Pentair 900S Series User manual

Carefully read and follow all safety instructions in this
manual or on pump.
This is the safety alert symbol. When you see this
symbol on your pump or in this manual, look for one of the
following signal words and be alert to the potential for personal
injury.
warns about hazards that will cause serious
personal injury, death or major property damage if ignored.
warns about hazards that can cause serious
personal injury, death or major property damage if ignored.
warns about hazards that will or can cause
minor personal injury or property damage if ignored.
The word NOTICE indicates special instructions which are
important but not related to hazards.
1. To avoid serious injury and/or property damage, read these
rules and instructions carefully.
2. Check your local codes before installing. You must comply
with their rules.
3. Vent sewage or septic tank according to local codes.
4. Pump normally runs hot. To avoid burns when servicing
pump, allow it to cool for 20 minutes after shut-down before
handling it.
5. Do not run pump dry. Dry running can overheat pump and
will void warranty.
6. Pump is permanently lubricated. No oiling or greasing is
required in normal operation. For overhaul, see instructions
under "Service".
Hazardous voltage. Can shock, burn, or
cause death. During operation the pump is in water. To avoid
fatal shocks, proceed as follows if pump needs servicing:
7A. Ground pump according to all applicable codes and
ordinances.
7B. Disconnect power to outlet box or circuit breakers before
servicing.
7C. To reduce risk of electric shock, take care when changing
fuses or resetting circuit breakers. Do not stand in water
when working on control box or with circuit breakers.
Single Phase Pumps:
7D. Do not modify cord and plug unless removing plug
completely and wiring pump directly into switch box or con-
troller. When using cord and plug, plug into a grounded
outlet only. When wiring to a system control, connect pump
ground lead to system ground.
Three Phase Pumps:
7E. Three phase pumps are intended for permanent connection
only. Provide strain relief at control box for power supply
cord connection to box.
INSTALLATION
NOTICE: Install pump on a hard, level surface (cement,
asphalt, etc.). Never place pump directly on earth, clay or gravel
surfaces. Basin must be at least 458 mm (18") in diameter and
762 mm (30") deep.
Piping
Piping must not be smaller than pump discharge. When installed
in a sewage system, pipe must be capable of handling semi-
solids of at least 51 mm (2") diameter.
OWNER'S MANUAL
Installation • Operation • Repair Parts
Submersible Sewage/Solids Handling Pumps
900S Series, 50 Hz, Single and Three Phase
Printed in U.S.A. © 2003 SX291 (Rev. 3/20/03)
SAFETY INSTRUCTIONS

The rate of flow in the discharge pipe must keep any solids
present in suspension in the fluid. To meet minimum flow
requirements of 61 cm/sec (2 feet per second) in discharge line,
size pipe as follows:
A Pipe Size Of: Will Handle a Flow Rate Of:
51 mm (2”) 79.5 L/M (21 GPM)
63.5 mm (2-1/2”) 113.5 L/M (30 GPM)
76 mm (3”) 182 L/M) (48 GPM)
Use a 51 mm (2") check valve in pump discharge to prevent
backflow of liquid into sump basin. The check valve should be a
free flow valve that will easily pass solids.
NOTICE: For best performance of check valve when handling
solids, do not install it with discharge more than 45° above the
horizontal. Do not install check valve in a vertical position as
solids may settle in valve and prevent opening on startup.
Drill a 5 mm (3/16") hole in discharge pipe about 25-50 mm
(1 to 2") above pump discharge connection (but below check
valve) to prevent airlocking the pump.
Electrical
Hazardous voltage. Can shock, burn, or
cause death. When installing, operating, or servicing this
pump, follow safety instructions below.
1. DO NOT splice the power cord, submerge electrical cord
plug, or use extension cords.
2. DO NOT handle or service pump while it is connected to
power supply.
