PENTAIR Myers Dry Pit Solids Handling Pumps Instruction Manual

PENTAIR Myers Dry Pit Solids Handling Pumps

GENERAL

Shipping:
When unpacking the unit, check for concealed damage. CLAIM FOR DAMAGE MUST BE MADE AT THE RECEIVING END THROUGH THE DELIVERING CARRIER. DAMAGE CANNOT BE PROCESSED FROM THE FACTORY.

CALIFORNIA PROPOSITION 65 WARNING:

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 nonoperational for 3 months or longer and prior to electrical start-up.

Pumps with carbide seals must have impellers manually rotated (6 revolutions) after setting nonoperational for 3 weeks or longer and prior to electrical start-up.

Seal Failure:
An electrode is installed in the seal chamber so if water enters the chamber through the first seal, the electrode will be energized and a signal will be transmitted to the sensing unit at the ground surface, causing an alarm activation. The electrode probe is installed in all units, but the sensing unit is supplied at an extra cost and must be ordered.

In operation, the seal failure unit indicates only that there is some water in the seal chamber. The pump will continue to operate, but the seal should be checked immediately after failure is indicated. The sensing unit is recommended on all installations as good insurance against motor failure.

Pump:
The dry pit submersible pump is supplied for 3 phases and for 200, 230, 460 or 575 volts. Power cable is supplied with green wire to connect to a good ground such as a water pipe or ground stake.

Heat Sensors:
All motors have heat sensor units embedded in the motor winding to detect excessive heat. The heat sensors are set to trip at 120ºC. The sensors automatically reset when the 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 Myers® electrical starting equipment is not supplied, the heat sensor circuit must be connected in series with the starter coil or warranty is void.

Wet Well Level Control:
Sump level is controlled by Myers 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.

Duplex systems use three controls:
one set at turn-off, one set at turn-on for one pump, and one set at turn-on for both pumps. Pumps then alternate lead and lag on each successive cycle. Two pumps operate together only when the 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 pump. Extra floats with appropriate 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. The pumps alternate with each successive cycle.

Three pumps operate together only if the 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 reaching the alarm level. This is particularly true in cases of low inflow capacity.

Electrical Control Panel:
It is recommended that the Myers control panel be used with all pumps as proper starter heaters and connections for heat sensor wires are furnished.

Myers electrical equipment is installed in a weatherproof NEMA 3R enclosure. The electrical equipment includes a main circuit breaker for each pump, a magnetic starter with overload protection for each pump, an H-O-A switch and a run light for each pump, an electrical alternator, and a transformer to provide appropriate control for the control circuit and alarms.

Overload Heaters:
Starters with 3-leg overload protection must be supplied if the Myers electrical panel is not used. The heaters must be sized in accordance with the nameplate amps on the motor. The amp draw on these oil-filled motors is slightly higher than a corresponding horsepower surface motor, so heaters must be sized by the nameplate rating.

Installation Instructions

Installing Pump in Dry Pit:
Before installing the pump in the dry pit, lay it on the side and turn the impeller manually. The impeller may be slightly stuck due to factory water testing, so it must be broken loose with a small bar or screwdriver in the edge of the vanes. The impeller must turn freely.

NUMBER OF CONDUCTORS REQUIRED BETWEEN CONTROL PANEL AND NEMA 4 JUNCTION BOX

Clean all trash and debris from the pump installation area and connect the pump to the plumbing. 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 the line pressure can be cut off to service the check valve. 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.

Mounting Pump Stand:
The pump will ship from the factory on a dry pit pump stand. The suction and discharge of the pump will be oriented at the factory per the prescribed customer order.

The dry pit pump must be anchored to the pump station floor. This must be done to alleviate stress on the suction and discharge piping while the pump is in service. When securing the pump stand to the contractor-supplied anchor bolts, it may be necessary to shim the stand to ensure the suction and discharge piping properly aligns.

Plumbing (General):
The site contractor must supply the use of necessary pipe hangers or other piping supports. Both the suction and discharge piping must be independently supported and properly aligned to ensure no strain is transmitted to the pump when connections are tightened. The use of expansion joints or vibration pads does not preclude the need to properly support the piping.

