LOW PRESSURE SEWAGE & EFFLUENT SYSTEMS
Contents
1. Fiberglass o x x S co oS Un gt co Ro gt For Anti Siphon Piping Assembly HPG SPG 12746 213 5 G1X GILX 12746 215 5 For pedestal spacer not depicted by drawing xxx Part number changes per tank depth RTF Refer to factory Notes S Parts in Seal Kit C Parts in Carbide Seal Kit I Parts in Impeller Kit R Parts in Rebuild Kit Consult Factory q Omens Ma e VALVE HANDLE EXTENSION Duy amp ae Ce 28 LOCK NUT w an oa WASHER CO A SEAL RING 2 22 DISCHARGE HUB 17 O RING ae 16 O RING a 15 SHUT OFF VALVE LOCK 14 PIPE ASSEMBLY WASHER PIPE PUMP FOOT BRACKET 2 FLAT WASHER G 7 SCREW 4 i RISER BRACKET 10 LIMITED PRODUCT WARRANTY HYDROMATIC warrants that its pacar are free from defects in material and workmanship for a period of twelve 12 months from the date of purchase or eighteen 18 months from the date of manufacture whichever occurs first During the warranty period and subject to the conditions hereinafter set forth HYDROMATIC will repair or replace to the original user or consumer parts which prove defective due to defective materials or workmanship of HYDROMATIC Contact the nearest authorized HYDROMATIC distributor HYDROMATIC authorized service center or HYDROMATIC for warranty servi2. a minimum of 24 diameter for a simplex station and a minimum of 36 diameter for a duplex station Step 2 Basin floor must be level for pumps to be orientated properly Step 3 Cast four 1 4 threaded studs into basin floor located per installation drawing Studs should protrude a minimum of 3 4 from basin floor Step 4 Grout in any discharge inlet or overflow pipes Correct positioning is the responsibility of the installer DO NOT locate the influent line where it would empty on the guiderail NOTE 1 1 2 NPT coupling mounted flush to inside basin wall is required for discharge hub mounting see above Step 5 For vertical discharge pumps mount stainless steel discharge pedestal to the four threaded sump floor studs Step 6 Apply thread sealant to the stainless steel discharge hub and thread into flush mounted 1 1 2 NPT wall coupling CONCRETE BASIN INSTALLATION F INLET gt BY OTHERS W FOUR 1 4 STUDS BY OTHERS Pump Installation Step 7 Ensure discharge pipe length is correct For vertical discharge pumps measure the distance from the center of the discharge hub opening to the top of the installed riser pedestal For horizontal discharge gr
3. lower than nameplate then the pump is air locked NOTE Nameplate amperage is rated at the largest impeller diameter trim Pumps with trimmed diameter impellers will draw slightly less amps than nameplate If pump is air locked refer to the troubleshooting section in this manual Step 6 Float systems adjustment for simplex Adjust floats so that the pump starts when the water level is just above the pump motor housing and the pump shuts off when the water level is 2 inches above the pump volute discharge Float adjustment for duplex systems Adjust floats so the lead pump will start when the water level is just above the motor housing The lag pump start float should be 5 to 6 inches above the lead pump start float Adjust pump shut off so that water level is within 2 inches above pump volute discharge Pumps should alternate starting between each other upon successive pump down cycles To check lag pump level set both H O A switches to Off position and allow water to surpass the lag pump level then set both H O A switches to Auto position and both pumps should start Turn off one pump and be sure second pump starts when lag pump level is reached on second trial If pumps fail to cycle in this manner retrace control float wiring panel Step 7 Ensure H O A switch is set to Auto before placing system into service Pump Troubleshooting Below is a list of common problems and possible solut
4. not protrude inside of basin so as to interfere with pump removal or float switch operation Step 2 Close shut off valve and make discharge line connection It is recommended that an additional shut off valve and redundant check valve by installing contractor be located outside the basin This can be at any force main entrances check local codes for specific requirements Internal Basin Connections Step 1 If system is supplied with a float bracket attach float switches to the float bracket by clamping strain relief bushings around the float cords then inserting and twisting the bushings into the float bracket slots Step 2 After grinder pump attachments have been made lower the pump unit down the guiderail to ensure the ball check valve s sealing flange aligns and connects properly with discharge elbow Pedestal Panel Mount Systems Step 1 Ensure power source or disconnected Step 2 Place insulator strip or bushing onto sump cover opening to protect insulation on incoming cords is off Pump Installation Step 3 Insert all cords through the cover opening and then through the pedestal Mount the pedestal on sump cover with vent openings pointing downward Step 4 Mount sealing block and panel to pedestal with hardware provided Ensure pedestal gasket seals against panel and tighten all cord nuts while leaving approximately 3 of play in the cords from the tank IMPORTANT Any un
