and a
run light for each pump, an electrical
alternator and a transformer to
provide appropriate control for
control circuit and alarms.

Overload Heaters:

Starters with 3 leg overload
protection must be supplied if the
Hydromatic electrical panel is not
used. The heaters must be sized
in accordance with the nameplate

amps on the motor. The amp
draw on these oil-filled motors
is slightly higher than a
corresponding horsepower surface
motor, so heaters must be sized by
the nameplate rating.

Installation
Instructions

Installing Pump in Dry Pit:

Before installing pump in the dry pit,
lay it on side and turn the impeller
manually. The impeller may be
slightly stuck due to factory water
testing, so it must be broken loose
with a small bar or screwdriver in
the edge of the vanes. The impeller
must turn freely.

Clean all trash and debris from
pump installation area and connect
pump to plumbing.

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 the line pressure
can be cut off to service the check
valve. Single pump systems are
sometimes installed without a
check valve where it is desirable
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.

Mounting Pump Stand:

The pump will ship from the
factory on a dry pit pump stand.
The suction and discharge of the
pump will be oriented at the factory
per the prescribed customer order.

The dry pit pump must be anchored
to the pump station floor. This
must be done to alleviate stress on
the suction and discharge piping
while the pump is in service. When
securing the pump stand to the
contractor supplied anchor bolts, it

may be necessary to shim the stand
to ensure the suction and discharge
piping properly aligns.

Plumbing (General):

The site contractor must supply
the use of necessary pipe hangers
or other piping supports. Both the
suction and discharge piping must
be independently supported and
properly aligned to ensure no strain
is transmitted to the pump when
connections are tightened. The use
of expansion joints or vibration
pads does not preclude the need to
properly support the piping.

NOTE: Do not support the piping
by the pump. Do not force piping
when making connections.

Suction-Inlet Piping:

The correct sizing and installation
of the suction plumbing is
particularly important. The suction
piping must be selected and
installed in such a manner that
it minimizes pressure losses and
allows for sufficient flow during
starting and operation. Most NPSH
problems can be traced directly
to improper design of suction
piping systems.

It is recommended that the piping
be as direct as possible and the
length should be at least 10 times
the diameter of the pipe. When
a pipe diameter larger than the
suction of the pump is used, an
eccentric reducer should be used
with the eccentric side down.
This will allow for the elimination
of a potential air pocket in the
suction plumbing.

NOTE: A pipe diameter smaller
than the suction of the pump
must never be used.

It is also recommended that a valve
be installed in the suction piping
to isolate the pump during routine
maintenance and shutdown. A
globe valve should not be used
when NPSH is critical.

It is recommended that a
compound pressure gauge be
installed in the suction piping to
assist in troubleshooting potential
performance problems.

Discharge-Outlet Piping:

The discharge piping for short
runs can be of the same size as
the discharge of the pump. It is
recommended that longer runs be
1 to 2 sizes larger depending on
the length. Any elevated points
will retain air pockets, and it is
recommended that air vents or
bleed lines be installed at these
points to evacuate the entrapped
air. Installation of a valve near
the discharge of the pump is
recommended to isolate the pump
during maintenance and shutdown.

It is recommended that a pressure
gauge be installed near the
discharge of the pump to
assist in troubleshooting potential
performance problems.

NEMA 4 Junction Box
(Optional):

A NEMA 4 junction box should
be used to make power and control
connections if electrical control
panel is to be set remote from
the pump station. The Hydromatic
NEMA 4 junction box is provided
with compression connections
for sealing all wires. No sealing
compound is needed to make
connections waterproof.

Wiring diagrams are provided with
the panel for making connections.
An extra set of diagrams is included
so that one set can be used in the
station when making connections.
The size wire to use from panel to
station depends on motor size and
distance in feet.

Be sure each wire is checked out so
that a wrong connection will not be
made. An ohmmeter or Megger can
be used to check the continuity.

®

3

Installing Switch Controls:

The controls are supported by a
mounting bracket that is attached
to wet well wall, cover or to the
NEMA 4 junction box. Control
level can be changed at any time
by loosening the snubber and
readjusting cord length.

