Non-Clog Dry Pit Pumps• Wastewater• Lift Stations• Treatment Plants• Sump• Drainage• Dewatering• Sludge and Slurry• Industrial Waste

DRY PIT

NOTE! To the installer: Please make sure you providethis manual to the owner of the pumping equipment or tothe responsible party who maintains the system.

Pump Installation and Service Manual

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SHIPPING

When unpacking unit, check forconcealed damage. CLAIM FORDAMAGE MUST BE MADEAT THE RECEIVING ENDTHROUGH THE DELIVERINGCARRIER. DAMAGE CANNOTBE PROCESSED FROM THEFACTORY.

PUMPS NOT OPERATING ORIN STORAGE

Pumps with carbon ceramic sealsmust have impellers manuallyrotated (6 revolutions) after settingnonoperational for 3 months orlonger and prior to electrical start-up.

Pumps with carbide seals musthave impellers manually rotated(6 revolutions) after settingnonoperational for 3 weeks orlonger and prior to electricalstart-up.

SEAL FAILURE

An electrode is installed in the sealchamber so if water enters thechamber through the first seal, theelectrode will be energized anda signal will be transmitted tothe sensing unit at ground surface,causing an alarm activation. Theelectrode probe is installed in allunits, but the sensing unit issupplied at an extra cost and mustbe ordered.

In operation the seal failure unitindicates only that there is somewater in the seal chamber. Thepump will continue to operatewithout damage, but the sealshould be checked immediatelyafter failure is indicated.

The sensing unit is recommendedon all installations as goodinsurance against motor failure.

GeneralInformation

PUMP

The dry pit submersible pump issupplied for 1 or 3 phase and for200, 230, 460 or 575 volts. Pumpis supplied with 30 feet of powercord and/or 30 feet of auxiliarycontrol cord. Longer cable lengthscan be furnished but must bespecified at time of order. Be suregreen wire is connected to a goodground such as water pipe ofground stake. The auxiliary cablefor the seal failure and heat sensorsis also 4 wire and color coded.

HEAT SENSORS

All motors have heat sensor unitsembedded in the motor windingto detect excessive heat. The heatsensors are set to trip at 120ºC.The sensors automatically resetwhen the motor cools to safetemperature.

The sensors are connected inseries with the motor starter coilso that the started is tripped if heatsensor opens. The motor starter isequipped with overload heaters soall normal overloads are protectedby the starter.

IMPORTANT

If Hydromatic® electrical startingequipment is not supplied, the heatsensor circuit must be connectedin series with the started coil orwarranty on the motor is void.Connection diagram is included inthe manual.

WET WELL LEVELCONTROL

Sump level is controlled byHydromatic switch controls. Thefloat is held in position in thesump by a weight attached powercord above the float. The cordsupports the float and is adjustedfor height from the surface.

Duplex systems use three controls:one set at turn-off, one set at turn-on for one pump, and one set atturn-on for both pumps. Pumpsthen alternate lead and lag on eachsuccessive cycle. Two pumpsoperate together only when thesump level rises to the third oroverride control. The overridecontrol also brings on the secondpump in case of failureof the first pump. Extra floatswith appropriate controls can besupplied for alarm functions.Triplex systems use four controls:One set at turn-off, one set atturn-on for one pump, one set atturn-on for two pumps, and oneset at turn-on for three pumps.The pumps alternate with eachsuccessive cycle.

Three pumps operate togetheronly if the sump level rises to thefourth control (second override).This control also brings on the thirdpump in case of failure of either orboth of the first two pumps.

ALARM CONTROLS

The alarm level is usually set abovethe override level so the alarmwill signal only if the overridelevel is exceeded. However, some engineers prefer to have the alarmlevel set below the override level asit is possible for one pump to failand the other pump to operate onthe override level with the sumplevel never reaching the alarmlevel. This is particularly true incases of low inflow capacity.

ELECTRICAL CONTROLPANEL

It is recommended that theHydromatic control panel be usedwith all pumps as proper starterheaters and connections for heatsensor wires are furnished.

