Waterco HYDROSTAR MK3 User manual

Waterco Limited ABN 62 002 070 733
OFFICES - AUSTRALIA
NSW - Sydney
(HEAD OFFICE)
Tel : [phone]
VIC/ TAS - Melbourne
Tel : [phone]
WA - Perth
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QLD - Brisbane
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SA/ NT - Adelaide
Tel : [phone]
ACT Distributor
Tel : [phone]
OFFICES - OVERSEAS
Waterco USA
Augusta, USA
Tel : [phone]
Waterco Canada
St-Hyacinthe, QC, Canada
Tel : [phone]
Waterco (Europe) Limited
Radfield, Kent, UK
Tel : [phone]
Waterco (NZ) Limited
Auckland, New Zealand
Tel : [phone]
Waterco (C) Limited
Guangzhou, China
Tel : [phone]
Waterco (Far East) Sdn. Bhd.
Selangor, Malaysia
Tel : [phone]
PT Waterco Indonesia
Jakarta, Indonesia
Tel : [phone]
(W99245) 03/2009
www.waterco.com
WARNING
!
COMMERCIAL PUMP
Owners Manual
Installation and Operation
This pool pump must be installed and serviced by a qualified pool/ spa technician
in accordance with all applicable codes and ordinances. Improper installation can
create electrical hazards which could result in death, serious injury, or property
damage. Improper installation will void the warranty.
Notice to Installer
This manual contains important information about the installation, operation and
safe use of this product. Once the product has been installed this manual must
be given to the owner/ operator of this equipment.
Hydrostar MK3
Hydrosteel Pump
Cast Iron Pump

Table of
PUMP INSTALLATION RECORD
Pump Model No: Pump Serial no:
Date of Purchase: Purchased from:
Installed by: Installer Phone No:
Notes:
I pg 01
Waterco Commercial Pump
INTRODUCTION --------------------------------------------- 01
SAFETY INFORMATION ------------------------------------ 02
INSTALLATION ----------------------------------------------- 04
Receive and Check Pump ---------------------------- 04
Lifting and Handling ----------------------------------- 04
a) Hydrostar Pump Procedure -------------------- 04
b) Hydrosteel Pump Procedure ------------------- 04
c) Cast Iron Pump Procedure --------------------- 04
Pump Location ---------------------------------------- 05
Piping Design and Installation ------------------------ 06
Piping Installation Guide ------------------------------ 06
Electrical Installation ---------------------------------- 06
Three Phase Connections ------------------------- 07
Electrical Installation Guide ----------------------- 08
START-UP ----------------------------------------------------- 09
Start-up procedure ------------------------------------ 09
MAINTENANCE ---------------------------------------------- 10
Strainer Basket Cleaning ----------------------------- 10
Winterizing --------------------------------------------- 11
Electric Motor Care ------------------------------------ 12
TROUBLESHOOTING --------------------------------------- 13
HYDROSTAR MK3 ------------------------------------------- 14
Pump Performance Curves/ Dimensional Drawings
HYDROSTEEL ------------------------------------------------ 15
Pump Performance Curves/ Dimensional Drawings
CAST IRON PUMP ------------------------------------------- 16
Pump Performance Curves/ Dimensional Drawings
WARRANTY -------------------------------------------------- 17
INTRODUCTION
Congratulations on choosing a Waterco Commercial pump. This manual contains information
pertaining to the installation, operation and maintenance of your Commercial pump. Please
read the instructions in this manual carefully.
All Waterco equipment is designed and manufactured to give many years of safe and reliable
operation. We hope that you obtain the maximum pleasure and benefit from your new
pump!

