smith loveless

7/27/2019 Smith Loveless

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Order locally from yourSmith & Loveless Representative2

Smith & Loveless will celebrateits 60th birthday in 2006. Wehave sold countless pumpstations during this time, infact, more than 21,000! Thisdoes not even include our gritremoval, wastewater or watertreatment equipment, whichare additional bench marks

within the industry.

With this kind of track record,tens of thousands ofcustomers work on Smith &Loveless equipment each day.While traveling across thecountry and around the world,we encounter many operatorsand engineers that inquireabout our vacuum primedpump stations. We have many

20+ year old vacuum primedpump station installations stillworking fine. And then thereare others that are in need ofa simple tune-up to carry themanother 20+ years. In thisbook, well step you through avacuum primed pump stationtune-up.

Youll want to check out ournew Sonic Start primesensing system, new largerported solenoid valve,improved wafer check valvesand now our new E-Forceimproved efficiency Smith &Loveless Pumps and I-Series Immersible Pumps.For truly robust and long-lifepumping equipment, Smith &Loveless just makes cents.

Unlike submersibles, the Smith & Loveless Wet Well Mounted PumpStation 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 requiresless maintenance equipment. In fact, for routine maintenance you dontneed a boom truck, 3 men and a safety harness . . . because on a WetWell Mounted Pump Station . . . for routine maintenance confined spaceissues simply dont come into play.

Additionally, because the Wet Well Mounted Pump Station is abovegrade and out of the highly corrosive wet well environment, it doesnthave the problems submersible pumps have with wastewater gettinginto the motor or problems with having to perform regular oil changes.

But hold on, Wet Well Mounted Pump Stations do need somemaintenance too. While it is not uncommon to put several thousandinto 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 PumpStation 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 WellMounted Pump Station. We are also going to offer 2 stages ofperformance upgrades. Our goal in this publication is to achieve thestandard upgrade for under $2,000 per pump station - seen in Sections1 through 5.


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3To Order, call 1-800-922-9048

We also want to allow you to reach our mostadvanced technology upgrade for under $3,000.This includes the standard upgrade (Sections1-5) - plus the advanced upgrade (Section 6).These upgrades are a small price to pay for manyyears of unparalleled reliability and reducedmanpower hours.

So lets get started. This is a general how toprocedure. Please consult your pump stationsO&M manual for exact service and maintenanceprocedures. Dont have your O&M manual? Giveus a call and well custom make you a new one.Call (800) 922-9048, Option 5.

One word before we get started. If your sewagepump primes and the seal does not leak, you

just saved an hour to hour and a half perpump. Simply stated, if it aint broke, dont fix it.But take advantage of our kit pricing for savingson a seal that you may need down the road.

Also, you can get this complete book bound andin color for your technical library for $25. Add tothat another $50 and we will send you anOperation & Maintenance Manual on yourspecific custom equipment . . . if you dont havea copy. In this booklet, we will not cover how toreplace the mechanical seal because we nowhave the new Replacing a Single Mechanical

Seal Videothat is so comprehensive we feel itwould be foolish to try to duplicate it in print.

Before starting any of these procedures, makesure the wet well is pumped down. And only doone pump at a time, both mechanically andelectrically. Also if you are changing seals, testthe seal before going on to the electricalmodifications. Most importantly, lock out and tagout the power at the disconnect. Smith &Loveless always recommends contacting yoursafety coordinator before performing station

modifications or repairs to ensure you are usingthe most current safety standards.

First, lets review your primary way of diagnosinghow well your pump station is performing, withthe Compound Vacuum Gauge.

Advanced Technology Upgrade

Under $3,000 Overhaul

Sections 1 through 5 and:

6. Sonic Start PrimeSensing System

(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)


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Place a compound vacuumgauge in the gauge port ofthe solenoid valve (seen

above). You can monitor thevacuum priming system ofyour pump station with asimple glance. Dependingupon the reading, youllinstantly know whether:

the vacuum primingsystem is operatingcorrectly

the wastewater pump is

operating correctlyThe compound vacuumgauge is the most valuablediagnostic tool you can havefor your pump station. It alsodiagnoses leaks andblockages both on thevacuum and wastewaterpump side. See page 14 forgauge sizing.