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IMPORTANT

If Hydromatic electrical controlsare not used and the motor failsbecause of improper componentsor if the heat sensors are notproperly connected, the motorguarantee is void.

Hydromatic electrical equipmentis installed in a weatherproofNEMA 3R enclosure. Theelectrical equipment includes amain circuit breaker for eachpump, a magnetic starter withoverload protection for eachpump, an H-O-A switch and a runlight for each pump, an electricalalternator and a transformer toprovide appropriate control forcontrol circuit and alarms.

OVERLOAD HEATERS

Starters with 3 leg overloadprotection must be supplied if theHydromatic electrical panel is notused. The heaters must be sized inaccordance with the nameplateamps on the motor. The amp drawon these oil filled motors is slightlyhigher than a correspondinghorsepower surface motor, soheaters must be sized by thenameplate rating.

InstallationInstructions

INSTALLING PUMP IN DRYPIT

Before installing pump in the drypit, lay it on side and turn theimpeller manually. The impellermay be slightly stuck due to factorywater testing, so it must be brokenloose with a small bar or screwdriverin the edge of the vanes. Theimpeller must turn freely.

Clean all trash and debris frompump installation area and connectpump to plumbing.

A check valve must be installed oneach pump. A gate or plug valve ineach pump discharge line is alsorecommended. This valve shouldbe installed on the discharge side ofthe check valve so the line pressurecan be cut off to service the checkvalve. Single pump systems aresometimes installed without acheck valve where it is desirable toself drain the discharge line toprevent freezing. This can be doneonly with short discharge lines.Otherwise water will return to thesump and cause short cycling ofthe pump.

MOUNTING PUMP STAND

The pump will ship from thefactory on a dry pit pump stand.The suction and discharge of thepump will be oriented at the factoryper the prescribed customer order.

The dry pit pump must beanchored to the pump station floor.This must be done to alleviatestress on the suction and dischargepiping while the pump is inservice. When securing the pumpstand to the contractor suppliedanchor bolts, it may be necessaryto shim the stand to ensure thesuction and discharge pipingproperly aligns.

PLUMBING (GENERAL)

The site contractor must supplythe use of necessary pipe hangersor other piping supports. Both thesuction and discharge piping mustbe independently supported andproperly aligned to ensure no strainis transmitted to the pump whenconnections are tightened. The useof expansion joints or vibrationpads does not preclude the need toproperly support the piping.

NOTE: DO NOT SUPPORT THEPIPING BY THE PUMP.

DO NOT FORCE PIPING WHENMAKING CONNECTIONS.

SUCTION-INLET PIPING

The correct sizing and installation ofthe suction plumbing is particularlyimportant. The suction piping mustbe selected and installed in such amanner that it minimizes pressurelosses and allows for sufficient flowduring starting and operation. MostNPSH problems can be traceddirectly to improper design ofsuction piping systems.

It is recommended that the pipingbe as direct as possible and thelength should be at least 10 timesthe diameter of the pipe. When apipe diameter larger than thesuction of the pump is used, aneccentric reducer should be usedwith the eccentric side down.This will allow for the eliminationof a potential air pocket in thesuction plumbing.

NOTE: A PIPE DIAMETERSMALLER THAN THESUCTION OF THE PUMPMUST NEVER BE USED.

It is also recommended that a valvebe installed in the suction piping toisolate the pump during routinemaintenance and shutdown. Aglobe valve should not be usedwhen NPSH is critical.

It is recommended that a compoundpressure gauge be installed inthe suction piping to assistin troubleshooting potentialperformance problems.

DISCHARGE-OUTLET PIPING

The discharge piping for shortruns can be of the same size asthe discharge of the pump. It isrecommended that longer runs be1 to 2 sizes larger depending onthe length. Any elevated pointswill retain air pockets, and it isrecommended that air vents orbleed lines be installed at thesepoints to evacuate entrapped air.Installation of a valve near the

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discharge of the pump isrecommended to isolate the pumpduring maintenance and shutdown.

It is recommended that a pressuregauge be installed near thedischarge of the pump toassist in troubleshooting potentialperformance problems.

