PENTAIR Hydromatic Standard Electrical Control Panel Owner’s Manual

PENTAIR Hydromatic Standard Electrical Control Panel

CONTROL PANEL

INSTALLATION AND SERVICE MANUAL

NOTE! To the installer: Please make sure you provide this manual to the owner of the equip ment or to the responsible party who maintains the system.

General Information

Thank you for purchasing your Hydromatic® control panel. To help ensure years of trouble-free op era tion, please read the fol low ing manual carefully.

Before Operation:

Read the following in 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 con tin ued safe product use. DO NOT THROW AWAY OR LOSE THIS MAN U AL. Keep it in a safe place so that you may refer to it often.

Unpacking Panel:

Remove panel from the carton. When un packing unit, check for conc ealed damage. Claims for damage must be made at the receiving end through the delivery carrier. Dam age cannot be processed from the factory.

CALIFORNIA PROPOSITION 65 WARNING:

This product and related accessories contain chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

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.

Electrical Connections:

The contractor must conform to the latest requirements of the National Electrical Code. All conduit and cables shall be in accordance with NEC Code NFPA #70. To maintain UL and CSA ENCL rating, use the same type UL and CSA weatherproof conduit hubs when connecting to this enclosure. Prior to conducting any installation, repair or service with regard to the control panel, refer to the schematic appropriate for that panel. The schematic will provide guidance with regard to the terminal block connections.

CAUTION: Nonmetallic enclosures do not provide grounding conduit connections. Use grounding bushing and jumper wires.

Make the Following Electrical Connections:

• Connect the pump leads to the control panel. If pump is single phase and the panel has start ca pac i tor, start relay and run ca paci tor, it is critical that the pump leads be connected prop er ly. The White, Black, and Red pump leads must be connected to the ap pro pri ate terminals as direct ed by the panel schematic and the label on the back panel below the terminals.
• Connect the pump heat sensor and seal failure leads (if available on the pump) to the appropriate ter mi nal blocks in the control panel. If the heat sensor lead from the pump is wired as indicated, re move jumpers as defined by the sche mat ic.
• Connect all the float control leads to the appropriate panel terminals. Contractor must be very careful in locating the floats at the proper elevations. The maximum dis tance from the control panel to the floats is the lesser of l00 feet, or the maximum distance rec om mend ed for the pump.
• Before connecting power to the control panel, make sure all con trol switches (e.g. H-O-A switch) and protective devices (e.g. breakers) are in the Off po si tion. Now connect power to the terminal block or the circuit break er as directed by the schematic.
• The control panel must be grounded properly per NEC and/or local codes. To facilitate this, a ground lug is provided on the control panel.

Pump Operation

1. Check junction box for moisture. Moisture may cause chattering of relays/contactors.
2. If pump is single phase with start capacitor, start relay and run capacitor in panel. Check that pump White, Black, and Red power wires are con nect ed to pan el correct ly.
3. WARNING! Live voltage can kill! Check incoming power volt age to make sure that it is correct for panel and pump model
4. Energize control panel. (Turn on power to panel.)
5. Check overload relay and verify reset mode (if overload is sup plied).
6. WARNING! Live voltage can kill! Check voltage to the panel and at secondary of control trans form er using a voltmeter. If no transformer is supplied, check volt age at the circuit breakers.
7. With H-O-A switch in hand, check dis charge to veri fy the pump is run ning. Check for flow. On three phase power, check to see if each pump has prop er ro ta tion. Wrong ro ta tion will give low flow.
8. Check full load current with amp probe and compare it with the name plate rat ing. On three phase pumps, check all three phases. On single phase pumps, check black pump 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 op er a tion and response to control panel sequence of op er a tion, refer to design specification.
11. Make sure H-O-A switch is left in the Auto position after start-up is completed.
12. Make sure all conduits from wet well to panel are sealed below panel. Septic gases will damage components in panel.

Pump Start-Up:
Refer to pump Installation and Service Manual.

Pump Maintenance

WARNING: Before handling these pumps and controls, always disc on nect the pow-er first. Do not smoke or use sparkable electrical devices or flames in a septic (gaseous) or possible septic sump.
The maintenance schedule will vary with operating and environmental con di tions. It will also vary with the specific type of control supplied. The list herein is a guide only.

1. Exercise breaker through two cy cles. Be careful not to overexercise as the break-er is not a switch ing device. Excessive operations tend to affect the trip curve of the breaker.
2. Check contactors and relays for excessive humming. This can be accomplished by turning pumps on and off in the Hand mode with the H- O-A switch.
3. Check pump run light(s) by run ning pump(s) in Hand mode. Check bulb(s) in any other light(s).
4. With the power off, check con ti nu ity of all control fuses.
5. Check voltage at primary and sec ond ary of control transformer.
6. Check the pump full load amps.
7. Check the start relay by using an amp probe around the red wire (start wind ing). 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 action must show no lazy movement.
8.  Check junction boxes for moisture. Moisture may cause chattering of relays and contactors.
9. Check for moisture inside control panel enclosure. Moisture can cause damage to electrical com ponents.
10. Check door gasket for prop er seal. Check labels to verify they have not been damaged.
11. Lubricate enclosure hinges.
12. Pull floats and check for proper operation and ensure there is no foreign buildup on them.

