HAYWARD ULTRA-MAX SERIES Hi-Performance Pumps Instruction Manual

HAYWARD ULTRA-MAX SERIES Hi-Performance Pumps

Product Information

The Hayward Ultra-Max self-priming centrifugal pump is a high-performance pump that is designed for efficient and dependable service. The motor housing is non-conductive and corrosion-proof, protecting the motor parts from outside contact and the elements. The advanced design reduces operation and maintenance to simple, common-sense procedures.

Locate the system below the pool water line and as close to the pool as possible for best performance.

• Make sure suction joints are tight and suction pipe should be as large or larger than discharge pipe.
• Avoid damp and non-ventilated locations for the motor, as it requires free circulation of air to aid in cooling.
• Ensure that the electrical supply available agrees with the motor’s voltage, phase, and cycle, and that wire size is adequate for the HP/KW rating and distance from the power source.
• The motor must always be properly grounded, and electrical circuits should be protected by proper size ground fault circuit interrupter (GFCI). All electrical wiring should be performed by qualified personnel and must conform to local codes and regulations.

Product Usage Instructions

1. Fill strainer/housing completely with water before starting the pump. Never operate the pump without water. Water acts as a coolant and lubricant for the mechanical shaft seal.
2. Open all suction and discharge lines and valves, as well as air bleed (if available) on the filter. (The air that is to be displaced from the suction line must have some place to go).
3. Turn on power and allow a reasonable time for priming. Priming time depends on suction lift and length of suction piping. If the pump will not start or prime, see the TROUBLESHOOTING GUIDE on the back page.
4. Clean the strainer basket regularly, but do not strike it to clean. Inspect the strainer cover gasket regularly and replace it if necessary.
5. Hayward pumps have self-lubricating motor bearings and shaft seals, so no lubrication is necessary.
6. Keep the motor housing clean and ensure that air vents are free from obstructions, debris, etc.
7. Occasionally, shaft seals must be replaced due to wear or damage. Refer to the instructions for replacement.
8. For storage or winterizing, the pump and motor must be protected from freezing. Shut off all electric power, disconnect cord/electrical connections and plumbing connections, drain thoroughly, and clean out any debris. Store the pump and motor in a dry, well-ventilated room.

Note: NSPI-4 Article V standard for above ground and on-ground pools advises that components such as the filtration system, pumps, and heater be positioned so as to prevent their being used as a means of access to the pool by young children.

For more information or troubleshooting, visit our website at www.haywardcanada.com

Your Hayward Ultra-Max self priming centrifugal pump has been quality-built and engineered to give you many years of efficient, dependable service. The non-conductive, corrosion-proof motor housing provides protection from the elements and insulates the electrical motor parts from outside contact. The advanced design reduces operation and maintenance to simple, common-sense procedures.

GENERAL TIPS ON PUMP INSTALLATION

For best pump performance, locate the system below the pool water line and as close to the pool as possible. If you own an above-ground pool please see Note: NSPI-4 Article V, for safe and proper installation of the equipment package. Make sure the suction joints are tight. The suction pipe should be as large or larger than the discharge pipe. Damp, non-ventilated locations should be avoided. Motors require free circulation of air to aid in cooling. Insure that the electrical supply available agrees with the motor’s voltage, phase and cycle, and that wire size is adequate for the HP/KW rating and distance from the power source. Motor must always be properly grounded. If cord is connected, use only a properly grounded outlet. Electrical circuits should be protected by proper size ground fault circuit interrupter (GFCI). All electrical wiring should be performed by qualifed personnel and must conform to local codes and regulations.

STARTING AND PRIMING INSTRUCTIONS

Fill the strainer/housing completely with water. Never operate the pump without water. Water acts as a coolant and lubricant for the mechanical shaft seal. Open all suction and discharge lines and valves, as well as air bleed (if available) on the filter. (The air that is to be displaced from the suction line must have someplace to go). Turn on the power and allow a reasonable time for priming. Priming time depends on the suction lift and the length of the suction piping. If pump will not start, or will not prime, see the TROUBLESHOOTING GUIDE on the back page.
Note: NSPI-4 Article V, the standard for above-ground and on-ground pools, advises that components such as the filtration system, pumps and heater be positioned so as to prevent their being used as a means of access to the pool by young children.