I pg 03
IMPORTANT SAFETY INSTRUCTIONS
When installing and using electrical equipment, basic safety precautions should always be
followed. This includes the following:
READ AND FOLLOW ALL INSTRUCTIONS
Do not block the pump suction; this can cause severe or fatal injury if blocked with the
body.
To reduce the risk of injury, do not permit children to use this product unless they are closely
supervised at all times.
Risk of Electric Shock: connect only to a grounding type receptacle protected by a residual
current device (RCD). Contact a qualified electrician if you cannot verify that the receptacle
is protected by an RCD.
Do not bury the electrical cable. Locate the cable in a manner that minimises abuse from lawn
mowers, hedge trimmers, and other equipment.
To reduce the risk of electric shock, replace damaged cable immediately.
Incorrectly installed equipment may fail, causing severe injury or property damage.
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
!
DANGER
Equipment that is incorrectly pressure tested may fail, causing severe injury or property
damage. Pressure testing should only be conducted by trained pool professionals.
Do not change the multiport valve position when the pump is running.
This pump is for use with permanently installed pools and may also be used with hot tubs
and spas if so marked. Do not use with storable pools. A permanently installed pool is
constructed in or on the ground or in a building such that it cannot readily be disassembled
for storage. A storable pool is constructed so that it may be readily disassembled for storage
and reassembled to its original integrity and has a maximum dimension of 18 feet (5.49m) and
a maximum wall height of 42 inches (1.07m).
To prevent overheating, do not install the pump within an enclosed area unless adequate
ventilation is provided.
Do not start the pump dry! Running the pump dry for any length of time will cause severe
damage and will void the warranty.
Chemical fumes and spills can weaken pool/spa equipment. Corrosion can cause pumps,
filters and other equipment to fail, resulting in severe injury or property damage. Do not store
pool chemicals near your equipment.
READ AND FOLLOW ALL INSTRUCTIONS
WARNING
!
WARNING
!
WARNING
!
!
CAUTION
!
CAUTION
!
CAUTION
Waterco Commercial Pump

INSTALLATION
Receive and Check Pump
Check the pump packaging for damage. Check for shipping damage such as dented, cracked
or bent parts. If damage is detected contact the shipper or distributor from which the pump
was purchased.
Lifting and Handling
a) Hydrostar Pump Procedure
This pump requires two people to move and position the pump into place.
b) Hydrosteel Pump Procedure
The eye bolt built into the motor body is not designed to support the combined weight of the
motor and pump body. DO NOT attempt to lift the pump by attaching a clip to this eye bolt.
Use a minimum of two chains or straps to support the entire motor and pump. The crane or
hoist used, as well as each individual chain or strap, must have a weight-bearing capacity in
excess of the combined weight of the motor and pump.
c) Cast Iron Pump Procedure
The eye bolt built into the motor body is not designed to support the combined weight of the
motor and pump body. DO NOT attempt to lift the pump by attaching a clip to the eye bolt.
Use a minimum of two (preferably three) chains or straps to support the entire motor and
pump. The crane or hoist used, as well as each individual chain or strap, must have a weight-
bearing capacity in excess of the combined weight of the motor and pump.
I pg 05
WARNING
!
Crushing Hazard. NEVER walk or reach under a suspended pump.
For models where the wet end is made out of a composite material instead of cast iron – DO
NOT place any straps under the wet end for lifting – this will cause the wet end to crack. In
these scenarios – place the lifting strap under the pump housing.
Lifting Procedure
i) Raise the pump slowly to ensure that the chains or straps will not slip when
under tension.
ii) Check that the pump is properly balanced when it is raised. If it is not, release the
tension on the chains or straps and readjust their position.
Pump Location
a) The pump should be located in a position that enables easy access for periodic servicing.
Leave the area above the pump lid clear for removal of the basket for cleaning.
b) The pump and other circulation equipment must be located a minimum of 1.5m (5ft) from
the water.
c) The pump elevation should not be more than a few feet above the water level of the pool;
it is recommended that the pump be located within 0.30m (1ft) of the water level.
d) If the pump is installed below water level, shut off valves (butterfly valve for 80mm or
larger) should be installed on both the suction and discharge piping to prevent back flow
of pool water during routine servicing of the pump and other circulation equipment.
e)
Place the pump on a solid foundation that will not vibrate. It is suggested that the pump
be bolted down to reduce noise from vibration.
f)
The pump foundation must have adequate drainage to prevent the motor from being flooded.
g) Protect the pump from the sun and rain.
h)
Install the pump in a well-ventilated area – ensure there is enough clearance around the
motor and fan cowl.
If the pump is installed under cover, provide adequate ventilation and lighting.
Attach harnesses at
these points. Ensure
that the pump is kept
level when lifting. Do not use this
eye bolt to lift
the pump.
Waterco Commercial Pump