Step 1: Know thecomponents of your vacuumpriming system seen on the

chart of this page above.

Step 2: Now take yourstations TDH (Total DynamicHead) from the Motor Adapter

and divide by 2.31.

Step 3: Evaluating yoursystem:

A perfect vacuum system is 30Hg (Inches of Mercury). A goodvacuum pump draws at least24-26 HG direct with the valve

closed.To test your vacuum pump withthe compound vacuum gauge,install the gauge. Nowmomentarily close the shut offvalve no. 1. The gauge shouldread at least 24-26 Hg. If itdoes, the vacuum pump isgood. If it doesnt, you will needto rebuild or replace the

vacuum pump before going tothe next step. See page 6 forvacuum pumps and repairparts.

Step 4:Test this example:

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

Step 5: Remember theseconstants:

Example:

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

TroubleshootingPumps the Simple

Way

To Order, call 1-800-922-90484


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Pump primes at 15 Hg

Step 6: EstablishingConstants for your pumpstation.

For this example, we will saythis pump primes at 15 Hg.Your station may vary based

on sea level. If you have aworking pump, check it to get

the constant.

Step 7:For this pump, anyreading less than 15 Hg meansthere is a leak in the vacuumsystem. Check the fittings and

mechanical seal.

Step 8: Any read inggreater than 15 Hg meansthere is a plug or blockage inthe vacuum system. Check forplugged suction on thevacuum line.

Step 9:For this example,we will say normal pump

operation is at 13 PSI.

Step 11: For this pump,any reading greater than13 PSI means there is ablocked discharge pipe.

Less than 15 Hg reading

means vacuum leak.

Greater than 15 Hg reading

means a vacuum line plug.

Step 10: For this pump,any reading less than 13 PSImeans there is suctionblockage or a collapsed force

main.

Normal pump operation is 13 PSI

Greater than 13 PSI reading means

blocked discharge pipe.

S&Ls Customer Service Teamrecommends you install onegauge on each pump in your

Recessed, Classic orFORMULA X Wet WellMounted Pump Station. At aminimum, you need one perpump station to establish theconstants of each pump. Thenwhen problems occur, you canquickly know where to look forproblems. See page 14 forcompound vacuum gauges.Less than 13 PSI reading means

suction pipe blockage or collapsed

force main.

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.

5Order locally from yourSmith & Loveless Representative


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1. ReviewingVacuum 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 shutoff the valve for 10 seconds or less). This was demonstrated on pages 4 and 5. If the vacuumpump motor is bad, a new vacuum pump will be required. If the vacuum pump is electricallysound, a reed kit will likely solve your problem and bring you back to 24-26 HG and save you timeand money.

Step 3: Match mark theallen screws for easyreassembly later. Remove thefour (4) Allen screws per head.

Step 4:Remove the head.Observe the reed platepositioning. Carefully watchthe orientation of the reeds.Careful removal and layout ofthe reeds will make the

procedure a snap.

Step 5:Remove the upperreed plate.

Step 6:Remove the reedspacer. Remember to lay thisout in the correct orientation.

Step 7:Remove the lowerreed plate and lay this out aswell. (again, keep everythingoriented correctly.)

Step 8: Inspect the reedpedal to insure that it is flushwith the reed plate (both upper

and lower). Whether thesereeds are bent, broken orcracked, they are the vital partof the priming system.Therefore, it is an ideal time toreplace them while you have itapart.

Tools Required:

Allen Wrench In some cases a socketand wrench set arerequired.

DANGER:

Disconnect and

lock out powerbefore servicing

equipment. Failure to do

so could result in serious

bodily injury or death.

Step 2: Disconnect andlock out power.

