Manual Hazardous location submersible grinder Pump.pdf

NOTE! To the installer: Please make sure you provide this manual to the owner of the equip ment or to the responsible party who maintains the system.

MODEL HPGX200

(Class I, Division 1, Groups C & D): FM

HAZARDOUS LOCATION

SUBMERSIBLE GRINDER PUMP

INSTALLATION AND SERVICE MANUAL

Item # E-03-438 | Part # 5625-438-1 | © 2018 Pentair plc | 4/16/18

General Information Attention:

This manual contains important information for the safe use of this product. Read this manual completely before using this product and refer to it often for con tinued safe product use.

DO NOT THROW AWAY OR

LOSE THIS MAN U AL.

Pump Warning IMPORTANT: Read all directions before replacing any parts.

WARNING: Before handling these pumps and controls, always dis con nect the pow er first.

Do not smoke or use sparkable elec tri cal devices or flames in a septic (gaseous) or possible septic sump.

Application:

These pumps are designed for on-site residential sewage discharge ap pli ca tions with a pH ranging from 6 to 9, specific gravities from 0.9 to 1.1, vis cosi ties ranging from 28 to 35 S.S.U., and temperatures up to 140 de grees Fahrenheit.

Receiving Pump:

Pump should be checked on arrival for possible concealed shipping dam age. Any damage should be reported immediately to de liv ery carrier. Claims for damage must originate at the receiving end. Claims for shipping damage cannot be processed by the factory.

Codes:

All local wiring codes must be observed. Consult the local inspector before installation to avoid de lays that can occur due to rejection after job is finished.

CALIFORNIA PROPOSITION

65 WARNING:

This product and related accessories contain chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Pumps Not Operating or in Storage:

Pumps with carbon ceramic seals must have impellers manually rotated (6 revolutions) after setting non-op er a tion al for 3 months or longer and prior to electrical start-up.

Seal Failure Probes:

All hazardous location submersible pumps have two factory-installed mois ture detectors (seal failure probes). They are in a normally open series circuit in the seal chamber. Un der normal operating con di tions the circuit remains open. If the lower seal leaks and moisture enters this cham ber, the moisture would settle to the bottom of the chamber and will com plete the circuit between the mois ture de tec tors.

This circuit must be connected to a sensing unit and signaling device. This is supplied in a Hydromatic® control panel.

NOTE: Failure to install such a device negates all warranties by Hydromatic.

Heat Sensors:

All motors in this family have heat sensors on or embedded in the motor winding to detect excessive heat. This prevents damage to the motor. If the sensor trips due to excessive winding temperature, the starter in the panel breaks power to the pump. Once the sensor resets, the starter is to be reset (automatic for FM) for continued operation of the pump. This circuitry is supplied in a Hydromatic con trol panel. The sensors are set to trip at 120 degrees Cel sius.

NOTE: Failure to install such cir cuit ry would ne gate FM approval and all warranties by Hydromatic.

Power Cords:

The power cord and heat sensor seal fail ure cord are potted into the con nec tion box cap. The cords must not be spliced.

NOTE: Each cable has a green lead. This is the ground wire and must be grounded properly per NEC and/or local codes.

Dur ing normal main te nance procedures power cords should be inspected for abnormal wear and replaced ac cord ing ly.

Overload Heaters:

If the Hydromatic electrical pan el is not used, starters with 3-leg overload relay must be supplied on 3-phase pumps.

Each leg is to have an identical heater sized in accordance with the nameplate amps on the motor housing. The amp draw on these sub mers ible motors is slightly higher than a corresponding horsepower sur face motor, so heaters must be sized by the nameplate rat ing.

Single-phase pumps with capacitor start have a run and a start winding, each drawing a different current. To adequately protect these windings with the appropriate heaters, consult the factory.

NOTE: Red lead is always the start wind ing of the single phase pump.

Pump Installation Installing Pump in Sump:

Before installing pump in sump, lay it on its side and rotate impeller. Im pel ler may be slightly stuck due to fac to ry test water so certifications. While prying evenly on both sides; separate the cord cap casting from the motor housing, the assembly is airtight and will have a vacuum effect when disassembling. Once separated, the cord cap can be inverted and rotated to the outside of the pump assembly, and a bolt can be re-used to secure the upside down cord cap to the motor housing for ease of rewiring.

Refer to the wiring diagram within this manual for wiring details.

Once all electrical connections are finished and secure (a crimped electrical connector is best to prevent issues due to vibration if required), the cord cap should be re-attached reversing the steps above. Ensure the o-ring is in place and perform a hi-pot test for safety once everything is complete.

Heat Sensor and Seal Failure Connections:

If a Hydromatic control panel is used, terminal blocks are provided for heat sensor and seal failure con nec tions. If a control panel is supplied by others, it must allow heat sensor and seal fail ure terminations.

Installing Sump Level Control Float Controls:

In either simplex, duplex or triplex systems the lower or turn-off control is to be set to maintain a minimum level in the sump. This level shall be no more than 31⁄4" from the top of the motor housing down to the surface of the sewage.