3. DO NOT remove grounding prong from plug or modify
plug. Power cord on 1-phase units is a 3-wire conductor with
a 3-prong grounded plug. Plug pump into a 3-wire,
grounded, grounding-type receptacle. If there is no 3-wire
grounded receptacle to plug into, remove plug completely
and wire pump directly into terminal block in automatic float
or duplex controller box. Connect pump according to all
applicable codes.
For automatic operation, plug or wire pump into an automatic
float switch or duplex controller. For continuous operation, plug
directly into an electrical outlet or wire directly into switch box.
Connect pump to its own circuit with nothing else on the circuit.
See chart below for fuse or circuit breaker sizes.
Risk of electrical shock and fire. Be sure
that power supply information (Voltage/ Hertz/Phase)
on pump motor nameplate matches incoming power
supply exactly. Install pump according to all electrical
codes that apply.
Fuse or Dual Element
Voltage/Hz/ Circuit Time Delay
H.P. Phase Breaker Amps Fuse Amps
1, 11⁄2, 2 220/50/1 25 15
1, 11⁄2, 2 220/50/3 20 12
1, 11⁄2, 2 380/50/3 15 8
Operation and Installation
NOTICE: Do not allow pump to run in a dry sump. It will void
the warranty and may damage the pump.
In 1-phase units, an automatic overload protector in the motor
will protect motor from burning out due to overheating/overload-
ing. When motor cools down, protector will automatically reset
and start motor.
If overload trips frequently, check for cause. It could be a stuck
impeller, wrong/low voltage, or electrical failure in motor. If an
electrical failure in the motor is suspected, have it serviced by a
competent repairman.
Pump is permanently lubricated. No oiling or greasing is
required in normal service.
SERVICE
General
Hazardous voltage. Can shock, burn, or
cause death. Before servicing pump, disconnect electrical
power to pump and control switch.
After removing basin cover and necessary discharge piping, lift
pump out of basin.
Place pump in an area where it can be cleaned thoroughly.
Remove all scale and deposits on pump.
Submerge pump in disinfectant (chlorox or chlorine) for at least
one hour before disassembling pump.
The pump motor housing contains a special lubricating oil. Keep
oil clean and free of water at all times.
NOTICE: Whenever motor housing is being removed for
service, remove oil and replace with new oil at reassembly. Use
only oil listed in parts list (Part No. U197-8A). When filling with
new oil, DO NOT overfill. To allow room for expansion, oil
level with cold motor should be about 1/4” above top of motor
assembly.
Impeller, Seal, and Capacitor Replacement
Risk of electrical shock. Disconnect
electrical power from pump before doing any service
work on it!
Disassembly
1. Remove motor assembly from volute and set it on its side in
a clean area.
2. Hold impeller; remove impeller screw and washer.
3. Slide impeller off of shaft for cleaning. If necessary, tap
impeller gently to loosen it.
4. Loosen cord connector, remove capacitor cover capscrews
and capacitor cover. Turn pump upside down to drain oil.
Risk of electric shock. Before
touching capacitor, discharge it by shorting the
terminals together with an amber handled
screwdriver.
2
Stator
Leads From
White
Red
Black
White
Green
Black
Capacitor
Cord Stator
Lead Leads
#L1 to #1 & 6
#L2 to #2 & 4
#L3 to #3 & 5
380 Volt
Cord Leads Stator Leads
#L1(Red) to #1
#L2(Black) to #2
#L3(White) to #3
Connect #4,5, and 6 together.
Capacitor Connections
(Single Phase Only)
3-Phase Connections
220V

3
5. If replacing capacitor, remove wires from capacitor. Remove
capacitor.
6. Slide a small screwdriver down beside shaft and pry lip seal
out. Discard lip seal. Be careful not to scratch shaft.
7. Remove retaining ring and washer from motor shaft and
slide rotating half of seal off of shaft.
8. Cradle motor assembly so that it stands vertically with motor
shaft extending out of the bottom.
9. Remove motor cover from seal plate. Remove through bolts
from motor assembly. Remove motor and shaft from seal
plate.
