Sta-Rite SP440120T Installation Manual

Models SP550120T

SP440120T

Preplumbed Sewage Pump Systems

INSTALLATION, OPERATION, & PARTS MANUAL

SAFETY INFORMATION

Carefully read and follow all safety instructions in this manual or on pump.

This is the safety alert symbol. When you see this

symbol on your pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury!

warns about hazards that will cause serious

personal injury, death or major property damage if ignored.

warns about hazards that can cause serious

personal injury, death or major property damage if ignored.

warns about hazards that will or can cause

minor personal injury or property damage if ignored. The word NOTICE indicates special instructions which are

important but not related to hazards.

1. Read these rules and instructions carefully. Failure to follow them could cause serious bodily injury and/or property damage.

2. Check your local codes before installing. You must comply with their rules.

Hazardous voltage. Can shock,burn, or

kill. During operation the pump is in water.To avoid fatal

shocks, proceed as follows if pump needs servicing:

3A. Disconnect power to outlet box before unplugging pump. 3B. Take extreme care when changing fuses. Do not stand

in water or put your finger in the fuse socket.

3C.Do not modify the cord and plug. When using the cord

and plug, plug into a grounded outlet only.When wiring to a system control, connect the pump ground lead to the system ground.

4. Do not run the pump dry.Dry running can overheat the pump, (causing burns to anyone handling it) and will void the warranty.

5. The pump normally runs hot. To avoid burns when servicing pump, allow it to cool for 20 minutes after shutdown before handling it.

6. The pump is permanently lubricated. No oiling or greasing is required in normal operation. for overhaul, see instructions under “Service”.

7. Vent sewage or septic tank according to local codes.

8. Do not install the basin or pump in any location classified as hazardous by the United States National Electrical Code (NEC), or by the Canadian Electrical Code (CEC), where applicable.

PUMP SPECIFICATIONS

Power Supply Required.................................................115V

Individual Branch Circuit Required ..........................15 Amps

Motor Duty...........................................................Continuous

Maximum Liquid Temperature ...........................130°F(55°C)*

Discharge Adapter..................................................... 2" NPT

DESCRIPTION

Sta-Rite Sewage Pump Systems, Model Numbers SP550120T and SP440120T are ideal for basement installations, pumping below-grade toilets, and laundry facilities. Both include a submersible sewage pump, a premium heavy duty structural foam, corrosion resistant sump/sewage basin and lid, and a check valve for easy installation.

These submersible pumps are designed for effluent and wastewater removal, sump drainage, dewatering and flood control.The pumps have built in thermal overload protection and an automatic reset.The mechanical seal and ball bearings on the motor shaft are permanently lubricated. Stainless steel hardware and a heavy duty lift out ring allow for easy disassembly after extended use.

These basins are used for residential, commercial, and industrial collection of sewage, effluent drainage and seepage water.The basin cover kit includes an inlet hub, a gas tight cover, cord seals, gaskets, and hardware.The split cover design of the SP5 allows for easy removal of the pump without disturbing the vent connection. No special tools or sealants are required.

NOTICE: This unit is not designed for applications involving salt water or brine! Use with salt water or brine will void warranty.

293 Wright Street • Delavan, WI 53115

Individual Switch Setting in inches (mm) Discharge

Model Motor Motor Full Branch Circuit Cord Length

Adapter

Number HP Load Amps Required (Amps) in ft. (m)

On Off Size

SC550120T 1/2 13.0 15 20 (6.1) 16 (406) 7 (178) 2" SC440120T 4/10 12.5 15 20 (6.1) 16 (406) 7 (178) 2"

PUMP, MOTOR, SWITCH, & CORD SPECIFICATIONS

INSTALLATION

Hazardous voltage. Can shock, burn or kill.

Do not lift pump by the power cord.See “Cord Lift Warning” on Page 3.

NOTICE: Install the pump on a hard, level surface (cement, asphalt, or inside a sump basin, etc.). Never place the pump directly on earth, clay or gravel surfaces.

