Sewage Pumps Installation Check List

The information provided here is for educational purposes only. We recommend that a qualified and competent contractor install all new systems and replace existing pumps and motors. Failure to install in compliance with local and national codes and manufacturers recommendations may result in electrical shock, fire hazard, unsatisfactory performance, and equipment failure.

TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN MANUFACTURER’S MANUAL AND ON PUMP. THE MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION AND OPERATION OF THE UNIT AND MUST BE KEPT WITH THE PUMP.

• SAFETY ALERT SYMBOL: When you see this symbol on the pump or in the manual, look for one of the following signal words and be alert to the potential for personal injury or property damage.
• DANGER SYMBOL: Warns of hazards that WILL cause serious personal injury, death or major property damage.
• WARNING SYMBOL: Warns of hazards that CAN cause serious personal injury, death or major property damage.
• CAUTION SYMBOL: Warns of hazards that CAN cause personal injury or property damage.
• NOTICE SYMBOL: INDICATES SPECIAL INSTRUCTIONS WHICH ARE VERY IMPORTANT AND MUST BE FOLLOWED.
• THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS PRIOR TO PERFORMING ANY WORK ON THE PUMP. MAINTAIN ALL SAFETY DECALS.

WARNING

• All electrical work must be performed by qualified and competent contractor. Always follow the National Electrical Code (NEC), or the Canadian Electrical Code, as well as all local, state and provincial codes. Code questions should be directed to your local electrical inspector.
• Failure to follow electrical codes and OSHA safety standards may result in personal injury or equipment damage.
• Failure to follow manufacturer’s installation instructions may result in electrical shock, fire hazard, personal injury or death, damaged equip¬ment, provides unsatisfactory performance, and may void manufacturer’s warranty.
• Standard units are not designed for use in swimming pools, open bodies of water, hazardous liquids, or where flammable gases exist. These fluids and gases may be present in containment areas. Tank or wet well must be vented per local codes.
• Only pumps specifically Listed for Class 1, Division 1 are allowable in hazardous liquids and where flammable gases may exist. See specific pump catalog bulletins or pump nameplate for all agency Listings.
• Disconnect and lockout electrical power before installing or servicing any electrical equipment. Many pumps are equipped with automatic thermal overload protection which may allow an over¬heated pump to restart unexpectedly.
• All three phase (3Ø) control panels for submersible pumps must provide Class 10, quick-trip, overload protection.
• Seal all controls from gases present which may damage electrical components.
• FAILURE TO PERMANENTLY GROUND THE PUMP, MOTOR AND CONTROLS BEFORE CONNECTING TO POWER CAN CAUSE SHOCK, BURNS OR DEATH.

PRE-INSTALLATION CHECKS

• Open all cartons and inspect for shipping damage.
• Report any damage to your supplier or shipping carrier immediately.
• Important: Always verify that the pump nameplate Amps, Voltage, Phase and HP ratings match your control panel and power supply.
• Warranty DOES NOT cover damage caused by connecting pumps and controls to an incorrect power source (voltage/phase supply).
• Many sewage pumps are oil-filled. Do not run pump if there are any signs of oil leakage.
• Record the model numbers and serial numbers from the pumps and control panel on the front of this instruction manual for future reference. Give it to the owner or affix it to the control panel when finished with the installation.

LIFTING Of THE PUMP

• DO NOT LIFT, CARRY OR HANG PUMP BY THE ELECTRICAL CABLES. DAMAGE TO THE ELECTRICAL CABLES CAN CAUSE SHOCK, BURNS OR DEATH.
• Lift the pump with an adequately sized chain or cable attached to the lifting eye bolt.
• DO NOT damage electrical and sensor cables while raising and lowering unit.

OPTIONAL GUIDE RAIL OR LIFT-OUT SYSTEM

• In many effluent and sewage basins or lift stations it is advisable to install the pump on a guide rail system or on a lift-out adapter to facilitate installation and removal for inspection and/or service.
• Most codes do not allow person¬nel to enter a wetwell without the correct protective equip¬ment and training. Guide rails are designed to allow easy removal of the pump without the need for entry into the wetwell or need to disturb piping.
• The guide rail or lift-out adapter should locate the pump opposite the influent opening preventing stagnate areas where solids can settle.
• The basin or pit must be capable of supporting the weight of the pump and guide rail. The pit floor must be flat.

