4WHV, V4WHV Submersible Solids Handling Pumps

4WHV, V4WHV Submersible Solids Handling Pumps V4WHV 4WHV Installation and Service Manual 2010 Pentair Pump Group, Inc. 23833A038 1210

PUMP MODELS These instructions cover the installation and service of the 4WHV and V4WHV series of solids handling pumps and guide rail systems for the horizontal discharge models only. Both models are designed for handling raw sewage and wastewater. Do not use for acid wastewater. The pumps have 2-vane, solids handling impellers. The 4WHV and V4WHV will pass 3" dia. solids and has a 4" std. flange discharge. CAUTION: In the initial installation, before sewage is admitted to wet well, there is no danger of entering the sump, but after sewage has been in the sump there is danger. Sewage water gives off methane and hydrogen sulfide gases, both of which are highly poisonous. Never enter wet well unless cover is open and an outside blower is used to force fresh air into the wet well. Also, the man in the wet well must wear a harness with rope to surface so that he can be pulled out in case of asphyxiation. One man should not work alone. SEAL FAILURE The 4WHV and V4WHV pumps have a probe installed in the seal chamber, so that any leakage past the lower seal is detected. A red warning light at the control panel comes on if water enters the seal chamber. This is an indicator only and does not stop the motor. It warns that the seal should be replaced within 2 to 3 weeks. LONGER RUNNING WITHOUT SEAL REPLACEMENT COULD DAMAGE MOTOR. MOTOR MUST GO TO AUTHORIZED SERVICE STATION FOR SEAL REPLACEMENT. HEAT SENSOR All 4WHV and V4WHV single and three phase pumps have motor heat sensors that are externally wired to the control panel. Any motor temperature above the sensor rating will open the heat sensor and stop the motor. The sensor will automatically close upon cooling. It is important that the heat sensor wires and seal failure wires are connected at the panel terminal block. Warranty is void if wires are not connected or are jumped. CAUTION: The single phase 4WHV and V4WHV pumps with automatic heat sensor reset will restart without warning as the motor cools. Therefore, never do service work on the pump unless power supply is disconnected. WARNING: On three phase pumps only qualified persons shall conduct services and installation of this pump. The pump must be wired by a qualified electrician, using an approved starter box and switching device. MOTOR POWER CABLE AND CONTROL CABLE Each power cord has 4 conductors: white, black, red and green. For 3 phase, the red, black and white conductors connect to the 3 line terminals and the green is connected to a good outside ground such as a ground rod at least 8 feet into the soil. Interchanging any two of the three power conductors will reverse a 3 phase motor. For single phase the white and black leads connect to the two-line terminals and the red connects to the start winding terminal. The green is for ground and must be connected to a good outside ground. The control cable has 4 conductors: black, white, red, and green. White and black connect to heat sensor terminals, red connects to the seal failure terminal, and green connects to the ground terminal. CAUTION: Never pull pump or work on control box until incoming power is disconnected. Never run motor until green ground conductor is connected to a good outside ground. Never pull electrical cable to lift pump. Power cables attached to the pumps are no. 10 gauge wire. If the control panel is not located near the pump, consult wire gauge table for permissible wire gauge to run between the control panel and the junction box at the wet well. Wire gauge no. 10 may be used for all pump models located within 200 feet of the control panel. OIL FILLED MOTOR The motor chamber and seal chamber are dielectric oil-filled for good heat transfer and lubrication of bearings and seals. The motor requires no other lubrication. Oil level in the motor housing should be to the bottom of the oil fill plug with the pump in a vertical position. Do not overfill the motor housing since some space is required for oil expansion. Oil level in the seal chamber of the 4WHV and V4WHV should be checked with the pump lying horizontally with the fill plug at the top. The oil level should be approximately 3/4" from the outside surface of the housing. Transformer oil SOHIO Factopure SE40 should be used and may be purchased from your Myers dealer. AIR VENTING Upon initial filling of the wet well with the water, air may be trapped in the pump volute. To vent off this air, a 5/32 diameter hole is located in the volute. BE SURE THIS VENT HOLE IS CLEAN AFTER ANY SERVICE WORK ON PUMP. 23833A038 1210 2

4WHV & V4WHV PUMP DIMENSIONS 21 533.4 mm 8 9 /16 217.5 mm 7 1 /16 179.4 mm 7 1 /16 179.4 mm 2 17 /32 64.3 mm 12 3 /4 323.9 mm 5 11 /16 144.5 mm 5 11 /16 144.5 mm 6 3 /8 162 mm 10 1 /2 266.7 mm 6 3 /8 162 mm 10 1 /2 266.7 mm 25 7 /8 657 mm 4" STD. FLANGE 29 3 /8 746 mm 101.6 mm 4" DIA. 85.7 mm 3 3 /8 9" DIA. 228.6 mm 89 mm 11 1 /2 292 mm 3/8 9.5 mm 3 1 /2 4WHV (SERIES) V4WHV (SERIES) 3 23833A038 1210

