Smith & Loveless will celebrate its 60th birthday in 2006.

We have sold countless pump stations during this time, in fact, more than 21,000! This does not even include our grit removal, wastewater or water treatment equipment, which are additional bench marks within the industry. With this kind of track record, tens of thousands of customers work on Smith & Loveless equipment each day. While traveling across the country and around the world, we encounter many operators and engineers that inquire about our vacuum primed pump stations. We have many 20+ year old vacuum primed pump station installations still working fine. And then there are others that are in need of a simple tune-up to carry them another 20+ years. In this book, well step you through a vacuum primed pump station tune-up. Youll want to check out our new Sonic Start prime sensing system, new larger ported solenoid valve, improved wafer check valves and now our new E-Force improved efficiency Smith & Loveless Pumps and ISeries Immersible Pumps. For truly robust and long-life pumping equipment, Smith & Loveless just makes cents.

Unlike submersibles, the Smith & Loveless Wet Well Mounted Pump Station product line is above grade, out of the highly corrosive wet well. This adds up to big cost savings for both the short and long haul. Bringing all pumps, motors, valves and piping above grade requires less maintenance equipment. In fact, for routine maintenance you dont need a boom truck, 3 men and a safety harness . . . because on a Wet Well Mounted Pump Station . . . for routine maintenance confined space issues simply dont come into play. Additionally, because the Wet Well Mounted Pump Station is above grade and out of the highly corrosive wet well environment, it doesnt have the problems submersible pumps have with wastewater getting into the motor or problems with having to perform regular oil changes. But hold on, Wet Well Mounted Pump Stations do need some maintenance too. While it is not uncommon to put several thousand into a submersible pump for a simple seal or cord grommet failure, $2,000 will serve as a full tune-up for your Wet Well Mounted Pump Station and for $3,000 it will include updating to the latest in prime sensing technology. Lets explain how. In this booklet, youll learn how to completely overhaul a Wet Well Mounted Pump Station. We are also going to offer 2 stages of performance upgrades. Our goal in this publication is to achieve the standard upgrade for under $2,000 per pump station - seen in Sections 1 through 5.

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We also want to allow you to reach our most advanced technology upgrade for under $3,000. This includes the standard upgrade (Sections 1-5) - plus the advanced upgrade (Section 6). These upgrades are a small price to pay for many years of unparalleled reliability and reduced manpower hours. So lets get started. This is a general how to procedure. Please consult your pump stations O&M manual for exact service and maintenance procedures. Dont have your O&M manual? Give us a call and well custom make you a new one. Call (800) 922-9048, Option 5. One word before we get started. If your sewage pump primes and the seal does not leak, you just saved an hour to hour and a half per pump. Simply stated, if it aint broke, dont fix it. But take advantage of our kit pricing for savings on a seal that you may need down the road. Also, you can get this complete book bound and in color for your technical library for $25. Add to that another $50 and we will send you an Operation & Maintenance Manual on your specific custom equipment . . . if you dont have a copy. In this booklet, we will not cover how to replace the mechanical seal because we now have the new Replacing a Single Mechanical Seal Video that is so comprehensive we feel it would be foolish to try to duplicate it in print. Before starting any of these procedures, make sure the wet well is pumped down. And only do one pump at a time, both mechanically and electrically. Also if you are changing seals, test the seal before going on to the electrical modifications. Most importantly, lock out and tag out the power at the disconnect. Smith & Loveless always recommends contacting your safety coordinator before performing station modifications or repairs to ensure you are using the most current safety standards. First, lets review your primary way of diagnosing how well your pump station is performing, with the Compound Vacuum Gauge.

(or less)

Standard Upgrade & Tune-Up Sections: 1. Vacuum Pumps 2. Float Check Valve 3. Solenoid Valve 4. Electrode Priming System 5. Single Mechanical Seal

(or less)

Advanced Technology Upgrade Under $3,000 Overhaul Sections 1 through 5 and: 6. Sonic Start Prime Sensing System

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Troubleshooting Pumps the Simple Way

Place a compound vacuum gauge in the gauge port of the solenoid valve (seen above). You can monitor the vacuum priming system of your pump station with a simple glance. Depending upon the reading, youll instantly know whether: the vacuum priming system is operating correctly the wastewater pump is operating correctly The compound vacuum gauge is the most valuable diagnostic tool you can have for your pump station. It also diagnoses leaks and blockages both on the vacuum and wastewater pump side. See page 14 for gauge sizing.