10. With screwdriver, gently tap seat ring out of seal plate;
thoroughly clean seat cavity.
Re-assembly
NOTICE: Make sure that seal faces are clean and undamaged.
1. Apply Permatex #2 or equivalent sparingly to outside edge
of seal body. Press new seal body into cavity in seal plate.
2. Reverse steps 7 through 9 above to reassemble motor and
shaft.
NOTICE: Do not overtighten through bolts!
3. Slide new rotating member of seal onto shaft.
NOTICE: Coat rubber bellows with soap or oil to aid in
installing seal on shaft.
NOTICE: Do not nick or scratch carbon seal face when
passing it over shaft shoulder. Seal faces must be clean and
undamaged or seal may leak.
4. Reinstall snap ring on shaft.
5. Reassemble impeller, washer, and impeller screw .
6. Install new capacitor (single phase). See picture below for
electrical connections to capacitor.
7. Fill motor with clean dielectric oil (Part No. U197-8A). To
allow room for expansion, oil level with cold motor should
be about 1/4” above top of motor assembly.
8. Inspect O-Ring gasket; replace if damaged. If it is not
nicked or scratch, clean and reinstall.
9. Reinstall capacitor cover, adjust power cord in connector
and retighten connector.
REPAIR PARTS
Rope Handle Ring
U97-102SS
Cord Assembly
Single Phase: PW117-232A-TSE
Single Phase Auto: PW117-240-TSE
Three Phase: PW117-235-TSE Oil Fill Plug U78-57DV
Dielectric Oil U197-8A
Capacitor (Single Phase Only)
U18-1566
5/16-18 Hex Capscrew
U30-62SS
Motor Through Bolt
U30-942
Capacitor Cover
PW3-16A
Motor Cover
PW3-32A
Impeller
1 HP: PW5-7B
1 1/2 HP: PW5-7A
2 HP: PW5-7
Seal Plate O-Ring
U9-351
Capacitor Cover O-Ring
U9-339
Motor Assembly
Single Phase: PW218-117
Three Phase: PW218-118
Seal Plate
PW3-34
Shaft Seal
U9-394SS
Woodruff Key
U65-2SS
1/4-20 Hex Capscrew U30-52SS
5/16-18 Hex Capscrew
U30-65SS
1/4 Flat Washer PW43-4SS
Retaining Washer PW43-5SS
Retaining Ring U9-353SS
Volute
PW1-5W
1/4-20 Socket Hd. Screw
U30-475SS
1307C 0597
Lip-Oil Seal
U9-417

TROUBLES-REMEDIES
A. Pump fails to operate: 1. Check to be sure that power cord is securely plugged into outlet or securely wired
into controller or switch box. Disconnect power to outlet before handling pump
or motor.
2. Check to be sure you have electrical power.
3. Check that liquid fluid level is high enough to activate switch or controller.
4. Check to be sure that 5 mm (3/16”) vent hole in discharge pipe is not plugged.
5. Check for blockage in pump inlet, impeller, check valve or discharge pipe.
6. Thermal overload may have tripped. Test start pump; if it starts and then stops
immediately, disconnect from power source for 30 minutes to allow motor to cool,
then reconnect to power source. Check for cause of overheating/overloading.
B. Pump fails to empty sump: 1. Be sure all valves in discharge valve are fully open.
2. Clean out discharge pipe and check valve.
3. Check for blockage in pump inlet or impeller.
4. Pump not sized properly. A higher capacity pump may be required.
C. Pump will not shut off: 1. Check switch or controller automatic floats for proper operation and location.
See installation instructions for switch/controller.
2. If pump is completely inoperative or continues to malfunction, consult your
local serviceman.
Sudden Starts. If power is on to pump
when thermal overload resets, pump may start without
warning. If you are working on pump, you
may get an electrical shock or impeller may catch
fingers or tools. Disconnect power before servicing pump.