PARTS LIST Ref. Description Qty. Part Number 1 CABLE, POWER, 8 GA. - 4 COND., SPEC. LENGTH As IN FEET Spec. 20014974900 2 CONNECTOR, CABLE, POWER, 8 GA. 1 18696A020 Use with these pumps only: 4WHV50M4-21, 4WHV75M403, 4WHV75M4-23, 4WHV100M4-03, 4WHV100M4-23, V4WHV50M4-21, V4WHV75M4-03, V4WHV75M4-23, V4WHV100M4-03, V4WHV100M4-23 Ref. Description Qty. Part Number 1 CABLE, POWER, 10 GA. 4 COND., SPEC. LENGTH As IN FEET Spec. 20014974600 - TERMINAL, GROUND 1 12074A010 2 CONNECTOR, CABLE, POWER, 10 GA. 1 18696A023 3 CAP, CORD 1 24405C000 4 CAP, SCREW, HEX HD., 3/8-16 x 1-1/4" 2 19101A017 5 MACHINE SCREW, RD. HD., #10-24 x 3/8" 6 05434A043 6 LOCKWASHER 1 06107A015 7 CONNECTOR, SCREW 3 15781A007 7A CONNECTOR, BUTT 3 12672A003 8 PLATE, UPPER SEALING 2 24321A000 9 CAP SCREW, HEX HD., SPECIAL, #10-24 UNC 2 24322A000 10 GASKET, TETRASEAL, 3-3/4" x 3-1/2" x 1/8" 1 05014A133 11 GROMMET, SEALING, POWER CORD 1 24323A001 12 PLATE, LOWER SEALING 2 24324A000 13 WIRE,, 10 GA. SOLID x 12" LG. 1 22500A121 14 WIRE,, 10 GA. SOLID x 12" LG. 1 22500A122 15 WIRE,, 10 GA. SOLID x 12" LG. 1 22500A123 16 PIPE PLUG, 1/4 NPT, HEX. HD. 2 05022A054 16A EMBLEM, OIL FILL 1 23395A000 17 WASHER, SPRING 2 19331A006 18 BEARING, BALL, UPPER 1 08565A022 19 HOUSING, MOTOR, ONLY 1 24406D000 22 BEARING, BALL, LOWER 1 08565A027 23 GASKET, TETRASEAL, 7" x 6-3/4" x 1/8" 1 05014A181 24 HOUSING, BEARING 1 24411D000 25 SEAL, 1-1/2" SHAFT 1 00920-001-1 26 RING, RETAINING 1 12558A018 27 HOUSING, LOWER SEAL 1 24412D000 28 KEY, 1/4" SQUARE 1 05818A066 29 CAP, SCREW, HEX HD., 1/2-13 x 1" 1 19103A052 30 SEALANT, LOCTITE GRADE 680 (SCREW, KEY & IMP. BORE) 1 14550A009 31 WASHER, RETAINING WITH PIN 1 23609A002 32 WASHER, BEARING LOCK 1 08001A008 33 CAP, SCREW, HEX HD., 7/16-14 x 1" 4 19102A006 34 GASKET, TETRASEAL, 7-1/2 x 7-1/4 x 1/8" 1 05014A176 35 GASKET, VELLUMOID 1 05231A079 36 CASE, VOLUTE 4WHV 1 22712D000* 36 CASE, VOLUTE V4WHV 1 22712E100* 37 IMPELLER, PUMP, SPECIFY O.D. 1 22711C500 38 CABLE, CONTROL, 16 GA.-4 COND. As SPEC. LENGTH IN FEET Spec. 20014974300 - TERMINAL, GROUND 1 12074A025 39 CONNECTOR, CABLE, GROUND 1 18696A004 40 CONNECTOR, SCREW 4 15781A005 41 WIRE,, 16 GA. SOLID x 12" LG. 1 22500A124 41A WIRE,, 16 GA. SOLID x 12" LG. 1 22500A125 42 GROMMET, SEALING, CONTROL CORD 1 24323A002 43 EYE, BOLT, 3/8-16 1 21929A002 44 DRIVE SCREW,.138 x 5/16" 2 05160A004 45 NAME PLATE, PUMP (NOT STAMPED) 1 24413A000 48 OIL, TRANSFORMER (1 GAL. CAN 11009A003K, 1.3 5 GAL. CAN 11009A004K) gal. As Noted 49 CAP, SCREW, HEX HD., 7/16-14 x 2" 4 19102A022 50 WIRE, YELLOW, 16 GA. SOLID x 20" LG. 1 22500A126 51 FERRULE, RUBBER 1 12619A001 52 PLUG, SPECIAL 1 21577A00 53 WIRE, ELECTRODE 1 21792A003 54 CONNECTOR, BUTT 3 12672A001 55 CAP, SCREW, SKT. HD., 3/8-16 x 1" 4 06106A028 56 BRASS WEAR RING FIELD REPAIR 1 22712D001A - LEG PKG. WITH 3 LEGS, LEG 625 (OPTIONAL) 1 23768A020 *Housing with stator includes ref. nos. 7A, 8, 9, 11, 12, 13, 14, 15, 19, 20, 41, 41A, 42, 50 and 54. Pump Cat. No. Shaft w/rotor Stator Only Housing w/stator 4WHV30M4-21 V4WHV30M4-21 24408C000 24407C200 24406D020K 4WHV30M4-03 V4WHV30M4-03 24408C000 24407C201 24406D025K 4WHV30M4-23 V4WHV30M4-23 24408C000 24407C202 24406D031K 4WHV30M4-43 V4WHV30M4-43 24408C000 24407C202 24406D035K 4WHV30M4-53 V4WHV30M4-53 24408C000 24407C203 24406D040K 4WHV50M4-21 V4WHV50M4-21 24408C000 24407C204 24406D045K 4WHV50M4-03 V4WHV50M4-03 24408C000 24407C205 24406D050K 4WHV50M4-23 V4WHV50M4-23 24408C000 24407C206 24406D055K 4WHV50M4-43 V4WHV50M4-43 24408C000 24407C206 24406D060K 4WHV50M4-53 V4WHV50M4-53 24408C000 24407C207 24406D065K 4WHV75M4-03 V4WHV75M4-03 24408C000 24407C208 24406D070K 4WHV75M4-23 V4WHV75M4-23 24408C000 24407C209 24406D075K 4WHV75M4-43 V4WHV75M4-43 24408C000 24407C209 24406D080K 4WHV75M4-53 V4WHV75M4-53 24408C000 24407C210 24406D085K 4WHV100M4-03 V4WHV100M4-03 24408C000 24407C208 24406D070K 4WHV100M4-23 V4WHV100M4-23 24408C000 24407C209 24406D075K 4WHV100M4-43 V4WHV100M4-43 24408C000 24407C209 24406D080K 4WHV100M4-53 V4WHV100M4-53 24408C000 24407C210 24406D085K 23833A038 1210 4