Step 3:
system:

Evaluating your

A perfect vacuum system is 30 Hg (Inches of Mercury). A good vacuum pump draws at least 24-26 HG direct with the valve closed. To test your vacuum pump with the compound vacuum gauge, install the gauge. Now momentarily close the shut off valve no. 1. The gauge should read at least 24-26 Hg. If it does, the vacuum pump is good. If it doesnt, you will need to rebuild or replace the

vacuum pump before going to the next step. See page 6 for vacuum pumps and repair parts.

Step 4: Test this example:

You have a pump that is designed to pump 100 gpm @ 30 TDH.

Step

Know the components of your vacuum priming system seen on the chart of this page above. Now take your stations TDH (Total Dynamic Head) from the Motor Adapter and divide by 2.31.

1:

Step 5: Remember these

constants: Example: 30 TDH/2.31 = 12.98 or 13 PSI for simplicity.

Step 2:

To Order, call

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Step 6:

Establishing Constants for your pump station. For this example, we will say this pump primes at 15 Hg. Your station may vary based on sea level. If you have a working pump, check it to get the constant.

Step 9: For this example,

we will say normal pump operation is at 13 PSI.

Step 11:

For this pump, any reading greater than 13 PSI means there is a blocked discharge pipe.

Normal pump operation is 13 PSI

Pump primes at 15 Hg

For this pump, any reading less than 13 PSI means there is suction blockage or a collapsed force main.

Step 10:

Greater than 13 PSI reading means blocked discharge pipe.

Step 7: For this pump, any

reading less than 15 Hg means there is a leak in the vacuum system. Check the fittings and mechanical seal.

Less than 13 PSI reading means suction pipe blockage or collapsed force main.

S&Ls Customer Service Team recommends you install one gauge on each pump in your Recessed, Classic or FORMULA X Wet Well Mounted Pump Station. At a minimum, you need one per pump station to establish the constants of each pump. Then when problems occur, you can quickly know where to look for problems. See page 14 for compound vacuum gauges.

Less than 15 Hg reading means vacuum leak.

Step 8:

Any reading greater than 15 Hg means there is a plug or blockage in the vacuum system. Check for plugged suction on the vacuum line.

Greater than 15 Hg reading means a vacuum line plug.

Establish the constants for your pump. In this diagram, we assume the pump primes at 15 Hg and has a normal operating condition of 13 PSI.

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1. Reviewing Vacuum Pumps

First, lets look at the vacuum pump. As we stated in the previous section, a good vacuum pump will pull 24-26 HG (Inches of Mercury) direct with the shut off valve closed (note: only shut off the valve for 10 seconds or less). This was demonstrated on pages 4 and 5. If the vacuum pump motor is bad, a new vacuum pump will be required. If the vacuum pump is electrically sound, a reed kit will likely solve your problem and bring you back to 24-26 HG and save you time and money. Tools Required: Allen Wrench In some cases a socket and wrench set are required.

Step 1. Pump down the wet

well.

Step 4: Remove the head.

Observe the reed plate positioning. Carefully watch the orientation of the reeds. Careful removal and layout of the reeds will make the procedure a snap.

Step 7: Remove the lower

reed plate and lay this out as well. (again, keep everything oriented correctly.)

DANGER: Disconnect and lock out power before servicing equipment. Failure to do so could result in serious bodily injury or death.
Disconnect and lock out power.

Step 2:

Step 5: Remove the upper

reed plate.

Step 8:

Step 3:

Match mark the allen screws for easy reassembly later. Remove the four (4) Allen screws per head.

Step 6: Remove the reed

spacer. Remember to lay this out in the correct orientation.

Inspect the reed pedal to insure that it is flush with the reed plate (both upper and lower). Whether these reeds are bent, broken or cracked, they are the vital part of the priming system. Therefore, it is an ideal time to replace them while you have it apart.

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lower reeds and spacer are correctly oriented. Be extremely careful to reassemble the reeds and spacer in the correct position.

Step 9: Replace old reeds

with new reeds. It is important to make sure that the upper,

Step 10: Install the head

and verify with a gauge you now have 24-26 Hg, preferably 26 Hg.

Vacuum Pumps
8L29 Top End Single Piston Model 8L44 Standard Single Piston Model 8L32 Rugged Dual Piston Model

Shown above, the 8L29, is the Top End Smith & Loveless Vacuum Pump for 4 piping. The 8L44 is the standard S&L Vacuum Pump for 4 piping. For pump stations with 6 piping, the rugged 8L32 S&L Vacuum Pump is the way to go for dependability.

