PENTAIR HCU Series Condensate Pumps Owner’s Manual

OWNER’S MANUAL
Condensate Pumps HCU Series
Installation/Operation/Parts

For further operating, installation, or maintenance assistance: Call 1-888-957-8677

Safety

READ ALL INSTRUCTIONS
BEFORE STARTING INSTALLATION
general safety Information
Electrically powered condensate pumps normally give many years of trouble-free service when correctly installed, maintained, and used. However, unusual circumstances (interruption of power to the pump, algae/debris in the reservoir, electrical or mechanical failure in the pump, etc.), may prevent your pump from functioning normally.
Consequently, any condensate pump installed in an area susceptible to water damage must be connected to a failure alarm or water sensing device or include an auxiliary safety shutoff switch activated by high water in the pump reservoir and connected to the thermostat of the furnace/AC unit. See the “Troubleshooting Chart” in this
manual for information about common condensate pump problems. For more information, see your dealer or call customer service at 1-888-957-8677.

1. Drain all water from system before servicing.
2. Periodically inspect reservoir, pump, and system components. Keep free of debris and foreign objects. Perform routine maintenance as required.
3. When installing an electrically driven pump, follow all electrical and safety codes that apply.
4. Make certain power source conforms to requirements of your equipment.
5. Protect electrical cord from sharp objects, hot surfaces, oil, and chemicals. Avoid kinking cord. Replace or repair damaged or worn cords immediately.
6. Personal Safety:
   a. Wear safety glasses at all times when working with pumps.
   b. Keep work area clean, uncluttered and properly lighted – replace all unused tools and equipment.
   c. Keep visitors at a safe distance from work area.
   d. Make workshop child-proof – with padlocks, master switches, and by removing starter keys.

Risk of electric shock. If your basement has water or moisture on floor, do not walk on wet area until all power has been turned off. If shut-off box is in asement, call electric company to shut-off service to house, or call your local fire department for instructions. Failure to follow this warning can result in fatal electrical shock.
When pump is plugged in, do not handle pump, cord, or plug with wet hands or when standing on a wet or damp surface or in water. unplug pump before servicing it or
doing any maintenance on it. 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.

Installation

Fire and explosion hazard. Do not use this pump to pump flammable or explosive liquids. Use pump only with liquids compatible with pump component materials. Do not use pump in explosive atmospheres.
Risk of flooding. If for any reason property damage or personal injury can result from an inoperative or leaking pump, an auxiliary switch backup system and/oran alarm should be installed with pump.

1. Mount pump on side of furnace (or on floor or wall).
   INSTALLATION
   Electrical shock and carbon monoxide hazards. When mounting the pump on the side of the furnace, make sure that the mounting holes clear the heatexchanger and all wiring. The mounting screw for the pump should touch only the pump reservoir flange and theexterior sheet metal on the furnace. If in doubt or if this is confusing, consult a qualified HVAC serviceman or the furnace manufacturer.

2. Run plastic tubing as shown into pump’s drain inlet hole(s).
   Make sure that the tubing to the pump intake is fastened securely so that it cannot come out of the pump intake port. Check for local code requirements. You must comply with codes.

3. Run tubing as shown from hose barb on pump discharge to floor drain or laundry tub.
   Check local codes for discharge water requirements. Run the discharge line to a point outside the house if possible. To do this easily, you may be able to run the condensate discharge line out through the wall along the AC Freon line. Use the existing line if possible (when replacing an existing pump).
   Clamping the plastic discharge line to the check valve with a 1/2” hose clamp (purchase separately) will help to keep it in place, especially with older tubing (plastic tubing tends to harden as it gets older).
   Common locations for the end of the discharge line are:
   A. Out a window or along the air conditioner Freon line to the outdoors.
   B. To a floor drain (leave an air gap between the end of the tube and the drain).
   C. To a laundry tub or sink (leave an air gap above the tub drain).

4. **** Hazardous voltage. Plug pump into a 115-volt outlet. Pump is double insulated; grounding is not required.ing is not required.
   With the unit plugged in and the discharge line installed, fill the pump reservoir until the pump starts. Allow it to pump down and shut itself off automatically to verify
   proper operation through one complete cycle.

safety switch:
Most models include an automatic safety switch which should be wired to activate an alarm or to cut off power in the event of high water in the condensate reservoir.
If you must run additional wire from the low voltage safety switch to the alarm or to the control wiring of your furnace/AC unit, use at least 18 gauge (AWG) copper wire rated at 105° C. Make connections with wire nuts as shown.
If your installation allows interruption of heating or cooling, follow procedure 1, below.
If your installation does not allow interruption of heating or cooling, follow procedure 2, “Safety Switch Sounds Alarm”.
Risk of electrical shock. disconnect power to furnace/aC unit and be sure condensate pump is unplugged before starting procedure.

