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.
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 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.
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 probe 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 transmitted to
the sensing unit at ground surface
causing a red light to flash. The
electrode probe is installed in
all units, but the sensing unit is
supplied 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
without damage, but the seal
should be checked immediately
after failure is indicated.
CAUTION: Failure to correct
leaking seal could result in water
entering motor chamber causing
shorting out of motor.
The sensing unit is recommended
on all installations as good
insurance against motor failure.
Seal Failure Probes:
All our hazardous location
submersible pumps have two
factory installed mois ture detectors
(seal failure probes). They are in
a normally open series cir cuit, in
the seal chamber. Un der normal
operating conditions, the circuit
remains open. If the lower seal
leaks and moisture enters this
cham ber, the moisture would settle
to the bottom of the chamber and
will com plete the circuit between
the mois ture detectors.
This circuit must be connected
to a sensing unit and signaling
device. This is supplied in a
Hydromatic® built control panel.
NOTE: Failure to install such a
device negates all war ran ties
by Hydromatic.
Pump:
Power cable is supplied with
sepa rate wire for ground. Be sure
green wire is con nect ed 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
sensors automatically reset when
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 equip ment is
not supplied, the heat sensor
circuit must be connected in
series with the starter coil or
warranty is void.
Once sensor re sets, the starter is to
be automatically reset for FM for
continued operation of the pump.
This circuitry is supplied in a
Hydromatic control panel.
Power Cords:
The power cord and heat sensor
seal failure cord are potted into
the con nec tion box cap. The cords
must not be spliced.
NOTE: Each cable has a green
lead. This is the ground wire
and must be grounded properly
per NEC and/or local codes.
Cords should be in spected
for abnormal wear and
replaced ac cord ing ly.
Sump Level Control:
Sump level is controlled by
Hydromatic float 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.
Typical duplex systems use three
con trols: 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
override control. The override
control also brings on the second
pump in case of failure of the first
2
pump. Extra floats with ap pro pri-
33131
53131
56162
76162
WIRE SIZE AND MAXIMUM LENGTH (FEET) FOR REMOTE LOCATION OF CONTROL PANEL
NOTE:For 460 volts obtain distance by multiplying by 2.0‡60˚C
For 570 volts obtain distance by multiplying by 2.5‡Rating 90˚C
*230 volt system not recommended for above 30 to 40 horsepower.Insulation @ 30˚C Amb.‡Based on 3 power conductors in cable or conduit; for 4 to 6 reduce ampacity to 80% & for 7 to 24 reduce to 70%.
MSpecial junction box required for wire sizes larger than #4.
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.
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 possible
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 ca pac i ty.
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.
The electrical equipment includes
a main circuit breaker for each
pump, a magnetic starter with
overload protec tion for each pump,
an H-O-A switch and run light for
each pump, an elec tric alternator
and a trans former to provide
appropriate con trol circuit
and alarms.
Overload Heaters:
If the Hydromatic electrical panel
is not used, starters with 3 leg
overload protection must be
supplied. The heaters must be
sized in ac cor dance 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 rating.
IMPORTANT: Be sure the
heat sensor wires are connected
in series with the starter
coil circuit.
Pump
Installation
Installing Pump in Sump:
Before installing pump in sump,
lay it on side and turn impeller
manually. Impeller may be slightly
stuck due to factory test water,
so it must be broken 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 if necessary to service the
check valve, the line pressure can
be cut off. 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.
Installing Sump Level Control
Float Controls:
In either simplex, duplex or triplex
systems the lower or turn-off
control is to be set to maintain a
minimum level in the sump. This
level shall be no more than 3-1/4"
from the top of the motor housing
down to the surface of the sewage.
The second or turn-on control is
set above the lower turn-off
control. The exact distance
between the two floats must be a
compromise between a fre quent
pumping cycle (10 starts per hour
max.) to control septicity, solids
and a slower cycle for energy
econ o my. This distance should be
de ter mined by the engineer or
con sult ing engineer de pend ing on
the con di tions of the application.
For installation of Hydromatic
sup plied level con trols, refer to
your sys tems installation and
service manual.
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 Hydromatic
NEMA 4 junction box is provided
with compression con nec tors
for sealing all wires. No sealing
compound is needed to make
con nec tions waterproof.
Wiring diagrams are provided with
panel for making connections.
NUMBER OF CONDUCTORS REQUIRED BETWEEN CONTROL PANEL AND NEMA 4 JUNCTION BOX
SystemNumber ofNumber ofNumber of
TypeControl WiresPower LinesGround Wires #8Number ofNumber of
Simplex
Simplex with Alarm
Duplex
Duplex with Alarm
Power lines and control wires can be carried in conduit or can be underground buried cable.