Vacuum Pump Single & Dual Piston PART # PIPING TYPE SIZE 8L29 8L44 8L32 4 4 6 Top End, Single Piston Standard, Single Piston Rugged, Dual Piston

8L29, 8L44 & 8L32 Repair Parts

8L44-36

8L44-45 8L44-15 8L29A1 8L29AB 9L25-13 8L44-27 8L32-1

Smith & Loveless carries a repair kit for the 8L29 & 8L32 Vacuum Pumps and a large array of repair parts for the 8L44 that can be ordered depending upon what the operator requires. See below for part numbers and part descriptions. 8L29 Single Piston Top End Rebuild Vacuum Pump Repair Kit PART # DESCRIPTION 8L29AB Repair Kit 8L29A1 Inlet Filter

8L44 Single Piston Vacuum Pump Repair Parts PART # DESCRIPTION 8L44-15 O-Ring 8L44-27 O-Ring Gasket 9L25-13 Inlet & Exhaust Valve Flapper 8L44-36 Screw for the Flapper Valve 8L44-45 Muffler Assembly 8L32 Dual Piston Vacuum Pump Repair Kit PART # DESCRIPTION 8L32-1 Repair Kit

To Order, call

1-800-922-9048

2. Reviewing the Float Check Valve

The Float Check Valve Assembly P/N: 1L443H is the next component in the vacuum priming system to review. Shown here is what to review.
1L443H

Tools Required: Paper Towels

Step 6: Visually inspect the Step 4: Visually inspect the

float check ball. Replace if there are cracks, dents, etc. brass check valve. If worn, replace it. Dirt can be cleared; however, S&Ls customer service team recommends replacing it. P/N: 1L333.

Step 1. Pump down the wet

well.

DANGER: Disconnect and lock out power before servicing equipment. Failure to do so could result in serious bodily injury or death.
Disconnect and lock out power.

Step 5: Visually inspect the

bowl for cracks. If cracks are found, replace the bowl.

Step 7: Reinstall the Float

Check Valve Assembly.
1L333

Step 2:

1L443HD 1L443B

1L443HA 1L443HB 1L443HC

1L443H Spare Parts

Smith & Loveless carries a full line of spare parts for the 1L443H Float Check Valve, put into use in 1996. Parts are also available to previous versions - call for availability.
1L443H Float Check Valve Spare Parts (See photos at right) PART # DESCRIPTION 1L443HD Body 1L443HA Ball Seat 1L443B 1-1/2 Diameter Float Ball 1L443HB O-Ring 1L443HC Bowl Assembly 1L333 Check Valve (Install with arrow pointing down)

Step 3: Visually inspect the

float check assembly for dirt or water. Now is a good time to verify the Float Check Valve P/N: 1L443H is in good shape on the bottom of the bowl.

To Order, call

1-800-922-9048

3. Reviewing the Solenoid Valve

The classic 3-way solenoid valve P/N: 1L406E is still supported at Smith & Loveless through the parts department. On all new pump stations, weve upgraded to a 2-way solenoid P/N: 1L545A or 1L545B valve with a 5/16 orifice. The new 2-way solenoid is one of the key components that has helped reduce routine maintenance of the vacuum priming system and decreases priming time by up to 40%. In the event does become clogged, pages 10 and 11 illustrate how easy it is to clean and no special tools are required. Simply put, this revision saves time and money.

Is it time to upgrade solenoid valves? Compare for yourself.

3/32 Orifice
P/N: 1L406E Old Style 3-Way Solenoid Valve

5/16 Orifice
P/N: H87A343A Conversion Kit Includes 2-way solenoid valve, mounting hardware, gauge port, shut off valve piping assembly. New Style 2-Way Solenoid Valve. Individually ordered there are two part numbers depending upon style of installation: P/N: 1L545A or 1L545B.

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Cleaning the 2-Way Solenoid Valve

Unlike the old style 3-Way Solenoid Valve P/N: 1L406E, the new 2-way Solenoid Valve not only has a larger ported orifice, it also does not require a special wrench in order to take it apart and clean the valve. Tools Required: Crescent Wrench Pipe Cleaners Paper Towels Small Screw Driver
This is done as illustrated above. Pry the locking tab up with the small screw driver and slide it over.

Step 4.

Step 1. Pump down the wet

well. D A N G E R : Disconnect and lock out power before servicing equipment. Failure to do so could result in serious bodily injury or death.

Remove the tension washer.

Step 7.

Step 8. Step 5. Remove the locking

tab. NOTE: Always support the float check valve assembly to prevent stress cracking.

Step 2. Disconnect and lock out power.

Remove the solenoid stem. Place one hand on wrench and other on the solenoid body to avoid damage to the float check assembly.

Inspect the stem and the poppet assembly.

Step 9.

Step 3.

Remove the locking tab with a small screw driver.

Remove the coil. The coil is removed as seen in the photo above.