NEMA 4 JUNCTION BOX(OPTIONAL)

A NEMA 4 junction box shouldbe used to make power and controlconnections if electrical controlpanel is to be set remote from the

pump station. The HydromaticNEMA 4 junction box is providedwith compression connectionsfor sealing all wires. No sealingcompound is needed to makeconnections waterproof.

Wiring diagrams are providedwith the panel for makingconnections. An extra set ofdiagrams is included so that oneset can be used in the station whenmaking connections. The sizewire to use from panel to stationdepends on motor size anddistance in feet.

The wire size table on Page 4 canbe used as a guideline for wiresize. Be sure each wire is checkedout so that a wrong connectionwill not be made. An ohmmeteror Megger can be used to checkthe continuity. Attach one side ofmeter to ground and the otherside to one side of the controlpanel. Then have a person in thestation touch the wire to ground.If the wire is correct, meter willshow reading. A handheld radiomay be useful if some distanceexists between station and panel.

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INSTALLING SWITCHCONTROLS

The controls are supported by amounting bracket that is attachedto wet well wall, cover or to theNEMA 4 junction box. Cordsnubbers are used to hold the cordin place. Control level can bechanged at any time by looseningthe snubber and readjustingcord length.

In either a simplex or duplexsystem, the lower or turn-offcontrol is set just above thedrywell inlet. This is dependenton the inlet velocity of the pump.The second or turn-on control isset at least 24 inches above thelower turn-off control.

More distance between turn-onand turn-off controls can be used,but sewage may become septic,and excessive solids may collectfor the pump to handle. A frequentpumping cycle is recommendedfor best operation.

If an alarm system is used, thiscontrol is usually set about 6 inchesabove the override control.

Some engineers, as describedpreviously, prefer to have thealarm control set below theoverride control.

MAKING ELECTRICALCONNECTIONS

All electrical wiring must be inaccordance with local codes, andonly certified electricians shouldmake the installations. Completewiring diagrams are adhered tothe inside cover of the panel, andan additional set of prints isincluded for use in making theinstallation. All wires shouldbe checked for ground withan ohmmeter or Megger afterthe connections are made.THIS IS IMPORTANT ASONE GROUNDED WIRECAN CAUSE CONSIDERABLETROUBLE.

IMPORTANT

If equipment is not properly wiredand protected as recommended,the motor guarantee is void.

HEAT SENSORS AND SEALFAILURE CONNECTIONS

Be sure heat sensor wires areconnected in series with thestarter coil. Connections areprovided on the terminal strip (seewiring diagram).

If seal failure unit is used, connectas shown with seal failure system.If seal failure unit is not used, thetwo seal failure wires are left open.

DO NOT CONNECT POWER TOTHESE LINES AT ANY TIME.

COOLING FINS (OPTIONAL)

When additional cooling isrequired, cooling fins arepermanently adhered to the motorhousing at the factory. Inspect thecooling fins to ensure that they areintact and not damaged prior toplumbing the pump in the system.

NOTE: The cooling fins mustbe intact to ensure the pumpoperates within the factoryspecified temperature.

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WATER JACKET (OPTIONAL)

When additional cooling isnecessary, a water jacket issupplied from the factory. Allnecessary plumbing of the waterjacket is supplied from the factoryconnecting to the suction and thedischarge piping. The plumbingincludes ball valves allowing forremoval of the water jacket forperiodic cleaning without shuttingthe system down.

The water jacket is held in placeby clamps and is sealed both topand bottom by O-rings. Uponremoval of the water jacket forcleaning care should be taken notto damage the O-rings and replaceif necessary.

NOTE: Clean fresh watersupplied to the water jacket willreduce the necessity of frequentperiodic cleaning of the waterjacket. This does not precludethat the water jacket should notperiodically be cleaned.

STARTING SYSTEM1. Turn H-O-A switch to Off

position and then turn on maincircuit breakers.

2. Open all discharge valves andallow water to rise in wet well.

3. Turn H-O-A switch to Handposition on one pump andnotice operation. If pump isnoisy and vibrates, rotation iswrong. To change rotation,interchange any two line leadsto a three phase motor only.DO NOT INTERCHANGEMAIN INCOMING LINES. Ifduplex system, check secondpump in the same manner.