HEAT SENSOR & SEAL FAILURE
Sensor WiresGround Wires
3
The size wire to use from panel to
NON-HAZARDOUS LOCATION ONLY
HAZARDOUS LOCATION ONLY
sump 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
wire continuity.
Installing Float Switch Controls:
The controls 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. Control lever
can be changed at any time by
loosening the snubber and
readjusting cord length.
In either 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 second
or turn-on control is set 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.
Making Electrical Connections:
All electrical wiring must be in
accordance with the local code,
and only competent electricians
should make the installations.
Complete wiring diagrams are
on the inside cover of the panel.
All wires should be checked for
ground 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
warranty is void.
Heat Sensors and Seal Failure
Connections:
Be sure that heat sensor wires are
connected in series with the starter
coil. Connections are provided on
the terminal strip.
DUAL VOLTAGE
3 PHASE MOTOR WIRING
230V 3N460V 3N
WHITEBLACK
WHITEBLACK
45 6
78 9
12 3
W
BL
(L2)
(L1)
ELECTRODE
REDORANGEDARK
ELECTRODE
REDDARK
(L3)
R
GREEN
GREEN
45 6
78 9
12 3
W
BL
(L2)
(L1)
HEAT SENSORS AND SEAL FAILURE CONNECTIONS
HEAT SENSORS
HEAT SENSORSSEAL FAILURE
HEAT SENSORS AND SEAL FAILURE CONNECTIONS
HEAT SENSORS
HEAT SENSORSSEAL FAILURE
GREENGREEN
R
(L3)
FOR ANY VOLTAGE MOTOR
IN MOTOR
WINDINGS
FOR ANY VOLTAGE MOTOR
IN MOTOR
WINDINGS
Pump
Operations
Starting System:
1. Turn H-O-A switch to
Off position, then turn on
main circuit breakers.
2. Open all discharge valves
and allow water to rise in
sump pump.
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 on 3ø 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
operate 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 operation.
6. Turn both H-O-A switches
to Off position and allow
sump 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
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 consulted.
Phase Converters:
Phase converters are generally not
recommended, but in cases where
only single phase current is
available phase converter 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.
4
Pump
Maintenance
NOTE: Any unauthorized field
repair voids the warranty, the
hazardous location rating, and
Factory Mutual approval.
If the heat sensor and seal failure
are hooked up properly, no
attention is necessary as long
as the seal failure indicator
light doesn’t come on. To ensure
continuity of the seal sensor
leads, a test light is provided on
in trin si cal ly safe Hydromatic®
panels as standard equipment.
Pump should be checked every
quar ter for cor ro sion and wear.
Maintenance:
As the motors are oil filled, no
lu bri ca tion or other maintenance
is required.
If the pump is used on a rail
system, it should be lifted once
every six months and checked for
corrosion and wear.
Generally these pumps give
very reliable service and can be
expected to operate for years
on normal sewage pumping
without failure.
Lightning:
In some areas where considerable
lightning occurs, it is recommended
that a lightning arrestor be installed
at the control panel to aid against
damage to the motor.
Field Service on Hydromatic
Hazardous Location Pumps:
If a Hydromatic hazardous location
pump is used in a hazardous
location, or if the pump is still
in war ran ty, the pump must be
returned to the factory for service
or repaired at an authorized
Factory Mutual Hydromatic
service center. Charges will not
be allowed if in war ran ty pump is
not taken to an authorized Factory
Mutual Hydromatic service center.
This will ensure the integrity of
the hazardous location rating of
the pump and com ply with our
warranty re quire ments.
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. Charg es 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.
COIL
WARNING
COIL
THERMOSTATS
IN SERIES
BLACK
BLACK
THERMOSTATS
IN SERIES
OL OLSTART
L2
WHITE
L2
WHITE
WARRANTY IS VOID IF HEAT SENSORS ARE NOT
CONNECTED AS SHOWN (IN SERIES WITH CONTACTOR OIL)
TWO WIRE CONTROL OFFERING AUTOMATIC RESET
L1
ON-OFF
SWITCH
THREE WIRE CONTROL OFFERING AUTOMATIC RESET
L1
IN CERTAIN APPLICATIONS THE NEC MAY REQUIRE THREE OVERLOAD RELAYS
Replacing 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 seals or bear ings.
2. 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.
3. After chamber is drained,
remove hold-down bolts and
lift off. Use care in lifting as
the seal failure connecting wire
must be dis con nect ed before
housing is com pletely 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 end
ring and an outside locking
screw to prevent stator
from turning.
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 DETERIORATE
THE TAPE AND CAUSE
DAMAGE TO STATOR AND
BEARINGS.
