Hydromatic Novus 1000 series Manual

STANDARD ELECTRICAL

CONTROLS

04/10

Item # H-03-481

Part # 5625-481-1

NOTE! To the installer: Please make sure

you provide this manual to the owner of

the equipment or to the responsible party

who maintains the system.

Installation and Service Manual

2

Thank you for purchasing your

Hydromatic®Novus Control

Panel. To help ensure years of

trouble-free operation, please read

the following manual carefully.

Before Operation:

Read the following 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

continued safe product use. DO

NOT THROW AWAY OR LOSE

THIS MANUAL. Keep it in a

safe place so that you may refer

to it often.

Unpacking Panel:

Remove panel from carton. When

unpacking unit, check for

concealed damage. Claims for

damage must be made at the

receiving end through the delivery

carrier. Damage cannot be

processed from the factory.

WARNING: Do not attempt to

wire this control box unless you

have a good working knowledge

of electricity and are familiar

with the state and local codes. If

you are in doubt about anything,

contact a qualified electrician.

Do not attempt to operate this unit

on any other voltage or power

distribution other than for which it

was originally designed (check

nameplate). Failure to comply

with this will result in the

immediate cancellation of all

warranties and claims.

It is advisable to put the panel on

its own circuit using a circuit

breaker adequately sized to

protect the pump(s). Check state

and local codes for the correct

wire size and circuit protection to

use. The wire should be sized

large enough to handle the full

load current of the pump(s) you

are operating, and any voltage

drop that might occur due to long

service runs.

Run power supply lines to the

control box and secure (knockouts

are not supplied in this box).

Select a convenient location on

the bottom to enter the box with

the power supply. Cut a hole with

a chassis punch. Caution should

be taken not to get metal chips in

the components while cutting

hole. After the hole is cut, any

metal particles must be removed

from the box. Failure to do so may

result in premature component

failure.

Connect incoming power to the

terminal blocks labeled L1, L2, L3,

and all necessary ground wires to

the ground lug at the bottom of the

box. The ground lug should be

fastened to a good driven earth

ground by one of the methods

described in the National Electric

Code. NEC does not permit using

ground as a current carrying

conductor, therefore a neutral

must be provided for 115 volt 1

phase, 208 volt 1 phase, 230 volt

1 phase, or 208 volt 3 phase

systems.

WARNING: Before handling

these pumps and controls,

General

Information

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: A nonmetallic

enclosure does not provide

grounding conduit connections.

Use grounding bushing and

jumper wires.

Make the Following Electrical

Connections:

a. Connect the pump leads to

the control panel. If pump is

single phase and the panel

has start capacitor, start relay

and run capacitor, it is critical

that the pump leads be

connected properly. The

White, Black, and Red pump

leads must be connected to

the appropriate terminals

as directed by the panel

schematic and the label on

the back panel below the

terminals.

b. Connect the pump heat sensor

and seal failure leads (if

available on the pump) to the

appropriate terminal blocks in

the control panel.

Power

Supply

3

c. Connect all the float control

leads or 4-20mA leads to the

appropriate panel terminals.

Contractor must be very

careful in locating the floats at

the proper elevations. The

maximum distance from the

control panel to the floats

is the lesser of l00 feet,

or the maximum distance

recommended for the pump.

d. Before connecting power to the

control panel, make sure all

control switches (e.g. H-O-A

switch) and protective devices

(e.g. breakers) are in the Off

position. Now connect power

to the terminal block or the

circuit breaker as directed by

the schematic.

e. Control panel must be

grounded properly per NEC

and/or local codes. To

facilitate this, a ground lug is

provided on the control panel.

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 connected to panel

correctly.

3. WARNING! Live voltage can

kill! Check incoming power

voltage 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 supplied).

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.

The maintenance schedule

will vary with operating and

environmental conditions. It will

also vary with the specific type of

control supplied. The list herein is

a guide only.

1. Exercise breaker through one

cycle. Be careful not to

overexercise as the breaker is

not a switching 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

running pump(s) in Hand

mode. Check bulb(s) in any

other light(s).

4. With the power off, check

continuity of all control fuses.

5. Check voltage at primary

and secondary of control

transformer.

6. Check the pump full

load amps.

7. For 1 phase panels with start

circuit, about 5 seconds after

the pump starts check the

voltage from terminal 1 to

terminal 2 on the start relay to

be sure that the relay has

operated. The voltage from

terminal 1 to terminal 2 on the

start relay must exceed 10

VAC. For some pumps the

voltage may exceed 400 VAC.