5. of basins may result in damage to the basin damage to basin components or leaks in the piping assemblies Fiberglass Basin Step 1 Inspect the fiberglass guiderail to ensure it is securely fastened to the basin wall Step 2 An inlet grommet is the standard supplied influent connection device If another type of inlet hub is used refer to the directions included with the hub Inlet grommet Determine point at which influent line will enter basin and using a hole saw sized per chart below drill a hole through the basin wall Clean cut hole and apply a sealant coating to the cut section to prevent fiberglass deterioration Insert the inlet grommet into the drilled hole PIPE HOLE SAW SIZE DIAMETER Step 3 Lifting of the basin may be done with a nylon or other nondamaging type material sling Do not wrap a chain or steel cable around the basin as damage may result Do not attach lifting mechanism around discharge hub or electrical hub Step 4 Lower the basin into excavation position and level properly Mount basin with base anchor bolts if an anti flotation tie down kit is used Inspect fiberglass basin and seal off any cuts or scratches to prevent fiberglass deterioration Influent and Discharge Connections for Fiberglass or Polyethylene Basins Step 1 Lubricate inside lip of inlet grommet with pipe soap Clean outer end of influent pipe and push pipe through grommet Ensure pipe does
6. ION HYDROMATIC DISCLAIMS ALL LIABILITY INCLUDING LIABILITY UNDER THIS WARRANTY FOR IMPROPER INSTALLATION HYDROMATIC RECOMMENDS INSTALLATION BY PROFESSIONALS Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This Warranty gives you specific legal rights and you may also have other rights which vary from state to state In the absence of suitable proof of this purchase date the effective date of this warranty will be based upon the date of manufacture Your Authorized Local Distributor LO wyDROMATIC Pentair Water USA CANADA 740 East 9th Street Ashland Ohio 44805 269 Trillium Drive Kitchener Ontario Canada N2G 4W5 Tel 419 289 3042 Fax 419 281 4087 www hydromatic com Tel 519 896 2163 Fax 519 896 6337 2008 Hydromatic Ashland Ohio All Rights Reserved Part 5625 370 1 Item E 03 370 3 08
7. Pump Installation and Service Manual L HYDROMATIC TRST LOW PRESSURE SEWAGE amp EFFLUENT SYSTEMS NOTE To the installer Please make sure you provide this manual to the owner of the pumping equipment or to Pentair the responsible party who maintains the system W t General Information Thank you for purchasing your Hydromatic pump To help ensure years of trouble free operation please read the following manual carefully Before Operation Read the following instructions 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 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 Systems Description Four basic models of the Hydromatic TRST g
8. and manufactured g to any unit which has been repaired or altered by anyone other than HYDROMATIC a HYDROMATIC distributor or a HYDROMATIC authorized service center and h to any unit which has been repaired using non factory specified parts OEM parts RETURN OR REPLACED COMPONENTS any item to be replaced under this Warranty must be returned to HYDROMATIC in Ashland Ohio or such other place as HYDROMATIC may designate freight prepaid PRODUCT IMPROVEMENTS 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 units sold and or shipped prior to such a change or improvement WARRANTY EXCLUSIONS HYDROMATIC MAKES NO EXPRESS OR IMPLIED WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF HYDROMATIC SPECIFICALLY DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE Some states do not permit some or all of the above warranty limitations and therefore such limitations may not apply to you No warranties or representations at any time made by any representatives of HYDROMATIC shall vary or expand the provision hereof LIABILITY LIMITATION IN NO EVENT SHALL HYDROMATIC BE LIABLE OR RESPONSIBLE FOR CONSEQUENTIAL INCIDENTAL OR SPECIAL DAMAGES RESULTING FROM OR RELATED IN ANY MANNER TO ANY HYDROMATIC PRODUCT OR PARTS THEREOF PERSONAL INJURY AND OR PROPERTY DAMAGE MAY RESULT FROM IMPROPER INSTALLAT
