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Pump Installation and Service Manual

HYDROMATIC
®

STANDARD ELECTRICAL
Q-PANEL

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.
Electrical Connectins: very careful in locating the
General The contractor must conform to floats at the proper elevations.
Information the latest requirements of the The maximum distance from
the control panel to the floats
National Electrical Code. All
conduit and cables shall be in is the lesser of l00 feet,
Thank you for purchasing your accordance with NEC Code or the maximum distance
HYDROMATIC Pump. To help NFPA#70. To maintain UL and recommended for the pump.
insure years of trouble free CSA ENCL rating, use same type d. Before connecting power to the
operation, please read the UL and CSA weatherproof control panel, make sure all
following manual carefully. conduit hubs when connecting to control switches (e.g. H-O-A
this enclosure. Prior to conducting switch) and protective devices
Before operation: any installation, repair or service (e.g. breakers) are in the off
with regard to the control panel, position. Now connect power
Read the following instructions
refer to the schematic appropriate to the terminal block or the
carefully. Reasonable care and
for that panel. The schematic will circuit breaker as directed by
safe methods should be practiced.
provide guidance with regard to the schematic.
Check local codes and
the terminal block connections. e. Control panel must be grounded
requirements before installation.
properly per NEC and/or local
CAUTION: Nonmetallic codes. To facilitate this, a
Attention: ground lug is provided on the
enclosure does not provide
This manual contains important grounding conduit connections. control panel.
information for the safe use of Use grounding bushing and
this product. Read this manual
completely before using this
jumper wires. Pump
product and refer to it often for
Make The Following
Operation
continued safe product use. DO
NOT THROW AWAY OR LOSE Electrical Connections:
THIS MANUAL. Keep it in a a. Connect the pump leads to the 1. Check junction box for
safe place so that you may refer control panel. If pump is single moisture. Moisture may cause
to it often. phase and the panel has start chattering of relays/contactors.
capacitor, start relay and run 2. If pump is single phase with
Unpacking Pump: capacitor, it is critical that start capacitor, start relay, and
Remove pump from carton. When the pump leads be connected run capacitor in panel, check
unpacking unit, check for properly. The White, Black, that pump White, Black, and
concealed damage. Claims for and Red pump leads must be Red power wires are connected
damage must be made at the connected to the appropriate to panel correctly.
receiving end through the delivery terminals as directed by the 3. WARNING! Live voltage can
carrier. Damage cannot be panel schematic and the kill! Check incoming power
processed from the factory. label on the back panel below voltage to make sure that
the terminals. is correct for panel and
b. Connect the pump heat sensor pump model.
WARNING: Before handling
and seal failure leads (if 4. Energize control panel. (Turn
these pumps and controls,
available on the pump) to the on power to panel.)
always disconnect the power
appropriate terminal blocks in
first. Do not smoke or 5. Check overload relay and
the control panel. If the heat
usesparkable electrical devices verify reset mode (if overload
sensor lead from the pump
or flames in a septic (gaseous) or is supplied).
is wired as indicated, remove
possible septic sump. 6. WARNING! Live voltage can
jumpers as defined by
the schematic. kill! Check voltage to the
c. Connect all the float control panel and at secondary of
leads to the appropriate panel control transformer using a
terminals. Contractor must be voltmeter. If no transformer is