4WHV & V4WHV CROSS SECTION CABLE, POWER CONNECTOR, CABLE, POWER CAP, CORD, 4WHV SCREW, CAP (2 REQ D.) SCREW, MACH. (5 REQ D.) LOCKWASHER CONNECTOR, SCREW (3 REQ D.) PLATE, UPPER, SEALING 2 REQ D.) SCREW, SPECIAL (2 REQ D.) GASKET, TETRASEAL 10 GROMMET, SEALING, POWER CORD 11 PLATE, LOWER SEALING (2 REQ D.) 12 WIRE, 13 WIRE, 14 WIRE, 15 CONNECTOR, (3 REQ D.) 7A PLUG, PIPE (2 REQ D.) 16 EMBLEM, OIL FILL 16A WASHER, FINGER SPRING (2 REQ D.) 17 BEARING, BALL, UPPER HSG., MOTOR, 4WHV STATOR SHAFT WITH ROTOR BEARING, BALL, LWR GASKET, TETRASEAL HOUSING, BRG SEAL 1-1/2" SHAFT (2 REQ D.) (REMOVE SPRING HOLDER FROM LOWER SEAL) RING, RETAINING HOUSING, LOWER SEAL KEY SCREW, CAP SEALANT 15 WASHER, RETAINING, W/PIN 31 LOCKWASHER, BRG 32 SCREW, CAP (4 REQ D.) 33 GASKET, TETRASEAL 34 GASKET 35 AIR VENT 1 2 3 4 5 6 7 8 5 18 19 20 21 22 23 24 25 26 27 28 29 30 9 38 CABLE, CONTROL 38 CONNECTOR, CABLE, CONTROL 40 CONNECTOR, SCREW (6 REQ D.) 41 WIRE, 41A WIRE, 42 GROMMET, SEALING, CONTROL CORD 43 BOLT, EYE 44 SCREW, DRIVE (2 REQ D.) 45 46 47 PLATE, NAME (2 REQ D.) TAG, NAME PLATE WIRE, TAG 48 OIL TRANSFORMER 54 CONNECTOR, BUTT 49 SCREW, CAP (4 REQ D.) 50 WIRE, YELLOW 40 51 FERRULE, RUBBER 52 PLUG SPECIAL 53 WIRE ELECTRODE 54 CONNECTOR (3 REQ D.) 55 SCREW, MACHINE, SOCKET HD. (4 REQ D.) CASE, VOLUTE 4WHV IMPELLER 36 37 36 CASE, VOLUTE V4WHV FLATTEN 2 TABS LOCATED 180º FROM WASHER LOCKING PROJECTION, FLATTEN ONE ON EACH SIDE OF PIN. AFTER ASSEMBLY OF HEX HEAD CAP SCREW, BEND REMAINING TABS UP AGAINST HEX HEAD. 5 23833A038 1210