MAINTENANCE

1. Clean the strainer basket regularly. Do not strike the basket to clean. Inspect the strainer cover gasket regularly and replace as necessary.
2. Hayward pumps have self-lubricating motor bearings and shaft seals. No lubrication is necessary.
3. Keep motor housing clean. Insure air vents are free from obstructions, debris, etc.
4. Occasionally, shaft seals must be replaced, due to wear or damage. See instructions

STORAGE/WINTERIZING

The pump and motor must be protected from freezing. Shut off all electric power. Disconnect cord/electrical connections and plumbing connections. Drain thoroughly and clean out any debris. Store the pump and motor in a dry, well- ventilated room.

MANUFACTURED EXCLUSIVELY BY HAYWARD

ELECTRONIC TIMER MODULE INSTRUCTIONS

Your integrated timer module is designed to be programmed to your filtration need, with four (4) possible settings.

TO SET TIMER

1. Move switch “OFF” to “PROGRAM” back to “OFF” – the resulting single tone indicates Setting #1. Repeat until a number of tones heard equals the setting desired. ie 3 rapid tones is Setting #3
2. Move the switch from “OFF” to “RUN: to begin the selected program setting.

TWO SPEED MOTOR SETTINGS

• Setting 1 – Pump runs 24 hours on Hi Speed ( single tone )
• Setting 2 – Pump runs 18 hours on Hi, 6 hours on Low ( 2 tones )
• Setting 3 – Pump runs 12 hours on Hi, 12 hours on Low ( 3 tones )
• Setting 4 – Pump runs 6 hours on Hi, 18 hours on Low ( 4 tones )

SINGLE SPEED MOTOR SETTINGS

• Setting 1 – Pump runs 24 hours Continuous ( single tone )
• Setting 2 – Pump runs 18 hours, off 6 hours ( 2 tones )
• Setting 3 – Pump runs 12 hours, off 12 hours ( 3 tones )
• Setting 4 – Pump runs 6 hours, off 18 hours ( 4 tones )

TO OVERIDE TIMER SETTINGS

• Move switch from “RUN” to “OFF” and back to “RUN” within 3 seconds.
• The pump will run for 1 hour and then return to the previous programmed setting.
• If a power failure occurs the timer automatically returns to the programmed setting.

SEAL CHANGE INSTRUCTIONS SP-2900 SERIES

GENERAL
Exercise extreme care in handling and installing the new seal and seat assembly. The lapped and polished surfaces may easily be damaged by dirt or scratching. For safety, all service must be performed with all power shut off.

REMOVING THE MOTOR COVER

• Turn off power and unplug power cord. Remove pump and motor assembly from piping system.
• Remove motor housing end cover by removing three (3) screws. Carefully pull cover away from motor and disconnect wires from motor terminals.

REMOVING THE MOTOR ASSEMBLY

• Remove the (4) 3/8” x 2” hex head bolts which hold the motor assembly to the pump/strainer housing.
• Slide the motor assembly out of the pump/strainer housing, exposing the diffuser. Pull the diffuser off of the seal plate, exposing the impeller. (The diffuser may remain in the pump/strainer housing. To remove, pull it straight out of the strainer housing.

REMOVING THE IMPELLER (see note)

• To hold motor shaft from turning, carefully slide a 7/16” wrench between the casting and the protector switch, and rotate the impeller so the wrench flts over the (2) flats on motor shaft.
• Rotate the impeller counter-clockwise and remove. The spring portion of the seal assembly is not exposed. Note carefully the position of the spring seal, and remove it.

REMOVING THE CERAMIC SEAT

• Remove the seal plate. Note the notch on the top of the plate and the mating lug on the top of the motor mounting bracket.
• Press the ceramic seat with O-ring out of the seal plate. If tight, use a small screwdriver to tap seat out.

STOP – Clean all recesses and parts to be reassembled. Inspect gaskets and replace if necessary.