Step 1. Pump down the wetwell.



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Step 9:Replace old reedswith new reeds. It is importantto make sure that the upper,

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 Pumps8L29

Top End SinglePiston Model

8L44

Standard SinglePiston Model

8L32Rugged Dual Piston Model

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

Vacuum Pump Single & Dual Piston

PART # PIPING TYPE

SIZE

8L29 4 Top End, Single Piston8L44 4 Standard, Single Piston

8L32 6 Rugged, Dual Piston

lower reeds and spacer arecorrectly oriented. Beextremely careful toreassemble the reeds andspacer in the correct position.

Step 10: Install the headand verify with a gauge younow have 24-26 Hg, preferably26 Hg.

8L44 Single Piston Vacuum Pump Repair PartsPART # 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

8L32-1

8L44-15

8L44-279L25-13

8L44-36

8L44-45

8L29AB

8L29A1

8L29, 8L44 & 8L32 Repair Parts

7To Order, call 1-800-922-9048


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2. Reviewing theFloat Check Valve

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

Tools Required:

Paper Towels

DANGER:

Disconnect and

lock out power

before servicing

equipment. Failure to do

so could result in serious


Step 3:Visually inspect thefloat check assembly for dirt orwater. Now is a good time toverify the Float Check ValveP/N: 1L443H is in good shapeon the bottom of the bowl.

Step 4:Visually inspect thefloat check ball. Replace ifthere are cracks, dents, etc.

Step 5:Visually inspect thebowl for cracks. If cracks arefound, replace the bowl.

1L443HC

1L443H

1L443H Spare PartsSmith & 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)

1L443HD 1L443HA

1L443B

1L333

1L443HB

Step 6:Visually inspect thebrass check valve. If worn,replace it. Dirt can be cleared;however, S&Ls customerservice team recommendsreplacing it. P/N: 1L333.

Step 7:Reinstall the Float

Check Valve Assembly.

Step 2: Disconnect andlock out power.


To Order, call 1-800-922-90488
http://localhost/var/www/apps/conversion/tmp/scratch_4/%7BDBF%20Phone%7Dhttp://localhost/var/www/apps/conversion/tmp/scratch_4/%7BDBF%20Phone%7D


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3. Reviewing the SolenoidValve

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

The classic 3-way solenoid valve P/N: 1L406E is still supported at Smith & Loveless through theparts department. On all new pump stations, weve upgraded to a 2-way solenoid P/N: 1L545A or1L545B valve with a 5/16 orifice. The new 2-way solenoid is one of the key components that hashelped reduce routine maintenance of the vacuum priming system and decreases priming timeby up to 40%. In the event does become clogged, pages 10 and 11 illustrate how easy it is toclean and no special tools are required. Simply put, this revision saves time and money.

3/32 OrificeP/N: 1L406E

Old Style 3-WaySolenoid Valve

5/16 OrificeP/N: H87A343A Conversion KitIncludes 2-way solenoid valve,mounting hardware, gauge port,shut off valve piping assembly.New Style 2-Way Solenoid Valve.

Individually ordered there are twopart numbers depending upon styleof installation: P/N: 1L545A or1L545B.



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Step 4. This is done asillustrated above. Pry thelocking tab up with the smallscrew driver and slide it over.

Step 5. Remove the lockingtab.

NOTE: Always support the

float check valve assembly to

prevent stress cracking.

Step 6. Remove the coil.The coil is removed as seen inthe photo above.

Step 7. Remove thetension washer.

Step 8. Remove thesolenoid stem. Place one hand

on wrench and other on thesolenoid body to avoiddamage to the float checkassembly.

Step 9. Inspect the stemand the poppet assembly.

Step 10. Check theO-Ring.

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.

Step 2. Disconnect andlock out power.

Step 3. Remove thelocking tab with a small screwdriver.

Cleaning the 2-WaySolenoid ValveUnlike the old style 3-Way Solenoid Valve P/N: 1L406E, the new 2-way Solenoid Valve not onlyhas a larger ported orifice, it also does not require a special wrench in order to take it apart andclean the valve.