In either a simplex or duplex
system, the lower or turn-off
control is set just above the
drywell inlet. This is dependent on
the inlet velocity of the pump. The
second or turn-on control is set at
least 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.

Making Electrical Connections:

All electrical wiring must be in
accordance with local codes.

IMPORTANT: If equipment is
not properly wired and protected
as recommended, the warranty
is void.

Heat Sensors and Seal Failure
Connections:

Be sure heat sensor wires are
connected in series with the starter
coil. Connections are provided on
the terminal strip.

DO NOT CONNECT POWER
TO THESE LINES AT ANY
TIME.

Cooling Fins (Optional):

When additional cooling is required,
cooling fins are permanently
adhered to the motor housing at the
factory. Inspect the cooling fins
to ensure that they are intact and
not damaged prior to plumbing the
pump in the system.

NOTE: The cooling fins must
be intact to ensure the pump
operates within the factory
specified temperature.

Water Jacket (Optional):

When additional cooling is
necessary, a water jacket is
supplied from the factory. All
necessary plumbing of the water
jacket is supplied from the factory
connecting to the suction and the
discharge piping. The plumbing
includes ball valves, allowing for
removal of the water jacket for
periodic cleaning without shutting
the system down.

The water jacket is held in place by
clamps and is sealed both top and
bottom by O-rings. Upon removal
of the water jacket for cleaning,
care should be taken not to damage
the O-rings. Replace if necessary.

4

starts. Allow pump to operate
until the level drops to turn­off point.

Pump
Maintenance

NOTE: Clean, fresh water
supplied to the water jacket will
reduce the necessity of frequent
periodic cleaning of the water
jacket. This does not preclude
that the water jacket should not
periodically be cleaned.

Pump
Operation

Starting System:

1. Turn H-O-A switch to Off
position and then turn on main
circuit breakers.

2. Open all discharge valves and
allow water to rise in wet well.

3. Turn H-O-A switch to Hand
position on one pump and
notice operation. If pump is
noisy and vibrates, rotation
is wrong. To change rotation,
interchange any two line leads
to a three phase motor only.
DO NOT INTERCHANGE
MAIN INCOMING LINES. If
duplex system, check second
pump in the same manner.

5. Allow wet well level to rise to
start the other pump. Notice
run lights on the panel. Pumps
should alternate on each
successive cycle of operation.

6. Turn both H-O-A switches
to Off position and allow wet
well to fill to the override
control level.

7. Turn both switches to Auto
position and both pumps should
start and operate together until
level drops to turn-off point.

8. Repeat this operation cycle
several times before leaving
job site.

9. Check voltage when pumps are
operating and check amp draw
of each pump. 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 amp draw on one
leg, the power company should
be consulted.

Phase Converters:

Phase converters are generally
not recommended, but in cases
where only single phase current is
available, phase converters can be
used. Be sure to size the phase
converter large enough for the
amp draw specified on the motor
nameplate, not necessarily by
motor horsepower. The warranty of
all three phase submersible motors
is void if operated with single phase
power through a phase converter
and 3 leg ambient compensated
extra-quick trip overload protectors
are not used.

Lubrication or other maintenance
is not required, as the motors are
oil filled.

Generally, these pumps give
very reliable service, and can
be expected to operate for many
years without failure under normal
operating conditions.

Lightning:

In some areas where considerable
lightning occurs, we recommend
that a lightning arrestor be installed
at the control panel. Lightning
arrestors are good insurance against
damage to an expensive motor.

Servicing Instructions:

IMPORTANT: Read all
instructions prior to replacing
any parts.

WARNING: Before handling
these pumps and controls, always
isolate and disconnect power first.

Do not smoke or use any
sparkable electrical devices or
flames in a septic (gaseous) or
possible septic environment.

Field Service on Motor:

All dry pit pump motors out of
warranty can be serviced in the
field by any reliable motor service
shop. Any pump (in warranty)
must be returned to the factory for
service or repaired at an authorized
Hydromatic
will not be allowed if (in warranty)
pump is not taken to an authorized
Hydromatic service center.