Piping

Piping must not be smaller than pump discharge. When installed in a sewage system, the pipe must be capable

of handling semi-solids of at least 2" (51mm) in diameter. The rate of flow in the discharge pipe must keep any solids

present in suspension in the fluid.To meet minimum flow requirements (2 feet per second in the discharge line), size the pipe as follows:

A Pipe Size Of: Will Handle a Flow Rate Of:

1-1/2" (38mm) 12 GPM 2" (51mm) 21 GPM 2-1/2"(64mm) 30 GPM 3"(76mm) 48 GPM

In a sewage system use a 2" (51mm) check valve in pump discharge to prevent backflow of liquid into sump basin. The check valve should be a free flow valve that will easily pass solids. Be sure check valve installation complies with local codes.

NOTICE: For best performance of check valve when handling solids, do not install it with the discharge more than 45° above the horizontal.Do not install the check valve in a vertical position as solids may settle in the valve and prevent it from opening on startup.

Drill a 3/16" (5mm) hole in the discharge pipe about 1–2" (25-51mm) above the pump discharge connection (but below check valve) to prevent airlocking the pump.

Electrical

Hazardous voltage. Can shock, burn, or kill.

When installing, operating, or servicing this pump, follow the safety instructions listed below.

1. DO NOT splice the electrical power cord.

2. DO NOT allow the electrical cord plug to be submerged.

3. DO NOT use extension cords.They are a fire hazard and can reduce voltage sufficiently to prevent pumping and/or damage motor.

4. DO NOT handle or service the pump while it is connect- ed to the power supply.

5. DO NOT remove the grounding prong from the plug or modify the plug.To protect against electrical shock, the

power cord is a three-wire conductor and includes a 3-prong grounded plug. Plug the pump into a 3-wire, grounded, grounding-type receptacle. Connect the pump according to the NEC or CEC and local codes.

For automatic operation, plug or wire the pump into an automatic float switch or duplex controller.The pump will run continuously when plugged directly into an electrical outlet.

Connect or wire pump to its own individual branch circuit with no other outlets or equipment in the circuit. Size fuses or circuit breakers according to the “Motor, Switch and Cord Specifications” chart.

Risk of electrical shock and fire. Be sure that power supply information (Voltage/ Hertz/Phase) on pump motor nameplate matches incoming power supply exactly. Install pump according to all electrical codes that apply.

Explosion hazard. Improper ventilation of

sewer gases can result in leakage of methane sewer gas, and a possible explosion of fumes, resulting in severe injury or death.Vent basin according to all local codes.

NOTICE: Proper ventilation is needed to prevent negative basin pressure and to provide air for proper aerobic activity within the basin.

The sewage basin should be located at the lowest place in the basement or area to be drained. Floor drains from other areas in the basement may be tiled into the basin.Drain tile around a house foundation may also be tiled into the basin, effectively removing water and relieving pressure from this area.

Basin covers are used to exclude refuse from the basin. NOTICE: Read and understand this instruction manual

before your concrete floor is poured.

Installation Instructions. See Figure 1.

1. Dig the hole for the sewage basin and the sub-base.The

hole must be deep enough so the finished floor is flush with the top of the basin. Refer to Figure 1, Page 3.

NOTICE: The sub-base should include 4" of sand or gravel.The maximum diameter of crushed rock should be 1/2".The recommended maximum diameter of pea gravel is 3/4".

2. Level the sub-base out, until it is smooth.Sharp rock can

damage the basin.

3. Install the basin on top of the sub-base.

4. Backfill around the basin with crushed rock, with a maxi-

mum diameter of 1/2", or use pea gravel.

5. Insert the 4" inlet pipe through the rubber grommet. Inser t

it 2 inches into the basin. Dish soap can be used to lubricate the rubber grommet. If necessar y, file the sharp edges of the pipe to prevent damage to the grommet.

NOTICE: The pipe should pitch down to the basin inlet at 1/4" per foot.This will cause the water to run into the basin.

6. Lubricate the square cut O-Rings with dish soap. Inser t

them into the groove on the bottom side of the flanged grommets.

7. Install the flanged grommets into the basin lid.

8. Install the discharge pipe into the 2" FNPT discharge

grommet.

GPM AT TOTAL FEET

Model 51015202530

CAPACITY GALLONS/MINUTE

SC550120T 120 90 45 – – – 18 SC440120T 90 66 25 – – – 18

No flow

at height

shown below

*For performance at maximum temperature see Catalog.