If after 5 seconds the voltage

from terminal 1 to terminal 2

on the start relay does not

exceed 10 VAC stop the pump

as damage to the start capacitor

may be damaged in about 15

seconds.

Start-up

Operation

6. WARNING! Live voltage can

kill! Check voltage to the

panel and at secondary of

control transformer using a

voltmeter. If no transformer is

supplied, check voltage at the

circuit breakers.

7. With H-O-A switch in hand,

check discharge to verify the

pump is running. Check for

flow. On three phase power,

check to see if each pump

has proper rotation. Wrong

rotation will give low flow.

8. Check full load current

with amp probe and compare it

with the nameplate rating. 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 operation and

response to control panel to

the float operation. For

sequence of operation, refer to

design specification.

11.Make sure H-O-A switch is left

in the Auto position after

start-up is completed.

Pump Start-Up:

Refer to pump Installation and

Service Manual.

Pump

Maintenance

4

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.

1. Pump does not run in

Hand position.

a. Check pump circuit

breaker and control fuse

for tripping or blown

condition.

b. Check incoming power

voltage and control

circuit voltage.

c. Check overload relay to see

if it is tripped. Reset relay

if tripped and check pump

current with ammmeter.

d. With the power off, check

motor heat sensor

continuity.

e. Check wiring of pump to

control panel. It should

agree with the schematic.

f. Check contactor coil

resistance.

2. Pump does not run in

Auto position.

a. Check items (a.) through

(f.) per Item #1 above.

Pump

Troubleshooting

If the start relay is not

operating check the pump and

the system voltage to be sure

that they match. Check the

power wiring to ensure that the

pump is connected properly.

Start the pump once more and

check that the voltage from the

terminal for the black wire to

the white wire is within system

tolerance. Call for help if you

cannot resolve the problem.

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 components. Check

door gasket for proper seal.

10.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 service

vary significantly and a general

list may not in its entirety be

applicable to a given installation.

The user should exercise

judgment in defining specific

requirements based on this guide.

1. Fuses for control transformer

primary and secondary. (If

required)

2. Contactor.

3. Bulbs for any light requiring

a bulb.

4. Control transformer. (If

required)

5. Alternator relay. (If required)

Optional: The LOW WATER /

REDUNDANT OFF float should

be installed just above where the

pump begins to ingest air

normally; this is about the top of

the volute.

The OFF float should be installed

about halfway down the pump. If

a LOW WATER / REDUNDANT

OFF float is used, then the off

float should be installed a

minimum of 4 inches above the

LOW WATER / REDUNDANT

OFF float.

Install the ON / LEAD floats a

minimum of 4 inches above the

OFF float. If additional volume is

to be pumped on each cycle or if

the pump running time for each

cycle needs to be increased, then

increase the distance from the

ON / LEAD float to the OFF float

as needed.

Install the HIGH WATER float

4 inches above the ON / LEAD

float.

For duplex systems install the

LAG / OVERRIDE float 4 inches

above the HIGH WATER float.

On duplex systems where both

pumps have to run on a daily basis

to keep up with the incoming

flow, then the HIGH WATER and

the LAG / OVERRIDE float

position should be reversed.

Float

Controls

b. Floats may be miswired to

control panel. Check float

type (N.O. or N.C.) and

hook up by referring to the

schematic. If the start and

stop floats are hooked in

reverse, pump will short

cycle and will not pump the

level down.

1. Is water level in the

system high enough to

activate the floats?

2. If there is enough water

in the system (with the

power turned off), mark

and disconnect the off

and on floats. Next,

install jumper wires in

the terminal blocks for

off and on floats. Turn

power back on, put H-O-

A switch in Auto and see

if pump runs.

3. If pump runs with

jumper, problem is with

floats. Remove jumpers

and troubleshoot floats

with ohmmeter.

4. If pump does not run

in Auto mode with

jumpers, check Auto

circuit wiring in panel.

3. Pump runs, but run light

does not energize.

a. Remove light and check

with an ohmmeter.

b. Check run light wiring.

4. Pump runs but does not

pump down the wet well.

a. On three phase only,

pump rotation may be

wrong. Wiring of pump to

control panel may be

reverse sequenced.

b. Impeller may be dragging in

volute due to solids. High

amperage draw would

identify this.

c. Refer to the pump manual

for other possibilities such

as closed discharge gate

valve, etc.