9. ce At all times HYDROMATIC shall have and possess the sole right and option to determine whether to repair or replace defective equipment parts or components Start up reports and electrical system schematics may be required to support warranty claims Warranty is effective only if HYDROMATIC supplied or authorized control panels are used where applicable All dual seal pumps must have seal failure and heat sensors attached functional and monitored for the warranty to be in effect If a seal failure should occur HYDROMATIC will only cover the lower seal and labor thereof If the heat sensor and seal fail sensor is not attached and functional the warranty is void LABOR ETC COSTS HYDROMATIC shall in NO EVENT be responsible or liable for the cost of field labor removal and or reinstallation charges of any HYDROMATIC product part or component thereof or the expense of freight THIS WARRANTY WILL NOT APPLY a to defects or malfunctions resulting from failure to properly install operate or maintain the unit in accordance with printed instructions provided b to failures resulting from a accident or negligence c to normal maintenance services sid te parts used in connection with such service d to units Orica are not installed in accordance with applicable local codes ordinances and good trade practices or e if the unit is moved from its original installation location f unit is used for purposes other than for what it was designed
10. ch Hand Position but is not Pumped Down with H O A Switch in Automatic Position 1 Floats are not hanging free in the basin or are dirty Pump the level down with the H O A switch on Hand so that the floats can be observed Relocate and clean float s as necessary If this is a new installation and original startup the floats may be miswired into the control panel If the On and Off floats are reversed the pump will short cycle on and off and will not pump the level down Floats or alternator are malfunctioning Pull the floats out of the basin and hang the Off and On floats from your hand Turn the H O A switch to Auto Tilt the Off float so that the large end is above the cord end nothing should happen While keeping the Off float tilted tilt the On float in the same manner the pump should come on Suspend the On float again from your hand the pump should continue to run Finally suspend the Off float the pump should stop running If this procedure does not cause the pump to operate as described either replace the float s or replace the alternator relay if the system is duplex Seal Failure Light Comes On This may indicate that the lower seal has failed and has allowed water to enter the seal housing and made contact with the seal failure probe Or this may indicate that a control circuit has become grounded Check out all control circuit wiring for moisture If this is not the case t
11. d pump power leads must be connected correctly to panel TRST Parts List ORDERING REPLACEMENT PARTS Product improvements are made from time to time The latest part design will be furnished as long as it is interchangeable with the old part When ordering replacement parts always furnish the following information 1 pump serial number 2 pump model and size 3 part description 4 part number 5 impeller diameter if ordering impeller 6 quantity required and 7 shipping instructions Ref Part Part LGA Part Part Ref Part Part No No Description Qty No No Description Qty No No Description Qty RIF Pump 10 14068 XXX 3 Rail Guide 19 12746 211 5 Pipe Assembly GIL GILX 13712 001 3 Pump Foot Bracket 11 12720 101 1 Elbow 19 12746 225 5 Pipe Assembly HPG 156 023 1 Flat Washer 12 12331 XXX 3 Pipe 20 14116 004 3 Lifting Bail GIL GILX HPG 101 022 1 Screw 13 176 003 1 Screw 21 13578 000 5 Riser Bracket Fiberglass 12745 200 5 Ball Check Valve 177 004 1 Lock Washer 21 9043 100 5 Riser Bracket Concrete 11945 000 1 Shackle 15 12777 200 5 Shut Off Valve 22 12726 001 1 Discharge Hub Fiberglass 176 005 1 Screw 16 150 051 1 0 Ring 22 12726 003 5 Discharge Hub Concrete 177 004 1 Lock Washer 17 150 052 1 O Ring 23 14082 000 1 Seal Ring Fiberglass 13325 100 3 Guide Rail Clip 18 13294 XXX 5 Valve Handle Extension 24 14079 000 1 Lock Nut