Step 6.

Step 10.
O-Ring.

Check the

10

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Step 11.

Use the pipe cleaner to clean any trash from the base of the orifice.

Step 14.

Tighten the assembly. Remember to support the valve body as mentioned previously.

Step 17. Install the locking

tab.

Step 12.
O-Ring.

Re-install the

Step 15. Install the tension

washer.

Step 18. Lock the locking

tab in place.

Step 19. Remove the lock

out, tag out and reconnect the power to start the equipment back up.

Step 13. Install the stem

and poppet assembly.

Step 16. Install the coil. Remember:

(see 5/16 orifice photo below)

In is piped to the
sewage pump.

Out is piped to
the vacuum pump.

To Order, call

1-800-922-9048

11

4. Reviewing the Electrode Priming System

Most of Smith & Loveless above grade pump station installations around the globe utilize the Electrode to sense prime. That is what well review next. Since the summer of 2005, Smith & Loveless has been offering the state-of-the-art Sonic Start Prime Sensing System that uses a patented frequency differential prime sensing system to sense prime. It virtually eliminates routine maintenance. In this section, well review the Electrode prime sensing system.

The Electrode and Vacuum Dome Evolution

Over the years, the Smith & Loveless Electrode and Vacuum Dome have changed. Depending upon which style of Electrode and Vacuum dome you currently have installed will vary which replacement parts you require. The newest Sonic Start Vacuum Dome Assembly is shown below, far right.

Original 2-hole Vacuum Dome with aluminum electrode. Only the Aluminum Electrode P/N: 87A72 is still available as a spare part.

1-hole Vacuum Dome with hollow stainless steel electrode. All parts are still available.

1-hole Vacuum Dome with solid stainless steel electrode. All parts are still available.

1-hole Vacuum Dome with no electrode. Smith & Loveless new stateof-the-art prime sensing technology.

Tools Required:
Rags Sand Paper Wire Brush 1/2" Socket and Ratchet or Wrench

D A N G E R : Disconnect and lock out power before servicing equipment. Failure to do so could result in serious bodily injury or death. Disconnect and lock out power.

Step 1. Pump down the wet

well.

Step 2.

Step 3.
electrode wire.

Remove the

12

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Step 7.

Remove the electrode housing.

Step 10.

Reinstall the compression plate.

Step 4.

Remove the vacuum tubing.

Step 11.
Use a ratchet or wrench to remove the compression plate nuts. If you do not have this type of electrode housing and have the two holed electrode dome, contact your Smith & Loveless representative for information on how to upgrade.

Step 5.

Clean the electrode. Sand paper or a wire brush may be helpful. If you are planning to install the state-of-the-art Sonic Start Prime Sensing System, refer to page 18 for electrode housing modifications.

Step

8.

Tighten the compression plate nuts.

Step 9. Reinstall the clean

electrode housing and electrode. Apply a light coating of non-hardening silicone on the o-ring to assist in reinstalling the electrode housing.

Step 12.

Step 6.

Remove the compression plate.

Check the condition of the vacuum tubing. A great preventative maintenance item is to replace the vacuum tubing if showing signs of wear. Reconnect the vacuum tubing and the electrode wire.

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13

Compound Vacuum Gauge

Smith & Loveless Compound Vacuum Gauge reads both vacuum and/or pressure and comes in heavy-duty glycerin filled and standard models. Used as a diagnostic tool for Wet Well Mounted Pump Stations, it easily mounts in the gauge port next to the solenoid valve in the vacuum priming system. Check to see if you have at least one per pump station that meets its flow conditions. Includes: (1) compound vacuum gauge.

Compound Vacuum Gauge Standard & Heavy-Duty

1L275C

PART # STANDARD
1L275C 1L275D 1L275E

PART # GLYCERIN-FILLED
1L275CB 1L275DB 1L275EB

SIZE
Handles Up To 50 TDH (0-30 HG: 0-30 PSI) Handles 51 to 110 TDH (0-30 HG: 0-60 PSI) Handles 111 to 200 TDH (0-30 HG: 0-100 PSI)

Solid S.S. Electrode Dome Assembly

6L51CF 5L52D Wire Ring Lug 6L60E 1L248G Fitting 3/8 Tubing 1/8 NPT 1L451A adapter with o-ring comes affixed to dome 87A31

6L20CE 6L71F 87A72

11L47D

The new solid stainless steel electrode dome assembly features quick disconnect fittings and solid electrode all designed to make maintenance easier. You can purchase it pre-assembled or as individual parts. This new assembly comes standard in all Vacuum Priming Retrofit Kits.
SOLID ALUMINUM ELECTRODE & DOME PARTS PART # DESCRIPTION 87B15 Electrode Cover: Obsolete 6L61F 5/16 Flat Washer 87A72 Aluminum Electrode 6L20CE 5/1618 x 1-1/2 Capscrew 6L51CF 1/420 X 2 Stud 6L60E 1/420 Hex Nut 87A31 Electrode Gasket 11L47D or 87A7 Quad Ring. Use 11L47D unless dome surface is flat, then use 87A7.

