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HYDROMATIC

NOTE! To the installer: Please make sure you provide

this manual to the owner of the pumping equipment or tothe responsible party who maintains the system.

STANDARD ELECTRICALQ-PANEL

Pump Installation and Service Manual

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Thank you for purchasing yourHYDROMATIC Pump. To help

insure years of trouble freeoperation, please read thefollowing manual carefully.

Before operation:

Read the following instructionscarefully. Reasonable care andsafe methods should be practiced.Check local codes andrequirements before installation.

Attention:

This manual contains importantinformation for the safe use ofthis product. Read this manualcompletely before using thisproduct and refer to it often forcontinued safe product use. DONOT THROW AWAY OR LOSETHIS MANUAL. Keep it in asafe place so that you may referto it often.

Unpacking Pump:Remove pump from carton. Whenunpacking unit, check forconcealed damage. Claims fordamage must be made at thereceiving end through the deliverycarrier. Damage cannot beprocessed from the factory.

WARNING: Before handling

these pumps and controls,always disconnect the powerfirst. Do not smoke orusesparkable electrical devicesor flames in a septic (gaseous) orpossible septic sump.

Electrical Connectins:

The contractor must conform tothe latest requirements of theNational Electrical Code. Allconduit and cables shall be inaccordance with NEC CodeNFPA#70. To maintain UL and

CSA ENCL rating, use same typeUL and CSA weatherproofconduit hubs when connecting tothis enclosure. Prior to conductingany installation, repair or servicewith regard to the control panel,refer to the schematic appropriatefor that panel. The schematic willprovide guidance with regard tothe terminal block connections.

CAUTION: Nonmetallicenclosure does not providegrounding conduit connections.Use grounding bushing andjumper wires.

Make The FollowingElectrical Connections:

a. Connect the pump leads to thecontrol panel. If pump is singlephase and the panel has start

capacitor, start relay and runcapacitor, it is critical thatthe pump leads be connectedproperly. The White, Black,and Red pump leads must beconnected to the appropriateterminals as directed by thepanel schematic and thelabel on the back panel belowthe terminals.

b. Connect the pump heat sensor

and seal failure leads (ifavailable on the pump) to theappropriate terminal blocks inthe control panel. If the heatsensor lead from the pumpis wired as indicated, removejumpers as defined bythe schematic.

c. Connect all the float controlleads to the appropriate panelterminals. Contractor must be

GeneralInformation

1. Check junction box formoisture. Moisture may causechattering of relays/contactors.

2. If pump is single phase withstart capacitor, start relay, andrun capacitor in panel, checkthat pump White, Black, andRed power wires are connectedto panel correctly.

3. WARNING! Live voltage cankill! Check incoming powervoltage to make sure thatis correct for panel andpump model.

4. Energize control panel. (Turnon power to panel.)

5. Check overload relay andverify reset mode (if overloadis supplied).

6. WARNING! Live voltage cankill! Check voltage to thepanel and at secondary ofcontrol transformer using avoltmeter. If no transformer is

very careful in locating thefloats at the proper elevations.The maximum distance fromthe control panel to the floatsis the lesser of l00 feet,or the maximum distancerecommended for the pump.

d. Before connecting power to thecontrol panel, make sure allcontrol switches (e.g. H-O-Aswitch) and protective devices(e.g. breakers) are in the offposition. Now connect powerto the terminal block or thecircuit breaker as directed bythe schematic.

e. Control panel must be groundedproperly per NEC and/or local

codes. To facilitate this, aground lug is provided on thecontrol panel.

PumpOperation

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supplied, check voltage at thecircuit breakers.

7. With H-O-A switch in hand,check discharge to verify thepump is running. Check forflow. On three phase power,check to see if each pump

has proper rotation. Wrongrotation will give low flow.

8. Check full load currentwith amp probe and compare itwith the nameplate rating. Onthree phase pumps, checkall three phases. On singlephase pumps, check blackpump lead.

9. Check operation of start relay,if supplied on single phase

panels, per procedure in Item#7 of Maintenance Instructions.

10.With H-O-A switch in Auto,check float operation andresponse to control panel tothe float operation. Forsequence of operation, refer todesign specification.

11.Make sure H-O-A switch is leftin the Auto position afterstart-up is completed.

Pump Start-Up:

Refer to pump Installation andService Manual.

PumpMaintenance

WARNING: Before handlingthese pumps and controls,

always disconnect the powerfirst. Do not smoke or usesparkable electrical devices orflames in a septic (gaseous) orpossible septic sump.