PIPING

• Discharge piping should be no smaller than the pump discharge diameter and kept as short as possible, avoiding unnecessary fittings to minimize friction losses.
• Install an adequately sized check valve matched to the solids handling capability of the pump to prevent fluid backflow.
• Backflow can allow the pump to “turbine” backwards and may cause premature seal and/or bearing wear. If the pump is turning backwards when it is called on to start the increased torque may cause damage to the pump motor and/or motor shaft and some single-phase pumps may actually run backwards.
• Install an adequately sized ball valve AFTER the check valve for pump, plumbing and check valve maintenance.
• All piping must be adequately supported, so as not to impart any piping strain or loads on the pump.
• The pit access cover must be of sufficient size to allow for inspection, maintenance and crane or hoist service.

REQUIRED RELIEF HOLE

• Before the pump is installed, drill a 3⁄16” relief hole in the discharge pipe.
• Relief hole should be located within the wetwell, 2” above the pump discharge but below the check valve.
• The relief hole allows any air to escape from the casing. Allowing liquid into the casing will insure that the pump can start when the liquid level rises.
• Unless a relief hole is provided, a bottom intake pump could “air lock” and will not pump water even though the impeller turns.

SAFETY ALERT

• Read Safety Instructions before proceeding with any wiring and grounding
• Use only stranded copper wire to pump/motor and ground. The ground wire must be at least as large as the power supply wires.
• Wires should be color coded for ease of maintenance and troubleshooting.
• Install wire and ground according to the National Electrical Code (NEC), or the Canadian Electrical Code, as well as all local, state and provincial codes.
• Install an all leg disconnect switch where required by code.
• Disconnect and lockout electrical power before performing any service or installation.
• The electrical supply voltage and phase must match all equipment requirements. Incorrect voltage or phase can cause fire, motor and control damage, and voids the warranty.
• All splices must be waterproof. If using splice kits follow manufacturer’s instructions.
• Select the correct type and NEMA grade junction box for the application and loca¬tion. The junction box must insure dry, safe wiring connections.
• All electrical work must be performed by qualified and competent contractor.
• Always follow the National Electrical Code (NEC), or the Canadian Electrical Code, as well as all local, state and provincial codes. Code questions should be directed to your local electrical inspector.
• Failure to follow electrical codes and OSHA safety standards may result in personal injury or equipment damage.
• Failure to follow manufacturer’s installation instructions may result in electrical shock, fire hazard, personal injury or death, damaged equipment, provides unsatisfactory performance, and may void manufacturer’s warranty.

FLOAT SWITCH TYPES

• There are two basic float switch designs; narrow angle and wide-angle.
  • Narrow Angle float switches operate over a range of 15º so they open and close quickly.
  • Wide-angle float switches operate over a 90 degree swing with the tether length between the float body and the pivot point controlling the On-Off range.
• The design determines how many floats are required with different systems or controls.
• Floats may be normally open (NO) for pump down applications or to empty a tank.
• Normally closed (NC) switches are used to pump up or to fill a tank.
• A narrow angle control switch may be used only with a control panel, never direct connected to a pump.
• The wide-angle, pump down switches may be used as direct connected pump switches or as control switches.

SETTING THE FLOAT SWITCHES

• All floats should be set below the Inlet pipe
• It is best to set the off switch so the water level is always above the top of the pump (motor dome). Next best is to set the off switch so the water level is not more than 6" below the top of the pump.
• The on switch should be set so the volume of water between the on and off floats allows pumps of 1½ HP and under to operate for 1 minute minimum. Two (2) HP and larger pumps should run a minimum of 2 minutes.
• Basin literatures state the gallons of storage per inch of basin height.
• Alarm float should be set at the level of the invert.
• Lag float should be set a few inches under the alarm float
• Try to use most of the available storage provided by the basin, save some space for reserve storage capacity.
• There are no absolute rules for where to set the float switches; it varies from job to job only.