14

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1L142BB Cut off top of boot. (This will allow both the vacuum tube and the electrode wire to fit thru the boot) 5L68B

1L190D

Hollow Electrode, Dome & Hardware Parts

Many pump stations still utilize the old style Hollow Electrode and Dome Parts. Even though this is no longer available as a preassembled part, Smith & Loveless still supports all of these parts. Just determine which parts you need and place your order.
HOLLOW ELECTRODE & DOME PARTS PART # DESCRIPTION 1L190D Male Elbow Connector 1L142BB Tubing 5L68B Insulator Boot 1L481C Bulkhead Union 5L52G Electrode Ring Terminal 11L4J Small O-Ring 87B133 Electrode Dome 6L200DH S.S. Stud HOLLOW ELECTRODE & DOME PARTS PART # DESCRIPTION 6L30K S.S. Nut 6L65F S.S. Washer 87A226 Retainer Ring 87A225 Retrofit Adapter Ring 11L4K Large O-Ring 87A229A Hollow Electrode (Long) 87A229B Hollow Electrode (Short) 11L47D Quad Ring

1L481C 11L4J 87B133

Wiring and tubing from existing electrode assembly. 5L52G

6L200DH 6L30K 6L65F 87A226 11L4K 87A225

Motor Adapter

11L47D 87A229A

(1L248A Optional Ferrule Fitting)

Solid S.S. Electrode, Dome & Parts

The new solid stainless steel electrode dome assembly features quick disconnect fittings and solid electrode all designed to make maintenance easier. You can purchase it pre-assembled or as individual parts. This new assembly comes standard in all Vacuum Priming Retrofit Kits.
SOLID S.S. ELECTRODE & DOME PARTS PART # DESCRIPTION 1L460D Quick Disconnect Male Fitting 1L248A Ferrule Connection Fitting (Optional) 1L552A Reducer Coupling 6L222A Jam Nut 5L75C Male Insulated Tab SOLID S.S. ELECTRODE & DOME PARTS PART # DESCRIPTION 5L52G Electrode Ring Terminal 11L4J Small O-Ring 11L4K Large O-Ring 87A285 5-1/4 Long Solid S.S. Electrode 87A285A 6 Long Solid S.S. Electrode

Solid S.S. Electrode Dome Assembly

The new solid stainless steel electrode dome assembly comes fully assembled and ready to plug and play. It features a new solid stainless steel electrode which eliminates having to scrape the inside of the electrode. The assembly also comes in two sizes - the 5-1/4 long electrode 87B309 and the 6 long electrode 87B309A for those who have installed the dome conversion kit. All brass fittings are now located outside of the dome. It comes with quick disconnect fittings, however, if you prefer the ferrule fitting, you can order P/N 1L248A and do a quick field change.
Includes: (1) Electrode Dome Assembly. Optional Ferrule Connection Fitting. SOLID S.S. PART # 87B309 87B309A 1L248A ELECTRODE DOME ASSEMBLY DESCRIPTION 5-1/4 Solid Stainless Steel Electrode Dome Assembly 6 Solid Stainless Steel Electrode Dome Assembly Ferrule Connection Fitting (Optional)
1L248A

87B309 or 87B309A

To Order, call

1-800-922-9048

15

5. Reviewing the Single Mechanical Seal

The Smith & Loveless single mechanical seal was designed for an extended life span. Certain things can shorten this life-span, such as debris in the wet well, touching the face of the seal upon installation of the seal and more. Smith & Loveless new Replacing a Smith & Loveless Single Mechanical Seal video P/N: 12L318DVD-1 or 12L318VHS-1 goes through the signs of a defective mechanical seal, troubleshooting the cause of seal failure, and step-by-step instructions on how to replace the seal.

12L318VHS-1

12L318DVD-1

The new Replacing a Smith & Loveless Single Mechanical Seal video is so comprehensive we feel it would be foolish to try and duplicate it in print. Each Smith & Loveless mechanical seal kit comes with written instructions on how to replace the mechanical seal. However, the most comprehensive set of instructions, including Smith & Loveless Customer Service Tech Tips, comes in the Replacing a Smith & Loveless Single Mechanical Seal video. You can also add to your video order this book, bound and in color, for just $25 per book. It makes a great one for your technical library or new employee training program. And if you have misplaced your O&M manual on your existing Smith & Loveless equipment, give us your equipment serial number and we can provide you with a duplicate copy of your customized Smith & Loveless equipments O&M manual for $75 per manual.