4. Now set H-O-A switch to Autoposition and allow water to risein the wet well until the pumpstarts. Allow pump to operateuntil level drops to turn-off point.

5. Allow wet well level to rise tostart the other pump. Noticerun lights on the panel. Pumpsshould alternate on eachsuccessive cycle of operation.

6. Turn both H-O-A switches toOff position and allow wetwell to fill to the overridecontrol level.

7. Turn both switches to Autoposition and both pumps shouldstart and operate together untillevel drops to turn-off point.

8. Repeat this operation cycleseveral times before leavingjob site.

9. Check voltage when pumps areoperating and check amp drawof each pump. Checks amps oneach wire, as sometimes a highleg will exist. One leg can besomewhat higher (5 to 10%)without causing trouble. Forexcessive amp draw on oneleg, the power company shouldconsulted.

PHASE CONVERTERS

Phase converters are generally notrecommended, but in cases whereonly single phase current isavailable, phase converters can beused. Be sure to size the phaseconverter large enough for theamp draw specified on the motornameplate, not necessarily bymotor horsepower. The warrantyof all three phase submersiblemotors is void if operated withsingle phase power through aphase converter and 3 leg ambientcompensated extra-quick tripoverload protectors are not used.

Lubrication or other maintenanceis not required, as the motors areoil filled.

If a seal failure unit is used, noattention is necessary as long asthe seal shows satisfactoryoperation.

If seal failure is not used, thepump should have the oil drainedfrom the seal chamber once everytwo years and inspected for water.

Generally, these pumps give veryreliable service, and can beexpected to operate for manyyears without failure undernormal operating conditions.

LIGHTNING

In some areas where considerablelightning occurs, we recommendthat a lightning arrestor beinstalled at the control panel.Lightning arrestors are goodinsurance against damage to anexpensive motor.

SERVICING INSTRUCTIONS

Important: Read all instructionsprior to replacing any parts.

Warning: Before handling thesepumps and controls, alwaysisolate and disconnect powerfirst.

Do not smoke or use anysparkable electrical devices orflames in a septic (gaseous) orpossible septic environment.

PumpOperation

PumpMaintenance

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FIELD SERVICE ON MOTOR

All dry pit pump motors can beserviced (out of warranty) in thefield by any reliable motor serviceshop. Any pump (in warranty) mustbe returned to the factory forservice or repaired in an authorizedHydromatic service center. Chargeswill not be allowed if (in warranty)pump is taken to a motor repairshop that is not an authorizedHydromatic service center.

When field service is performedon a pump, these instructionsshould be carefully followed.

REPLACING STATOR

If motor winding is burned orshorted it can be rewound orreplaced with a new factory woundstator. Refer to the sectional drawingof the pump and motor and thenuse the following steps to removeand replace the stator.

1. Un-plumb and drain waterjacket if pump was suppliedwith a water jacket and remove.

2. If stator only is damaged it maynot be necessary to completelydismantle pump as stator andhousing can be lifted frompump without disturbing sealsor bearings.

3. Drain all oil from upper housing,remove drain plug in bottom ofstator housing and remove plugin top of housing to allow airto enter.

4. After chamber is drained,remove hold-down bolts and liftoff. Use care in lifting as theseal failure connecting wiresmust be disconnected beforehousing is completely removed.See sectional drawing.

5. Set assembly on bench andremove connection box. Whenbox is lifted off, connectionwires to motor will be exposed.These wires will probably be

burned, but each wire will beidentified with a metal wiremarking number. Cut the wires.

If the leads in the connectionbox are burned, a completenew connection box with newwires must be used. The wiresare potted in with sealingcompound and a new unit mustbe obtained from the factory.

6. The stator is held in the housingwith a bolted-in clamp ring.

7. After ring is removed, turnhousing upright and bump onhardwood blocks. This shouldjar the stator loose and allow itto drop out.

8. Thoroughly clean housingbefore replacing new stator.Replace stator and make allwire connections to connectionbox before replacing housingon pump. This is important asleads must be tucked behindthe windings by using hands upthrough rotor core.