Tools Required:

Crescent Wrench

Pipe Cleaners

Paper Towels

Small Screw Driver




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Step 11. Use the pipecleaner to clean any trash fromthe base of the orifice.

Step 12. Re-install the

O-Ring.

Step 13. Install the stem

and poppet assembly.

Step 14.Tighten the

assembly. Remember tosupport the valve body asmentioned previously.

Step 15. Install the tensionwasher.

Step 16.Install the coil.

Step 17.Install the lockingtab.

Step 18.Lock the lockingtab in place.

Step 19.Remove the lockout, tag out and reconnect thepower to start the equipmentback up.

Remember:(see 5/16 orifice photo below)

In is piped to the

sewage pump.

Out is piped to

the vacuum pump.

11To Order, call 1-800-922-9048


12/24

4. Reviewing the ElectrodePriming System

Most of Smith & Loveless above grade pump station installations around the globe utilize theElectrode 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 apatented frequency differential prime sensing system to sense prime. It virtually eliminates routinemaintenance. In this section, well review the Electrode prime sensing system.

The Electrode and Vacuum Dome Evolution

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 solid stainless steel

electrode. All parts are

still available.

Over the years, the Smith & Loveless Electrode and Vacuum Dome have changed.Depending upon which style of Electrode and Vacuum dome you currently have installedwill vary which replacement parts you require. The newest Sonic Start Vacuum Dome

Assembly is shown below, far right.

1-hole Vacuum

Dome with no

electrode. Smith &

Loveless new state-

of-the-art prime

sensing technology.

1-hole Vacuum Dome with

hollow stainless steel

electrode. All parts are still

available.

D A N G E R :

Disconnect and

lock out power

before servicing



injury or death.


Tools Required:

Rags

Sand Paper

Wire Brush

1/2" Socket and

Ratchet or Wrench


Step 3. Remove theelectrode wire.

To Order, call 1-800-922-904812


13/24

Step 4. Remove thevacuum tubing.

Step 5. Use a ratchet orwrench to remove thecompression plate nuts. If youdo not have this type of

electrode housing and havethe two holed electrode dome,contact your Smith & Lovelessrepresentative for informationon how to upgrade.

Step 6. Remove thecompression plate.

Step 7. Remove theelectrode housing.

Step 8. Clean theelectrode. Sand paper or awire brush may be helpful. Ifyou are planning to install the

state-of-the-art Sonic StartPrime Sensing System, referto page 18 for electrodehousing modifications.

Step 9. Reinstall the cleanelectrode housing andelectrode. Apply a light coatingof non-hardening silicone onthe o-ring to assist inreinstalling the electrodehousing.

Step 10. Reinstall thecompression plate.

Step 11. Tighten thecompression plate nuts.

Step 12. Check thecondition of the vacuumtubing. A great preventativemaintenance item is to replacethe vacuum tubing if showingsigns of wear. Reconnect thevacuum tubing and theelectrode wire.



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Compound Vacuum Gauge

1L275C

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.

Solid S.S. Electrode Dome Assembly

The new solid stainless steel electrode dome assemblyfeatures quick disconnect fittings and solid electrode alldesigned to make maintenance easier. You can purchase itpre-assembled or as individual parts. This new assemblycomes standard in all Vacuum Priming Retrofit Kits.

1L451A adapter

with o-ring comes

affixed to dome

6L51CF

5L52D

Wire Ring Lug

6L60E

87A31

6L20CE

6L71F

87A72

11L47D

1L248G Fitting 3/8

Tubing 1/8 NPT

Smith & Loveless Compound Vacuum Gauge readsboth vacuum and/or pressure and comes in heavy-dutyglycerin filled and standard models. Used as a diagnostictool for Wet Well Mounted Pump Stations, it easilymounts in the gauge port next to the solenoid valve in thevacuum priming system. Check to see if you have at leastone per pump station that meets its flow conditions.