2
supplied, check voltage at the action must show no
circuit breakers. Pump lazy movement.
7. With H-O-A switch in hand, Maintenance 8. Check junction boxes for
check discharge to verify the moisture. Moisture may
pump is running. Check for cause chattering of relays
flow. On three phase power, WARNING: Before handling and contactors.
check to see if each pump these pumps and controls,
always disconnect the power 9. Check for moisture inside
has proper rotation. Wrong control panel enclosure.
rotation will give low flow. first. Do not smoke or use
sparkable electrical devices or Moisture can cause damage to
8. Check full load current flames in a septic (gaseous) or electrical components. Check
with amp probe and compare it possible septic sump. door gasket for proper seal.
with the nameplate rating. On 10.Check labels to verify they
three phase pumps, check have not been damaged.
all three phases. On single The maintenance schedule
phase pumps, check black will vary with operating and 11.Lubricate enclosure hinges.
pump lead. environmental conditions. It will 12.Pull floats and check for
9. Check operation of start relay, also vary with the specific type of proper operation and insure
if supplied on single phase control supplied. The list herein is there is no foreign build-up
panels, per procedure in Item a guide only. on them.
#7 of Maintenance Instructions. 1. Exercise breaker through two
10.With H-O-A switch in “Auto”, cycles. Be careful not to Spare Parts List:
check float operation and over exercise as the breaker is
not a switching device. The following is a list of
response to control panel to recommended spare parts.
the float operation. For Excessive operations tend
to affect the trip curve of However, conditions of service vary
sequence of operation, refer to significantly and a general list may
design specification. the breaker.
not in its entirety be applicable to a
11.Make sure H-O-A switch is left 2. Check contactors and relays given installation. The user should
in the “Auto” position after for excessive humming. This exercise judgement in defining
start-up is completed. can be accomplished by specific requirements based on
turning pumps on and off in this guide.
the “Hand” mode with the
Pump Start-Up: H-O-A switch. 1. Fuses for control transformer
primary and secondary.
Refer to pump Installation and 3. Check pump run light(s) by
Service Manual. running pump(s) in “Hand” 2. Contactor.
mode. Check bulb(s) in any 3. Bulbs for any light requiring a
other light(s). bulb. Standard pump run light
4. With the power off, check is neon. Optional NEMA rated
continuity of all control fuses. run lights have bulb.
5. Check voltage at primary 4. Control transformer.
and secondary of 5. Duplex or simplex pump
control transformer. control board.
6. Check the pump full
load amps.
7. Check the start relay by using
an amp probe around the red
wire (start winding). Amp
probe should display a very
brisk action from zero to
locked rotor and back to
operating load. This action
occurs on pump start, and the
3
DUPLEX 1. Is water level in the
Pump system high enough
Troubleshooting
OFF PUMP 1 to activate the lead
FLT CALL
(ON) float?
LEAD PUMP 2 2. If #1 checks out, shut off
WARNING: Before handling FLT CALL
power to the panel.
these pumps and controls, Remove the lead (ON)
always disconnect the power No Lights On float wires and run a
first. Do not smoke or use jumper between the
(No call from the floats)
sparkable electrical devices or “LEAD FLOAT” (“ON
flames in a septic (gaseous) or SIMPLEX FLOAT”) connections. If
possible septic sump. one or two pumps start,
OFF FLT check the lead (ON) float
for “hang up” or loose
1. Pump does not run in
wiring connections.
hand position. ON FLT
1. Check hand-off-auto
a. Check pump circuit breaker
(H-O-A) switch for
and control fuse for tripping
correct position.
or blown condition. 1. Make sure there is power to
b. Check incoming power the controller.
voltage and control 2. Is water level in the
circuit voltage. DUPLEX ONLY
system high enough to
c. Check overload relay to see activate the floats? PUMP 1 OFF
CALL FLT
if it is tripped. Reset relay 3. If #1 and #2 check out, shut
if tripped. power off to the panel. PUMP 2 LEAD
Remove the off float wires CALL FLT
d. With the power off, check
motor heat sensor continuity. and run a jumper between “FLOAT” light ON, “LEAD FLOAT” light
e. Check wiring of pump to the “OFF FLOAT” ON, and either “PUMP 1” or “PUMP 2”
connections. If “OFF light ON tells you the lead float is calling
control panel. It should for pump.
agree with the schematic. FLOAT” light comes on,
the float is “hung up” or OR
f. Check contactor coil the wiring connections PUMP 1 OFF
resistance. are loose. CALL FLT

PUMP 2 LEAD
2. Pump does not run in DUPLEX CALL FLT
auto position.
a. Check items (a.) through PUMP 1 OFF All lights ON on pump controller tells
CALL FLT you all float circuits are good and the
(f.) per Item #1 above. problem lies elsewhere.
b. Floats may be miswired to PUMP 2 LEAD
CALL FLT
control panel. Check float
type (N.O. or N.C.) and
hook up by referring to the 2. Check heat sensor
schematic. If the start and Off Light On trip in pump with
stop floats are hooked in a jumper between “HEAT
reverse, pump will short SIMPLEX SENSOR 1” and “HEAT
cycle and will not pump the SENSOR 2” terminals.
level down. OFF FLT 3. Reset overload(s) if tripped.
c. Check pump controller 4. Reset circuit breakers
indicating lights. ON FLT if tripped.