IMPORTANT: Use onlycompression type insulatedconnectors on the wires.

Do not tape leads as oil willdeteriorate the tape and causedamage to stator and bearings.9. Drain oil from lower seal

chamber. If oil is clean and nowater is present, seals can beconsidered satisfactory to reuse.

10.Check top bearing. If clean anddoes not turn rough, bearingscan be reused and it is notnecessary to completelydismantle pump and changebearings. If bearings aredamaged with dirt or heat theymust be replaced. See additionalinstructions on replacing sealsand bearings. Remember toreinstall the upper bearingload spring.

11. Replace stator housing ontoseal chamber and bolt in place.BE SURE SEAL FAILUREWIRE IS CONNECTEDBEFORE HOUSING ISASSEMBLED.

Be sure O-ring seal has beenreplaced. If O-ring appearsnicked or cut, replace with newones. This applies to O-ringsin the assembly.

12. After all leads are reconnectedin the connection box, make ahigh voltage ground test oneach wire. The only wire thatshould show ground is thegreen power lead and theground lead in the auxiliarypower cable.

13.For safety, complete pumpshould be air checked underwater for leaks. If seals are OK,refill seal chamber with oil.Lay pump on side for this oilfilling with oil fill hole upright.Do not completely fill; leave oil about 1 inch below plughole. Use only Hydromaticsubmersible oil in this chamberor high grade transformer oil.Replace plug; use Permatex onthreads. Install air valve in topplug opening of motor housingand charge housing with about10 psi of air. Be sure air is dry.Do not use air line where watermay be trapped in the line.Submerge complete unit underwater and check for leaks.

14.Refill motor chamber with oil.Use only a high gradetransformer oil or Hydromaticspecial submersible oil. Fillchamber until oil covers top ofwindings. Leave air spacein top for expansion. UsePermatex on plug threads.

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REPLACING SEALS ANDBEARINGS1. Drain all oil from motor

chamber and seal chamberas described.

2. Remove motor housing asdescribed.

3. Remove bolts that hold sealchamber to pump housing.Use back-off screws to breakloose.

4. Lift rotating assembly (rotor,shaft, and impeller) from pumpcase and place horizontally onbench.

5. Remove the impeller by holdingthe rotor and removing theimpeller retaining washer andbolt. The impeller will be taperfitted to the shaft with a key.The impeller may need to bejarred from the shaft by tappingwith a block of wood.

6. A shaft sleeve may be used inconjunction with the lower sealand will need to be removed.

7. Remove lower seal springand pry out the seal with ascrewdriver.

8. To remove the seal housing,take out socket head bolts andusing the bolts in the back-outholes, pry plate loose. This willforce out lower seal if notalready removed.

9. Remove snap ring that holdsupper seal. Pull seal if it is free.If not free, it can be forced offwhen shaft is removed.

10.Remove 4 bolts that holdbearing housing in place. Setassembly in upright positionand bump end of shaft withhardwood block. This willpush the bearing from thehousing and will force upperseal from shaft.

11. Use a bearing puller to removebearings. Replace with new

bearings. Press only on innerface of bearing when replacing.Pressing on the outer face candamage the bearing. Bearingsare standard size that can beobtained from any bearingsupply house or can beobtained from the factory.

12. IMPORTANT: DO NOT USEANY OF THE OLD SEALPARTS. REPLACE WITHALL NEW SEALS.

13.Thoroughly clean all castingsbefore replacing seals. Any dirtbetween the seal faces cancause failure.

14.Examine all O-rings for nicksbefore using and replacedamaged O-rings with newones.

15.Use Loctite on socket headimpeller locking screw in endof shaft.

Below is a list of commonproblems and the probable causes:

Pump will not start1. No power to the motor. Check

for blown fuse or open circuit.

2. Selector switch may be in theOff position.

3. Control circuit transformerfuse may be blown.

4. Overload heater on starter maybe tripped. Push to reset.

Pump will not start andoverload heaters trip1. Turn off power and check

motor leads with Megger orohmmeter for possible ground.