The maintenance schedulewill vary with operating andenvironmental conditions. It willalso vary with the specific type ofcontrol supplied. The list herein is

a guide only.1. Exercise breaker through two

cycles. Be careful not toover exercise as the breaker isnot a switching device.Excessive operations tendto affect the trip curve ofthe breaker.

2. Check contactors and relaysfor excessive humming. Thiscan be accomplished by

turning pumps on and off inthe Hand mode with theH-O-A switch.

3. Check pump run light(s) byrunning pump(s) in Handmode. Check bulb(s) in anyother light(s).

4. With the power off, checkcontinuity of all control fuses.

5. Check voltage at primaryand secondary of

control transformer.6. Check the pump full

load amps.

7. Check the start relay by usingan amp probe around the redwire (start winding). Ampprobe should display a verybrisk action from zero tolocked rotor and back tooperating load. This actionoccurs on pump start, and the

action must show nolazy movement.

8. Check junction boxes formoisture. Moisture maycause chattering of relaysand contactors.

9. Check for moisture insidecontrol panel enclosureMoisture can cause damage toelectrical components. Checkdoor gasket for proper seal.

10.Check labels to verify theyhave not been damaged.

11.Lubricate enclosure hinges.

12.Pull floats and check forproper operation and insurethere is no foreign build-up

on them.

Spare Parts List:

The following is a list ofrecommended spare partsHowever, conditions of service varysignificantly and a general list maynot in its entirety be applicable to agiven installation. The user shouldexercise judgement in definingspecific requirements based on

this guide.1. Fuses for control transformer

primary and secondary.

2. Contactor.

3. Bulbs for any light requiring abulb. Standard pump run lightis neon. Optional NEMA ratedrun lights have bulb.

4. Control transformer.

5. Duplex or simplex pump

control board.

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1. Make sure there is power tothe controller.

2. Is water level in thesystem high enough toactivate the floats?

3. If #1 and #2 check out, shutpower off to the panel.Remove the off float wiresand run a jumper betweenthe OFF FLOATconnections. If OFFFLOAT light comes on,the float is hung up orthe wiring connectionsare loose.

1. Is water level in thesystem high enoughto activate the lead(ON) float?

2. If #1 checks out, shut offpower to the panel.Remove the lead (ON)

float wires and run ajumper between theLEAD FLOAT (ONFLOAT) connections. Ifone or two pumps start,check the lead (ON) floatfor hang up or loosewiring connections.

1. Check hand-off-auto(H-O-A) switch forcorrect position.

2. Check heat sensortrip in pump witha jumper between HEATSENSOR 1 and HEATSENSOR 2 terminals.

3. Reset overload(s) if tripped.

4. Reset circuit breakersif tripped.

WARNING: Before handlingthese pumps and controls,

always disconnect the powerfirst. Do not smoke or usesparkable electrical devices orflames in a septic (gaseous) orpossible septic sump.

1. Pump does not run inhand position.

a. Check pump circuit breakerand control fuse for trippingor blown condition.

b. Check incoming powervoltage and controlcircuit voltage.

c. Check overload relay to seeif it is tripped. Reset relayif tripped.

d. With the power off, checkmotor heat sensor continuity.

e. Check wiring of pump tocontrol panel. It should

agree with the schematic.f. Check contactor coil

resistance.

2. Pump does not run inauto position.

a. Check items (a.) through(f.) per Item #1 above.

b. Floats may be miswired tocontrol panel. Check floattype (N.O. or N.C.) andhook up by referring to theschematic. If the start andstop floats are hooked inreverse, pump will shortcycle and will not pump thelevel down.

c. Check pump controllerindicating lights.

PumpTroubleshooting OFFFLT PUMP 1CALL

LEAD

FLT

PUMP 2

CALL

DUPLEX

OFF FLT

ON FLT

SIMPLEX

PUMP 1

CALL

OFF

FLT

PUMP 2

CALL

LEAD

FLT

DUPLEX

OFF FLT

ON FLT

SIMPLEX

No Lights On(No call from the floats)

Off Light On

PUMP 1

CALL

PUMP 2

CALL

OFF

FLT

LEAD

FLT

PUMP 1

CALL

OFF

FLT

PUMP 2

CALL

LEAD

FLT

DUPLEX ONLY

OR

FLOAT light ON, LEAD FLOAT lightON, and either PUMP 1 or PUMP 2light ON tells you the lead float is callingfor pump.

All lights ON on pump controller tellsyou all float circuits are good and theproblem lies elsewhere.

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3. Pump runs, but run lightdoes not energize.

a. Standard run light is neon.Remove light and check onoutside 120 volt source.

b. Check run light wiring.

