Pentair MYERS K4563 Manual

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.
STANDARD
ELECTRICAL CONTROLS
INSTALLATION AND SERVICE MANUAL
Part # K4563 | © 2012 Pentair Pump Group, Inc. | 11/08/12

K4563 11/08/12 2
GENERAL INFORMATION:
Thank you for purchasing your Myers 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.
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.
POWER SUPPLY:
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 per
the included schematic, 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, 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 motor main and start winding
leads must be connected to the appropriate
terminals as directed by the panel schematic
and the pump owner’s manual.
b. Connect the pump heat sensor and seal failure
leads (if available on the pump) to the appropriate
terminal blocks in the control panel.
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.

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3
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.
START-UP 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 main and start winding power wires
are connected to panel correctly. Refer to
your pump owner’s manual for lead colors.
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).
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:
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
occur in about 15 seconds.
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.

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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)
FLOAT CONTROLS:
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.
SEAL FAILURE INPUTS:
Your pump may be equipped with a seal fail (moisture)
sensor. Refer to your pump owner’s manual to
determine if your pump is so equipped.
The presence of water energizes the seal leak warning
output. This activates a warning light or alarm only,
and does not stop the motor. It indicates a leak
has occurred and the pump must be repaired. The
resistance across the moisture seal (seal failure)
probes should be checked after a seal leak warning
light has lit. This can be done by disconnecting the
control wires from the control panel and measuring
the resistance with an ohmmeter between the
wires. Refer to the control panel schematic for wire
identification. For a standard, non-hazardous location
pump the reading should be 100,000 ohms or greater,
and for a hazardous location pump the reading should
be above 30,000 ohms. If the measured values are
below those indicated above, then the pump may
have a lower seal failure and require service.
On control panels for hazardous location applications
the seal leak test switch tests the seal leak circuitry
continuity. When pushed the seal leak test bulb
should light. If the test bulb does not light, it means
either the wiring circuitry to the seal leak probes has
been broken or the bulb has burned out.
Note: Myers control panels supply the correct
circuitry for moisture and heat sensor connections.
Failure to install the correct circuitry with proper
connection would negate warranty and Factory
Mutual Approval.
TEMPERATURE FAILURE INPUTS:
Your pump may be equipped with a temperature
fail sensor. Refer to your pump owner’s manual to
determine if your pump is so equipped.
If so equipped, your pump is provided with heat
sensor thermostats attached directly to the motor
windings. The thermostats open if the motor windings
see excessive heat and, in turn, open the motor

K4563 11/08/12
5
contactor in the control panel, breaking the power to
the pump.
When the motor is stopped due to an overheated
condition, it will not start until the motor has cooled,
at which time the control panel will automatically reset
unless the control panel includes the optional manual-
reset function or is for a hazardous location.
These control panels require that the reset button on
the control panel be pushed to reset the control panel.
Note: Failure to use proper circuitry and to connect
the motor overheat protection in the control panel
would negate all warranties and Factory Mutual
Approval.
CHECK LIST IF PUMP DOES NOT OPERATE PROPERLY
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.
Pump does not run in Auto position. 1. Check items (1) through (6) per
condition above.
2. 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.
3. Is water level in the system high
enough to activate the floats?
4. 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.
5. If pump runs with jumper,
problem is with floats. Remove
jumpers and troubleshoot floats
with ohmmeter.
6. If pump does not run in Auto
mode with jumpers, check Auto
circuit wiring in panel.
Pump runs, but run light does not energize. 1. Remove light and check with
an ohmmeter.
2. Check run light wiring.
Pump runs but does not pump down
the wet well.
1. On three phase only, pump
rotation may be wrong. Wiring of
pump to control panel may be
reverse sequenced.
2. Impeller may be dragging
in volute due to solids.
High amperage draw would
identify this.
3. Refer to the pump manual
for other possibilities such as
closed discharge gate valve, etc.
CONDITION
Pump does not run in Hand position.
PROBABLE CAUSE
1. Check pump circuit breaker
and control fuse for tripping or
blown condition.
2. Check incoming power voltage
and control circuit voltage.
3. Check overload relay to see if
it is tripped. Reset relay if
tripped and check pump current
with ammeter.
4. With the power off, check motor
heat sensor continuity.
5. Check wiring of pump to
control panel. It should agree
with the schematic.
6. Check contactor coil resistance.

K4563 11/08/12 6
CHECK LIST IF PUMP DOES NOT OPERATE PROPERLY (CONTINUED)
CONDITION
Severe humming/chattering of contactors
and control relays.
PROBABLE CAUSE
1. 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
contactors and relays.
2. Contactor may have dust around
magnet of coil structure. Dry or
clean as required.
3. 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.
4. Make sure the floats are located
away from any turbulence.
5. Dry out the junction box (if
furnished)); moisture in the
junction box may cause relays to
energize intermittently.
Short cycling pump. 1. Check float controls.
Run light stays on. 1. Selector switch may be in the
Hand position.
Nuisance tripping of overload on motor
starters or circuit breakers.
1. Check pump amp draw with
amp probe and compare to
nameplate amps on pump.
2. The impeller may be locked
up due to excessive debris
or solids.
3. Possible motor failure
(fault in windings).
4. Pump may be miswired to
terminal block.
5. 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.
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.
10. Connections and start components.
Single phase only.
11. Disconnect all power from the panel before
making these checks.

K4563 11/08/12
7
12. 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.
Winding Resistance Reading
Main Lowest
Start Next
Lowest
(Middle)
Both Highest
(Main & Start)
13. 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).
14. 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.
15. Motor voltage check:
Component Mode Voltage
Reading
Main Winding Start Line Voltage
Main Winding Run Line Voltage
Start Winding Start Line Voltage
Start Winding Run 120%
Line Voltage

STANDARD LIMITED WARRANTY
Myers®warrants its products against defects in material and workmanship for a period of 12 months from the date
of shipment from Myers or 18 months from the manufacturing date, whichever occurs first - provided that such
products are used in compliance with the requirements of the 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, Myers, at its discretion, will repair or replace to
the original user, the parts which prove defective in materials and workmanship. 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 Myers website: http://forms.pentairliterature.com/startupform/startupform.asp?type=m.
Warranty is effective only if 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. Myers will only cover the lower seal and labor
thereof for all dual seal pumps. Under no circumstance will 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 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 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 Myers or an authorized
Myers service provider; (h) to any unit which has been repaired using non factory specified/OEM parts.
Warranty Exclusions: MYERS MAKES NO EXPRESS OR IMPLIED WARRANTIES WHICH EXTEND BEYOND
THE DESCRIPTION ON THE FACE HEREOF. MYERS SPECIFICALLY DISCLAIMS THE IMPLIED WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE.
Liability Limitation: IN NO EVENT SHALL MYERS BE LIABLE OR RESPONSIBLE FOR CONSEQUENTIAL,
INCIDENTAL OR SPECIAL DAMAGES RESULTING FROM OR RELATED IN ANY MANNER TO ANY MYERS
PRODUCT OR PARTS THEREOF. PERSONAL INJURY AND/OR PROPERTY DAMAGE MAY RESULT FROM
IMPROPER INSTALLATION. MYERS DISCLAIMS ALL LIABILITY, INCLUDING LIABILITY UNDER THIS
WARRANTY, FOR IMPROPER INSTALLATION. 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 Myers shall vary or expand the provision hereof.
740 East 9th Street
Ashland, Ohio 44805-1969
419-289-1144
www.femyers.com
Warranty Rev 12/11