I pg 07
Piping Design and Installation
Both the suction and discharge lines should have a minimum pipe size as follows:
a) Hydrostar Mk3
• 80mm inlet and outlet
b) Hydrosteel Pump
• 80mm inlet and outlet
c) Cast Iron Pump
•150mm at the inlet and 100mm at the outlet
WARNING
!
Do not pressure test the pump above 35 psi. Pressure testing must be done by a trained
pool professional. Circulation equipment that is not properly tested may fail, resulting in
severe injury or property damage.
Piping Installation Guide
a) Use only the pump barrel unions that are supplied with Hydrostar & Hydrosteel pumps.
For CI pumps, bolts & nuts will be supplied for connection.
b) The piping must be well supported to reduce piping load on the equipment and excess
stress on the piping.
c)
To reduce difficulty in priming, install suction piping without high points that can trap air. If
the circulation equipment is located more than 30m (100ft) from the water, increase the
suction piping diameter to the next size.
d)
Install the piping with the least number of bends (elbows) and fittings.
e)
Every new installation must be pressure tested according to local codes.
Waterco Commercial Pump
This pool pump must be installed by a licensed or certified electrician or serviceman
in accordance with all applicable local codes and ordinances. Improper installation
can create electrical hazards, which could result in death, serious injury or damage to
property.
Always disconnect power to the pool pump at the circuit breaker before servicing the
pump. Failure to do so could result in death or serious injury to servicemen, pool users
or others due to electric shock.
Electrical Installation
WARNING
RISK OF ELECTRIC SHOCK
Three Phase Connections
Three phase connections should be installed as follows:
a) Hydrostar Mk3: WYE/STAR CONNECTION for export market
DELTA CONNECTION for Aus/NZ market
b) Hydrosteel: DELTA CONNECTION
c) Cast Iron: DELTA CONNECTION
Check that the information on the nameplate corresponds to the power supply.
Every motor requires either a fused disconnect switch or a circuit breaker.
A separate device must be available for permanent installation so the pump can be isolated
from the mains power. A contact distance of at least 3mm per pole is required for three
phase units.
Three Phase Motors require a starter switch or magnetic starter with correctly sized overload
protection in addition to the fused disconnect switch.
Check The Rotation Of Three Phase Motors. The motor is only suitable for clockwise
operation when viewed from the motor end fan (cowl) cover.
Three phase motors could rotate in either direction. Interchanging any 2 cables on a three
phase motor will reverse the direction of rotation. To check the rotation of the motor, turn on
for approximately 1 second. If it is running in the wrong direction turn off power, interchange
the wiring and repeat the above step to check.
The installer must protect all three phases on the supply of the motor so that the pump cannot
run on 1 or 2 phases only. An external current limiting device must be installed to protect the
motor in the event of a phase drop out.
If the pump is to be used for a swimming pool situation, it is MANDATORY that an earth
circuit breaker with a rated tripping current not exceeding 30mA be installed.
Motor protection MUST be installed corresponding to the nominal current of the motor. SEE
VALUE ON RATING PLATE.
It is the RESPONSIBILITY of the user to ensure that there is adequate protection between
the motor and the power supply.

I pg 09
WARNING
!
Failure to provide data plate voltage (within 10%) during operation will cause motor
overheating and will void the warranty.
Electrical Installation Guide
a) Make sure all electrical breakers and switches are turned off before wiring the motor.
b) Make sure that the wiring voltage matches the motor voltage. If they do not match the
motor will be damaged.
c)
It is the responsibility of the electrical installer to provide data plate operating voltage and
current to the pump by ensuring proper circuit and wire sizes.
d) Make sure all electrical connections are clean and tight.
e)
Cut wires to the appropriate length so they don’t overlap or touch when connected to the
terminal board.
f)
Permanently ground the motor using the green ground terminal located on the inside of the
motor canopy or access plate. Use the correct wire size and type specified by local codes.
g) Make sure the ground wire is connected to an electrical service ground. Bond the motor
to the pool structure in accordance with the National Electrical Code. Use a solid No.8
AWG or larger copper conductor. Run a wire from the motor external bonding to the pool
bonding structure.
h)
Connect the pump permanently to a dedicated circuit. No other lights, equipment, or
appliances can be used on the same circuit.
WARNING
!
Install the control switch or time clock well away from the pool pump, filter, and other
equipment. Should there be an equipment failure or loose fitting, access to the switch
away from the failed equipment is important.
Waterco Commercial Pump
START-UP
These pumps are designed to be used in pool recirculation systems with water at temperatures
above 4°C (39.2°F) and not exceeding 40°C (104°F). Please refer to the Waterco Warranty
Terms and Conditions booklet supplied with the pump.
Start-up procedure
a) Clear all piping of construction debris and verify that the piping has passed a proper
pressure test.
b) Check the filter and other equipment for proper installation, verifying all clamps and
connections are properly installed as per the manufacturer’s instructions.
c)
Open any shut off valves on the suction and discharge lines.
d) Open the filter pressure relief valve and release all pressure from the system.
e)
If the pump is located below the water level of the pool, opening the pressure relief valve
will fill the pump with water.
f)
If the pump is located above the pool water level, remove the lid from the strainer pot and
fill with water before starting the pump.
g) Check to see that the lid O-ring and seat areas are clean and lubricated. Debris in the
sealing area can cause air to leak into the system and make it difficult to prime the pump.
Use a silicone based lubricant.
h) Close/tighten the lid to make an airtight seal.
i)
Turn on the pump.
j)
Bleed air from the filter until a steady stream of water comes out. Close the air relief valve.
k)
If the pump does not prime and all instructions to this point have been followed, check
for suction leaks and repeat steps (b) through (j).
Never run the pump without water. Running the pump dry for any length of time can
cause severe damage to the mechanical seal, pump and motor. Maintain the water level
in your pool half way up the skimmer opening. If the water level falls below the skimmer
opening, the pump will draw air through the skimmer. This will cause to pump to lose
prime and run dry.
!
CAUTION
WARNING
!
High suction lift or long suction line will require additional time to prime and can severely
affect the performance of the pump.

