Pentair Hydromatic HRS 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.
MODEL HRS
HYDROMATIC RETRACTABLE SYSTEM
INSTALLATION AND SERVICE MANUAL
Item # H-03-430 | Part # 5625-430-1 | © 2012 Pentair Pump Group, Inc. | 11/02/12

2
Thank you for purchasing your
Hydromatic®HRS. To help ensure
years of trouble-free operation,
please read the following manual
carefully.
Before Operation:
Read the following instruc-
tions 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.
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.
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.
Electrical Connections:
The contractor must conform
to the latest requirements of the
National Electrical Code and
any local codes. All conduit and
cables shall be in accordance with
NEC code NFPA#70. To maintain
UL type 4X and CSA ENCL 4
rating, use UL type 4 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: 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. When
connecting the pump leads it
is very critical that the proper
sequence be maintained.
On single phase pumps,
the color coded pump leads
black, white, red, must be
connected to the appropriate
terminals as directed by the
control schematic.
b. Connect all the float control
leads to the appropriate panel
terminal blocks. Contrac-
tor must be very careful in
locating the floats at the proper
elevations.
General
Information
Installation
Instructions
c. 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 circuit breaker as
directed by the schematic.
d. Power must be the correct
voltage for the pump model.
Power must have neutral to
supply 120 volts to control
circuit.
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
Checklist
WARNING: Before handling
these pumps and controls,
always disconnect power first.
Do not smoke or use sparkable
electrical devices or flames in
a septic (gaseous) or possible
septic sump.
Check List:
1. Check junction box for
moisture.
2. Check wiring of pump black,
white, red power wires.
3. Check wiring of heat sensor
and seal failure wires if
supplied.
4. Energize control panel. (Turn
on power to panel.)
5. Check overload relay and
verify it has reset.
6. WARNING! Live voltage
can kill! Check voltage to the
panel and to the control circuit
using a voltmeter.

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Start-up
Checklist
7. Check float operation and
response to control panel to
the float operation. For
sequence of operation, refer to
design specification.
8. Check full load current with
amp probe and compare it
with the nameplate rating.
(Clamp amp probe around
black pump wire.)
9. With pump running, check
discharge to verify the pump
is running. Check for flow.
10. Check operation of start relay,
per procedure in Item #6 of
Maintenance Instructions.
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.
Excessive operations tend to
affect the trip curve of the
breaker.
2. Check run light operation by
running pump in Hand.
3. Check continuity through
control fuse.
4. Check voltage to the panel and
to the control circuit.
5. Check the pump full load
amps.
6. Check the start relay by using
an amp probe around the red
wire (start winding). Amp
probe should display a very
brisk action from zero to locked
rotor and back to operating
load. This action occurs on
pump start, and the action must
show no lazy movement.
7. Check enclosure for moisture.
Moisture may cause chattering
of relays and contactors.
8. Check control capsule gasket
for proper seal. This can be a
visual inspection.
9. Check labels to verify they
have not been damaged.
10.Pull floats and check for
proper operation and ensure
there is no foreign buildup on
them.
b. Check incoming power
voltage and control circuit
voltage.
c. Check overload relay to see
if it is tripped. Reset relay
if tripped.
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. It should be 125
to 150 ohms.
2. Pump does not run in Auto
position.
a. Check items (a.) through
(d.) per Item #1.
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.
c. Is the water level in the
system high enough to
activate floats?
d1.With the power off, remove
off float and on float
wires and replace with
two jumpers made from
insulated wire.
d2.Turn power on (with
H-O-A switch in Auto
position). If pump runs, the
problem is in one of the
floats.
d3. If the problem is in a float,
Turn power off, remove
jumper and reconnect the
upper float. Turn power on
and see if pump will run in
Auto.This will help identify
which float is the problem.
Turn power off before
Periodic
Maintenance
WARNING: Before handling
these pumps and controls,
always disconnect the pow-
er 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 the 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
two cycles. Be careful not
to overexercise as the break-
er is not a switching device.
WARNING: Before handling
these pumps and controls,
always disconnect the pow-
er 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 for blown condition.
Panel
Troubleshooting