Spare Parts List:

The following is a list of recommended spare parts. However, conditions of ser vice vary significantly and a general list may not in its entirety be applicable to a given installation. The user should ex er cise judgment in defining specific require ments based on this guide.

1. Fuses for control transformer primary and secondary.
2. Contactor.
3. Bulbs for any light requiring a bulb.
4. Control transformer.
5. Alternator relay or duplex alternator board, whichever is required.

Pump Troubleshooting

WARNING: Before handling these pumps and controls, always disc on nect the pow-er first. Do not smoke or use sparkable electrical devices or flames in a septic (gas eous) or possible septic sump.

1. Pump does not run in Hand position.
   • Check pump circuit breaker and control fuse for trip ping or blown condition.
   • Check incoming power volt age and control cir cuit volt age.
   • Check overload re lay to see if it is tripped. Reset relay if tripped.
   • With the power off, check motor heat sensor continuity.
   • Check wiring of pump to con trol panel. It should agree with the sche mat ic.
   • Check contactor coil re sis tance.
2. Pump does not run in Auto position.
   • Check items (a.) through (f.) per Item #1 above.
   • Floats may be miswired to control panel. Check float type (N.O. or N.C.) and hook up by re fer ring to the schematic. If the start and stop floats are hooked in reverse, pump will short cycle and will not pump the level down.
   • Check pump controller in di cat ing lights. No Lights On (No call from the floats)
   1. Make sure there is power to the controller.
   2. Is water level in the sys tem high enough to ac ti vate the floats?
3. If #1 and #2 check out, shut power off to the pan el. Remove the OFF FLOAT wires and run a jump er between the OFF FLOAT connections. If OFF FLOAT light comes on, the float is “hung up” or the wiring connections are loose.

Off Float Light On

1. Is water level in the system high enough to activate the lead (ON) float?

2. If #1 checks out, shut off pow er to the panel. Remove the lead (ON) float wires and run a jum per between the LEAD FLOAT (ON FLOAT) connec tions. If one or two pumps start, check the lead (ON) float for “hang up” or loose wir ing con nec tions.

   • Check Hand-Off-Auto (H-O-A) switch for correct position.
   •  Check for heat sensor trip in pump with a jumper between HEAT SEN SOR 1 and HEAT SEN SOR 2 terminals.
   • Reset overload(s) if tripped.
   • Reset circuit breakers if tripped.

3. Pump runs, but run light does not energize.

   • Re move light and check with ohmmeter.
   • Check run light wir ing.

4. Pump runs but does not pump down the wet well.

   • On three phase only, pump rotation may be wrong. Wiring of pump to con-trol pan el may be re verse sequenced.
   • Impeller may be dragging in volute due to sol ids. High am per age draw would identify this.
   • Refer to the pump manual for other possibilities such as closed discharge gate valve, etc.

5. Severe humming/chat ter ing of contactors and control relays.

   • There may be low voltage. Check voltage at primary and secondary of control transformer us ing a volt me ter. This low voltage condition may cause severe chat ter ing and burnout of contactors and relays.
   • Contactor may have dust around magnet of coil struct ure. Dry or clean as re quired.
   • Check voltage to the control panel. Contactors require a minimum of 85% of full volt age to pull in without chatter. If the problem is a re cur ring one, measure voltage with recorder on a 24 hour basis. 85% of full volt age to pull in without chatter. If the problem is a re cur ring one, measure voltage with recorder on a 24 hour basis.
   • Make sure the floats are locate d away from any turbu lence.
   • Dry out the junction box (if furnished); moisture in the junction box may cause relays to energize intermittent ly.

6. Short cycling pump.

   • Check float controls.

7. Run light stays on.

   • Selector switch may be in the Hand position.

8. Nuisance tripping of
   over load on motor starters or cir cuit break ers.

   • Check pump and draw with amp probe and compare to nameplate amps on pump.

   • The impeller may be locked up due to excessive debris or solids.

   • Possible motor failure (fault in windings).

   • Pump may be miswired to ter mi nal block.

   • Voltage and current unbalance. Three phase only. Voltage un bal ance on three phase power sources can cause motor current to become un bal anced and exces sive heating will re sult. Trip ping of the overl oad protectors and premature motor failures can be expected if the current unbalance exceeds five percent.
     To determine if motor current un bal ance is a function of the motor or the power supply:

   • • Label the leads and the ter mi nals 1, 2, and 3 respectively.

