Pentair Hydromatic S4MN 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 S4MN
SUBMERSIBLE
SOLIDS HANDLING PUMP
INSTALLATION AND SERVICE MANUAL
Item # E-03-311 | Part # 5625-311-1 | © 2013 Pentair Pump Group, Inc. | 11/11/13

2
General Information
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. Reasonable care
and safe methods should be practiced.
Check local codes and requirements
before installation.
Unpacking Pump:
Remove pump 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: 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.
Pumps Not Operating or in Storage:
Pumps with carbon ceramic seals
must have impellers manually rotated
(6 revolutions) after setting non-
operational for 3 months or longer and
prior to electrical start-up.
Pumps with tungsten carbide seals
must have impellers manually rotated
(6 revolutions) after setting non-
operational for 3 weeks or longer and
prior to electrical start-up.
Seal Failure:
An electrode is installed in the seal
chamber so if any water enters the chamber
through the first seal the electrode will be
energized and a signal will be transmitted
to the sensing unit at ground surface
causing a red light to turn on. The electrode
probe is installed in all units, but the
sensing unit is supplied at extra cost and
must be ordered.
In operation the seal failure unit indicates
only that there is some water in the seal
chamber. The pump will continue to
operate but the seal should be checked
immediately after failure is indicated.
The sensing unit is recommended on all
installations as good insurance against
motor failure.
Pump:
The S4MN submersible pump is supplied
for 1 and 3 phase and for 200, 230, 460
or 575 volts. Power cable is supplied
with the green wire for ground. Be sure
green wire is connected to a good ground
such as water pipe or ground stake.
Heat Sensors:
All motors have heat sensor units
embedded in the motor winding to detect
excessive heat. The heat sensors are set to
trip at 120°C on the S4MN. The sensors
automatically reset when motor cools to
safe temperature.
The sensors are connected in series with
the motor starter coil so that the starter is
tripped if heat sensor opens. The motor
starter is equipped with overload heaters
so all normal overloads are protected by
the starter.
IMPORTANT: If Hydromatic®
electrical starting equipment is not
supplied, the heat sensor circuit must
be connected in series with the starter
coil or warranty is void.
Sump Level Control:
Sump level is controlled by Hydromatic
switch controls. The float is held in
position in the sump by a weight attached
to the power cord above the float. The
cord supports the float and is adjusted for
height from the surface.
Duplex systems use three controls:
one set at turn-off, one set at turn-on
for one pump, and one set for turn-on for
two pumps. Pumps alternate operation
on each successive cycle.
Two pumps operate together only if sump
level rises to the third or override control.
The override control also brings on
the second pump in case of failure of
the first pump. Extra floats with
appropriate controls can be supplied for
alarm functions. Triplex systems use four
controls: one set at turn-off, one set at
turn-on for one pump, one set at turn-on
for two pumps, and one set at turn-on
for three pumps. Pumps alternate each
successive cycle.
Three pumps operate together only if
sump level rises to the fourth control
(second override). This control also
brings on the third pump in case of
failure of either or both of the first
two pumps.
Alarm Controls:
The alarm level is usually set above the
override level so the alarm will signal
only if the override level is exceeded.
However, some engineers prefer to have
the alarm level set below the override
level as it is possible for one pump
to fail and the other pump to operate
on the override level with the sump
level never reaching the alarm level.
This is particularly true in cases of low
inflow capacity.
Electrical Control Panel:
It is recommended that the Hydromatic
control panel be used with all pumps as
proper starter heaters and connections for
heat sensor wires are furnished.
Hydromatic electrical equipment is
installed in a weatherproof NEMA 3R
enclosure. The electrical equipment
includes a main circuit breaker for each
pump, a magnetic starter with overload
protection for each pump, an H-O-A
switch and run light for each pump, and
an electric alternator and a transformer
to provide appropriate control for control
circuit and alarms.
Overload Heaters:
Starters with 3 leg overload
protection must be supplied if the
Hydromatic electrical panel is not
used. The heaters must be sized in
accordance with the nameplate amps
on the motor. The amp draw on these
submersible motors is slightly higher
than a corresponding horsepower surface
motor, so heaters must be sized by the
nameplate rating.

3
Installation
Instructions
Installing Pump in Sump:
Before installing the pump in
the sump, lay it on side and turn
impeller manually. Impeller may be
slightly stuck due to factory test water,
so it must be broken loose with small
bar or screwdriver in edge of vanes. The
impeller should turn freely.
Clean all trash and sticks from sump and
connect pump to piping.
A check valve must be installed on each
pump. A gate or plug valve in each pump
discharge line is also recommended.
This valve should be installed on the
discharge side of the check valve so the
line pressure can be cut off if necessary
to service the check valve. Single pump
systems are sometimes installed without
a check valve where it is desirable to
self-drain the discharge line to prevent
freezing. This can be done only with
short discharge lines. Otherwise water
will return to the sump and cause short
cycling of the pump.