4
removing any jumper or
reconnecting any float.
3. Pump runs, but run light
does not energize.
a. Run light is neon. Remove
light and check on outside
120V source.
b. Check for loose wire at
light or in panel.
4. Pump runs but does not
pump down the wet well.
a. Impeller may be dragging
in volute due to solids.
High amperage draw would
identify this.
b. 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 to the panel
and to the control circuit
using a voltmeter. This low
voltage condition may even
cause severe chattering
and burnout of relays.
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.
b. Contactor may have dust
around magnet of coil
structure. Dry or clean as
required.
c. Make sure the floats are
located away from any
turbulence.
d. Dry out the junction box
(if furnished); moisture in
the junction box may tend
to cause relays to energize
intermittently.
6. Nuisance tripping of
overload on the motor
starters or the circuit
breakers.
a. Check all reset buttons and
tripped breakers.
b. Check pump and draw with
amp probe and compare to
nameplate amps on pump.
c. The impeller may be locked
up due to excessive debris
or solids.
d. Possible motor failure (fault
on windings).
e. Pump may be miswired to
terminal block.
WARNING: Disconnect all
power from the panel before
making these checks.
7. Motor winding resistance
readings.
a. Disconnect all three motor
leads.
b. Using a volt-ohm meter,
with the scale set on RX1,
measure the resistance
between the leads with chart
figure A.
Chart Figure A
Typical
Motor Resistance
Winding Leads Reading
Main Black to Lowest
White
Start Black to Next
Red Lowest
(Middle)
Both White to Highest
Red
8. Capacitor Check.
a. Make sure the capacitors
are discharged. Use
extreme caution; severe
shock hazard may exist
with capacitors.
b. Disconnect the capacitor
leads and connect a
volt-ohm meter to the
capacitor terminals.
c. 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).
NOTE: Set the meter on the
RX10,000 scale to check
the run capacitor.
Set the meter on the
RX1,000 scale to check the
start capacitor.
9. Start relay check.
a. Check the coil resistance.
It should be 5500 to
6000 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 full
load current or less.
Panel
Troubleshooting

5
10. Motor voltage check:
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
11. Short cycling pump.
a. Check float controls.
12. Run light stays on.
a. Selector switch may be in
the Hand position.
13. Test for blown fuse.
a. Check for continuity with a
V-O-M set on ohm scale.

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Panel
Schematics

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740 EAST 9TH STREET 490 PINEBUSH ROAD, UNIT #4
ASHLAND, OHIO, USA 44805 CAMBRIDGE, ONTARIO, CANADA N1T 0A5
419-289-1144 800-363-PUMP
WWW.HYDROMATIC.COM
Warranty Rev. 12/13
STANDARD LIMITED WARRANTY
Pentair Hydromatic®warrants its products against defects in material and workmanship for a period of 12 months
from the date of shipment from Pentair Hydromatic or 18 months from the manufacturing date, whichever
occurs first – provided that such products are used in compliance with the requirements of the Pentair Hydromatic
catalog and technical manuals for use in pumping raw sewage, municipal wastewater or similar, abrasive-free,
noncorrosive liquids.
During the warranty period and subject to the conditions set forth, Pentair Hydromatic, at its discretion, will repair
or replace to the original user, the parts that prove defective in materials and workmanship. Pentair 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. Submit at the time of start up
through the Pentair Hydromatic website: http://forms.pentairliterature.com/startupform/startupform.asp?type=h.
Warranty is effective only if Pentair 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. Pentair Hydromatic will cover
only the lower seal and labor thereof for all dual seal pumps. Under no circumstance will Pentair 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 Pentair 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 that
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 that has been repaired or altered by anyone other than Pentair Hydromatic or an
authorized Pentair Hydromatic service provider; (h) to any unit that has been repaired using non factory specified/
OEM parts.
Warranty Exclusions: PENTAIR HYDROMATIC MAKES NO EXPRESS OR IMPLIED WARRANTIES THAT EXTEND
BEYOND THE DESCRIPTION ON THE FACE HEREOF. PENTAIR HYDROMATIC SPECIFICALLY DISCLAIMS THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE.
Liability Limitation: IN NO EVENT SHALL PENTAIR HYDROMATIC BE LIABLE OR RESPONSIBLE FOR
CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES RESULTING FROM OR RELATED IN ANY MANNER TO
ANY PENTAIR HYDROMATIC PRODUCT OR PARTS THEREOF. PERSONAL INJURY AND/OR PROPERTY DAMAGE
MAY RESULT FROM IMPROPER INSTALLATION. PENTAIR HYDROMATIC DISCLAIMS ALL LIABILITY, INCLUDING
LIABILITY UNDER THIS WARRANTY, FOR IMPROPER INSTALLATION. PENTAIR 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 Pentair Hydromatic shall vary or expand the provision hereof.