ELECTRICAL CONTROLS (All Models) FLOAT SWITCH INSTALLATION 1. Level Controls are held by support bracket and cords are adjusted for proper depth. a. Lower Turn-Off Control should be set so that pump stops when water level is about at the top of the volute. b. First Turn-On Control is set to start pump when level is at height specified above pump. c. Second Turn-On Control of a duplex pump system is set at height specified above first turnon control. d. Alarm Control is set about 6" to 12" above the highest Turn-On Control. e. No control should be set above basin inlet invert. MAKING ELECTRICAL CONNECTIONS 1. If control panel is mounted directly on basin top, the power and control wires are taken directly to control box and are sealed in the cord pallet with cord grip connectors. 2. If panel is installed remote from basin, the cords can be taken through a conduit to control panel, or junction box can be used in the basin to make connections. The Myers junction box has a built-in sealing connector to seal the outgoing wires. If other than Myers junction box is used, a separate sealing connector must be used where wires leave the basin. CAUTION: If cords are taken directly through a conduit to control box, a seal fitting must be used at inlet of conduit to prevent gas vapors from getting to control box. This type of installation is generally not recommended because the sealing cement must be broken to remove a cord. MOTOR ELECTRICAL CONNECTIONS Single phase motors are for 130 volts only. A special control panel with start and run capacitors and start relay are required for these pumps. These control panels must be obtained from Myers (or must be approved by Myers) or warranty on motor is void. Also, warranty is void if the heat sensor and seal fixture wires are not connected properly to control box terminal strip. CAUTION: Pump motor is not to be taken apart in the field. Motors under warranty must be serviced by Myers authorized repair station or be sent to factory. 23833A038 1210 6

4WHV & V4WHV WIRING DIAGRAMS Power Cord Control Cord Power Cord Control Cord 10 /4 16 /4 10 /4 16 /4 7 WHT. BLK. BLK. WHT. 40 7 WHT. BLK. BLK. WHT. 40 7A BLUE WHT. Motor Stator Ground Screw Grommets 54 230 V. - SINGLE PHASE PURPLE BROWN YELLOW Heat Sensor On Stator 40 54 7A T1 WHT. T2 T3 Motor Stator Ground Screw Grommets 54 200 OR 575 V. - THREE PHASE P1 P2 YELLOW Heat Sensor On Stator 40 54 Seal Leak Electrode Seal Leak Electrode Power Cord Control Cord Power Cord Control Cord 7 T9 T3 WHT. BLK. WHT. T8 T2 Motor Stator 10 /4 16 /4 T7 Ground Screw Grommets T1 T6 7B T5 T4 230 V. - THREE PHASE BLK. P1 WHT. P2 YELLOW Heat Sensor On Stator 54 40 40 Seal Leak Electrode 54 T1 7 WHT. T2 T3 WHT. BLK. Motor Stator 10 /4 16 /4 Ground Screw Grommets 7B 54 7 T9 T6 T5 T8 T7 T4 460 V. - THREE PHASE BLK. WHT. P1 P2 YELLOW Heat Sensor On Stator 40 40 Seal Leak Electrode 54 7 23833A038 1210

0 IN SUMP CONNECTION BOX, SIMPLEX SYSTEM, FLCW 3 BALL CONTROL PUMP CONTROL CORD PUMP POWER CORD SEALING COMPOUND DO NOT SEAL UNTIL UNIT HAS BEEN RUN * POWER CORDS MUST BE SIZED DEPENDING ON PUMP SIZE AND VOLTAGE AND DISTANCE FROM WET WELL SEE TABLE 2 CAN BE INDIVIDUAL WIRES INSTEAD OF CORD AS SHOWN 23833A038 1210 8

IN SUMP CONNECTION BOX, DUPLEX SYSTEM, FLCW 4 BALL CONTROL PUMP #1 POWER CORD PUMP #2 POWER CORD PUMP #1 CONTROL CORD PUMP #2 CONTROL CORD PRIMARY PUMP ON SWITCH PUMP #1 CONTROL CORD PUMP #1 POWER CORD PUMP #2 POWER CORD PUMP #2 CONTROL CORD SECONDARY PUMP ON SWITCH ALARM CORD 16-2 FLCW PRIMARY PUMP ON SWITCH 16-2 G REEN FLCW OVERRIDE SECONDARY PUMP ON SWITCH 16-2 FLCW PUMP OFF SWITCH 16-2 PUMP OFF SWITCH FLCW ALARM CORD 16-2 (OPTIONAL) SEALING COMPOUND DO NOT SEAL UNTIL UNIT HAS BEEN RUN 16-2 16-4 * 10-4 0 10-4 0 16-4 16-2 16-2 CAN BE INDIVIDUAL WIRES INSTEAD OF CORD AS SHOWN POWER LINES MUST BE SIZED DEPENDING ON PUMP SIZE AND VOLTAGE AND DISTANCE FROM WET WELL. SEE TABLE 2. 9 23833A038 1210