When field service is performed on
a pump, these instructions should
be carefully followed.

®

service center. Charges

4. Now set H-O-A switch to Auto
position and allow water to rise
in the wet well until the pump

5

Replacing Stator:

1. Un-plumb and drain water
jacket if pump was supplied
with a water jacket and remove.

2. 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 seals
or bearings.

3. Drain all oil from upper
housing, remove drain plug in
bottom of stator housing and
remove plug in top of housing
to allow air to enter.

4. After chamber is drained,
remove hold-down bolts
and lift off. Use care in
lifting as the seal failure
connecting wires must be
disconnected before housing is
completely removed.

5. Set assembly on bench and
remove connection box. When
box is lifted off, connection
wires to motor will be exposed.
These wires will probably
be burned, but each wire will
be identified with a metal
wire marking number. Cut
the wires.

If the leads in the connection

box are burned, a complete
new connection box with
new wires must be used. The
wires are potted in with sealing
compound and a new unit must
be obtained from the factory.

6. The stator is held in the housing
with a bolted-in clamp ring.

7. After ring is removed, turn
housing upright and bump on
hardwood blocks. This should
jar the stator loose and allow it
to drop out.

8. Thoroughly clean housing
before replacing new stator.
Replace stator and make all wire
connections to the connection
box before replacing housing
on pump. This is important as

6

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.

9. Check top bearing. If clean
and does not turn rough,
bearings can be reused and it
is not necessary to completely
dismantle pump and change
bearings. If bearings are
damaged with dirt or heat they
must be replaced. Remember
to reinstall the upper bearing
load spring.

10. Replace stator housing onto
seal chamber and bolt in place.
BE SURE SEAL FAILURE
WIRE IS CONNECTED
BEFORE HOUSING IS
ASSEMBLED.

Be sure O-ring seal has been

replaced. If O-ring appears
nicked or cut, replace with new
ones. This applies to O-rings
in the assembly.

11. After all leads are reconnected
in the connection box, make
a high voltage ground test
on each wire. The only wire
that should show ground is
the green power lead and the
ground lead in the auxiliary
power cable.

12. For safety, complete pump
should be air checked under
water for leaks. Lay pump on
side for this oil filling with
oil fill hole upright. Do not
completely fill; leave oil about
1 inch below plug hole. Use
only Hydromatic

®

submersible
oil in this chamber or high
grade transformer oil. Replace
plug; use Permatex on threads.
Install air valve in top plug
opening of motor housing and

charge housing with about 10
psi of air. Be sure air is dry.
Do not use air line where water
may be trapped in the line.
Submerge complete unit under
water and check for leaks.

13. Refill motor chamber with
oil. Use only a high grade
transformer oil or 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 and seal chamber
as described.

2. Remove motor housing as
described.

3. Remove bolts that hold seal
chamber to pump housing.
Use back-off screws to
break loose.

4. Lift rotating assembly (rotor,
shaft, and impeller) from pump
case and place it horizontally
on bench.

5. Remove impeller by holding
the rotor and removing the
impeller retaining washer
and bolt. The impeller will be
taper fitted to the shaft with a
key. The impeller may need
to be jarred from the shaft by
tapping with a block of wood.

6. A shaft sleeve may be used in
conjunction with the lower seal
and will need to be removed.

7. Remove lower seal spring
and pry out the seal with
a screwdriver.

8. To remove the seal housing,
take out socket head bolts and
using the bolts in the back-out
holes, pry plate loose. This
will force out lower seal if not
already removed.

9. Remove snap ring that holds
upper seal. Pull seal if it is free.
If not free, it can be forced off
when shaft is removed.

10. Remove 4 bolts that hold
bearing housing in place. Set
assembly in upright position
and bump end of shaft with
hardwood block. This will
push the bearing from the
housing and will force upper
seal from shaft.

11. Use a bearing puller to
remove bearings. Replace
with new bearings. Press only
on inner face of the bearing
when replacing. Pressing on
the outer face can damage
the bearing.

