146437 2 Hydromatic S4S Owners Manual Pump 146437_2_Hydromatic User

146369 2 Hydromatic S4S Owners Manual 146369_2_Hydromatic S4S Owners Manual 146369_2_Hydromatic S4S Owners Manual pdf pumpproducts

User Manual: Pump 146437 2 Hydromatic S4S Owners Manual

Open the PDF directly: View PDF .
Page Count: 12

HYDROMATIC®

NOTE! To the installer: Please make sure you provide

this manual to the owner of the pumping equipment or to

the responsible party who maintains the system.

Submersible Sewage Pump

S4S

Pump Installation and Service Manual

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 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.

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

General

Information

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

controls 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 electrical

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 transformer to

provide appropriate control for

control circuit and alarms.

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.

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

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.

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 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

Pump

Installation

29 15 16

6 (Not Shown)

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 Mercury

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

the snubber and readjusting

cord length.

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

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.

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

WIRE SIZE TABLE

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 wires 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 3335557

1⁄271⁄271⁄210 10 10 15 15 15 20 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.

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

(3 phase), interchange any two

line leads to motor. DO

NOT INTERCHANGE MAIN

INCOMING LINES. If duplex

system, check second pump in

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 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 job.

9. Check voltage when pumps are

operating and check the amp

draw of each pump. On 3

phase pumps, check amps on

Pump

Operations

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.

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.

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 seals 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

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.

Remember 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.

2. Remove bolts that hold motor

housing to pump housing.

Remove screws holding seal

plate to motor housing.

3. 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.

4. Shaft sleeves are not used.

5. Remove lower seal spring and

pry out seal with screwdriver.

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 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 460 VOLTS

GREEN GREEN

L3L2L1L3L2L1 32 1

98 7

65 4

321

987

654

Fig. 1

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

0and 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 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. Turn on power

and if pump starts, trouble is in

float control. Replace control.

Pump

Troubleshooting

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

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 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.

5. If pump has been in service for

some time and capacity falls

off, remove pump and check

for wear or clogged impeller.

29 15 16

6 (Not Shown)

1 00589-002-1 Eyebolt 2

2 00178-004-1 Capscrew 2

3 13425-023-1 Nameplate 1

4 04580-001-1 Drive Screw 4

5 00087-004-1 Pipe Plug 1

6 01032-003-1 Nut-Hex- 3/8-16 SST 2

7 00064-003-1 Load Spring R 1

8 00065-021-1 Upper Bearing R 1

9 00065-018-1 Lower Bearing R 1

10 04916-000-1 Shaft Seal S 1

04916-001-1 Shaft Seal (Carbide) Opt C 1

11 00239-016-1 Capscrew 4

12 01130-003-1 Machine Screw (Flat Head) 4

13 09995-000-2 Volute Case 1

14 10108-000-1 Impeller Washer 1

15 00238-001-1 Impeller Capscrew 1

16 08908-002-1 Key 1

17 09996-002-2 Seal Plate 1

18 00150-021-1 O-Ring SC 1

19 00517-007-1 Capscrew 4

20 00995-008-1 Lockwasher 4

21 00299-002-1 Stator Retaining Ring 1

22 05454-001-1 Roll Pin 1

23 13391-000-2 Motor Housing 1

24 00834-015-1 O-Ring SC 1

25 10922-024-5 Rotor w/Shaft (3HP 1ø) 1

01329-025-5 Rotor w/Shaft (All 3ø) 1

12750-023-5 Rotor w/Shaft (5HP 1ø) 1

26 14698-003-1 Stator (3HP 1ø 230V) R 1

14699-003-1 Stator (3HP 3ø 230/460V) R 1

14699-203-1 Stator (3HP 3ø 200V) R 1

14699-603-1 Stator (3HP 3ø 575V) R 1

14711-003-1 Stator (5HP 1ø 230V) R 1

14712-003-1 Stator (5HP 3ø 230/460V) R 1

14712-203-1 Stator (5HP 3ø 200V) R 1

14712-603-1 Stator (5HP 3ø 575V) R 1

Ref. Part Part

No. No. Description Qty.

14713-003-1 Stator (71⁄2HP 3ø 230/460V) R 1

14713-203-1 Stator (71⁄2HP 3ø 200V) R 1

14713-603-1 Stator (71⁄2HP 3ø 575V) R 1

27 02577-000-1 Wire Connector As Recq.

00282-001-1 Wire Connector (14 & 16 wire size) As Recq.

01006-001-1 Wire Connector (10 & 12 wire size) As Recq.

28 06461-023-5 Cord Cap Assy. 15' Single 10/4 1

06461-024-5 Cord Cap Assy. 30' Single 10/4 1

06461-002-5 Cord Cap Assy. 15' Single 12/4 1

06461-014-5 Cord Cap Assy. 30' Single 12/4 1

10418-000-5 Cord Cap Assy. 15' Single 8/4 1

10418-002-5 Cord Cap Assy. 30' Single 8/4 1

29 09978-007-2 Impeller (3HP) 1

09978-008-2 Impeller (5HP) 1

09978-009-2 Impeller (71⁄2HP) 1

51700-061-7 Seal Kit R

51700-361-7 Carbide Seal Kit

* Rebuild Kit

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

No. No. Description Qty. Ref. Part Part

No. No. Description Qty.

S4S

Parts List

Notes: S — Parts in Seal Kit C — Parts in Carbide Seal Kit I — Parts in Impeller Kit R — Parts in Rebuild Kit *Consult Factory

29 15 16

6 (Not Shown)

S4S

Pump

Notes

______________________________________________

Pump

Notes

______________________________________________

Item# E-03-321 5M 1/01

– Your Authorized Local Distributor –

1840 Baney Road Ashland, Ohio 44805

Tel: 419-289-3042 Fax: 419-281-4087

www.hydromatic.com ISO 9001 Certified

Part# 5625-321-1

WARRANTY

Hydromatic Pumps, Inc. warrants to the original purchaser of each 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 & 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. Any 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.

146437 2 Hydromatic S4S Owners Manual Pump 146437_2_Hydromatic User

146369 2 Hydromatic S4S Owners Manual 146369_2_Hydromatic S4S Owners Manual 146369_2_Hydromatic S4S Owners Manual pdf pumpproducts

Navigation menu

Versions of this User Manual:

Views

Navigation