I pg 11
Waterco Commercial Pump
MAINTENANCE
Strainer Basket Cleaning
a) Turn off the power to the pump.
b) Turn the filter MPV to ‘Recirculate’ before shutting off any valves. This will keep the filter
flooded while servicing the pump, and there will be no need to bleed air from the filter
after servicing. Revert the MPV back to ‘Filter’ position after the pump lid is back on
and sealed. If the pump is installed below water level, close any shut off valves on the
suction and discharge lines.
c)
Relieve pressure in the system.
d) Turn the quarter turn lock ring lid in counter - clockwise direction for Hydrostar and
Hydrosteel pumps and for CI pumps, handles must be screwed on for turning the lock ring
anti - clockwise for removal of lid.
e)
Lift and remove the lock ring and lid set from the wet end of the pump.
f)
Put the debris from the basket into the trash and rinse out the basket.
g) Replace the basket.
h) If the pump is located above the pool water level, fill the basket with water.
i)
Clean the lid, lid O-ring, and sealing surface of the pump pot.
j)
Replace the lid by placing the lock ring and the lid on the pot. Make sure the lid O-ring is
properly placed. Seat the lock ring and lid then turn clockwise until the lid is hand tight. Do
not use any tools to tighten the lid. For the Cast Iron Pump, turn the lock ring clockwise
until stop.
k)
Open all valves on the suction and discharge lines.
l)
If the pump is located below the water level of the pool, the pump will fill with water.
m)
Stand clear of the filter. Turn on the power to the pump.
n) If the pump does not prime and all instructions to this point have been followed, check for
suction leaks and repeat steps (h) through (o).
WARNING
!
DO NOT open the strainer pot if the pump fails to prime or if the pump has been operating
without water in the strainer pot. Pumps operated in these circumstances may experience
a build up of vapor pressure and may contain scalding hot water. Opening the pump may
cause serious personal injury. In order to avoid the possibility of personal injury, make
sure the suction and discharge valves are open and strainer pot temperature is cool to
touch, then open with extreme caution.
To prevent damage to the pump and filter and for proper operation of the system, clean
pump strainer and skimmer basket regularly.
!
CAUTION
Winterizing
If the air temperature drops below 0°C (35°F), the water in the system can freeze and cause
damage. Freezing damage is not warrantable.
To prevent freezing damage follow the procedures listed below:
a)
Shut off electrical power for the pump at the house circuit breaker.
b)
Drain the water out of the pump case by removing the two drain plugs from the case.
Store the plugs in the pump basket.
c)
Cover the motor to protect it from severe rain, snow and ice.
d) If it is possible, store the pump in a dry location during this time.
e)
Do not wrap the motor in plastic. It will cause condensation and rust on the inside of the
motor.
f
) Where possible, have a qualified service technician or electrician disconnect the electrical
wiring at the switch or junction box and store the pump indoors.
g) When the pump is reactivated, ensure all seals and o-rings are in operational condition. If
they are not, re-greasing or replacing may be necessary.
In cold climate areas, when temporary freezing conditions may occur, run your filtering
equipment all night to prevent freezing.
!
CAUTION