NOTE:
Do not support the piping by the pump. Do not force piping when making connections.

Suction-Inlet Piping:
The correct sizing and installation of the suction plumbing is particularly important. The suction piping must be selected and installed in such a manner that it minimizes pressure losses and allows for sufficient flow during starting and operation. Most NPSH problems can be traced directly to the improper design of suction piping systems.

It is recommended that the piping be as direct as possible and the length should be at least 10 times the diameter of the pipe. When a pipe diameter larger than the suction of the pump is used, an eccentric reducer should be used with the eccentric side down. This will allow for the elimination of a potential air pocket in the suction plumbing.

NOTE:
A pipe diameter smaller than the suction of the pump must never be used.

It is also recommended that a valve be installed in the suction piping to isolate the pump during routine maintenance and shutdown. A globe valve should not be used when NPSH is critical. It is recommended that a compound pressure gauge be installed in the suction piping to assist in troubleshooting potential performance problems.

Discharge-Outlet Piping:
The discharge piping for short runs can be of the same size as the discharge of the pump. It is recommended that longer runs be 1 to 2 sizes larger depending on the length. Any elevated points will retain air pockets, and it is recommended that air vents or bleed lines be installed at these points to evacuate entrapped air. Installation of a valve near the discharge of the pump is recommended to isolate the pump during maintenance and shutdown.
It is recommended that a pressure gauge be installed near the discharge of the pump to assist in troubleshooting potential performance problems.

NEMA 4 Junction Box (Optional):
A NEMA 4 junction box should be used to make power and control connections if the electrical control panel is to be set remote from the pump station. The Myers® NEMA 4 junction box is provided with compression connections for sealing all wires. No sealing compound is needed to make connections waterproof.

Wiring diagrams are provided with the panel for making connections. An extra set of diagrams is included so that one set can be used in the station when making connections. The size of the wire to use from panel to station 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 the continuity.

Installing Switch Controls:
The controls are supported by a mounting bracket that is attached to the wet well wall, cover, or to the NEMA 4 junction box. The control level can be changed at any time by loosening the snubber and readjusting the cord length. In either a simplex or duplex system, the lower or turn-off control is set just above the drywall inlet. This is dependent on the inlet velocity of the pump. The second or turn-on control is set at least 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 the 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 local codes, and only certified electricians should make the installations. 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 heat sensor wires are connected in series with the starter coil. Connections are provided on the terminal strip.

DO NOT CONNECT POWER TO THESE LINES AT ANY TIME.

Cooling Fins (Optional):
When additional cooling is required, cooling fins permanently adhere to the motor housing at the factory. Inspect the cooling fins to ensure that they are intact and not damaged prior to plumbing the pump in the system.

NOTE:
The cooling fins must be intact to ensure the pump operates within the factory specified temperature.

Water Jacket (Optional):
When additional cooling is necessary, a water jacket is supplied from the factory. All necessary plumbing of the water jacket is supplied from the factory connecting to the suction and the discharge piping. The plumbing includes ball valves allowing for the removal of the water jacket for periodic cleaning without shutting the system down.

The water jacket is held in place by clamps and is sealed both top and bottom by O-rings. Upon removal of the water jacket for cleaning, care should be taken not to damage the O-rings and replace if necessary.

NOTE:
Clean, fresh water supplied to the water jacket will reduce the necessity of frequent periodic cleaning of the water jacket. This does not preclude that the water jacket should not periodically be cleaned.

Pump Operation

Starting System:

1. Turn H-O-A switch to the Off position and then turn on the main circuit breakers.
2. Open all discharge valves and allow water to rise in the wet well.
3. Turn H-O-A switch to the Hand position on one pump and notice operation. If the pump is noisy and vibrates, rotation is wrong. To change rotation, interchange any two lines leads to a three-phase motor only. DO NOT INTERCHANGE MAIN INCOMING LINES. If duplex system, check the second pump in the same manner.
4. Now set H-O-A switch to Auto position and allow water to rise in the wet well until the pump starts. Allow the pump to operate until the level drops to the turn-off point.
5. Allow the wet well level to rise to start the other pump. Notice the run lights on the panel. Pumps should alternate on each successive cycle of operation.
6. Turn both H-O-A switches to the Off position and allow the wet well to fill to the override control level.
7. Turn both switches to Auto position and both pumps should start and operate together until the level drops to the turn-off point.
8. Repeat this operation cycle several times before leaving the job site.
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 a single phase current is available, phase converters 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 of 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.