PUMP MODEL TABULATION Single and Three Phase Available Models Motor Electrical Data Standard (Also V4WHV models) HP Volts Phase Start Amps Run Amps Service Factor Amps Run kw Service Factor kw Start KVA Run KVA NEC Code Letter Service Factor 4WHV30M4-21 3 230 1 101 17.5 21 2.1 2.5 23.2 4.0 J 1.2 4WHV30M4-03 3 200 3 66.7 15 18 3.5 4.3 23.0 5.0 G 1.2 4WHV30M4-23 3 230 3 58 12 14.4 3.5 4.3 23.0 5.0 G 1.2 4WHV30M4-43 3 460 3 29 6 7.2 3.5 4.3 23.0 5.0 G 1.2 4WHV30M4-53 3 575 3 21.3 5 6 3.5 4.3 23.0 5.0 G 1.2 4WHV50M4-21 5 230 1 141 34 41 6.3 7.7 32.4 7.8 H 1.2 4WHV50M4-03 5 200 3 111 21.6 26 5.6 6.9 38.4 7.2 H 1.2 4WHV50M4-23 5 230 3 96 18 21.6 5.6 6.9 38.4 7.2 H 1.2 4WHV50M4-43 5 460 3 48 9 10.8 5.6 6.9 38.4 7.2 H 1.2 4WHV50M4-53 5 575 3 39 7.2 8.6 5.6 6.9 38.4 7.2 H 1.2 4WHV75M4-03 7.5 200 3 172 32.2 37 8.0 9.9 59.5 11.1 J 1.2 4WHV75M4-23 7.5 230 3 150 28 32 8.0 9.9 59.7 11.1 J 1.2 4WHV75M4-43 7.5 460 3 74.8 14 16 8.0 9.9 59.7 11.1 J 1.2 4WHV75M4-53 7.5 575 3 67.2 11.2 13 8.0 9.9 66.8 11.1 K 1.2 4WHV100M4-03 10 200 3 172 37 37 10.1 10.1 59.5 12.8 G 1.0 4WHV100M4-23 10 230 3 150 32 32 10.1 10.1 59.7 12.8 G 1.0 4WHV100M4-43 10 460 3 74.8 16 16 10.1 10.1 59.7 12.8 G 1.0 4WHV100M4-53 10 575 3 67.2 13 13 10.1 10.1 66.8 12.8 H 1.0 ELECTRICAL COMPONENTS - Single Phase Only Model Number HP Start Cap, Number Run Cap, Number Start Relay, Number 12141A8 23839A 4WHV30M4-21 21990A4 (43 Amp) 3 220 VAC 370 Volt V4WHV30M4-21 PU, VL 290-310 DO, VL 95 430-516 MFD 30 MFD 4WHV50M4-21 V4WHV50M4-21 5 12141A6 220 VAC 270-324 MFD 23186A (2 in Parallel) 410-440 Volt 25 MFDS 21990A5 (23 Amp) PU, VL 220-240 DO, VL 80 23833A038 1210 10

CABLE SIZE REQUI DEPENDING ON MOTOR HORSEPOWER VOLTAGE AND DISTANCE OF CONTROL PANEL FROM PUMP MAX. OFFSET DISTANCE (FEET) PER WIRE GA. Motor HP Phase Voltage 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 1 1 230 292 465 740 1175 1870 1-1/2 1 230 245 385 615 980 1560 2 1 230 205 330 520 830 1320 3 1 230 153 245 385 615 980 5 1 230 92 145 230 370 590 1 3 200 315 500 790 1260 2000 1 3 230 430 685 1090 1730 2750 1 3 460 1720 2740 4360 1 3 575 2690 4280 1-1/2 3 200 260 410 655 1040 1655 1-1/2 3 230 345 545 870 1380 2195 1-1/2 3 460 1375 2185 3475 1-1/2 3 575 2160 3435 2 3 200 200 315 500 800 1275 2 3 230 260 420 665 1055 1680 2 3 460 1050 1670 2660 2 3 575 1635 2600 3 3 200 150 240 380 605 960 3 3 230 205 330 520 830 1320 3 3 460 825 1310 2085 3315 3 3 575 1285 2050 3260 5 3 200 110 170 270 430 690 5 3 230 150 235 375 600 950 5 3 460 595 947 1505 2395 3805 5 3 575 930 1480 2355 3740 7-1/2 3 200 80 125 200 320 510 7-1/2 3 230 110 175 280 450 715 7-1/2 3 460 450 710 1130 1795 2855 7-1/2 3 575 700 1110 1765 2805 10 3 200 65 105 170 270 430 10 3 230 90 140 225 360 575 10 3 460 360 560 900 1440 2300 10 3 575 560 875 1400 2250 3600 11 23833A038 1210