     • Record the amperage for each lead.

     • Move each lead to the next terminal (1 to 2, 2 to 3, 3 to 1).

     • Again read the amperage of  each lead.

     • Move each lead to the next terminal (1 to 3, 2 to 1, 3 to 2).

     • Again read the amperage of each lead.

     • If the unbalance moves with the motor leads, the un bal ance is caused by the mo tor. If the unbalance remains with the terminals, the unbal ance is in the pow er supply.

     • If the current unbalance exceeds five percent, nui sance tripping or ex ces sive heating will result.

     • Connect leads for the lowest percent of current un bal ance.

   • Connections and start components. Single phase only.

9. Disconnect all power from the panel before making these checks.

10. Motor winding resistance read ings.

    • Disconnect all three motor leads from panel terminal blocks. 85% of full volt age to pull in without chatter. If the problem is a re cur ring one, measure voltage with recorder on a 24 hour basis.
    • Make sure the floats are locate d away from any turbu lence.
    • Dry out the junction box (if furnished); moisture in the junction box may cause relays to energize intermittent ly.

11. Capacitor check.

    • Make sure the ca pac i tor is dis charged. Use extreme caution as a spark might occur.
    • Disconnect the ca pac i tor leads and connect an analog-type volt-ohmmeter to the capacitor terminals.
    • Set the meter on the RX1,000 scale to check the start ca pac i tor. Set the meter on the RX10,000 scale to check the run ca pac i tor.
    • The meter should in di cate low ohms when it is first connected, but as the ca pac i tor becomes charged (by the meter), it will return to a read ing of infinity (open circuit).

12. Start relay check.

    • Check the start relay coil re sis tance. It should be 3,000 to 15,000 ohms.
    • Install a clamp on amp meter around the start wind ing lead.
    • Set the amp meter scale to at least 2 times the pump motor full load current.
    • Place the H-O-A switch in the Hand position to start the pump.
    • The meter should read ap prox i mate ly 2 times full load current during starting.
    • After the motor has started (within one sec ond) the cur rent should drop to a value much less than full load cur rent.

13. Motor voltage check:

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STANDARD LIMITED WARRANTY

Pentair Hydromatic® warrants its products against defects in material and workmanship for a period of 12 months from the date of shipment from Pentair Hydromatic or 18 months from the manufacturing date, whichever occurs first – provided that such products are used in compliance with the requirements of the Pentair Hydromatic catalog and technical manuals for use in pumping raw sewage, municipal wastewater or similar, abrasive-free, noncorrosive liquids.
During the warranty period and subject to the conditions set forth, Pentair Hydromatic, at its discretion, will repair or replace to the original user, the parts that prove defective in materials and workmanship. Pentair Hydromatic 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 Hydromatic website: http://forms.pentairliterature.com/startupform/startupform.asp?type=h. Warranty is effective only if Pentair Hydromatic 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 Hydromatic will cover only the lower seal and labor thereof for all dual seal pumps. Under no circumstance will Pentair Hydromatic 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 Hydromatic service facility.
This limited warranty will not apply:

• to defects or malfunctions resulting from failure to properly install, operate or maintain the unit in accordance with the printed instructions provided;
• to failures resulting from abuse, accident or negligence;
• to normal maintenance services and parts used in connection with such service;
• to units that are not installed in accordance with applicable local codes, ordinances and good trade practices;
• if the unit is moved from its original installation location;
• if unit is used for purposes other than for what it is designed and manufactured;
• to any unit that has been repaired or altered by anyone other than Pentair Hydromatic or an authorized Pentair Hydromatic service provider;
• to any unit that has been repaired using non factory specified/OEM parts.

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

Liability Limitation: IN NO EVENT SHALL PENTAIR HYDROMATIC BE LIABLE OR RESPONSIBLE FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES RESULTING FROM OR RELATED IN ANY MANNER TO ANY PENTAIR HYDROMATIC PRODUCT OR PARTS THEREOF. PERSONAL INJURY AND/OR PROPERTY DAMAGE MAY RESULT FROM IMPROPER INSTALLATION. PENTAIR HYDROMATIC DISCLAIMS ALL LIABILITY, INCLUDING LIABILITY UNDER THIS WARRANTY, FOR IMPROPER INSTALLATION. PENTAIR HYDROMATIC 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 Hydromatic shall vary or expand the provision hereof.

740 EAST 9TH STREET ASHLAND,
OHIO, USA 44805 419-289-1144
WWW.HYDROMATIC.COM
Warranty Rev. 12/13
490 PINEBUSH ROAD,
UNIT #4 CAMBRIDGE,
ONTARIO,
CANADA N1T 0A5 800-363-PUMP
Item # H-03-000
Part # 5625-000-1
© 2012 Pentair Pump Group, Inc.
10/31/12

References

• Start-Up Report

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