NEMA 4 Junction Box: (Optional)
A NEMA 4 junction box should
be used to make power and
control connections if electrical control
panel is to be set remote from the pump
sump. The Hydromatic®NEMA 4
junction box is provided with
compression connectors for sealing all
wires. No sealing compound is needed to
make connections waterproof.
Wiring diagrams are provided with panel
for making connections. The size wire
to use from panel to sump depends on
motor size and distance in feet.
Be sure each wire is checked out so that
a wrong connection will not be made.
An ohmmeter or Megger can be used to
check wire continuity.
Installing Switch Controls:
The controls are supported by a mounting
bracket that is attached to sump wall,
cover, or to the NEMA 4 junction box.
Control level can be changed at any time
by loosening the snubber and readjusting
cord length.
In either a simplex or duplex system,
the lower or turn-off control is set just
above the top of volute, so that the volute
will always be submerged during the
pumping cycle. The second, or turn-on
control, is set about 24 inches above the
lower turn-off control.
More distance between turn-on and turn-
off controls can be used, but sewage
may become septic, and excessive solids
may collect for the pump to handle. A
frequent pumping cycle is recommended
for best operation.
If an alarm system is used, this control
is usually set about 6 inches above the
override control.
Making Electrical Connections:
All electrical wiring must be in
accordance with local codes, and only
competent electricians should make the
installations. All wires should be checked
for grounds with an ohmmeter or Megger
after the connections are made. THIS IS
IMPORTANT, AS ONE GROUNDED
WIRE CAN CAUSE CONSIDERABLE
TROUBLE.
IMPORTANT: If equipment is not
properly wired and protected as
recommended, the warranty is void.
Heat Sensors and Seal Failure
Connections:
Be sure heat sensor wires are connected
in series with the starter coil. Connections
are provided on the terminal strip.
Pump Operations
Starting Systems:
1. Turn the H-O-A switch to
Off position and then turn on main
circuit breakers.
2. Open all discharge valves and allow
water to rise in sump.
3. Turn H-O-A switch to Hand
position on one pump and notice
operation. If pump is noisy and
vibrates, rotation is wrong. To
change rotation, interchange any
two line leads to motor 3ø only.
Do not interchange main incoming
lines. If duplex system, check
second pump in the same manner.
4. Now set both H-O-A switches to
Auto position and allow water to
rise in sump until one pump starts.
Allow pump to operate until level
drops to turn-off point.
5. Allow sump level to rise to start
other pump. Notice run lights on
panel. Pumps should alternate on
each successive cycle of operation.
6. Turn both H-O-A switches to Off
position and allow sump to fill to
the override control level.
7. Turn both switches to Auto position
and both pumps should start and
operate together until level drops to
turn-off point.
8. Repeat this operation cycle several
times before leaving the job.
9. Check voltage when pumps are
operating and check the amp draw
of each pump. Check amps on
each wire, as sometimes a high
leg will exist. One leg can be
somewhat higher (5 to 10%) without
causing trouble. For excessive
amp draw on one leg, the power
company should be consulted.
WIRE SIZE TABLE
FOR REMOTE LOCATION OF CONTROL PANEL
LENGTHS ARE BASED ON A VOLTAGE DROP OF TWO PERCENT
Maximum length in feet from NEMA 4 Junction Box to control panel. All control wires can be = 14-16 or 18 gauge wire. If power lines are greater the 300
volts, and the control wires are used in the same conduit, then the insulation of the control wires must be for 600 volts.
1 Phase 3 Phase
HP HP
Wire Size Volts 11/2 2 3 5 Volts 11/2 2 3 5 71/2 10 15
200V - - - - 200 217 190 101 - - - -
230 105 95 - - 230 291 250 134 - - - -
12 460 1165 1019 540 412 333 233 -
575 1820 1450 820 624 515 364 -
200 121 111 103 - 200 340 297 158 119 - - -
230 163 148 139 - 230 456 390 210 161 - - -
10 460 1822 1594 846 645 522 364 -
575 2847 2270 1360 976 806 569 -
200 190 175 162 - 200 533 466 249 187 155 - -
230 257 232 219 - 230 715 613 330 252 204 - -
8460 2860 2500 1328 1013 819 572 390
575 4468 3570 2145 1532 1266 894 -
200 296 272 252 - 200 830 726 387 291 242 170 -
230 400 362 340 181 230 1114 955 514 393 318 223 -
6460 4455 3898 2068 1577 1275 891 607
575 - - 3341 2386 1972 1392 -
200 452 416 384 - 200 1268 1110 592 444 370 260 -
230 610 553 520 276 230 1701 1458 785 601 486 340 232
4460 - - 3160 2410 1449 1361 928
575 - - - 3646 2513 2127 -
200 689 633 586 - 200 1932 1690 902 676 563 395 -
230 930 842 792 421 230 2592 2222 1196 915 741 578 353
*2 460 - - - 3672 2969 2074 1414
575 - - - - 4590 3240 -
*Special Junction Box required for wire sizes larger than #4.