2. Check resistance of motorwindings. All 3 phases shouldshow the same reading.

3. If no grounds exist and themotor windings check OK,remove discharge elbow coverand check for clogged orblocked impeller.

Pump operates with selectorswitch in Hand position but willnot operate in Auto position1. This indicates trouble in the

float level control or alternatorrelay.

2. Check control panel for trouble.

Pump runs but will not shut off1. Pump may be air locked. Turn

pump off and let set for severalminutes, then restart.

2. Lower float control may behung up in the closed position.Check in wet well to be surethe control is free.

3. Selector switch may be in theHand position.

Pump does not deliver propercapacity1. Discharge gate valve may be

partially closed or partiallyclogged.

2. Check valve may be partiallyclogged. Raise lever up anddown to clear.

3. Pump may be running in thewrong direction. Low speedpumps can operate in reversedirection without much noiseor vibration.

4. Discharge head may be toohigh. Check total head withgauge when pump is operating.

5. If pump has been in service forsome time and capacity fallsoff, remove pump and inspectimpeller for wear.

Pump Troubleshooting

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Motor stops and then restartsafter short period but overloadheaters in starter do not trip1. This indicates heat sensors in

the motor are tripping due toexcessive heat. Impeller maybe partially clogged givingsustained overload but nothigh enough to trip overloadheaters.

2. Pump may be operating on ashort cycle due to faulty checkvalve in the wet well.

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Pump Notes

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Pump Notes

Item # E-03-458 4/07Part # 5625-458-1

WARRANTY

Hydromatic® warrants to the original purchaser of each Hydromatic product(s) that any partthereof that proves to be defective in material or workmanship within one year from date of installation or 18 months from manufacture date, whichever comes first, will be replaced at no charge with a new or remanufactured part, F.O.B. factory. Purchaser shall assume all responsibility and expense from removal, reinstallation and freight. Any item(s) designated as manufactured by others shall be covered only by the express warranty of the manufacturer thereof. This warranty does not apply to damage resulting fromaccident, alteration, design, misuse or abuse. The pump must be installed, operated and maintained in accordance with the published instructions of the appropriate Installation & Service Manual.

All dual seal non-clogs and 3–5 HP grinders must have seal failure and heat sensors attached and functionalfor Warranty to be in effect. If a seal failure should occur, Hydromatic will cover only the lower seal and laborthereof. Labor is based on Authorized Service Center contract allowance. If the heat sensor is not attachedand functional, Warranty is void. If the seal failure sensor is not attached and functional, Warranty is void.

If the material furnished to the Buyer shall fail to conform to this contract or to any of the terms of this written warranty, Hydromatic shall replace such nonconforming material at the original pointof delivery and shall furnish instruction for its disposition. Any transportation charges involved in suchdisposition shall be for the Buyer’s account. The Buyer’s exclusive and sole remedy on account or in respectof the furnishing of material that does not conform to this contract or to this written warranty, shall be to secure replacement thereof as aforesaid. Hydromatic shall not in any event be liable for the cost of any laborexpended on any such material or for any incidental or consequential damages to anyone byreason of the fact that such material does not conform to this contract or to this written warranty.

ALL IMPLIED WARRANTIES, INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITYAND THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, ARE DISCLAIMEDTO THE SAME EXTENT AS THE EXPRESS WARRANTY CONTAINED HEREIN. Some states do notallow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

MANUFACTURER EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIEDWARRANTY ARISING IN CONNECTION WITH THIS PRODUCT, INCLUDING WITHOUTLIMITATION, WHETHER IN TORT, NEGLIGENCE, STRICT LIABILITY CONTRACT OR OTHERWISE. Some states do not allow the exclusion or limitation of incidental or consequential damages,so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, andyou may also have other rights which vary from state to state.

– Your Authorized Local Distributor –

USA740 East 9th Street, Ashland, Ohio 44805Tel: 419-289-3042 Fax: 419-281-4087 www.hydromatic.com

CANADA269 Trillium Drive, Kitchener, Ontario, Canada N2G 4W5

Tel: 519-896-2163 Fax: 519-896-6337

© 2007 Hydromatic® Ashland, Ohio. All Rights Reserved.