REMOVING PUMP CASE AND IMPELLER In case of wear, damage due to dropping, plugged pump, or replacing a defective motor, the pump volute case and impeller can be removed in the field. 1. Remove bolts between seal housing flange and volute case. The motor and impeller can now be lifted off as a unit. 2. If necessary to remove impeller, lay pump on its side. With a screwdriver bend the tabs of the lockwasher away from the hex head bolt. 3. Loosen and remove the bolt by turning counterclockwise. Since Loctite is used to secure the bolt and is applied to the shaft/impeller interface, heating of the shaft end to 450º F will usually be required. 4. Impeller is mounted by a straight fit with driving key. Pry evenly on opposite impeller sides with two large screwdrivers or small bars behind the impeller. 5. Set motor on end with shaft up after removing impeller so that oil will not drain past the seal. REPLACING IMPELLER AND PUMP CASE 1. Apply Loctite #680; before assembly, in keyway, in the impeller bore (lower shaft O.D.), and on the threads of the hex head cap screw. 2. Before placing the impeller on the shaft, be sure the mechanical seal and its spring are in place. 3. Position retaining washer with long pin extension in keyway. 4. Obtain a new lockwasher and flatten two tabs located 180º from the locking projection on the inner edge of the washer. There should be one flatten tab on each side of the pin extending from the retaining washer. 5. Assemble hex head cap screw and tighten securely. 6. Bend lockwasher tabs up against hex head on the bolt; do not bend up the two tabs flattened on each side of the pin in the retaining washer. SEAL SPRING IMPELLER HUB 1 2 WASHER LOCK PROJECTION 3 4 4WHV & V4WHV (1) KEY 05818A066 ( 1 /4 x 1 /4 x 13 /16) (2) RETAINING 23609A002 WASHER W/PIN ( 17 /32 x 1 5 /8 O.D. x 1 /4 THK.) (2) LOCKWASHER 08001A008 BEARING (W-02) (1) CAP SCREW 19103A052 HEX HEAD ( 1 /2-13 x 1 1 /4 LG.) FLATTEN 2 TABS LOCATED 180º FROM WASHER LOCKING PROJECTION (FLATTEN ONE ON EACH SIDE OF PIN). AFTER ASSEMBLY OF HEX HEAD CAP SCREW, BEND REMAINING TABS AGAINST HEX HEAD. CAP SCREW TORQUE VALUE 3/8-16 20 ft.-lbs. 1/2-13 43 ft.-lbs. 5/8-11 93 ft-lbs. 3/4-10 128 ft.-lbs. 23833A038 1210 12

TROUBLE CHECK LIST Troubles listed generally pertain to the pump and auxiliary components.. Other trouble can occur from a faulty control box. These will be listed with the control box instructions. CONDITION Pump runs but does not pump liquid from basin. PROBABLE CAUSE 1. Pump impeller may be air locked; this occasionally occurs on a new installation. Start and stop pump several times to purge air. Be sure air vent hold in volute case is clean. 2. Run additional water into basin so that pump will be submerged deeper to clear air. 3. If pump is three phase, rotation may be wrong. See instructions for checking proper rotation. 4. If pump has been installed for some time and does not pump, it may be clogged at inlet. 5. Discharge gate valve may be closed. 6. Discharge check valve may be clogged or have a broken clapper or spring. 7. Discharge head may be too high. Check elevation. Maximum pump head at zero flow is shown on pump curve sheet. 8. If above checks do not locate trouble, motor rotor may be loose on shaft which allows motor to run but will not turn impeller or only at low RPM. Red light comes on at control box. This indicates some water has leaked past the lower seal and has entered the seal chamber and made contact with the electrode probe. Pump must be removed from basin within approximately two (2) weeks for replacement of lower seal. This preventive repair will save an expensive motor. Overload trips at control box and alarm buzzer or flashing red light comes on due to high water level in basin. 1. Push red reset button to reset overload. If overload trips again after short run, pump has some damage and must be removed from basin for checking. 2. Trouble may be from clogged impeller causing motor to overload or could be from failed motor. 3. Trouble may be from faulty component in control box. Always check control box before removing pump. Yellow run light stays on continuously. 1. Indicates H-O-A switch may be in the Hand position. 2. Level control switch may have failed causing pump to continue to operate when water is below lower control. 3. Impeller may be partially clogged causing pump to operate at much reduced capacity. 4. Gate valve or check valve may be clogged causing low pump flow. 5. Pump may be air logged. Lift arm on check valve to vent off air. Also, check that the 5/32" vent hole in volute is open. 13 23833A038 1210

TROUBLE CHECK LIST (Cont d) CONDITION Circuit breaker trips PROBABLE CAUSE 1. Reset breaker by pushing clear down on handle then back to On position. If breaker trips again in few seconds, it indicates excessive load probably caused by a short in the motor or control box. Check out instructions given with control box before pulling pump. 2. If this condition happens after an electrical storm, motor or control box may be damaged by lightning. 3. Resistance reading of the motor with lead wires disconnected from the control box can determine if trouble is in motor or control box. Pump is noisy and pump rate is low 1. Impeller may be partially clogged with some foreign objects causing noise and overload on the motor. 2. Impeller may be rubbing on wear ring due to bent shaft or misalignment. 3. Pump may be operating too close to shut-off. Check head. Grease and solids have accumulated around pump and will not pump out of basin. 1. Lower control which may be set too high. 2. Run pump on manual operation for several minutes with small amount of water running into basin to clean out solids and grease. This allows pump to break suction and surge, breaking up the solids. If level switch is set properly, this condition generally will not occur. 3. Trash and grease may have accumulated around floats causing pump to operate erratically. 23833A038 1210 14