NUMBER OF CONDUCTORS REQUIRED BETWEEN CONTROL PANEL AND NEMA JUNCTION BOX
POWER LINES AND CONTROL WIRES CAN BE CARRIED IN CONDUIT OR CAN BE UNDERGROUND BURIED CABLE
HEAT SENSOR & SEAL FAILURE
System Number of Number of Number of Number of Number of
Type Control Power Lines Ground Wires #8 Sensor Wires Ground Wires
Simplex 4 3 1 3 1
Simplex with Alarm 6 3 1 3 1
Duplex 6 6 2 6 2
Duplex with Alarm 8 6 2 6 2

4
IMPORTANT: Use only
compression type insulated
connectors on the wires.
Do not tape leads as oil will
deteriorate the tape and cause damage to
stator and bearings.
8. Check top bearing. If clean
and does not turn rough,
bearings can be reused and it is not
necessary to completely dismantle
pump to change bearings. If
bearings are damaged with dirt
or heat, they must be replaced.
Remember to reinstall the upper
bearing load spring.
9. Replace stator housing onto seal
chamber and bolt in place. BE
SURE SEAL FAILURE WIRE
IS CONNECTED BEFORE
HOUSING IS ASSEMBLED.
Be sure O-ring seal has been
replaced. If O-ring is nicked or
cut, replace with new ring.
This applies to all O-rings used in
assembly.
10. After all leads are reconnected in
the connection box, make a high
voltage ground test on each wire.
The only wire that should show
ground is the green power lead and
the ground lead in the auxiliary
control cable.
11. For safety, complete pump should
be air checked under water for
leaks. Lay pump on side for this oil
filling with oil fill hole upright. Do
not completely fill; leave oil about
1 inch below plug hole. Use only
Hydromatic submersible oil in this
chamber or high grade transformer
oil. Replace plug; use Permatex
on threads. Install air valve in top
plug opening of motor housing
and charge housing with about
10 psi of air. Be sure air is dry. Do
not use air line where water may
Replacing Stator:
1. If stator only is damaged, it may
not be necessary to completely
dismantle pump as stator and
housing can be lifted from pump
without disturbing seals or bearings.
2. Drain all oil from upper
housing, remove from upper
housing, remove drain plug
in bottom of stator housing and
remove plug in top of housing to
allow air to enter.
3. After chamber is drained, remove
hold-down bolts and lift off.
Use care in lifting as the seal
failure connecting wire must be
disconnected before housing is
completely removed.
4. Set assembly on bench and remove
connection box. When box is lifted
off, connection wires to motor
will be exposed. These wires will
probably be burned, but each wire
is tagged with a metal marker
giving wire number. Cut the wires.
If the leads to the connection box are
burned, a complete new connection
box with new wire must be used.
The wires are potted in with sealing
compound and a new unit must be
obtained from the factory.
5. The stator is held in the housing
with a bolted-in clamp ring.
6. After ring is removed, turn
housing upright and bump on
hardwood blocks. This should
jar the stator loose and allow it to
drop out.
7. Thoroughly clean housing before
replacing new stator. Replace stator
and make all wire connections to
connection box before replacing
housing on pump. This is important
as leads must be tucked behind
the windings by using hands up
through rotor core.
CONNECTION DIAGRAM FOR LEADS IN
MOTOR AND CONNECTION BOX
(Y) WYE MOTOR CONNECTIONS
230 VOLTS 460 VOLTS
GREEN GREEN
L3L2L1L3L2L1
32 1
98 7
65 4
32 1
98 7
65 4
HEAT SENSORS AND SEAL FAILURE CONNECTIONS
FOR ANY VOLTAGE MOTOR
ELECTRODE
HEAT SENSORS
IN MOTOR
WINDINGS
WHITEBLACK
HEAT SENSORS SEAL FAILURE
RED DARK
GREEN
Phase Converters:
Phase converters are generally not
recommended, but in cases where only
single phase current is available, phase
converters can be used. Be sure to size
the phase converter large enough for
the amp draw specified on the motor
nameplate, not necessarily by motor
horsepower. The warranty on all three
phase submersible motors is void
if operated with single phase power
through a phase converter, and 3 leg
ambient compensated extra-quick
trip overload protectors are not used.
Pump Maintenance
Lubrication or other maintenance is not
required, as the motors are oil filled.
Generally, these pumps give very reliable
service, and can be expected to operate
for many years without failure under
normal operating conditions.
