Pentair HYDROMATIC H3H, HYDROMATIC H4H, HYDROMATIC S4HRC, HYDROMATIC S4P, HYDROMATIC S4MRC Installation And Service Manual

H3H Shown S4M ShownS4HRC Shown

MODELS H3H, H4H, S4M,
S4P, S4HRC and S4MRC

SUBMERSIBLE
SOLIDS HANDLING PUMPS

INSTALLATION AND SERVICE MANUAL

For use with product built with GE® motor.

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-03-467 | Part # 5625-467-1 | © 2013 Pentair Pump Group, Inc. | 11/06/13

General
Information

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 con tin ued safe product use.
DO NOT THROW AWAY OR
LOSE THIS MAN U AL. Keep
it in a safe place so that you
may refer to it often. Reasonable
care and safe meth ods should be
practiced. Check local codes and
requirements before installation.

Unpacking Pump:

Remove pump from carton.
When un pack ing unit, check for
con cealed damage. Claims for
damage must be made at the
receiving end through the delivery
carrier. Dam age 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.

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

Seal Failure:

An electrode is installed in the
seal chamber so if any water
enters the chamber through
the first seal the electrode will
be energized and a signal will
be trans mit ted to the sen sing
unit at ground surface causing
a red light to turn on. The
elec trode probe is installed in
all units, but the sensing unit
is sup plied at extra cost and
must be ordered.

In operation the seal failure
unit in di cates only that there is
some water in the seal chamber.
The pump will con tin ue to
operate, but the seal should be
checked immedi ate ly after failure
is indicated.

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

Pump:

The submersible pumps in this
manual are supplied for 1 and 3
phase and for 200, 230, 460 or
575 volts. Power cable is supplied
with the green wire for ground. Be
sure green wire is connected to a
good ground such as water pipe or
ground stake.

Heat Sensors:

sensor opens. The motor starter is
equipped with overload heaters so
all normal over loads are protected
by the starter.

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

Sump 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 turn-on for one pump, and
one set for turn-on for two pumps.
Pumps alternate op er a tion on each
successive cycle.

Two pumps operate together only
if sump level rises to the third
or over ride control. The override
control also brings on the second
pump in case of failure of the
first pump. Extra floats with
ap pro pri ate 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. Pumps alternate each
successive cycle.

Pumps Not Operating or in
Storage:

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

2

All motors have heat sensor units
em bed ded in the motor winding
to detect ex ces sive heat. The
heat sen sors are set to trip at
130°C on the H3H. The sensors
au to matcally reset when motor
cools to safe tem per a ture.

The sensors are connected in
series with the motor starter coil
so that the starter is tripped if heat

Three pumps operate together
only if 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 pos si ble
for one pump to fail and the other
pump to operate on the override
level with the sump level never
reach ing the alarm level. This is
par tic u lar ly 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 heat ers and connections for
heat sensor wires are fur nished.

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

Overload Heater:

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 submersible
motors is slightly higher than

a corresponding horsepower
surface motor, so heaters must be
sized by the nameplate rating.

IMPORTANT: Make certain
the heat sensor wires are
connected in series with the
starter coil circuit if other than
Hydromatic starters are used.

Installation
Instructions

Installing Pump in Sump:

Before installing pump in sump,
lay it on side and turn impeller
manually. Im pel ler may be
slightly stuck due to factory test
water, so it must be bro ken loose
with small bar or screwdriver
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 the line pressure can be cut
off if necessary to service the
check valve. Single pump systems
are sometimes installed without a
check valve where it is desirable
to self-drain the dis charge 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):

A NEMA 4 junction box should
be used to make power and
control con nec tions if electrical
control panel is to be set remote
from the pump sump. The
Hydromatic NEMA 4 junction
box is provided with com pres sion
con nec tors for sealing all wires.
No sealing compound is need ed
to make con nec tions wa ter proof.

Wiring diagrams are provided
with the panel for making
connections. The size wire to use
from the panel to sump de pends
on motor size and distance in feet.

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

Installing Switch Controls:

The controls are supported by a
mount ing bracket that is attached
to sump 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 top
of volute, so that the volute will
always be submerged during
the pumping cycle. The sec ond,
or turn-on control, is set about
24 inches above the lower
turn-off con trol.