16

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Single Mechanical Seal Replacement Parts Kit

Single Mechanical Seal Replacement Parts Kit Includes: (1) carbon, (1) ceramic, (1) spring, (1) instruction booklet on how to install.

Specifically designed by Smith & Loveless for the Smith & Loveless pump is the Single Mechanical Seal. Designed to last more than 7 years, it has been proven to have one of the longest life-cycles of any mechanical seal in the industry. Dont be caught without a spare seal. Order one today!
PARTS TIP: It is recommended to replace the Seal Housing Gasket or Quad Ring (see below) and the Volute Gasket whenever a rotating assembly is removed.

PART # H87A28 H87A97 H87A182

SHAFT SIZE B-Shaft: 1-7/8 C-Shaft: 2-1/8 D-Shaft: 3

Seal Housing Gasket & Quad Ring

Seal Housing Gasket Quad Ring

Embedded Nylock

Impeller Bolts
S&Ls Impeller Bolts feature embedded Nylock. Each time you remove the impeller, replace the Impeller Bolt. Remember to torque impeller bolts to 150 ft/lbs. Here are the part numbers for the Impeller Bolt. PART # 60A12 60A12 60A86 SHAFT SIZE B-Shaft: 1-7/8 C-Shaft: 2-1/8 D-Shaft: 3

Each time the mechanical seal is replaced, S&L recommends the Seal Housing Gasket or Quad Ring also be replaced. PARTS TIP: The older Seal Housing has a flat surface and uses the flat Gasket. The newer Seal Housing has a groove and it can use either the flat Gasket or the Quad Ring. GASKET PART # 60A11 60A17 60A84 QUAD RING PART # 60A110 60A111 60A112 SHAFT SIZE B-Shaft:1-7/8 C-Shaft: 2-1/8 D-Shaft: 3

Volute Gaskets
Each time the rotating assembly is taken apart, install a new volute gasket to increase the life span of your pump. Vacuum Priming Pump Volute Gaskets. PART # PUMP SIZE 60A26 4B2B, 4B2C, 4B2D, 4C2B, 4C2D, 4B2X, 4C2X 60A28 4B3B, 4C3B, 4D3B, 6B3B, 6C3B, 6D3B Vacuum Priming Pump Volute Gaskets. PART # PUMP SIZE 60A88 8C4D, 8D4D 60A106B 4D4B

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17

6. Upgrading to the Sonic Start Prime Sensing System

BEFORE YOU START!
See below to determine whether you have a Figure A or Figure B dome. If you have a Figure A dome, you must purchase the dome conversion kit S&L P/N: H87A329 before starting to install this kit.

Figure A

Figure B

H87A391A (1 Pump Kit) Also verify that your pump station has been modified H87A391B (2 Pumps Kit) electrically from the original O&M electrical schematic. If you need an electrical drawing, please specify when you order the Sonic Start Retrofit Kit. There will be a $10.00 additional charge for the replacement wiring diagram of the original control panel. Make sure you have the pumps flow conditions monitored during this procedure to prevent overflow. Depending upon the flow conditions of the pump station, it may be necessary to pump the wet well down to the off level float. Some pump stations may require a Vac Truck on site during this installation. Only work on one pump at a time, in case the wet well needs to be pumped down. Close the plug valve for the pump that is going to be worked on.

CAUTION: Use proper personal safety equipment when installing this kit. Eye protection, nonskid safety shoes, hard-hat, hearing protection and gloves must be used for the appropriate condition. Failure to do so could result in bodily injury.

Tools Required: Phillips Screwdriver Standard Screwdriver Adjustable Wrench or Set of Open End Wrenches Socket Wrench and Extension, 3/8 drive Socket 3/4 socket Wire, 16 gauge, red, THHN Wire cutters Wire strippers Wire nuts Teflon tape

Plumbers Grease, Petroleum Jelly or non pumice hand soap Drill and Tap Kit (S&L part number H87A390A) or Tools to Tap a NPT Hole Drill drive 11/16 Drill Bit or Knockout (to put an 11/16 hole in the control panel) Hammer Punch Torque Wrench Knife

18

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TECH TIP: Before starting, make sure the vacuum pump and solenoid are in good working order. Each vacuum pump must be able to pull 26 HG (inches of mercury). This kit prevents electrode fouling, not vacuum problems with the vacuum pump or solenoid valve, Smith & Loveless Customer Service Team highly recommends converting from the 3/32 orifice 3-way solenoid to the larger ported 5/16 orifice 2-way solenoid valve H87A343A for the best results. If you havent purchased the conversion yet, put it on your list for coming purchases.