Includes: (1) compound vacuum gauge.

PART # PART # SIZE

STANDARD GLYCERIN-FILLED

1L275C 1L275CB Handles Up To 50 TDH (0-30 HG: 0-30 PSI)

1L275D 1L275DB Handles 51 to 110 TDH (0-30 HG: 0-60 PSI)

1L275E 1L275EB Handles 111 to 200 TDH (0-30 HG: 0-100 PSI)

Compound Vacuum Gauge Standard & Heavy-Duty



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(1L248A OptionalFerrule Fitting)

Solid S.S. Electrode, Dome & PartsThe new solid stainless steel electrode dome assembly features quickdisconnect fittings and solid electrode all designed to make maintenanceeasier. You can purchase it pre-assembled or as individual parts. Thisnew assembly comes standard in all Vacuum Priming Retrofit Kits.

SOLID S.S. ELECTRODE & DOME PARTS

PART # DESCRIPTION

1L460D Quick Disconnect Male Fitting1L248A Ferrule Connection Fitt ing (Optional)

1L552A Reducer Coupling

6L222A Jam Nut

5L75C Male Insulated Tab

5L52G Electrode Ring Terminal11L4J 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 PARTS

PART # DESCRIPTION

Solid S.S. Electrode Dome AssemblyThe new solid stainless steel electrode dome assembly comes fully assembled andready to plug and play. It features a new solid stainless steel electrode which eliminateshaving 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 whohave installed the dome conversion kit. All brass fittings are now located outside ofthe dome. It comes with quick disconnect fittings, however, if you prefer the ferrulefitting, you can order P/N 1L248A and do a quick field change.

Includes: (1) Electrode Dome Assembly. Optional Ferrule Connection Fitting.

SOLID S.S. ELECTRODE DOME ASSEMBLY

PART # DESCRIPTION

87B309 5-1/4 Solid Stainless Steel Electrode Dome Assembly

87B309A 6 Solid Stainless Steel Electrode Dome Assembly

1L248A Ferrule Connection Fitting (Optional)87B309 or87B309A

1L248A

Hollow Electrode, Dome &Hardware PartsMany pump stations still utilize the old style Hollow Electrode andDome Parts. Even though this is no longer available as a pre-

assembled part, Smith & Loveless still supports all of these parts.Just determine which parts you need and place your order.

1L190D1L142BBCut off top of boot.

(This will allow both the

vacuum tube and the

electrode wire to fit

thru the boot)5L68B

Wiring and

tubing from

existing

electrode

assembly.

87B133

1L481C

5L52G

11L4J

6L200DH

6L65F

87A226

87A225

6L30K

Motor

Adapter11L47D

87A229A

11L4K

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 Dome6L200DH S.S. Stud

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

HOLLOW ELECTRODE & DOME

PARTS

PART # DESCRIPTION

15To Order, call 1-800-922-9048


16/24

5. Reviewing the SingleMechanical Seal

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

The new Replacing a Smith & Loveless Single Mechanical Sealvideois so comprehensive we feel it would be foolish to try and duplicate it inprint.

Each Smith & Loveless mechanical seal kit comes with written instructionson how to replace the mechanical seal. However, the most comprehensiveset of instructions, including Smith & Loveless Customer Service TechTips, comes in the Replacing a Smith & Loveless Single Mechanical

Sealvideo.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 newemployee training program. And if you have misplaced your O&M manualon your existing Smith & Loveless equipment, give us your equipmentserial number and we can provide you with a duplicate copy of yourcustomized Smith & Loveless equipments O&M manual for $75 permanual.