INSTALLING RAIL SYSTEM PARTS (Horizontal Models Only) MOUNTING COVER, DISCHARGE BASE & RAILS 1. Set concrete cover with hatch opening in position. If basin cover is steel or aluminum, secure the cover to basin walls with expansion bolts. 2. Bolt rail guide plates to frame. Stainless steel bolts are screwed through the frame angles when shipped and nuts are provided to hold the plate. Brackets have vertical slots so that they can be adjusted for final fit on rails. The plate has slots so the two plates in a duplex system can be adjusted to obtain 16" center-to-center distance between pumps. 3. Lower the base or base/elbow assembly into the basin. IMPORTANT Concrete bottom must be level and smooth for mounting discharge base. 4. Position the base so that the pipe rail locating pins protruding from the top of the base are directly below the rail guides attached at the top of the basin. The rail guides should be positioned about midway in the vertical adjustment slots. Cut the pipe guide rails to the proper length and install them between the rail guides at the top of the basin and the pins on the base. Guide rails are 3/4" Schedule 40, galvanized or stainless steel or fiberglass reinforced plastic pipe. 5. Using a bubble level held against the rails, move the base until both rails are vertical. Now mark the position of the base, hold-down bolts, through the holes in the base. 6. Remove the guide rails and move the base aside to allow drilling of the concrete for 5/8" expansion bolts 2-1/2" long. Then move the base over the bolt holes and reinstall the guide rails. Recheck rails with bubble level and install the bolts. 7. Install discharge pipe as required by the particular job specifications. If one size larger discharge pipe is required, such as 6" pipe on a 4" pump, a reducing elbow may be attached to the base. 8. If the top rail guide plate cannot be attached to the hatch cover frame, a special rail bracket can be furnished for mounting directly to a pipe cemented in the basin wall. This bracket is set and aligned with discharge base the same as described for the rail guide plate attached to the frame. ATTACHING MOUNTING PLATE TO PUMP 1. With a gasket between the mounting plate and pump discharge, attach the mounting plate with the bolts supplied. The mounting plate should be turned so that two pins are horizontal and one pin vertical pointing up. LOWERING PUMP TO DISCHARGE BASE 1. Attach lifting chains to eye bolts on top of the pump with the clevis furnished. 2. A hook is located on the top guide rail bracket to hold the upper end of the chain when not in use. 3. Check pump rotation if 3 phase. Connect power cords to motor control panel and lay pump on its side so that impeller can be seen. Turn all switches to off position. 4. Close main circuit breaker, then jog manual switch to ON then OFF. Note rotation direction of impeller. Impeller must turn counterclockwise when looking into the impeller s inlet. If rotation is wrong, interchange any two line leads to the motor. BE SURE MAIN BREAKER IS OFF WHEN THIS CHANGE IS MADE. MARK WIRES SO THEY CAN BE REPLACED IN SAME ORDER. 5. Mount the guide plate on the vertical pin of the mounting plate. Position the guide openings parallel with the face of the mounting plate. Snug the two set screws but do not overtighten at this time. 6. Slowly lower the pump down the guide rails to the base. Inspect the mating of the mounting plate face to the base face; they should be flat against one another. If necessary, loosen the two set screws of the guide plate and rotate the guide plate until an equal amount of clearance exists between the guide plate and the guide rails. Retighten the set screws. If no adjustment was necessary, check that the set screws are tight. 7. The pumps are now properly positioned for operation. 15 23833A038 1210

TOP RAIL GUIDE PLATE FOR 4" LIFT-OUT SYSTEM 3/8 1 PLATE, MOUNTING 3 7 2 WASHER 4 REQ D. 15/32 x 1 x 1/16 3 SCREW, CAP 4 REQ D. 7/16-14 x 1 4 SUPPORT 2 REQ D. 5 HOOK FOR LIFT CHAIN 111/2 16" TO CENTERLINE OF SECOND GUIDE PLATE IN DUPLEX PUMP SYSTEM 6 NUT 5/16-18 HOLES IN SUPPORT ARE SLOTTED FOR VERTICAL ADJUSTMENT 3 /4 SCH. 40 PIPE PIPE MOUNTED GUIDE RAIL BRACKET DIA. 115/16 35/8 75/8 SCREW, SET 7/16-14 UNC x 5/8 2 REQ D. 16" TO CENTERLINE OF SECOND BRACKET IN DUPLEX PUMP SYSTEM HOOK FOR LIFT CHAIN 7 3 /4 SCH. 40 PIPE 23833A038 1210 16