I pg 13
Waterco Commercial Pump
Electric Motor Care
a) Protect from heat
• Shade the motor from the sun.
• Any enclosure must be well ventilated to prevent overheating.
• Provide ample cross ventilation.
b) Protect against contamination
• Protect from any foreign matter.
• Do not store (or spill) pool chemicals near the motor.
• Avoid sweeping or stirring up dust near the motor while it is operating.
• If a motor has been damaged by dirt it voids the motor warranty.
c) Protect against moisture
• Protect from splashing pool water.
• Protect from the weather.
• Protect from lawn sprinklers.
• If a motor has become wet, let it dry before operating. Do not allow the
pump to operate if it has been flooded.
• If a motor has been damaged by water it voids the motor warranty.
d) Regularly verify:
• That the mechanical parts and support screws of the pump are correctly attached.
• The position, attachment and condition of the supply cables and insulating parts.
• The temperature of the motor.
• Whether the pump is vibrating abnormally.
DO NOT wrap with plastic or other airtight materials. The motor may be covered during a
storm, for winter storage, etc. but never when operating or set up for automatic operation.
conditions may occur, run your filtering.
!
CAUTION
SYMPTOMS PROBABLE CAUSE ACTION
1. PUMP WILL NOT
PRIME
Suction air leak Make sure water level is correct through suction points.
Ensure baskets and strainers are free of debris. Tighten
all fittings/unions on the suction side of the pump,
remove and replace mechanical seal.
No water in the pump Make sure hair and lint pot is full.
Closed valves or blocked lines Open all valve in system, clean skimmer and pump
basket, check pump impeller for blockage.
2. MOTOR WILL NOT
RUN
No power to motor Check that all electrical switches are on. Ensure the
circuit breakers are properly set. Check if timer is set
properly. Check motor wiring at terminals.
Pump jammed With power switched off turn pump shaff (should spin
freely). If not, contact electrician or nearest Waterco
Limited branch for service.
3. LOW FLOW Dirty filter Backwash or clean cartridge.
Dirty Skimmer and Pump strainer Clean skimmer and pump strainer.
Suction air leak See 1.
Closed valve or blocked line See 1.
4. MOTOR RUNS
HOT
Low or incorrect voltage Supply to be corrected by electrician. Motors run hot
to touch and is normal. Thermal overload protector will
function to turn them off if there is an overload or high
temperature problem.
Installed in direct sunlight Shield from the weather.
Poor ventilation Do not tightly cover or enclose motor.
5. NOISY PUMP
OPERATION
Bad bearing Have electrician replace.
Air leak in suction See 1.
Suction blockage Locate and clear blockage
Foreign matter in impeller Dismantle pump and remove foreign matter and debris
from around impeller.
Cavitations Improve suction, reduce suction lift, reduce number
of fittings on suction side, increase pipe size, increase
dischange pressure and reduce flow by throttling
dischange valve.
6. MOTOR
OVERLOAD CUTS
OUT
Motor not connected properly Have electrician check wiring.
Low incoming voltage Have electrician check voltage, ensure pump is not
running on an extension cord. Report low supply to
authorities.
Overload due to binding in pump or
wrong size impeller
Contact Waterco Limited for servise.
7. WATER LEAK
BETWEEN MOTOR
AND PUMP BODY
Damged or failed mechanical seal Replace mechanical seal.
TROUBLESHOOTING
Waterco strongly recommends you have a qualified service technician service your pump.
However, many problems may be solved by consulting the table below.
If the Waterco Limited pump is within the stated warranty period and you experience faults,
always contact your supplier or the nearest Waterco Limited branch for advice. Failure to do
this may void the warranty. Refer to warranty documentation supplied with the pump.
All electrical work is to be carried out by a qualified electrician. Under no circumstances
should you attempt repairs on the electrical components of Waterco Limited pumps unless
you are qualified to do so.
WARNING
!

I pg 15
HYDROSTAR MK3
Pump performance curves
Waterco Commercial Pump
Flow (lpm) 0 200 400 600 800 1000 1200 1400
Flow (m3/hr) 0 12 24 36 48 60 72 84
Hydrostar Mk3 Performance Curves
Pump dimensional drawings
Hydrosteel Pump Performance Chart
Flow (lpm) 0 200 400 600 800 1000 1200 1400 1600 1800
Flow (m3/hr) 0 12 24 36 48 60 72 84 96 108
HYDROSTEEL
Pump performance curves
Pump dimensional drawings

I pg17
A B D E F L R S T W
4kW 260 180 112 95 140 1017 48 727 190 657
5.5kW 298 200 132 108 140 1070 28 749 216 660
7.5kW 298 200 132 108 140 1070 28 749 216 660
11kW 325 220 160 127 210 1198 0796 254 688
Dimensions - all in mm
Waterco Commercial Pump
Flow (lpm) 0 500 1000 1500 2000 2500
Flow (m3/hr) 0 30 60 90 120 150
CAST IRON PUMP
Pump performance curves
Pump dimensional drawings
WARRANTY
WARNING
!
Waterco Commercial pumps are covered by a comprehensive 1 year warranty for commercial
installations. Please consult the Waterco Warranty Terms & Conditions booklet included
with the pump for further information.