IMPORTANT: DO NOT

USE ANY OF THE OLD
SEAL PARTS. REPLACE
WITH ALL NEW SEALS.

12. Thoroughly clean all castings
before replacing seals. Any
dirt between the seal faces can
cause failure.

13. Examine all O-rings for
nicks before using and
replace damaged O-rings with
new ones.

14. Use Loctite
impeller locking screw in end
of shaft.

®

on socket head

Pump
Troubleshooting

Pump will not start.

1. No power to the motor. Check
for blown fuse or open circuit.

2. Selector switch may be in the
Off position.

3. Control circuit transformer
fuse may be blown.

4. Overload heater 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 the same reading.

3. If no grounds exist and the
motor windings check OK,
remove discharge elbow cover
and check for clogged or
blocked impeller.

Pump operates with selector
switch in Hand position but will
not operate in Auto position.

1. This indicates trouble in
the float level control or
alternator relay.

2. Check the control panel
for trouble.

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 wet well to be sure
the 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 lever up and
down to clear.

3. Pump may be running in the
wrong direction. Low speed
pumps can operate in reverse
direction without much noise
or vibration.

4. Discharge head may be
too high. Check total head
with gauge when the pump
is operating.

5. If pump has been in service for
some time and capacity falls
off, remove pump and inspect
impeller for wear.

Motor stops and then restarts
after short period but overload
heaters in starter do not trip.

1. This indicates heat sensors
in the motor are tripping due
to excessive heat. Impeller
may be partially clogged,
giving sustained overload
but not high enough to trip
overload heaters.

2. Pump may be operating on a
short cycle due to faulty check
valve in the wet well.

7

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 original user, the parts that prove defective in materials and workmanship. Pentair Hydromatic
reserves the right to change or improve its products or any portions thereof without being obligated to provide such
a change or improvement for prior sold and/or shipped units.

Start-up reports and electrical 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 only if Pentair Hydromatic authorized control panels are used. All seal fail and heat sensing
devices must be hooked up, functional and monitored or this warranty will be void. Pentair Hydromatic will cover
only the lower seal and labor thereof for all dual seal pumps. Under no circumstance will Pentair Hydromatic be
responsible for the cost 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: (a) to defects or malfunctions resulting from failure to properly install, operate or
maintain the unit in accordance with the printed instructions provided; (b) to failures resulting from abuse, accident
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 applicable local codes, ordinances and good trade practices; (e) if the unit is
moved from its original installation location; (f) if unit is used for purposes other than for what it is designed and
manufactured; (g) to any unit that has been repaired or altered by anyone other than Pentair Hydromatic or an
authorized Pentair Hydromatic service provider; (h) to any unit that has been repaired using non factory specified/
OEM parts.

Warranty Exclusions: PENTAIR HYDROMATIC MAKES NO EXPRESS OR IMPLIED WARRANTIES THAT EXTEND
BEYOND THE DESCRIPTION ON THE FACE HEREOF. PENTAIR HYDROMATIC SPECIFICALLY DISCLAIMS THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE.

Liability Limitation: IN NO EVENT SHALL PENTAIR HYDROMATIC BE LIABLE OR RESPONSIBLE FOR
CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES RESULTING FROM OR RELATED IN ANY MANNER TO
ANY PENTAIR HYDROMATIC PRODUCT OR PARTS THEREOF. PERSONAL INJURY AND/OR PROPERTY DAMAGE
MAY RESULT FROM IMPROPER INSTALLATION. PENTAIR HYDROMATIC DISCLAIMS ALL LIABILITY, INCLUDING
LIABILITY UNDER THIS WARRANTY, FOR IMPROPER INSTALLATION. PENTAIR HYDROMATIC RECOMMENDS
INSTALLATION BY PROFESSIONALS.

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.

740 EAST 9TH STREET 490 PINEBUSH ROAD, UNIT #4
ASHLAND, OHIO, USA 44805 CAMBRIDGE, ONTARIO, CANADA N1T 0A5
419-289-1144 800-363-PUMP

WWW.HYDROMATIC.COM

Warranty Rev. 12/13