1. safety switch shuts down Furnace/aC
   A. Make sure the pump is unplugged.
   B. Find the red wire in the bundle from the thermostat and disconnect it from the furnace/AC unit.
   C. Connect the red wire to one of the white wires from the safety switch as shown in Figure 1.
   D. Connect the other white wire from the switch to the furnace/AC terminal strip where the red wire from the thermostat was connected.
   E. Plug in the pump.
   F. The furnace/AC will now operate as long as the condensate pump empties the reservoir. If the reservoir overfills, the switch will open and cut off the power to the furnace/AC. Figure 1: Low Voltage Auxiliary Safety Switch connection for Furnace/AC shutdown installation.
   Risk of freezing/overheating. This installation
   will shut down the furnace/AC unit if the water level in the pump reservoir rises to within about 1/2” from the top of the reservoir (thereby stopping the production of condensate and preventing flooding), but it will not allow the furnace/AC unit to restart until the condensate pump reservoir is emptied. It should be monitored so that in case of high water in the reservoir, corrective action can be taken before freezing/overheating occurs.
   : When installing the pump in a new home or after a renovation project, be sure that debris in the duct work does not get into the reservoir; it will clog the system.

2. safety switch sounds alarm
   A. Make sure the pump is unplugged.
   B. Remove the two screws holding the motor cover to the pump deck. Remove the cover.
   C. Do not disturb the two yellow wires going through the deck and into the motor (they are potted into the top of the motor so there are no wire ends visible) .
   D. Remove the white wire from the bottom terminal (NC or Normally Closed) on the end of the safety switch and reattach it to the upper terminal (NO or Normally Open) on the end of the switch.
   E. Run the white switch wires out through the notch in the motor cover and replace the motor cover.
   Make sure all wires (power cord and safety switch) run through the notch. Hook the cover under the catch on the deck and secure it with two screws.
   F. Connect the white wires from the safety switch to the alarm of your choice (purchase separately). Consult the alarm manufacturer’s instructions for correct connections to the alarm.
   G. Plug in the pump.
   Risk of Flooding. With installation
   H. ****No. 2 (“Safety Switch Sounds Alarm”), the alarm is activated when the water level in the reservoir is within about 1/2” of the top of the reservoir.
   However, the furnace/AC unit will continue to produce condensate because the alarm will not shut it down. Monitor the installation so that in case of high water level in the condensate reservoir you can take action before the reservoir overflows and flooding occurs.

Figure 2: Low Voltage Auxiliary Safety Switch connection for alarm circuit installation (does not shut down furnace/AC unit).
Testing auxiliary safety switch:
NOTICE: Some appliances may not start immediately due to a built-in delay circuit that prevents rapid cycling of the compressor.

1. Start appliance.
2. Unplug the condensate pump so that it cannot pump out.
3. Pour water into the pump reservoir until it is almost full.
4. As the water rises in the reservoir, the safety switch should shut down the appliance or set off the alarm (depending on the installation procedure used).
5. Plug in the condensate pump and allow it to empty the reservoir. As the water level goes down in the reservoir, the safety switch should reset, allowing the appliance to start or shutting off the alarm.

MAINTENANCE

1. Disconnect the power to the furnace/AC unit and unplug the pump.
2. Disconnect the tubing to the pump. Drain the tubing into a container.
3. Remove the two mounting screws and remove the pump from the furnace or wall. Dump the reservoir into a floor drain or container.
4. After you have dumped the pump, remove the four screws securing the reservoir to the pump deck. Lift the deck/pump assembly off of the reservoir.
5. Turn the deck/pump assembly upside down and remove the five screws holding the impeller cover to the motor.
6. Remove the impeller cover. The rotor/ impeller assembly may come out with it. If not, pull it out of the rotor chamber in the motor. (You may have to pull it hard to get it out against the magnetism in the motor windings.)
7. Clean the impeller, rotor, rotor cavity, and O-Ring. Use a rag to clean the O-Ring groove in the impeller cover and the sealing surface on the bottom of the motor block.
8. Clean out the reservoir.
9. Reassemble the impeller and the impeller cover; tighten the screws carefully. Do not overtighten!
10. Turn everything right side up and reassemble the reservoir to the deck. Be sure the impeller cover fits into the molded ring in the bottom of the reservoir. Fasten the reservoir with the four screws at the corners.
11. Reinstall the pump on the furnace.
12. Plug in the pump, fill the reservoir, and run the pump through one complete pump-down cycle to be sure it works correctly.
13. The pump is ready for operation.