PUMP MAINTENANCE

Lubrication or other maintenance is not required, as the motors are oil filled. Generally, these pumps give very reliable service and can be expected to operate for many years without failure under normal operating conditions.

Lightning:
In some areas where considerable lightning occurs, we recommend that a lightning arrestor be installed at the control panel. Lightning arrestors are good insurance against damage to an expensive motor.

Servicing Instructions:

• IMPORTANT: Read all instructions prior to replacing any parts.
• WARNING: Before handling these pumps and controls, always isolate and disconnect power first. Do not smoke or use any sparkable electrical devices or flames in a septic (gaseous) or possible septic environment.
• Field Service on Motor: Any pump, in warranty, must be returned to the factory for service or repaired at an authorized Myers® service center. Charges will not be allowed if in warranty pump is not taken to an authorized Myers service center.

Replacing Seals and Bearings

1. Drain all oil from the motor chamber and seal the chamber as described.

2. Remove motor housing as described.

3. Remove bolts that hold the seal chamber to the pump housing. Use back-off screws to break loose.

4. Lift the rotating assembly (rotor, shaft, and impeller) from the pump case and place it horizontally on the bench.

5. Remove the impeller by holding the rotor and removing the impeller retaining washer and bolt. The impeller will be taper fitted to the shaft with a key. The impeller may need to be jarred from the shaft by tapping with a block of wood.

6. A shaft sleeve may be used in conjunction with the lower seal and will need to be removed.

7. Remove the lower seal spring and pry out the seal with a screwdriver.

8. To remove the seal housing, take out socket head bolts and using the bolts in the back-out holes, pry the plate loose. This will force out the lower seal if not already removed.

9. Remove the snap ring that holds the upper seal. Pull the seal if it is free. If not free, it can be forced off when the shaft is removed.

10. Remove bolts that hold the bearing housing in place. Set the assembly in an upright position and bump the end of the shaft with a hardwood block. This will push the bearing from the housing and will force the upper seal from the shaft.

11. Use a bearing puller to remove bearings. Replace with new bearings. Press only on the inner face of the bearing when replacing it. Pressing on the outer face can damage the bearing.
    IMPORTANT: DO NOT USE ANY OF THE OLD SEAL PARTS. REPLACE WITH ALL NEW SEALS.

12. Thoroughly clean all castings before replacing seals. Any dirt between the seal faces can cause failure.

13. Examine all O-rings for nicks before using and replace damaged O-rings with new ones.

14. Use Loctite® on the socket head impeller locking screw at the end of the shaft.

PUMP TROUBLESHOOTING

Pump will not start

1. 1. No power to the motor. Check for blown fuse or open circuit.
   2. Selector switch may be in the Off position.
   3. Control circuit transformer fuse may be blown.
   4. Overload heater on the starter may be tripped. Push to reset.

Pump will not start and overload heaters trip.

1. Turn off the power and check motor leads with Megger or ohmmeter for possible ground.
2. Check the resistance of motor windings. All 3 phases should show the same reading.
3. If no grounds exist and the motor windings check OK, remove the discharge elbow cover and check for a clogged or blocked impeller.

Pump operates with a selector switch in the Hand position but will not operate in the Auto position.

1. This indicates trouble in the float level control or alternator relay.
2. Check the control panel for trouble.

Pump runs but will not shut off.

1. The pump may be air locked. Turn the pump off and let set for several minutes, then restart.
2. Lower float control may be hung up in the closed position. Check-in wet well to be sure the control is free.
3. The selector switch may be in the Hand position.

Pump does not deliver proper capacity.