Lightning:
In some areas where considerable lightning
occurs, it is recommended that a lightning
arrestor be installed at the control panel.
Lightning arrestors are good insurance
against damage to an expensive motor.
Field Service on Motor:
All S4MN submersible motors out of
warranty can be serviced in the field by any
reliable motor service shop. Any pump (in
warranty) must be returned to the factory
for service or repaired at an authorized
Hydromatic®service center. Charges will
not be allowed if in warranty pump is
not taken to an authorized Hydromatic
service center.
When field service is performed on
a pump, these instructions should
be carefully followed.

5
WARNING
BLACK
COIL
ON-OFF
SWITCH
L1 THERMOSTATS
IN SERIES
WHITE
L2
TWO WIRE CONTROL OFFERING AUTOMATIC RESET
THERMOSTATS
IN SERIES
WHITE
L2
BLACK
THREE WIRE CONTROL OFFERING AUTOMATIC RESET
L1
COIL OL OLSTART
IN CERTAIN APPLICATIONS THE NEC MAY REQUIRE THREE OVERLOAD RELAYS
COLOR PURPOSE
DARK GREEN SEAL FAILURE
RED SEAL FAILURE
BLACK HEAT SENSOR
WHITE HEAT SENSOR
WARRANTY IS VOID IF HEAT SENSORS ARE NOT
CONNECTED AS SHOWN (IN SERIES WITH CONTACTOR OIL)
DESIGNATION FOR OPTIONAL
SEAL FAILURE & SENSOR CORD
See Wiring Diagram of seal failure
unit #4673 or 4674 for connecting
dark green and red wires. If seal
failure unit #4673 or 4674 is not used,
leave dark green and red wires open.
IMPORTANT: The impeller is
designed to be self-tightening when
running so impeller may be difficult
to break loose. If this is the case, use
plastic or rubber hammer on impeller
tip to free. Remove impeller.
6. Remove lower seal spring and pry
out seal with screwdriver.
7. To remove seal housing, take out
socket head bolts and using bolts
in back of holes, pry plates loose.
This will force out lower seal if not
already removed.
8. Remove snap ring that holds upper
seal. Pull seal if it is free. If not
free, it can be forced off when shaft
is removed.
9. Remove 4 bolts that hold
bearing housing in place. Set
assembly in upright position
and bump end of shaft on
hardwood block. This will push the
bearing from the housing and will
force upper seal from shaft.
10. Use bearing puller to remove
bearings. Replace with new
bearings. Press only on inner
face of bearing when replacing.
Pressing on outer face can damage
the bearing.
IMPORTANT: Do not use any of
these old seal parts. Replace with
all new seals.
be trapped in the line. Submerge
complete unit under water and
check for leaks.
12. Refill motor chamber with oil.
Use high grade transformer oil or
Hydromatic®special submersible
oil. Fill chamber until oil covers top
of windings. Leave air space in top
for expansion. Use Permatex®on
plug threads.
Replacing Seals and Bearings:
1. Drain all oil from motor chamber
and seal chamber as described.
2. Remove motor housing as
described.
3. Remove bolts that hold seal
chamber to pump housing. Use
back-off screws to break loose.
With hardwood block, tape end
of impeller to loosen from shaft.
When free, remove impeller
from shaft.
4. Lift rotating assembly (rotor,
shaft and impeller) from pump
case and place horizontally
on bench.
5. Impeller removal
Hold motor and remove bolt and
washer from impeller end of shaft.
Impeller is threaded to the shaft so
tap face of impeller with hardwood
block to free threads. Holding rotor,
turn impeller counterclockwise as
thread is right-hand.
11. Thoroughly clean all castings
before replacing seals. One grain
of dirt between the seal faces can
cause failure.
12. Examine all O-rings for nicks
before using.
13. Use Locktite®on socket head
locking screw in end of shaft.
Pump
Troubleshooting
Below is a list of common problems and
the probable causes:
Pump will not start.
1. No power to the motor.
Check for blown fuse or open
circuit breaker.
2. Selector switch may be in the Off
position.
3. Control circuit transformer fuse
may be blown.
4. Overload heater on starter may be
tripped. Push to reset.
Pump will not start and overload
heaters trip.
1. Turn off power and check motor
leads with Megger or ohmmeter for
possible ground.
2. Check resistance of motor windings.
All three phases should show the
same reading.
3. If no grounds exist and the motor
windings check OK, remove pump
from sump and check for clogged
or blocked impeller.
Pump operates with selector switch in
Hand position but will not operate in
Auto position.
1. This indicates trouble in the float
level control or the alternator relay.
2. Check control panel for trouble.
Pump runs but will not shut off.
1. Pump may be air locked.
Turn pump off and let set for
several minutes, then restart.
2. Lower float control may be hung-
up in the closed position. Check in
sump to be sure control is free.
3. Selector switch may be in the Hand
position.