12L318VHS-1 12L318DVD-1

To Order, call 1-800-922-904816


17/24

Single Mechanical SealReplacement Parts Kit

Specifically designed by Smith & Loveless for the Smith &

Loveless pump is the Single Mechanical Seal. Designed to lastmore than 7 years, it has been proven to have one of the longestlife-cycles of any mechanical seal in the industry. Dont be caughtwithout 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 # SHAFT SIZE

H87A28 B-Shaft: 1-7/8

H87A97 C-Shaft: 2-1/8H87A182 D-Shaft: 3

Single Mechanical Seal

Replacement Parts Kit Includes:

(1) carbon, (1) ceramic, (1) spring,

(1) instruction booklet on how to

install.

Seal Housing Gasket &Quad Ring

Each time the mechanical seal is replaced, S&Lrecommends the Seal Housing Gasket or Quad Ring alsobe replaced.

PARTS TIP: The older Seal Housing has a flat surfaceand uses the flat Gasket. The newer Seal Housing has agroove and it can use either the flat Gasket or the QuadRing.

GASKET QUAD RING

PART # PART # SHAFT SIZE

60A11 60A110 B-Shaft:1-7/8

60A17 60A111 C-Shaft: 2-1/8

60A84 60A112 D-Shaft: 3

Seal HousingGasket

Quad Ring

Impeller BoltsS&Ls Impeller Bolts featureembedded Nylock. Each time youremove the impeller, replace theImpeller Bolt. Remember to torqueimpeller bolts to 150 ft/lbs. Here are

the part numbers for the Impeller Bolt.

PART # SHAFT SIZE

60A12 B-Shaft: 1-7/8

60A12 C-Shaft: 2-1/8

60A86 D-Shaft: 3

EmbeddedNylock

Volute GasketsEach 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



18/24

Tools Required:

Phillips Screwdriver Standard Screwdriver Adjustable Wrench orSet 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

CAUTION: Useproper 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.

Plumbers Grease,Petroleum Jelly or non

pumice hand soap Drill and Tap Kit (S&Lpart number H87A390A)or Tools to Tap a NPTHole

Drill drive 11/16 Drill Bit or Knock-out (to put an

11/16 hole in the controlpanel) Hammer Punch Torque Wrench Knife

Figure AFigure B

Also verify that your pump station has been modifiedelectrically from the original O&M electrical schematic.If you need an electrical drawing, please specify whenyou order the Sonic Start Retrofit Kit. There will be a $10.00 additional charge for the replacementwiring diagram of the original control panel. Make sure you have the pumps flow conditions monitoredduring this procedure to prevent overflow. Depending upon the flow conditions of the pump station, it maybe necessary to pump the wet well down to the off level float. Some pump stations may require a VacTruck on site during this installation. Only work on one pump at a time, in case the wet well needs to bepumped down. Close the plug valve for the pump that is going to be worked on.

6. Upgrading to theSonic Start Prime

Sensing System


H87A391A (1 Pump Kit)H87A391B (2 Pumps Kit)

BEFORE YOU START!

See below to determine whether you have a Figure Aor Figure B dome. If you have a Figure A dome, youmust purchase the dome conversion kit S&L P/N:H87A329 before starting to install this kit.


19/24


TECH TIP:Before starting, make sure the vacuum pump and solenoid arein good working order. Each vacuum pump must be able to pull 26 HG

(inches of mercury). This kit prevents electrode fouling, not vacuum problemswith the vacuum pump or solenoid valve, Smith & Loveless Customer ServiceTeam 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 youhavent purchased the conversion yet, put it on your list for coming purchases.

D A N G E R :

Disconnect and

lock out power

before servicing



injury or death.


Photo 1

Electrode

Dome

O-Ring

Mounting

Hardware

Bulk Head

Fitting

Assembly

Grounding

Wire

Connector

Step 3. Disconnect theelectrode grounding wire fromthe existing electrode domeassembly. The grounding wire

is no longer used and can beremoved. Additionally, theexisting bulk head fittings canalso be removed as a newarrangement has beensupplied in this kit. Removethe existing electrode domeassembly from the motoradapter. The dome, o-ring, and

mounting hardware will bereused.