NUMBER OF CONDUCTORS REQUIRED BETWEEN CONTROL PANEL AND NEMA 4 JUNCTION BOX

POWER LINES AND CONTROL WIRES CAN BE CARRIED IN CONDUIT OR CAN BE UNDERGROUND BURIED CABLE

System Number of Number of Number of
Type Control Wires Power Lines Ground Wires #8 Number of Number of
Sensor Wires Ground Wires

Simplex 4 3 1 3 1

Simplex with Alarm 6 3 1 3 1

Duplex 6 6 2 6 2

Duplex with Alarm 8 6 2 6 2

HEAT SENSOR & SEAL FAILURE

3

More distance between turn-on
and turn-off controls can be used,
but sew age may become septic,
and excessive solids may collect
for the pump to handle. A frequent
pumping cycle is recommended
for best op er a tion.

If an alarm system is used, this
con trol is usually set about 6
inches above the override control.

Making Electrical Connections:

All electrical wiring must be in
ac cor dance with local codes, and
only competent electricians should
make the installations. Complete
wiring diagrams are glued to the
inside cover of the panel. All wires
should be checked for grounds
with an ohm me ter or Megger
after the connections are made.
THIS IS IMPORTANT, AS ONE
GROUNDED WIRE CAN CAUSE
CON SID ER ABLE TROU BLE.

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

Heat Sensors and Seal
Failure Connections:

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

Pump Operations

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 sump.

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 motor 3f only.
DO NOT INTERCHANGE
MAIN INCOMING LINES.
If duplex system, check
second pump in the
same manner.

4. Now set both H-O-A switches
to Auto position and allow
water to rise in sump until one
pump starts. Allow pump to
op er ate until the level drops
to turn-off point.

5. Allow sump level to rise to
start other pump. Notice run
lights on panel. Pumps should
alternate on each successive
cycle of op er a tion.

6. Turn both H-O-A switches
to Off position and allow
sump to ll to the override
control level.

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

8. Repeat this operation cycle
sev er al times before leaving
the job.

9. Check voltage when pumps
are operating and check the
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 con sult ed.

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 on 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.

230V 3ø 460V 3ø

45 6

78 9

12 3

BL

(L1)

4

W

(L2)

DUAL VOLTAGE

3 PHASE MOTOR WIRING

45 6

78 9

GREEN GREEN

R

(L3)

12 3

W

BL

(L2)

(L1)

R

(L3)

HEAT SENSORS AND SEAL FAILURE CONNECTIONS

FOR ANY VOLTAGE MOTOR

ELECTRODE

HEAT SENSORS

IN MOTOR
WINDINGS

WHITEBLACK

HEAT SENSORS SEAL FAILURE

RED DARK

GREEN

Pump Maintenance

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 con di tions.

Lightning:

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

Field Service on Motor:

All submersible 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 re paired
at an authorized Hydromatic
service center. Charges 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.

Replacing Stator:

®

the seal failure con nect ing
wire must be dis con nect ed
before housing is com plete ly
removed.

4. Set assembly on bench and
re move connection box.
When box 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.

If the leads to the connection

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

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

6. After ring is removed, turn
hous ing upright and bump
on hard wood 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 con nec tions
to connection box 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
com pres sion type insulated
connectors on the wires.

Do not tape leads as oil will
de te ri o rate the tape and cause
damage to stator and bear ings.

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

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

Be sure O-ring seal has been

replaced. If O-ring is nicked
or cut, replace with new one.
This ap plies to all O-rings
used in as sem bly.

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 seals or bear ings.

2. To drain all oil from upper
hous ing, remove drain plug in
bot tom of stator housing and
remove plug in top of housing
to allow air to enter.

3. After chamber is drained,
remove hold-down bolts and
lift off. Use care in lifting as

WARNING

WARRANTY IS VOID IF HEAT SENSORS ARE NOT

CONNECTED AS SHOWN (IN SERIES WITH CONTACTOR OIL)

TWO WIRE CONTROL OFFERING AUTOMATIC RESET

BLACK

BLACK

THERMOSTATS

IN SERIES

THERMOSTATS

IN SERIES

L2

WHITE

L2

WHITE

L1

ON-OFF
SWITCH

THREE WIRE CONTROL OFFERING AUTOMATIC RESET

L1

IN CERTAIN APPLICATIONS THE NEC MAY REQUIRE THREE OVERLOAD RELAYS

COIL

COIL

OL OLSTART

5