TYPICAL INSTALLATION 22 7 /16" 12 11 /16" COVER FRAME CHAIN AND CLEVIS NOT SHOWN RAIL GUIDE SUPPORT PLATE BOLTS TO HATCH COVER FRAME GUIDE RAILS (BY OTHERS) DISCHARGE PIPE (BY OTHERS) POST PINS PLATE, GUIDE GASKET GASKET SCREW CAP 16 REQ D. FOR 4" 6 1 /2 PLATE MOUNTING BASE BOTTOM OF BASIN MUST HAVE SMOOTH LEVEL TROWLED SURFACE 17 23833A038 1210

INSTALLATION DIMENSIONS FOR 4WHV PUMPS, LIFT-OUT SYSTEM, HATCH AND COVER B 2 USE 3 /4 x 2 1 /2 EXPANSION BOLTS 3 1 /2 7 A 4 E 11 1 /2 7 5 1 /4 A H A B C G 11 1 /2 7 A C B 5 3 /4 SIMPLEX & DUPLEX BASE & DISCHARGE D F 5/8 x 1 (6) SLOTS USE 1 /2 x 2 1 /2 EXPANSION BOLTS SURFACE BELOW FRAME MUST BE SMOOTH AND NOT PROTRUDE INTO FRAME OPENING. HATCH ASSEMBLY TO BE CEMENTED IN PLACE WHEN BASIN TOP IS POU. ANCHORS AND PLATE MTG. BOLT HEADS ARE CEMENTED INTO TOP. INSTALLATION DIMENSIONS Pump Disch. Basin Cover/Hatch A B C D E F G H 4WHV Duplex 4" 60" HCD-60-4WHV, HCR-60-4HWV, 13 7 7 /8 7 5 /16 28 46 11 23 66 HA-60-4WHV, HS-60-4WHV 23833A038 1210 18

TYPICAL INSTALLATION FOR DUPLEX SYSTEM WITH CONCRETE BASIN AND OUTSIDE VALVE BOX FLCW MOUNTING BRACKET SERVICE POLE OPTION FLASHING ALARM LIGHT WEATHERPROOF CONTROL BOX CORD SEAL CONNECTIONS FOR POWER AND CONTROL CORDS (NOT SHOWN) HINGED ACCESS DOOR ALUM. OR STEEL OPT. JUNCTION BOX MUST BE USED IF CONTROL BOX IS OFFSET FROM BASIN TOP RAIL SUPPORT OUTSIDE VALVE BOX GATE VALVE INLET AS REQ D LIFTING CHAIN CHECK VALVE BELOW FROST LINE DISCHARGE PIPING 3/4" GUIDE RAILS MUST BE PLUMB DISCH. AND RAIL SUPPORT CASTING 19 23833A038 1210

NOTES 23833A038 1210 20

NOTES 21 23833A038 1210

START-UP REPORT Distributor: Order No.: Installing Contractor: Phone: Sales Contact: Phone: Customer: Location: cut along dotted line 1. SYSTEM INFORMATION Size of Wet Well: Manufacturer: Discharge from Bottom of Basin: Discharge Location: Inlet from Bottom of Basin: Inlet Location: Type of Check Valves: Type of Piping: Does System Have Suction Gauges? Yes No Suction Pressure Reading: Does System Have Discharge Gauges? Yes No Discharge Pressure Reading: Liquid Being Pumped: Temperature (F ): Pct. of Solid (%): Is a Sketch or Photograph of System Available? Yes No If So, Please Attach. Any Additional Comments on System: 2. ELECTRICAL INFORMATION Control Panel Part Number: Panel Rated Amps: Manufacturer: Voltage: Phase: Heater Size: Location of Panel to Wet Well: Incoming Line Voltage: Actual? Voltage to Pumps: Actual? Type of Junction Box: Manufacturer of Junction Box: Are Floats Installed in Wet Well? Yes No Are Floats Set to Engineer s Specs? Yes No Are Floats Wired for Proper Sequencing? Yes No Are Heat Sensors Hooked Up? Yes No Is the Seal Leak Detection Hooked Up? Yes No Any Additional Comments on Electrical: 3. PUMP INFORMATION Type of Pump: Serial Number of Pump: Voltage of Pump: Phase: RPM: Amps: Impeller Size: C.O.S. TDH: GPM: Voltage Supplied from Panel: Actual? Actual Amperage (All Phases): Phase 1 Amps: Phase 2 Amps: Phase 3 Amps: Define the Rotation of the Pump: Clockwise Counterclockwise Method Used to Check Rotation: Viewed from the Top Viewed from the Bottom Any Additional Comments on Pumps: 4. ACKNOWLEDGE Acknowledge that all information is accurate and proper procedures have been followed. Customer: Date: Start-up Technician: Date: Send to Warranty Manager, 1101 Myers Parkway, Ashland, OH 44805 or Fax to 419-207-3344 or email to startupreport@femyers.com or submit online at http://forms.pentairliterature.com/startupform/startupform.asp?type=m