PERFORMANCE

9. Pull the power cords up, through the center electric cord hole and install the electric cord grommet, into the cover.

10. Install the 2" vent pipe into the 2" FNPT threaded vent grommet.The vent pipe must go through the roof of the building or it can be connected to an existing vent pipe. The sewage basin must be vented.

Explosion hazard. Improper ventilation of sewer gases can result in leakage of methane sewer gas, and a possible explosion of fumes, resulting in severe injury or death.Vent basin according to all local codes.

NOTICE: Proper ventilation is also needed to prevent negative basin pressure and to provide the necessary air for proper aerobic activity within the basin.

11. Install the 2" check valve in the horizontal portion of the discharge pipe. See Figure 1. Make certain, the flow indicating arrow, points away from the pump. This check valve will keep the water from running back into the basin when the pump is not running.

12. Double check the connection between the discharge pipe and the septic or sewage tank.They must be connected before the pump is plugged in.

13. Insert the float switch piggy-back plug into a properly grounded outlet.

14. Plug the pump into the piggy-back plug.

15. Check the operation by filling the sump basin with water and observing pump operation through one complete cycle. Make sure that no parts of the assembly interfere with the float.

Failure to make this operational check may

lead to improper operation, premature failure, and flooding.

OPERATION

The shaft seal depends on water for lubrication and cooling. Do not operate the pump unless it is submerged in water as the seal may be damaged if allowed to run dry.

NOTICE: Do not allow the pump to run in a dry sump. It will void the warranty and may damage the pump.

An automatic overload protector in the motor will protect the motor from burning out due to overheating/overloading. When the motor cools down, the overload protector will automatically reset and start the motor.

If the overload trips frequently, check for the cause. It could be a stuck impeller, wrong/low voltage, or an electrical failure in the motor.If an electrical failure in the motor is suspected, have it serviced by a competent repairman.

The pump is permanently lubricated. No oiling or greasing is required.

MAINTENANCE

Hazardous voltage. Can shock, burn, or kill.

Before removing the pump from the basin for service, always disconnect electrical power to the pump and the control switch. Do not lift the pump by the power cord. See the “Cord Lift Warning” below.

After removing the basin cover and the necessary discharge piping, lift the pump out of the basin.

Place the pump in an area where it can be cleaned thoroughly. Remove all scale and deposits on the pump.

Submerge the complete pump in a disinfectant solution (chlorox or chlorine bleach) for at least one hour before disassembling the pump.

The pump motor housing contains a special lubricating oil which should be kept clean and free of water at all times.

1. Attempting to lift or support pump by power cord can damage cord and cord connections.

2. Cord may pull apart, exposing bare wires with possibility of fire or electrical shock.

3. Lifting or supporting pump by power cord will void warranty.

4. Use lifting ring or handle on top of pump for all lifting/lowering of pump.Disconnect power to pump before doing any work on pump or attempting to remove pump from sump.

Risk of electrical shock. Can burn or kill. Do not lift pump by

power cord.

WARNING

CORD LIFT WARNING

Extend vent through roof or connect to existing vent.

Purchase vent and discharge pipes locally.

2" Check Valve

Vent Pipe

Vent Grommet

Lid

Basin

2" Discharge Pipe

Do Not Mount Vertically

Plug the Float Switch into a Properly Grounded Outlet

Discharge Grommet

Discharge Flange

O-Ring Groove

Square-Cut O-Ring

Electric Cord Grommet

Finished Floor

4" Snap-in Inlet Hub

4" Inlet Pipe Slope @ 1/4" Per Foot

4" Backfill

4" Compacted Sub-base

NOTICE: Whenever the motor housing is being removed for service, remove oil and replace it with new oil at reassembly. Use only oil listed in parts list in this manual. When filling with new oil, DO NOT overfill. Allow about 7/8" (22mm) air space from top of boss in housing for expansion of oil when the pump is operating.

Pump Disassembly

(The SP5 System with the SC550120T Pump only)

Impeller and Seal Replacement A. Impeller removal (See the pump disassembly drawing):

1. Remove the oil fill plug and turn the pump upside down to drain oil.

2. Remove the capscrews holding the upper motor housing to the lower motor housing; lift off the upper motor housing and remove the motor lead wires from the connector to detach upper housing from assembly.The lead wires are fitted with quick connect terminals for this purpose.