8. Drain oil from seal chamber.
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. Remember
to reinstall the upper bearing
load spring.
9. Before replacing stator housing
be sure outside lock screw is
in place and that O-ring is used
under head of bolt. A leak here
can cause a motor failure.
5
10. Replace stator housing onto
seal chamber and bolt in
place. Be sure seal failure
wire is connected before
hous ing is assembled.
Be sure back-off screws have
been loosened so that parts
can come metal to metal. Be
sure O-ring seal has been
replaced. If O-ring is nicked
or cut, replace with new rings.
This applies to all O-rings used
in 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 aux il ia ry
control 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. 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
Hydromatic submersible oil.
Fill chamber until oil covers
top of the windings. Leave air
space in the 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 the motor housing
as de scribed.
3. Remove bolts that hold seal
cham ber to pump housing.
Use back-off screws to break
loose. With hardwood block,
tap end of impeller to loosen
from shaft. When free, remove
impeller from shaft.
4. Lift rotating assembly (rotor,
shaft and impeller) from pump
case and place horizontally
on bench.
5. Remove screw and washer
from end of shaft and then
screw socket head bolt back
into shaft. Using a screwdriver
on opposite sides behind
impeller apply force, then
tap on end of socket bolt to
break impeller loose from
taper shaft.
6. Remove key and then slide
seal off the shaft.
7. To remove seal plate, take out
socket head flat screws and
using screws in back off holes,
pry plate loose. This will
also force seal off if not
already removed.
8. 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.
9. Set assembly in upright
position and bump end of shaft
on hardwood block. This will
push the bearing from the
housing and will force upper
seal from shaft.
10. Use bearing puller to remove
bearings. Replace with new
bear ings. Press only on
inner face of bearing when
replacing. Pressing on outer
face can damage the bearing.
IMPORTANT: Do not use
any of the old seal parts.
Replace with all new seals.
11. Thoroughly clean all castings
before replacing seals. One
grain of dirt between the seal
faces can cause failure.
12. Examine all O-rings for nicks
before using.
13. Use Locktite® on socket head
locking screw in end of shaft.
14. Before refilling chamber
with oil, air test as described
above and refill both chambers
with oil.
15. Always check all leads with
high voltage or with Megger
for grounds before operating
the pump.
Replacing Cords:
The power cord and heat sensor seal failure cord is potted into the
con nec tion box cap, forming the
cord and cap assembly.
If cords require replacement due to
damage or cords being too short,
cord and cap assembly must be
replaced as a complete assembly
avail able from factory.
Check pump for proper rotation
before re turn ing to normal service.
Disconnecting Pump Cords:
If a Hydromatic hazardous location
pump is to be removed from its
loca tion, the pump cords may be
disconnected at control panel (on
sump mounted con trol panels) and
cord as sem bly taken with pump.
CAUTION: If cord openings
from sump to con trol panel are
open, gas es from sump could
enter panel and an explosive
condition could ex ist.
Replacing Lower Seal, Impeller
or Volute:
The wet end components may
be repaired or replaced by an
authorized Hydromatic service
facility without compromising
the hazardous location rating to
the pump.
NOTE: Any time the seal is
disturbed, it must be replaced.
6
Pump
Troubleshooting
The following is a list of common
problems and their probable causes.
Pump will not start.
1. No power to the motor. Check
for blown fuse or open
circuit breaker.
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 pump from sump
and check for clogged or
blocked impeller.
Pump operates with selector
switch in Hand position but will
not operate in Auto 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
direction without much noise
or vibration.
4. 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 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.
5. If pump has been in service for
some time and capacity falls
off, remove pump and check
for wear or clogged impeller.
Motor stops and then restarts
after short period but overload
heaters in starter do not trip.
1. This indicates trouble in the
float level control or the
alternator relay.
2. Check 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 sump to be sure
control is free.
3. Selector switch may be in the
Hand position.
1. This indicates heat sensors in
the motor are tripping due to
excessive heat. Impeller may
be partially clogged giving
a sustained overload but not
high enough to trip overload
heater switch.
2. Motor may be operating out
of liquid due to a failed
level control.
3. Pump may be operating on a
short cycle due to sump being
too small or from water
returning to sump due to a
leaking check valve.
7
D3D4
D2D1D6D5
D3D4
D5D2D1
Wet End Components
D4D3
S4L(X)
D3
D1D2
S4LRC
D3D4
D4D3
S4LVX
D4
D1D2
D5D6D1D2
S4B(X)
D3D4
D5D2D1
D4D3
S6L(X)S8F(X)
S4K(X)
D5D6D1D2
S6A(X)
H4Q(X)
D1D2D5
D5D1D2D6
D3D4
8
Wet End Parts List For use with product built with USEM motor.