Step 4. Look at your stationor pump. Decide which side ofyour motor adapter the SONICSTART Prime Sensor

Probe must be installed. TheSONIC START Prime

Sensor Probe will stick outfrom the side of the motor

adapter.

TECH TIP: If theSONIC START

Prime Sensor

Probe is to be installed in apump station, make sure thereis room for the hood to close ifthe SONIC START PrimeSensor Probe were stickingout towards the hood. Check

other wall and equipment forclearance. It may benecessary to rotate the motoradapter to create enoughclearance for the SONICSTART Prime SensorProbe to be located betweenthe motor adapter and hood/wall/or other piece of

equipment.

Step 5. Depending on yourstation/pump, you may be ableto drill and tap the hole for theSONIC START PrimeSensor Probe with the pumpin place. Otherwise you willhave to pull the rotatingassembly to get proper accessto the motor adapter for the

drilling and tapping process.See the O&M instructions thatcome with the Sonic StartPrime Sensing Kit for step-by-step instructions on how to pullthe rotating assembly. If youchoose not to drill & tap, youcan purchase a pre-tappedmotor adapter from the factory.

Step 6. Mark the location

for the SONIC STARTSensoron the motor adapter.Use a hammer and punch tomake a mark at the properlocation.

Step 7. Drill a pilot hole atthe punch mark with the3/16 drill bit (see Photo 2).Make sure the hole is asstraight as possible to make iteasier when tapping. Then drillthe hole out with the drillbit, and then finish drilling the

hole with the 45/64 drill bit.

Photo 2

Motor

Adapter

19To Order, call 1-800-922-9048


20/24

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.

Step 8. Thread the holewith the NPT tap as inPhoto 3.

NOTE: Do not tap the

threads too deep, otherwise

it will not seal and will create

a vacuum leak.

Photo 3

Photo 4Photo 7

Step 9. Put the Teflon

tape on the SONIC STARTPrime Sensor Probe threads.Make sure the Teflon tapecovers the threads as shownin Photo 4. Thread the SONICSTART Prime Sensor

Probe into the tapped hole.

Sonic Start

Fitting RingPhoto 5

Photo 6

Place the Sonic StartFitting Ring onto the end ofthe Sonic Start PrimeSensing Probe as seen inPhotos 5 & 6. There is onlyone way it can be installed,with the more square side

closest to the prongs.Additionally, it is cut on theinside to match the end of theSonic Start Prime Sensing

Probe, which was two 90degree corners and tworounded corners. Make sure itfits snugly against the SonicStart Prime Sensing

Probe.

Step 10. Tighten theSONIC START Prime

Sensor Probe (Photo 7).

Step 11. Install the DINconnector cable onto theSONIC START Prime

Sensor Probe.Line the largerpin on the SONIC STARTPrime Sensor Probe with thelarger slot on the DINconnector cable as shown

in photo 8.

Photo 8

Photo 9

Photo 10

Step 12. Tighten the screwon the DIN connector cableto secure it in place on theSONIC START Prime

Sensor Probe, see photo 9.

Step 13. Run the DINconnector cable back to thecontrol panel. Run the cablealong the motor conduit and

fasten it to the motor conduitwith cable ties, as shown inphoto 10.

Step 14. Use the cordgrip nut to hold the cord gripin place. Run the DINconnector cable through thecord grip or existing panelhole and tighten the cord gripto secure the DIN connector

cable.

To Order, call 1-800-922-904820


21/24

Step 15. The fourelectrode relays that havebeen used over the years inthe Smith & Loveless ControlPanel are shown on this page.Please see yourSonic StartPrime Sensing Retrofit KitO&M for complete step-by-

step wiring instructions foreach individual relay shownabove.

Step 16. Verify the pumpstation wiring in the controlpanel is per the Smith &Loveless OEM wiring diagramsupplied with the originalPump Station. If you do nothave a wiring diagram, pleaseconsult the Smith & LovelessCustomer Service

WARNING: Allelectrical work

should be

performed by a qualified

electrician and per all

applicable codes. Failure to

do so may result in severe


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

Step 17. Smith & LovelessSonic Start Prime Sensing Kitscome with complete step-by-step wiring diagrams for allfour Electrode Relays above.