4. Pump runs but does notpump down the wet well.

a. On three phase only,pump rotation may be wrong.Wiring of pumpto control panel may bereverse sequenced.

b. Impeller may be dragging involute due to solids. Highamperage draw wouldidentify this.

c. Refer to the pump manual forother possibilities suchas closed discharge gatevalve, etc.

5. Severe humming/chatteringof contactors andcontrol relays.

a. There may be low voltage.Check voltage at primaryand secondary of controltransformer using a

voltmeter. This low voltagecondition may even causesevere chattering andburn-out of relays.

b. Contactor may have dustaround magnet of coilstructure. Dry or cleanas required.

c. Check voltage to thecontrol panel. Contactorsrequire a minimum of 85%

of full voltage to pullin without chatter. If theproblem is a recurring one,measure voltage withrecorder on a 24 hour basis.

d. Make sure the floatsare located away fromany turbulence.

e. Dry out the junction box(if furnished); moisture inthe junction box may tend

to cause relays toenergize intermittently.

6. Short cycling pump.

a. Check float controls.

7. Run light stays on.

a. Selector switch may be in

the hand position.8. Nuisance tripping of

overload on motor startersor circuit breakers.

a. Check pump and draw withamp probe and compare tonameplate amps on pump.

b. The impeller may be lockedup due to excessive debrisor solids.

c. Possible motor failure (faulton windings).

d. Pump may be miswired toterminal block.

e. Voltage and currentunbalance. Three phase only.

Voltage unbalance on threephase power sources cancause motor current tobecome unbalanced andexcessive heating will

result. Tripping of theoverload protectors, andpremature motor failurescan be expected if thecurrent unbalance exceedsfive percent.

Percent Maximum Current

Current = Difference from x 100

Unbalance Average Current_______________

Average Current

To determine if motor current

unbalance is a function of themotor, or the power supply:

1. Label the leads andthe terminals 1, 2, and3 respectively.

2. Record the amperage foreach lead.

3. Move each lead to the nextterminal (1 to 2, 2 to 3,3 to 1).

4. Again read the amperageof each lead.

5. Move each lead to thenext terminal (1 to 3, 2to 1, 3 to 2).

6. Again read the amperageof each lead.

7. If the unbalance moveswith the motor leads, theunbalance is caused bythe motor. If the unbalanceremains with the terminals,the unbalance is in thepower supply.

8. If the current unbalanceexceeds five percent,nuisance tripping orexcessive heatingwill result.

9. Connect leads forthe lowest percent ofcurrent unbalance.

f. Connections and startcomponents. Single phase only.

1. Disconnect all powerfrom the panel beforemaking these checks.

2. Motor winding

resistance readings.a. Disconnect all three

motor leads.

b. Using a volt-ohm meterwith the scale set onRX1, measure theresistance betweenthe leads with thechart below.

Typical

Motor Resistance

Winding Leads Reading

Main Black to Lowest

White

Start Black to Next

Red Lowest

(Middle)

Both White to Highest

Red (Main & Start)

5

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PumpTroubleshooting

3. Capacitor check.

a. Make sure the capacitoris discharged. Useextreme caution as aspark might occur.

b. Disconnect the capacitorleads and connectan analog-type volt-ohmmeter to thecapacitor terminals.

c. Set the meter on theRX1,000 scale to checkthe start capacitor. Set themeter on the RX10,000scale to check therun capacitor.

d. The meter should indicatelow ohms when it is firstconnected, but as thecapacitor becomes charged(by the meter), it willreturn to a reading ofinfinity (open circuit).

4. Start relay check.

a. Check the coil resistance.It should be 3,000 to15,000 ohms.

b. Install a clamp on ampmeter around the startwinding lead.

c. Set the amp meterscale to at least 2 timesthe pump motor fullload current.

d. Place the HOA switch inthe hand position to startthe pump.

e. The meter should readapproximately 2 timesfull load currentduring starting.

f. After the motor hasstarted (within onesecond) the current

should drop to avalue much less than fullload current.

5. Motor voltage check:

TypicalMotor Voltage

Component Lead Mode Reading

Main Winding Black to Start Line VoltageWhite

Main Winding Black to Run Line VoltageWhite

Start Winding Black to Start Line VoltageRed

Start Winding Black to Run 120%Red Line Voltage

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PumpNotes

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1999 Hydromatic, Ashland, Ohio. All Rights Reserved.

Item# H-03-000 3M 1/01

Your Authorized Local Distributor

1840 Baney Road Ashland, Ohio 44805Tel: 419-289-3042 Fax: 419-281-4087

www.hydromatic.com ISO 9001 Certified

Part# 5625-000-1

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 or18 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 35 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, Warrantyis 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 Buyers account. The Buyers 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.