SEAL INSTALLATION

• Clean and lightly lubricate the impeller hub and seal recess in the seal plate with silicone or Jack’s N° 327 O-ring lube.
• Gently wipe the black, polished surface of the spring seal assembly with a clean, soft cotton cloth. Press the spring seal assembly onto the impeller hub  black polished surface facing away from the impeller.
• Gently wipe the polished face of the ceramic seal with a soft, cotton cloth. Lubricate the O-ring on the ceramic seat and
• press it firmly and evenly into the recess in the seal plate – polished side facing out.
• Place the seal plate onto the motor bracket aligning the positioning lug and guide.

REPLACING THE IMPELLER AND DIFFUSER

• Screw the impeller onto the motor shaft in a clockwise direction. Tighten snugly by holding the motor shaft with a wrench.
• Place the diffuser over the impeller onto the seal plate, fitting the positioning lug between the two guides.

REPLACING THE MOTOR ASSEMBLY

• Slide the motor assembly, with the diffuser in place, into pump/strainer housing, being careful not to dislodge the diffuser.
• Fasten assembly to the housing using the (4) 3/8” x 2” bolts. (Be sure the housing gasket is in place). Tighten alternately and evenly.

REPLACING THE MOTOR COVER

• Reconnect electric wires to pump motor terminals. Line 1 from power cord; jumper wire from switch to line 2; and ground wire to ground screw on
• motor. Replac motor housing and end cover and secure with three (3) screws.
• Reconnect pump to piping system. Be sure to fill the strainer with water before restarting.

ELECTRICAL GUIDE – 60 CYCLE MOTORS – SINGLE PHASE

A separate electrical circuit, utilizing a rating as above, is recommended.

TROUBLESHOOTING GUIDE

• A. MOTOR WON’T START

1. Check for improper or loose connections, open switches or relays, blown circuit breakers or fuses.
2. Manually check rotation of motor shaft for free movement and lack of obstruction.

• B. MOTOR CUTS OUT – Check for

1. Wiring, loose connections, etc.
2. Low voltage at motor (frequently caused by undersized wiring.
3. Binding and overload. (Amperage reading)

NOTE: Your Hayward pump motor is equipped with Automatic Thermal Overload Protection. The motor will automatically shut off, under normal conditions, before heat damage build-up, due to an improper operating condition, can occur. The motor will auto-restart when safe heat level is reached.

• C. MOTOR HUMS BUT DOES NOT START

1. Centrifugal switch stuck in open position.
2. Binding of motor shaft.

• D. PUMP WON’T PRIME

1. Make sure pump/strainer housing is filled with water, and that cover O-Ring is clean and properly seated. Make sure strainer cover is locked firmly in position.
2. Make sure all suction and discharge valves are open and unobstructed, and that pool water level is above all suction openings.
3. If pump develops a vacuum, check for blocked suction line or strainer, or air leak in suction piping.
4. If pump does not develop a vacuum and pump has sufficient “priming water”:
5. Tighten all bolts and things.
6. Check voltage to make sure pump is up to speed.
7. Open pump and check for clogging and obstruction.
8. Remove and replace shaft seal.

• E. LOW FLOW – Generally, Check for

1. Clogged or restricted strainer or suction line; undersized pool piping.
2. Plugged or restricted discharge line of filter (high discharge gauge reading).
3. Air leak in suction (bubbles issuing from return things).
4. Pump operating underspeed (low voltage).
5. Plugged or restricted impeller.

• F. NOISY PUMP – Check for

1. Air leak in suction causing rumbling in pump.
2. Cavitation due to restricted or undersized suction line and unrestricted discharge lines. Correct suction condition or throttle discharge lines, if practical.
3. Vibration due to improper mounting, etc.
4. Foreign matter in pump housing.
5. Motor bearings made unserviceable by wear, rust, or continual overheating.

SERVICE AND REPAIRS

Consult your local authorized Hayward dealer or service center. No pumps or motors may be returned directly to the factory without the express written authorization of Hayward Pool Products Canada, Inc. www.haywardcanada.com

References

• Welcome to Hayward Canada

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