CLEANING THE CHECK VALVE

1. Unplug the condensate pump.

2. Remove the discharge line from the check valve.

3. Use a 9/16” wrench to remove the check valve from the pump deck.

4. Inspect the valve for obstructions or damage. Clean or replace it as needed.

5. Thread the valve back into the pump discharge by hand, plus 1/2 turn with the wrench.
   NOTICE: Don’t overtighten the valve, as overtightening can distort the O-Ring that seals the valve, causing leaks.

6. Plug in the pump, fill the reservoir, and run the pump through one complete pump-down cycle to be sure it works correctly. 7. The pump is ready for operation.

TROUBLESHOOTING

Pump does not run

• Check power to furnace/AC and to pump circuit. Be sure pump is plugged in.
• Condensate level in reservoir may not be high enough to start pump. (Water must be 2″ below the top of the reservoir for pump to start.)
• Dirt or algae clogging reservoir.
• Inlet line clogged.
• Stuck float resulting from dirty reservoir.
• Make sure that float switch is not stuck in the down (off) position.

Pump runs, no discharge

• Make sure the discharge tubing (especially the end of the tubing) is not plugged.
• UNPLUG pump and make sure check valve and impeller discharge port are not plugged.
• Make sure the float switch is not stuck in the on (up) position.

PREVENTIVE MAINTENANCE

Unplug the pump and clean out the reservoir at the beginning and end of each heating season.
Use a commercial algaecide and follow manufacturer’s instructions. Putting about a gallon of algaecide solution in the reservoir and then cycling the pump several times will keep the reservoir and the discharge line free of algae build-up. Be sure to dump the cleaner and rinse the reservoir with water before starting the pump.
Be sure you do not clog the impeller discharge port or the check valve when starting the pump after cleaning.
Whenever you replace the motor cover and screws, be sure that the motor cover catches the float switch pivot pin and does not pinch either the power cord or the safety switch leads. Do not over-tighten the screws.
SERVICING A DOUBLE-INSULATED APPLIANCE
A double insulated product uses two layers of insulation (one inside the other) to provide protection from electrical shock hazards. No separate grounding wire is required. DO NOT try to install a grounding wire on a double-insulated device. Only qualified service personnel should attempt to service a double-insulated product, because safe servicing requires extreme care and knowledge of the system. Any replacement parts installed in a double- insulated product must be identical to the original parts that they replaced. A double insulated product is marked with the words “DOUBLE INSULATION” or “DOUBLE INSULATED”.

Limited Warranty

HYDROMATIC warrants to the original consumer purchaser (“Purchaser” or “You”) of HYDROMATIC Sump Pumps, Effluent Pumps, Sewage Pumps (other than 2-1/2”), and Package Systems, that they will be free from defects in material and workmanship for the Warranty Period of 36 months from date of manufacture.
Our warranty will not apply to any product that, in our sole judgement, has been subject to negligence, misapplication, improper installation, or improper maintenance. Without limiting the foregoing, operating a three phase motor with single phase power through a phase converter will void the warranty. Note also that three phase motors must be protected by three-leg, ambient compensated, extra-quick trip overload relays of the recommended size or the warranty is void.
Your only remedy, and HYDROMATIC’s only duty, is that HYDROMATIC repair or replace defective products (at HYDROMATIC’s choice). You must pay all labor and shipping charges associated with this warranty and must request warranty service through the installing dealer as soon as a problem is discovered. No request for service will be accepted if received after the Warranty Period has expired. This warranty is not transferable.
EXCEPTIONS: Hydromatic Special Application Pumps, Battery Back-Up Sump Pumps, Filtered Effluent Pumps, Grinder Pumps, and 2-1/2” Sewage Pumps are warranted for a period of 12 months from date of purchase or 18 months from date of manufacture, whichever comes first.
HYDROMATIC SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT DAMAGES WHATSOEVER.
THE FOREGOING LIMITED WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE FOREGOING LIMITED WARRANTIES SHALL NOT EXTEND BEYOND THE DURATION PROVIDED HEREIN.
Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on the duration of an implied warranty, so the above limitations or exclusions 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.
This Limited Warranty is effective June 1, 2011 and replaces all undated warranties and warranties dated before June 1, 2011.

HYDROMATIC
293 Wright Street, Delavan, WI 53115
Phone:888-957-8677
Fax: 800-426-9446
Web Site: hydromatic.com

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