12. ems for proper backfill materials Ensure backfill material is free of rocks clods and debri CAUTION In freezing conditions the backfill must be dry and free of ice Support for all piping and electrical lines must be provided during backfilling At least a 4 6 inch wide band of compacted aggregate must be placed in successive layers 6 lifts around the entire periphery of the basin Carefully compact aggregate under all piping and electrical lines Cover grade should slope down 3 to the normal surrounding grade Care must be taken to prevent damage to any influent discharge or electrical connections made to the basin Pump Operations Step 1 Run clear water into the basin until motor housing is covered Step 2 Open the shut off valve to the discharge line CAUTION Do not use excessive force when operating the shutoff valve or damage to the valve or valve handle may occur The valve is closed when a noticeable stop is felt upon closing The valve is completely open upon 9 full counterclockwise turns from the closed position Step 3 Turn H O A switch to the Off position and turn on main breaker Step 4 Start the pump by turning the H O A switch to the Hand position Step 5 Check the pump amperage with clamp on ammeter on black pump lead Readings higher than nameplate indicate clogged pump miswiring or improper voltage If basin is not being pumped down and amperage readings are considerably
13. hen the pump must be pulled for maintenance Refer to pump installation and 5 service manual for replacing the lower seal NOTE Use twisted shielded cable for seal failure cable runs in excess of 100 feet Pump Run Light Stays On 1 H O A switch may be in Hand position Lower float may have failed causing the pump to continue operating below the Off level Pump may be air locked Cutters may be clogged Circuit Breaker Trips When Pump Tries to Start l 2 Short circuit in pump motor Water may have entered the motor housing through either worn out mechanical seals or O rings Contactor failure for three phase pumps Check pump contactor for burnt contacts Start component s failure for single phase pumps Check start capacitor and start relay for failure Single phase pump may be miswired to panel The white black and red pump power leads must be connected correctly to panel Overload Trips Is Manually Reset and Then Trips Off Again 1 4 Cutters may be clogged It is possible that the pump stalled during operation and starting and stopping cleared the cutters If resetting the overloads solves this problem return the H O A switch to Auto and observe operation Pump motor may have failed Start component s failure for single phase pumps Check start capacitor and start relay for failure Single phase pump may be miswired to panel The white black and re
14. ical location This material is commonly known as pea gravel B Stone or gravel crushings with angular particle size of not less than 1 8 nor more than 1 2 diameter washed and free flowing is acceptable as an alternative material CAUTION In freezing conditions the backfill must be dry and free of ice Do not use other backfill materials The basin warranty is automatically void if materials other than the recommended bed and backfill materials are used Step 3 The entire periphery including under the basin requires 4 to 6 inches of appropriate fill The ideal basin pad is concrete in conjunction with anti flotation tie down studs Basin anti flotation tie down kits are available from Hydromatic If concrete pad is not used the aggregate must be compacted to 85 standard proctor density Concrete pad or aggregate surface must be leveled flat and free of voids to conform to the basin bottom Basin bedding depth should be calculated such that the basin top will protrude 3 above the normal grade upon final installation CAUTION If the basin is not tied down during installation rain or flood conditions may cause the basin to float upward causing damage to the basin or basin connections Claims for this type of damage cannot be processed by Hydromatic Basin System Handling Factory built fiberglass basin systems must not be dropped dragged rolled or handled with sharp objects Improper handling