5. Severe humming/chattering

of contactors and control

relays.

a. There may be low voltage.

Check voltage at primary

and secondary of control

transformer using a

voltmeter. This low voltage

condition may cause severe

chattering and burnout of

contacters and relays.

b. Contactor may have dust

around magnet of coil

structure. Dry or clean

as required.

c. Check voltage to the

control panel. Contactors

require a minimum of 85%

of full voltage to pull

in without chatter. If the

problem is a recurring

one, measure voltage with

recorder on a 24 hour basis.

d. Make sure the floats are

located away from any

turbulence.

e. Dry out the junction box

(if furnished); moisture

in the junction box may

cause relays to energize

intermittently.

6. Short cycling pump.

a. Check float controls.

7. Run light stays on.

a. Selector switch may be in

the Hand position.

8. Nuisance tripping of

overload on motor starters

or circuit breakers.

a. Check pump amp draw with

amp probe and compare to

nameplate amps on pump.

b. The impeller may be locked

up due to excessive debris

or solids.

c. Possible motor failure (fault

in windings).

d. Pump may be miswired to

terminal block.

e. Voltage and current

unbalance. Three phase

only.

Voltage unbalance on three

phase power sources can

cause motor current to

become unbalanced and

excessive heating will

result. Tripping of the

overload protectors and

premature motor failures

can be expected if the

current unbalance exceeds

five percent.

Percent Maximum Current

Current = Difference from x 100

Unbalance Average Current

_______________

Average Current

To determine if motor current

unbalance is a function of the

motor or the power supply:

1. Label the leads and

the terminals 1, 2, and 3

respectively.

2. Record the amperage for

each lead.

3. Move each lead to the

next terminal (1 to 2, 2 to

3, 3 to 1).

4. Again read the amperage

of each lead.

5. Move each lead to the

next terminal (1 to 3, 2

to 1, 3 to 2).

6. Again read the amperage

of each lead.

5

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 H-O-A 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

should drop to a value

much less than full load

current.

5. Motor voltage check:

6

Pump

Troubleshooting

7. If the unbalance moves

with the motor leads, the

unbalance is caused by

the motor. If the

unbalance remains with

the terminals, the

unbalance is in the

power supply.

8. If the current unbalance

exceeds five percent,

nuisance tripping or

excessive heating will

result.

9. Connect leads for the

lowest percent of current

unbalance.

f. Connections and start

components. Single phase

only.

1. Disconnect all power

from the panel before

making these checks.

2. Motor winding resistance

readings.

a. Disconnect all three

motor leads from panel

terminal blocks.

b. Using a volt-ohmmeter,

with the scale set

on RX1, measure the

resistance between the

leads with the chart.

Typical

Motor Resistance

Winding Leads Reading

Main Black to Lowest

White

Start Black to Next

Red Lowest

(Middle)

Both White to Highest

Red (Main & Start)

3. Capacitor check.

a. Make sure the capacitor

is discharged. Use

extreme caution as a

spark might occur.

b.Disconnect the capacitor

leads and connect

an analog-type volt-

ohmmeter to the capacitor

terminals.

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).

Typical

Motor Voltage

Component Lead Mode Reading

Main Winding Black to Start Line Voltage

White

Main Winding Black to Run Line Voltage

White

Start Winding Black to Start Line Voltage

Red

Start Winding Black to Run 120%

Red Line Voltage

7

Pump

Notes

______________________________________________

Pump

Notes

______________________________________________

8

Pump

Notes

______________________________________________

9

– Your Authorized Local Distributor –

www.hydromatic.com

STANDARD LIMITED WARRANTY

HYDROMATIC®warrants its products against defects in material and workmanship for a period of 12 months

from the date of shipment from Hydromatic or 18 months from the manufacturing date, whichever occurs first -

provided that such products are used compliance with the requirements of the Hydromatic 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, Hydromatic, at its discretion, will repair or

replace to the original user, the parts which prove defective in materials and workmanship. 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. Warranty is

effective only if 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. Hydromatic will only cover the lower seal

and labor thereof for all dual seal pumps. Under no circumstance will 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 Hydromatic 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 which 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 unit is used for purposes other

than for what it is designed and manufactured; (g) to any unit which has been repaired or altered by anyone

other than Hydromaticor an authorized Hydromatic service provider; (h) to any unit which has been repaired

using non factory specified/OEM parts.