1. The discharge gate valve may be partially closed or partially clogged.
2. Check valve may be partially clogged. Raise the lever up and down to clear.
3. The pump may be running in the wrong direction. Low-speed pumps can operate in the reverse direction without much noise or vibration.
4. The discharge head may be too high. Check the total head with the gauge when the pump is operating.
5. If the pump has been in service for some time and capacity falls off, remove the pump and inspect the impeller for wear.

Motor stops and then restarts after a short period but overload heaters in the starter do not trip.

1. This indicates heat sensors in the motor are tripping due to excessive heat. Impeller may be partially clogged giving sustained overload but not high enough to trip overload heaters.
2. The pump may be operating on a short cycle due to a faulty check valve in the wet well.

STANDARD LIMITED WARRANTY

Pentair Myers® warrants its products against defects in material and workmanship for a period of 12 months from the date of shipment from Pentair Myers or 18 months from the manufacturing date, whichever occurs first – provided that such products are used in compliance with the requirements of the Pentair Myers catalog and technical manuals for use in pumping raw sewage, municipal wastewater or similar, abrasive-free, non-corrosive liquids.

During the warranty period and subject to the conditions set forth, Pentair Myers, at its discretion, will repair or replace to the original user, the parts that prove defective in materials and workmanship. Pentair Myers reserves the right to change or improve its products or any portions thereof without being obligated to provide such a change or improvement for prior sold and/or shipped units.

Start-up reports and electrical schematics may be required to support warranty claims. Submit at the time of start-up through the Pentair Myers website: http://forms.pentairliterature.com/startupform/startupform.asp?type=m. Warranty is effective only if Pentair Myers authorized control panels are used. All seal fail and heat sensing devices must be hooked up, functional, and monitored or this warranty will be void. Pentair Myers will cover only the lower seal and labor thereof for all dual-seal pumps. Under no circumstance will Pentair Myers be responsible for the cost of field labor, travel expenses, rented equipment, removal/reinstallation costs, or freight expenses to and from the factory or an authorized Pentair Myers service facility.

This limited warranty will not apply: (a) to defects or malfunctions resulting from failure to properly install, operate or maintain the unit in accordance with the printed instructions provided; (b) to failures resulting from abuse, accident or negligence; (c) to normal maintenance services and parts used in connection with such service; (d) to units that are not installed in accordance with applicable local codes, ordinances and good trade practices; (e) if the unit is moved from its original installation location; (f) if the unit is used for purposes other than for what it is designed and manufactured; (g) to any unit that has been repaired or altered by anyone other than Pentair Myers or an authorized Pentair Myers service provider; (h) to any unit that has been repaired using nonfactory specified/OEM parts.

Warranty Exclusions:
PENTAIR MYERS MAKES NO EXPRESS OR IMPLIED WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. PENTAIR MYERS SPECIFICALLY DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE.

Liability Limitation:
IN NO EVENT SHALL PENTAIR MYERS BE LIABLE OR RESPONSIBLE FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES RESULTING FROM OR RELATED IN ANY MANNER TO ANY PENTAIR MYERS PRODUCT OR PARTS THEREOF. PERSONAL INJURY AND/OR PROPERTY DAMAGE MAY RESULT FROM IMPROPER INSTALLATION. PENTAIR MYERS DISCLAIMS ALL LIABILITY, INCLUDING LIABILITY UNDER THIS WARRANTY, FOR IMPROPER INSTALLATION. PENTAIR MYERS RECOMMENDS INSTALLATION BY PROFESSIONALS.

Some states do not permit some or all of the above warranty limitations or the exclusion or limitation of incidental or consequential damages and therefore such limitations may not apply to you. No warranties or representations at any time made by any representatives of Pentair Myers shall vary or expand the provision hereof.

1101 MYERS PARKWAY ASHLAND, OHIO, USA 44805 419-289-1144
WWW.FEMYERS.COM.
Warranty Rev. 12/13
490 PINEBUSH ROAD, UNIT #4 CAMBRIDGE, ONTARIO, CANADA N1T 0A5 800-363-PUMP.

References

• Start-Up Report
• Myers | Municipal Commercial & Industrial Pumps | Pentair

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