PANEL WIRING DIAGRAMS

• Control panels are shipped with instructions and wir¬ing diagrams. Use those instructions in conjunction with the Operations and Installation Manual.
• All electrical work must be performed by qualified and competent contractor. Always follow the National Electrical Code (NEC), or the Canadian Electrical Code, as well as all local, state and provincial codes. Code questions should be directed to your local electrical inspector.
• Failure to follow electrical codes and OSHA safety standards may result in personal injury or equipment damage.

HIGH WATER ALARMS

• Alarms should be installed in all Waste¬water pump installations .
• Many standard control panels come equipped with alarm circuits.
• If a control panel is not used, a standalone high liquid level alarm is avail¬able.
• The alarm alerts the owner of a high liquid level in the system so they can contact the appropriate service personnel to investigate the situation.

SINGLE PHASE PUMPS

• Single phase pumps may be operated using a piggy¬back or hard wired float switch, a contactor, or a Simplex or Duplex control panel.
• All 1/3 and ½ HP, 115 or 230 volt pumps, and some ¾ and 1 HP pumps, are supplied with plug style power cords. They may be plugged into piggyback float switches for simple installations.
• It is allowable to remove the plugs in order to hardwire or connect to a Simplex or Duplex controller. Removing the plug neither voids the warranty nor violates the agency Listings
• PLUG-CONNECTED UNITS MUST BE CONNECTED TO A PROPERLY GROUNDED, GROUNDING TYPE RECEPTACLE.
• On plug-in units, do not remove cord and strain relief.
• Do not connect conduit to pump. Pumps with bare lead power cords can be hard-wired to a float switch, wired to a single phase contactor, a Simplex controller or a Duplex controller.
• Always verify that the float switch is rated for the maximum run amperage, maximum starting amperage, and the HP rating on the pump.
• Single-phase wastewater pumps have internal overloads devices, unless noted differently on the pump nameplate.

THREE PHASE PUMPS:

• As a Minimum a 3 phase pump requires a 3 pole circuit breaker/fused circuit, an across the line magnetic starter rated for the pump HP, and ambient compensated Quick Trip Class 10 overloads

SINGLE AND THREE PHASE CONTROL PANELS:

• Control panels are available as Simplex (controls 1 pump) or Duplex (controls 2 pumps).
• Standard Panels are available with many standard features and can be built with our most popular options.
• There are also custom build panels which offer many more design options than the standard panels.
• Custom control panels are available in many different configurations.
• Standard Duplex panels usually feature a solid-state printed circuit board design with standard high level alarm circuits. Other standard features are: an auxiliary dry alarm contact for signaling a remote alarm , H-O-A switches for each pump, running lights and elapse time meters for each pump.
• The 3 phase panels have built-in, adjustable, Class 10 overloads. The adjustable overloads on all our 3Ø phase panels mean less labor for the installer and no need to order specific overloads.
• Some dual seal pumps are equipped with a standard, built-in seal failure circuit, which may also be called a moisture detection circuit. This circuit must be connected to a control panel with an optional seal fail relay.
• The panel must be special ordered with the seal fail relay and alarm. There are also stand alone seal fail panels

INSTALLATION

• Connect the pump(s) to the guide rail pump adapters or to the discharge piping. Slide rail bases should be anchored to the wetwell floor.
• Complete all wiring per the control panel wiring diagrams and NEC, Canadian, state, provincial and/or local codes. This a good time to check for proper rotation of the motors/impellers.
• DO NOT PLACE HANDS IN PUMP SUCTION WHILE CHECKING MOTOR ROTATION. TO DO SO WILL CAUSE SEVERE PERSONAL INJURY.
• Always verify correct rotation. Correct rotation is indicated on the pump casing.
• Three phase motors are reversible. It is allowable to bump or jog the motor for a few seconds to check impeller rotation. It is easier to check rotation before installing the pump. Switch any two power leads to reverse rotation.
• Lower the pump(s) into the wetwell.
• Check to insure that the floats will operate freely and not contact the piping.