See illustration 1, to see how

Relay 1

Relay 2 Relay 3 Relay 4

Photo 11

simple the minor wiringchanges are to install theSonic Start. Most electricalwiring changes will take lessthan 60 minutes per controlpanel provided the controlpanel has not been modifiedby an unqualified technician.Illustration 1 shows the

general layout.

- Red of DIN Connector to Pin 2- Black of DIN Connector to Neutral- White of Din Connector to Ground

General Wiring Arrangement ONLYDANGER: See the specific Sonic Start Prime Sensing System Retrofit Kit O&MManual 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 PowerTo Vacuum Contactor/Pump

Starter

FORMULA XONLY

Neutral

120 VAC Power

Illustration 1



22/24

Photo 12

Complete Sonic StartSystem Kits

Sonic Start Prime

Sensing System

1-Pump Retrofit Kit

H87A391A

Sonic Start Prime

Sensing System

2-Pump Retrofit Kit

H87A391B

5/16 Diameter Orifice

2-Way Solenoid Valve

Retrofit Kit

H87A343A

Sonic Start

Drill & Tap Kit

H87A390A

RETROFIT KIT

PART NUMBER

Recommended Kits

Sonic Start

Operating Module

Sonic Start Prime

Sensing Probe

Sonic Start

Dome Fittings

Sonic Start

Dome Assembly

Drill & Tap Kit

Cable & Cable Ties

2-Way Solenoid

Valve

Vacuum Tubing,

Fittings & Hardware

Vapor Filter(s)

Sonic Start

Dome Assembly

87B452

ComponentParts

Sonic Start Priming System eliminates electrodes & electrode cleaning

The Sonic Start Priming System is state-of-the-art prime sensingtechnology. Using frequency differential, the Sonic Start Prime

Sensing System dramatically changes the way Smith & LovelessVacuum Primed Pumps sense prime. Even with grease buildup onthe Sonic Start probe, it still continues to accurately monitor thefrequency and detect frequency changes. Additionally, the SonicStart does not require routine cleaning like the electrodes.

For Smith & Loveless state-of-the-art prime sensing system, orderSonic Start Kit H87A391A or H87A391B seen below. All of thekits and individual components on these two pages represent thelatest in Sonic Start Priming System technology. We believe sostrongly in the Sonic Start Priming System Retrofit Kit that it comeswith a 60-Day Money Back Guarantee and a 5-year prorated

warranty. Youre going to love it!

Step 18. Photo 12 showsa fully installed Sonic Start

System.



23/24

Pump Flow Sensor

H87A376

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

No matter what angle your check valve is,the Smith & Loveless Pump Flow Sensorbolts on and adjusts to that angle. Itsenses even the smallest check valve armdeflections, preventing many false pumpfailure alarms.

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 newContinuous Hinge/Backing Bar Retrofit Kit

(seen above) installs right over the old holes -

dramatically extending the life of your hood.

Additional New PartsProducts To Consider

Hood Lift Assist Kit & Continuous Hinge

Add the Hood Lift Assist Kit and

dramatically reduce the effort

required to open and close theClassic Wet Well Mounted Pump

Station hood.

23To Order, call 1-800-922-9048


24/24

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Need a part number? Go online and lookup the part number by downloading oropening the Adobe Acrobat parts catalogfor your type of equipment. Currently wehave the Wet Well Mounted Pump Station,FORMULA X Wet Well Mounted PumpStation, Recessed Wet Well MountedPump Station and Underground PumpStation Parts lookup Catalogs loadedonline.

www.smithandloveless.com/aftermarket_parts_lookup.htm

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After Market Division

Smith & Loveless, Inc.

14040 Santa Fe Trail Drive

Lenexa, KS 66215-1284, USA

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