15. inder pumps measure the distance from the center of the discharge hub opening to the sump floor Subtract 8 3 16 from the previous measurement to calculate the pipe length required If supplied pipe is incorrect cut pipe and install a solvent weld pipe coupling to achieve the correct dimension 4 Step 8 Assemble discharge elbow pipe and shutoff valve using pipe sealant on all threads Tighten threads until correct discharge height is achieved Step 9 Ensure O ring seal is in place on shutoff valve then mount unit into place using six lock washers and screws provided Step 10 Install all other components as depicted by installation drawing Excavation for Fiberglass Basin Systems Step 1 Effect appropriate excavation based on size of the basin desired 1 1 2 X 1 1 4 REDUCER COUPLING MOUNTED FLUSH TO INSIDE BASIN WALL BY OTHERS 3 gt 4 1 4 DISCHARGE is BY OTHERS entrance point of the influent line and entrance of power connection Step 2 Obtain proper backfill material The backfill material provides as much as 90 of the basin s support under certain stress conditions The installer must be positive that correct bed and backfill materials are used per instructions as follows A Gravel clean and free flowing with particle size not less than 1 8 nor more than 3 4 in diameter Use this description when ordering or specifying as material varies upon geograph
16. ions Refer to the pump and panel installation and service manuals for details regarding any necessary adjusting dismantling or repair work Pump Runs but Does Not Pump Down the Basin with the H O A Switch in Either Hand or Automatic Position 1 Cutters may be clogged Amperage higher than nameplate may indicate this problem 2 Pump rotation may be reversed on three phase pumps only Switching any two power leads on three phase pumps will correct the rotation 3 Discharge gate valve may be closed 4 Pump may be air locked Fill basin approximately 10 inches or more above the ball check valve assembly Raise pump assembly so that the ball check valve disengages the discharge elbow approximately 6 inches Stand clear from the sump opening to avoid spray and turn pump on for a brief second to clear trapped air in the volute 5 Clogging anywhere from cutters to check valve This is evident if no water discharged out of the check valve after raising the pump to disconnect the sealing flange Pull pump assembly and check for cause of clogging 6 Discharge head may be too high Check elevation against design point of pump Clogging beyond the sealing flange This is evident if water is discharged through the check valve when raising the pump from the disconnect sealing flange Inspect system basin piping or discharge piping from basin to locate clogging Basin Level is Pumped Down With H O A in Swit
17. oid IMPORTANT Properly connect the panel ground wire to a grounding rod Improper grounding voids warranty Preoperation Grinder Pumps Step 1 Remove pump from basin Step 2 With power off turn radial cutter with a screwdriver to be sure it rotates freely If necessary to adjust refer to pump service manual Step 3 Stand clear from pump and with power on check for proper rotation of pump by turning H O A switch to Hand momentarily and then Off The impeller should turn counterclockwise when viewed from the suction end If rotation is wrong or pump does not rotate turn main power source off then for single phase pumps Check panel wiring to ensure white black and red pump leads are connected according to the schematic and panel wire labels Single phase pumps will run only if connected one way for three phase pumps Interchange any two line leads to the motor inside the panel IMPORTANT Do not leave pump in basin unless it is placed in operation If a pump has been out of service for an extended period of time with the power off rotate the impeller by turning the radial cutter with a screwdriver to be sure it rotates freely FINAL BACKFILL FOR FIBERGLASS BASIN SYSTEMS 4 to 6 of e 1 1 4 DISCHARGE BACKFILL ANCHOR BOLTS ANTI FLOTATION FLANGE MOUNTING 4 TO 6 BEDDING CONCRETE PAD OR AGGREGATE Refer to section Excavation for Fiberglass Basin Syst
18. pump service manual for all Hydromatic pumps when adjusting dismantling or repairing the pump Inspection Check to be sure that all items for your particular system are included Check that the phase and voltage on the pump nameplate are correct as ordered and match available job site voltage Codes WARNING To reduce the risk of electric shock electric installations shall be in accordance with the National Electric Code and all applicable local codes and ordinances Consult the local inspector s before installation to avoid costly delays or rework Excavation Location Excavation location shall be made according to local codes and regulations Care should be taken to avoid buried utility lines piping and other buried structures and foundations Pump Installation Installation Skill Requirements The installation of a TRST basin system is a specialized skill which requires individuals with a basic understanding of excavating pipe fitting and electrical wiring Hydromatic cannot assume responsibility for problems or damage resulting from inexperienced or undersupervised laborers These instructions are meant only to be an installation guide therefore installation conditions not covered in these instructions rely on the experience and mechanical aptitude of those installing the system Grinder Pump Attachments Step 1 Attach the stainless steel foot bracket to bottom of the pump with t