Single Pump Operation

• Once the piping connections are made and checked you can run the pumps.
• Plug the piggyback switch into a dedicated grounded outlet and then plug the pump into the switch. Test the pump by filling the wetwell until the pump goes On.
• If the pumps run but fail to pump, they are probably air locked; drill the relief holes per the instructions in the Piping Section.
• Check the operating range to insure minimum one minute run time and that the pump goes off in the correct position.

Control Panel Operation

• Fill the wetwell with clear water.
• Use the pump H-O-A (Hand-Off-Automatic) switches in Hand to test the pumps. If they operate well in Hand proceed to test
• If the pumps run but fail to pump, they are probably air locked, drill the relief holes per the instructions in the Piping Section.
• Place Control Panel H-O-A (Hand-Off-Auto) switches in Automatic position and thoroughly test the operation of the ON, OFF, and Alarm floats by filling the wetwell with clear water.
• Many Control Panels require a Neutral wire. Failure to provide a Neutral from the power supply to a 1Ø, 230 volt Control Panel will not allow the panel control circuit to operate. The Neutral is necessary to complete the 115 volt control circuit.
• Check voltage and amperage and record the data on the front of this manual for future reference.
• Compare the amperage readings to the pump nameplate maximum amperage. If higher than nameplate amperage investigate cause.
• Operating the pump off the curve, i.e. with too little head or with high or low voltage will increase amperage.
• The motor will operate properly with voltage not more than 10% above or below pump nameplate ratings. Performance within this range will not necessarily be the same as the published performance at the exact rated nameplate frequency and voltage.
• Correct problems before proceeding.
• Three phase unbalance is also a possible cause. See Three Phase Power Unbalance and follow the instructions.
• Reset the Alarm circuit, place pump switch (es) in the Automatic position and Control Switch in ON position. The system is now ready for automatic operation.

THREE PHASE POWER UNBALANCE

• A full three phase supply consisting of three individual transformers or one three phase transformer is recommended. “Open” delta or wye connections using only two transformers can be used, but are more likely to cause poor performance, overload tripping or early motor failure due to current unbalance.
• Check the current in each of the three motor leads and calculate the current unbalance as explained below.
• If the current unbalance is 2% or less, leave the leads as connected.
• If the current unbalance is more than 2%, current readings should be checked on each leg using each of the three possible hook-ups.
• Roll the motor leads across the starter in the same direction to prevent motor reversal.

To calculate percent of current unbalance:

• Add the three line amp values together.
• Divide the sum by three, yielding average current.
• Pick the amp value which is furthest from the average current (either high or low).
• Determine the difference between this amp value (furthest from average) and the average.
• Divide the difference by the average. Multiply the result by 100 to determine percent of unbalance.
• Current unbalance should not exceed 5% at service factor load or 10% at rated input load. If the unbalance cannot be corrected by rolling leads, the source of the unbalance must be located and corrected. If, on the three possible hookups, the leg farthest from the average stays on the same power lead, most of the unbalance is coming from the power source.
• Contact your local power company to resolve the imbalance.

INSULATION RESISTANCE READINGS

Normal Ohm and Megohm Values between all leads and ground
• Motor out of basin
  • New motor (without drop cable). 20,000,000 (or more) Ohms or 20 (or more) Megohm
  • Used Motor: 10,000,000 (or more) Ohms or 10 (or more) Megohm
• Motor in basin (with drop cable).
  • New motor. :2,000,000 (or more) Ohms or 2 (or more)
  • Motor in good condition.: 500,000 - 2,000,000 Ohms or 0.5 - 2 Megohm
  • Insulation damage: Less than 500,000 Less than 0.5
• Insulation resistance varies very little with rating. Motors of all HP, voltage and phase ratings have similar values of insulation resistance.
• Insulation resistance values above are based on readings taken with a megohmmeter with a 500V DC output. Readings may vary using a lower voltage ohmmeter, consult factory if readings are in question.