4
3. Pump runs, but run light to cause relays to 4. Again read the amperage
does not energize. energize intermittently. of each lead.
a. Standard run light is neon. 6. Short cycling pump. 5. Move each lead to the
Remove light and check on a. Check float controls. next terminal (1 to 3, 2
outside 120 volt source. to 1, 3 to 2).
7. Run light stays on.
b. Check run light wiring. 6. Again read the amperage
a. Selector switch may be in of each lead.
4. Pump runs but does not the hand position.
pump down the wet well. 7. If the unbalance moves
8. Nuisance tripping of with the motor leads, the
a. On three phase only, overload on motor starters
pump rotation may be wrong. unbalance is caused by
or circuit breakers. the motor. If the unbalance
Wiring of pump
to control panel may be a. Check pump and draw with remains with the terminals,
reverse sequenced. amp probe and compare to the unbalance is in the
nameplate amps on pump. power supply.
b. Impeller may be dragging in
volute due to solids. High b. The impeller may be locked 8. If the current unbalance
amperage draw would up due to excessive debris exceeds five percent,
identify this. or solids. nuisance tripping or
c. Possible motor failure (fault excessive heating
c. Refer to the pump manual for will result.
other possibilities such on windings).
as closed discharge gate d. Pump may be miswired to 9. Connect leads for
valve, etc. terminal block. the lowest percent of
current unbalance.
5. Severe humming/chattering e. Voltage and current
of contactors and unbalance. Three phase only. f. Connections and start
control relays. components. Single phase only.
Voltage unbalance on three
a. There may be low voltage. phase power sources can 1. Disconnect all power
Check voltage at primary cause motor current to from the panel before
and secondary of control become unbalanced and making these checks.
transformer using a excessive heating will 2. Motor winding
voltmeter. This low voltage result. Tripping of the resistance readings.
condition may even cause overload protectors, and a. Disconnect all three
severe chattering and premature motor failures motor leads.
burn-out of relays. can be expected if the
current unbalance exceeds b. Using a volt-ohm meter,
b. Contactor may have dust with the scale set on
around magnet of coil five percent.
RX1, measure the
structure. Dry or clean Percent Maximum Current
resistance between
as required. Current = Difference from x 100
Unbalance Average Current
the leads with the
c. Check voltage to the _______________ chart below.
control panel. Contactors Average Current
require a minimum of 85%
of full voltage to pull To determine if motor current Typical
in without chatter. If the unbalance is a function of the Motor Resistance
problem is a recurring one, motor, or the power supply: Winding Leads Reading
measure voltage with 1. Label the leads and Main Black to Lowest
recorder on a 24 hour basis. the terminals 1, 2, and White
d. Make sure the floats 3 respectively.
Start Black to Next
are located away from 2. Record the amperage for Red Lowest
any turbulence. each lead. (Middle)
e. Dry out the junction box 3. Move each lead to the next Both White to Highest
(if furnished); moisture in terminal (1 to 2, 2 to 3, Red (Main & Start)
the junction box may tend 3 to 1).
5
should drop to a
Pump value much less than full
Troubleshooting load current.
5. Motor voltage check:

Typical
3. Capacitor check. Motor Voltage
a. Make sure the capacitor Component Lead Mode Reading
is discharged. Use Main Winding Black to Start Line Voltage
extreme caution as a White
spark might occur. Main Winding Black to Run Line Voltage
b. Disconnect the capacitor White
leads and connect Start Winding Black to Start Line Voltage
an analog-type volt-ohm Red
meter to the
capacitor terminals. Start Winding Black to Run 120%
Red Line Voltage
c. Set the meter on the
RX1,000 scale to check
the start capacitor. Set the
meter on the RX10,000
scale to check the
run capacitor.
d. The meter should indicate
low ohms when it is first
connected, but as the
capacitor becomes charged
(by the meter), it will
return to a reading of
infinity (open circuit).
4. Start relay check.
a. Check the coil resistance.
It should be 3,000 to
15,000 ohms.
b. Install a clamp on amp
meter around the start
winding lead.
c. Set the amp meter
scale to at least 2 times
the pump motor full
load current.
d. Place the HOA switch in
the hand position to start
the pump.
e. The meter should read
approximately 2 times
full load current
during starting.
f. After the motor has
started (within one
second) the current
6
Pump
Notes
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7
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.

© 1999 Hydromatic®, Ashland, Ohio. All Rights Reserved.


– 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# 5625-000-1 Item# H-03-000 3M 1/01

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