3. Remove the capscrews holding the lower motor housing to the volute; lift off the lower motor housing.

4. Hold the rotor shaft assembly and unscrew the impeller by turning it counter-clockwise. Remove impeller and clean it.

If no more service is needed, reverse instructions above to reassemble the pump. Reattach the motor lead wires as shown in Figure 2, fill with clean dielectric oil (Part No. U197-8A), check the oil level and replace fill plug. Oil should cover the motor windings.

B. Shaft seal replacement:

1. Follow the instructions to remove the impeller, above.

2. Remove the stator capscrews and the spacers (if applicable). Lift off the stator.

3. Remove the seal’s ceramic seat from the shaft and tap the body of the seal out of the lower motor housing.

4. Clean the seal cavity thoroughly before installing the new seal. NOTICE: Make sure that the seal faces are clean; do not scratch or damage the new seal face during seal replacement. Apply Permatex #2 or an equivalent sparingly to the outside edge of seal body before installing the seal in the lower motor housing.

5. Press the new seal body into position in the lower housing cavity.

6. Press the ceramic seat onto the motor shaft.The impeller will pull it into position.

7. Reassemble the stator and tighten the stator capscrews.

Risk of electrical shock. Discharge capacitor before handling it. Electrical shock can burn or kill.

8. Reassemble the impeller and the pump (reverse instructions 1 through 4 above).

9. Reattach the motor lead wires as shown in Figure 2.

10. Fill with clean dielectric oil (Part No. U197-8A), check the oil level and replace the oil fill plug.

The sump basin and cover, pump, and piping should be protected from freezing temperatures. If there is any danger of freezing temperatures, the unit should be drained. Consult your pump manual for instructions on how to drain the pump to protect it from freezing.

Figure 2

Oil Fill

Pump Disassembly

Green Wire (connected between the two tallest dividers)

Either Black Wire Short Divider

Plug

Housing Capscrew

Insulating Disk

Rotor/Stator Assembly

Stator Capscrew

Grn Blk

B k

Power Cord

O-Ring

Lower Motor Housing

Shaft Seal, Stationary Head Ass’y

Shaft Seal, Rotating Mating Ring

Impeller

Volute

410 0893

Either Black Wire

View A-A

409 0893

12A 12B

13 14

Key Part SC550120T

No. Description Qty. 1/2 HP 115V

1 Power Cord 1 PW17-122 2 Cord Connector 1 PS17-46P 3 Handle Ring 1 U97-102SS 4 1/4" NPT Plug 1 U78-57DV 5 Upper Motor Housing 1 PW18-22F 6 #10-32 x 3/4" Capscrew 6 U30-482SS 7 Insulating Disk 1 PS18-82 8 Rotor/Stator Assembly 1 PS218-151

9 #10-32 x 3-1/8" Capscrew 2 U30-949ZP 10 O-Ring 1 U9-339 11 Lower Motor Housing 1 PW18-23AA

12A Shaft Seal, Stationary Head

Assembly 1 U9-379A

12B Shaft Seal, Rotating

Mating Ring 1 U9-321A 13 Impeller 1 PW5-11P 14 Volute 1 PW1-13 15 Automatic Float Switch 1 PS217-64

• Switch Cord Clamp 1 CC0030-13

• #8-32 x 1/2" Capscrew 1 U30-539SS

• Dielectric Oil 1 U197-8A

• Not Illustrated.

REPAIR PARTS – PUMP

Key Part SC440120T

No. Description Qty. 4/10 HP 115V

1 Tethered Float Swtich 1 PS217-64 2 Cable Clamp 1 CC0030-13 3 Screw, #8-32 x 1/2",

Self-tapping, Hex Head 1 U30-539SS 4 Pump Ring Handle 1 U97-102SS 5 Cord Connector 1 PS17-46P

5A O-Ring 1 U9-370

6 Power Cord and Plug 1 PW17-122 7 Motor Housing * 8 Impeller 1 PW5-11P 9 Lower V olute 1 PW1-20P

10 Screw, #10 - 32 X 1" Long,

Hex Head 8 U30-966SS

• Not Illustrated. * If the motor fails, replace the entire pump.

REPAIR PARTS – PUMP

SC550120T EXPLODED VIEW SC440120T EXPLODED VIEW

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