Step 1. Pump down the wet

well. D A N G E R : Disconnect and lock out power before servicing equipment. Failure to do so could result in serious bodily injury or death.

is no longer used and can be removed. Additionally, the existing bulk head fittings can also be removed as a new arrangement has been supplied in this kit. Remove the existing electrode dome assembly from the motor adapter. The dome, o-ring, and mounting hardware will be reused.

Step 5. Depending on your

station/pump, you may be able to drill and tap the hole for the SONIC START Prime Sensor Probe with the pump in place. Otherwise you will have to pull the rotating assembly to get proper access to the motor adapter for the drilling and tapping process. See the O&M instructions that come with the Sonic Start Prime Sensing Kit for step-bystep instructions on how to pull the rotating assembly. If you choose not to drill & tap, you can purchase a pre-tapped motor adapter from the factory.

Step 2.
Grounding Wire Connector

Disconnect and lock out power.

Bulk Head Fitting Assembly

Step 4. Look at your station

or pump. Decide which side of your motor adapter the SONIC START Prime Sensor Probe must be installed. The SONIC START Prime Sensor Probe will stick out from the side of the motor adapter. TECH TIP: If the SONIC START Prime Sensor Probe is to be installed in a pump station, make sure there is room for the hood to close if the SONIC START Prime Sensor Probe were sticking out towards the hood. Check other wall and equipment for clearance. It may be necessary to rotate the motor adapter to create enough clearance for the SONIC START Prime Sensor Probe to be located between the motor adapter and hood/ wall/or other piece of equipment.

Dome

Step 6.

Electrode

Mark the location for the SONIC START Sensor on the motor adapter. Use a hammer and punch to make a mark at the proper location.
Motor Adapter

Mounting Hardware O-Ring

Photo 2

Photo 1

Step 7. Drill a pilot hole at

the punch mark with the 3/16 drill bit (see Photo 2). Make sure the hole is as straight as possible to make it easier when tapping. Then drill the hole out with the drill bit, and then finish drilling the 19 hole with the 45/64 drill bit.

Step 3.

Disconnect the electrode grounding wire from the existing electrode dome assembly. The grounding wire

To Order, call

1-800-922-9048

Photo 3 Thread the hole with the NPT tap as in Photo 3. NOTE: Do not tap the threads too deep, otherwise it will not seal and will create a vacuum leak.

Step 8.

Place the Sonic Start Fitting Ring onto the end of the Sonic Start Prime Sensing Probe as seen in Photos 5 & 6. There is only one way it can be installed, with the more square side closest to the prongs. Additionally, it is cut on the inside to match the end of the Sonic Start Prime Sensing Probe, which was two 90 degree corners and two rounded corners. Make sure it fits snugly against the Sonic Start Prime Sensing Probe.

Photo 9

Step 12. Tighten the screw

on the DIN connector cable to secure it in place on the SONIC START Prime Sensor Probe, see photo 9.

Photo 10
Photo 4 Put the Teflon tape on the SONIC START Prime Sensor Probe threads. Make sure the Teflon tape covers the threads as shown in Photo 4. Thread the SONIC START Prime Sensor Probe into the tapped hole.

Step 13.
Photo 7

Step 9.

Step 10. Tighten the SONIC START Prime Sensor Probe (Photo 7).

Run the DIN connector cable back to the control panel. Run the cable along the motor conduit and fasten it to the motor conduit with cable ties, as shown in photo 10.

Step 14.

Photo 8
Sonic Start Fitting Ring

Use the cord grip nut to hold the cord grip in place. Run the DIN connector cable through the cord grip or existing panel hole and tighten the cord grip to secure the DIN connector cable.

Photo 5

Photo 6

Install the DIN connector cable onto the SONIC START Prime Sensor Probe. Line the larger pin on the SONIC START Prime Sensor Probe with the larger slot on the DIN connector cable as shown in photo 8.

Step 11.

D A N G E R : Disconnect and lock out power before performing any electrical work. Failure to do so could result in electrical shock, serious bodily injury or death.

20

To Order, call

1-800-922-9048

WARNING: All electrical work should be performed by a qualified electrician and per all applicable codes. Failure to do so may result in severe bodily injury or death.

Relay 2 Relay 1

Relay 3

Relay 4

Step 15.

The four electrode relays that have been used over the years in the Smith & Loveless Control Panel are shown on this page. Please see your Sonic Start Prime Sensing Retrofit Kit O&M for complete step-bystep wiring instructions for each individual relay shown above.