Warranty Exclusions: HYDROMATIC MAKES NO EXPRESS OR IMPLIED WARRANTIES WHICH EXTEND

BEYOND THE DESCRIPTION ON THE FACE HEREOF. HYDROMATIC SPECIFICALLY DISCLAIMS THE IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE.

Liability Limitation: IN NO EVENT SHALL HYDROMATIC BE LIABLE OR RESPONSIBLE FOR

CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES RESULTING FROM OR RELATED IN ANY MANNER

TO ANY HYDROMATIC PRODUCT OR PARTS THEREOF. PERSONAL INJURY AND/OR PROPERTY DAMAGE

MAY RESULT FROM IMPROPER INSTALLATION. HYDROMATIC DISCLAIMS ALL LIABILITY, INCLUDING

LIABILITY UNDER THIS WARRANTY, FOR IMPROPER INSTALLATION. 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 Hydromatic shall vary or expand the

provision hereof.

USA

740 East 9th Street, Ashland, Ohio 44805

Tel: 419-289-3042 Fax: 419-281-4087

CANADA

269 Trillium Drive, Kitchener, Ontario, Canada N2G 4W5

Tel: 519-896-2163 Fax: 519-896-6337

Warranty Rev 02/09

START-UP REPORT

cut along dotted line

Distributor:__________________________________________________ Order No.: _________________________

Installing Contractor: _________________________________________ Phone: ____________________________

Sales Contact: ______________________________________________ Phone: ____________________________

Customer: ______________________________________________________________________________________

Location: _______________________________________________________________________________________

1. SYSTEM INFORMATION

Size of Wet Well:_______________________________________Manufacturer: _____________________________

Discharge from Bottom of Basin: ________________________Discharge Location:________________________

Inlet from Bottom of Basin: _____________________________Inlet Location: _____________________________

Type of Check Valves: __________________________________Type of Piping: ____________________________

Does System Have Suction Gauges? ❑Yes ❑No Suction Pressure Reading: __________________

Does System Have Discharge Gauges? ❑Yes ❑No Discharge Pressure Reading:________________

Liquid Being Pumped:_______________________Temperature (F°): __________ Pct. of Solid (%):___________

Is a Sketch or Photograph of System Available? ❑Yes ❑No If So, Please Attach.

Any Additional Comments on System:______________________________________________________________

_______________________________________________________________________________________________

2. ELECTRICAL INFORMATION

Control Panel Part Number: _____________________________Panel Rated Amps: ________________________

Manufacturer: _________________________________________Voltage: _______________ Phase: ____________

Heater Size:___________________________________________Location of Panel to Wet Well: _______________

Incoming Line Voltage: _________________________________Actual?___________________________________

Voltage to Pumps: _____________________________________Actual? ___________________________________

Type of Junction Box: __________________________________Manufacturer of Junction Box: ______________

Are Floats Installed in Wet Well? ❑Yes ❑No Are Floats Set to Engineer’s Specs? ❑Yes ❑No

Are Floats Wired for Proper Sequencing? ❑Yes ❑No Are Heat Sensors Hooked Up? ❑Yes ❑No

Is the Seal Leak Detection Hooked Up? ❑Yes ❑No

Any Additional Comments on Electrical: ____________________________________________________________

_______________________________________________________________________________________________

3. PUMP INFORMATION

Type of Pump:_________________________________________Serial Number of Pump: ____________________

Voltage of Pump: ________________ Phase: _______________RPM: _________________ Amps: ____________

Impeller Size:____________________ C.O.S. TDH: __________GPM: _________________

Voltage Supplied from Panel:____________________________Actual? ___________________________________

Actual Amperage (All Phases): Phase 1 Amps: ________ Phase 2 Amps: ________ Phase 3 Amps: ________

Define the Rotation of the Pump: ❑Clockwise ❑Counterclockwise

Method Used to Check Rotation: ❑Viewed from the Top ❑Viewed from the Bottom

Any Additional Comments on Pumps: ______________________________________________________________

_______________________________________________________________________________________________

4. ACKNOWLEDGE

Acknowledge that all information is accurate and proper procedures have been followed.

Customer: ___________________________________________________________________ Date: _____________

Start-up Technician:___________________________________________________________ Date: _____________

Send to Warranty Manager, 1101 Myers Parkway, Ashland, OH 44805

or Fax to 419-207-3344

or email to [email protected]

or submit online at http://forms.pentairliterature.com/startupform/startupform.asp?type=h

Hydromatic Novus 1000 Series Manual

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