19. rinder systems are covered by these instructions 1 FBTRSTSG Simplex TRST system using a fiberglass basin 2 TRSTS Simplex TRST system installed by others in a concrete basin 3 FBTRSTDG Duplex TRST system using a fiberglass basin 4 TRSTD Duplex TRST system installed by others in a concrete basin Factory built fiberglass basin systems are available in 24 minimum diameter basins for simplex systems and 36 minimum diameter for duplex systems In a TRST system the pump is raised and lowered in the basin while being guided by a fiberglass guiderail A hydraulic sealing flange at the pump discharge allows the pump to be removed without disconnecting piping or electrical connections Application These pump systems are basically designed for pumping fresh effluent or sewage water with a pH ranging from 5 to 9 specific gravities from 0 9 to 1 1 viscosities ranging from 28 to 35 S S U and temperatures up to 140 F WARNING Pump is not to be installed in locations considered hazardous in accordance with the National Electric Code ANSI NFPA 70 Pump Models The TRST rail system may employ any Hydromatic 2 HP submersible grinder pump that uses cutter blades to grind solids into a slurry The TRST rail system may also employ any MHydromatic 1 maximum sphere size handling effluent pump Effluent is clear liquid waste left in a septic basin after the solids settle to the bottom Refer to the
20. used holes in the sealing block must be plugged to prevent the corrosive atmosphere of the basin from entering the control panel Plug any unused hole s with the nylon plug s provided Junction Box amp Direct Burial Cable Systems Step 1 Ensure power source or disconnected Step 2 Push pump power seal failure heat sensor cord and float cords through cord grips in the junction box and tighten To prevent corrosion or electrical short plug any unused holes in junction box is off Step 3 Remove junction box cover and make all connections inside junction box to all incoming control panel wires Step 4 Junction Box Conduit Systems It is recommended that the customer furnish and install a conduit seal outside the basin to prevent surface water from entering the junction box Direct Burial Cable Incoming burial cable s must be fed through basin cord grip s then tightened Panel Wiring Step 1 Ensure power source or disconnected Step 2 Connect pump power seal failure heat sensor and float cords to panel terminals per the schematic provided If the pump is single phase the white black and red power leads must be connected to the proper terminals in the control panel marked W BK and R or the pump will not operate All conduits and cables entering the panel must be sealed off is off NOTE A Hydromatic approved control panel must be used or the pump warranty is v
21. wo bolts and lock washers provided See Figure 1 Figure 1 Step 2 For horizontal discharge pumps apply pipe thread sealant to the ball check valve threads and screw the valve into the pump discharge For vertical discharge pumps apply pipe thread sealant to pipe threads and screw the discharge piping assembly into the pump discharge Tighten piping until a measurable distance of 23 3 4 1 8 from the floor to the center of the ball check valve discharge diaphragm hole is achieved See Figure 2 ALA la z im T S yoh 23 5 8 y to a 23 7 8 i IS ae b 4 i gd p HORIZONTAL VERTICAL Figure 2 Step 3 Install the stainless steel lifting bail to pump with two bolts and two lock washers provided Position the lifting bail with mounting tabs directed toward the pump power cord See Figure 3 a lo Z _ gs VERTICAL Figure 3 Step 4 Attach lifting chain cable or rope as supplied to the lifting bail shackle Tighten threaded shackle pin with pliers WARNING To reduce risk of electric shock do not connect conduit to pump Concrete Basin Installation Step 1 Concrete basin must be
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