Photo 11

Step 16.

Verify the pump station wiring in the control panel is per the Smith & Loveless OEM wiring diagram supplied with the original Pump Station. If you do not have a wiring diagram, please consult the Smith & Loveless Customer Service

Departments for a complete wiring diagram at (800) 922-9048, Option 7.

Step 17. Smith & Loveless

Sonic Start Prime Sensing Kits come with complete step-bystep wiring diagrams for all four Electrode Relays above. See illustration 1, to see how

simple the minor wiring changes are to install the Sonic Start. Most electrical wiring changes will take less than 60 minutes per control panel provided the control panel has not been modified by an unqualified technician. Illustration 1 shows the general layout.

General Wiring Arrangement ONLY

DANGER: See the specific Sonic Start Prime Sensing System Retrofit Kit O&M Manual for Detailed Step-By-Step Wiring Instructions per electrode relay noted above. Failure to do so could result in electrical shock, serious bodily injury or death.
To Motor Starter To Vacuum Pump Contactor Not Used FORMULA X ONLY To DI-1 & 2 on PROTRONIX Red From DIN Connector 120 VAC Power
To Vacuum Contactor/Pump Starter

FORMULA X ONLY Neutral 120 VAC Power

- Red of DIN Connector to Pin 2 - Black of DIN Connector to Neutral - White of Din Connector to Ground Order locally from your

Illustration 1

Smith & Loveless Representative

21

Sonic Start Priming System

eliminates electrodes & electrode cleaning
The Sonic Start Priming System is state-of-the-art prime sensing technology. Using frequency differential, the Sonic Start Prime Sensing System dramatically changes the way Smith & Loveless Vacuum Primed Pumps sense prime. Even with grease buildup on the Sonic Start probe, it still continues to accurately monitor the frequency and detect frequency changes. Additionally, the Sonic Start does not require routine cleaning like the electrodes. For Smith & Loveless state-of-the-art prime sensing system, order Sonic Start Kit H87A391A or H87A391B seen below. All of the kits and individual components on these two pages represent the latest in Sonic Start Priming System technology. We believe so strongly in the Sonic Start Priming System Retrofit Kit that it comes with a 60-Day Money Back Guarantee and a 5-year prorated warranty. Youre going to love it!

Photo 12 Step 18. Photo 12 shows a fully installed Sonic Start System.

Complete Sonic Start System Kits

Recommended Kits

Component Parts

RETROFIT KIT

Sonic Start Prime Sensing System 1-Pump Retrofit Kit H87A391A

Sonic Start Prime Sensing System 2-Pump Retrofit Kit H87A391B

Sonic Start Drill & Tap Kit

5/16 Diameter Orifice 2-Way Solenoid Valve Retrofit Kit H87A343A

Sonic Start Dome Assembly

PART NUMBER
Sonic Start Prime Sensing Probe Sonic Start Operating Module Sonic Start Dome Fittings Sonic Start Dome Assembly Cable & Cable Ties Drill & Tap Kit 2-Way Solenoid Valve Vacuum Tubing, Fittings & Hardware Vapor Filter(s)

H87A390A

87B452

Order locally from your

22

Smith & Loveless Representative

Additional New Parts Products To Consider

Hood Lift Assist Kit & Continuous Hinge

If your hinges are starting to tear loose or have already torn loose from the lip of the fiberglass hood, you can now fix it without having to buy an entirely new hood. The new Continuous Hinge/Backing Bar Retrofit Kit (seen above) installs right over the old holes dramatically extending the life of your hood.

Add the Hood Lift Assist Kit and dramatically reduce the effort required to open and close the Classic Wet Well Mounted Pump Station hood.

Pump Flow Sensor

The Pump Flow Sensor is a cost effective way to keep you advised. This Kit Includes Everything For
A 2-Pump Station

H87A376

No matter what angle your check valve is, the Smith & Loveless Pump Flow Sensor bolts on and adjusts to that angle. It senses even the smallest check valve arm deflections, preventing many false pump failure alarms.

To Order, call

1-800-922-9048

23

Parts Look-Up
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Need a part number? Go online and look up the part number by downloading or opening the Adobe Acrobat parts catalog for your type of equipment. Currently we have the Wet Well Mounted Pump Station, FORMULA X Wet Well Mounted Pump Station, Recessed Wet Well Mounted Pump Station and Underground Pump Station Parts lookup Catalogs loaded online.

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After Market Division Smith & Loveless, Inc. 14040 Santa Fe Trail Drive Lenexa, KS 66215-1284, USA