The second, or turn-on control, is set above the lower turn-off control. The exact distance between the two floats must be a com pro mise between a frequent pumping cycle (10 starts per hr.

max.) to control septicity, solids and a slower cycle for energy econ o my. This distance should be determined by the engineer or con-sult ing engineer, depending on the conditions of the ap pli ca tion.

and that the pumps are submerged in a vertical position. The complete factory-built packaged sys tem is recommended for the most satisfactory and economical in stal la tion.

Making Electrical Connections:

All electrical wiring must be in ac cor dance with local code, and only qual i fied electricians should make the in stal la tions. All wires should be checked for shorts to ground with an ohmmeter or Megger after the con nec tions are made. This is important, as one grounded wire can cause considerable trouble.

IMPORTANT: If equipment is not properly wired and protected as recommended, Hydromatic warranty is void.

Caution: The 230 volt 3 phase pump has a dual marked nameplate. Voltage may be rewired by the manufacturer or a Class I Div 1 equipment qualified electrician. Once the voltage is changed, the factory cord tag indicating 230 volt 3 phase must be removed.

For record keeping purposes, we suggest the pump be marked externally with the new voltage and qualified personnel that performed the change. Pumps shipped from the factory as 460 volt 3 phase cannot be rewired to any other voltage.

To Re-wire the pump from 230V to 460V 3 phase:

Only a 230V pump from the factory is considered dual voltage, a cord label clearly states the factory wound voltage.

Remove bolts securing cord assembly then raise the cord cap assembly enough to slip a prying instrument on opposite sides between the cord cap casting and the junction box. Take care to not damage the o-ring or the machined surfaces of the castings.

Doing so could void FM agency it must be broken loose with a small bar or screwdriver in edge of vanes. The impeller should turn freely. Do not connect the power until after this test.

Clean all trash and sticks from sump and connect pump to piping.

A check valve must be installed on each pump.

Location:

If pumps are installed in an existing basin or concrete sump, the piping can either be connected permanently or rails and brackets can be furnished for mounting to walls of basin. In either case, be sure the Hydromatic® solids handling ball check valve is used

208 - 230V SINGLE PHASE

T4 T5 T8

BLACK

L2

WHITE

L1

RED

L3

P1 (PURPLE)

P2 (BROWN)

MOTOR LEADS

230V (DUAL VOLTAGE) THREE PHASE

P1 (PURPLE)

P2 (BROWN)

T7 T8 T9

T1 T2 T3

T4 T5 T6

BLACK

L2

WHITE

L1

RED

L3

200V AND 575V THREE PHASE

T1 T2 T3

BLACK

L2

WHITE

L1

RED

L3

P1 (PURPLE)

P2 (BROWN)

460V (DUAL VOLTAGE) THREE PHASE

PL (PURPLE)

P2 (BROWN)

T7 T8 T9

T1 T2 T3

T4 T5 T6

BLACK

L2

WHITE

L1

RED

L3

SENSOR LEADS

COLOR PURPOSE

Red Seal Failure

Pink Seal Failure

White Heat Sensor

Black Heat Sensor

Green Ground

Pump Operations WARNING: Keep hands and cloth ing away from cutters and impeller!

1. If pump is 3 phase, the rotation of the impeller must first be checked. Lift pump from sump, lay it down, and quickly turn pump on and then off.

The impeller should turn coun ter clock wise when viewed from the suction. If rotation is wrong, turn off main breaker and interchange any two line leads to motor to correct rotation.

If pump is single phase, no ro ta tion check is necessary.

2. Run water into sump until motor is covered.

3. Open gate valve in discharge line.

4. Turn pump on. If pump runs and sump liquid does not pump down, stop pump and close discharge gate valve.

Then lift pump until sealing flange is open to vent off trapped air. Lower pump, open discharge valve, and start the pump again.

5. If pump is 3 phase, piped in per ma nent ly, and still does not op er ate properly after venting, rotation is wrong and can be re versed by interchanging any two line leads.

6. Level controls should be set in accordance with “Installing Sump Level Control Float Controls”.

CAUTION: Be sure ground wire is connected to a good ground. This is important for safety.

Pump Maintenance As the motors are oil filled, no lubrication or other maintenance is re quired.

If the heat sensor and seal failure are hooked up properly, no attention is necessary as long as the seal failure indicator light doesn’t come on. To ensure continuity of the seal sensor leads, a test light is provided on intrinsically safe Hydromatic® panels as standard equipment.

Pump should be checked every quar ter for corrosion and wear.

Servicing Instructions:

Field Service on Hydromatic Hazardous Location Pumps:

If a Hydromatic hazardous location pump is used in a hazardous location, or if the pump is still in warranty, the pump must be returned to the factory for service or repaired at an au thorized Hydromatic service center. This will ensure the integrity of the hazardous location rating of the pump and comply with the warranty require ments.

Disconnecting Pump Cords:

If a Hydromatic hazardous location pump is to be removed from its lo ca tion, the pump cords may be dis con nect ed at the control panel (on sump mount ed control panels) and cord assembly taken with pump.

CAUTION: If cord openings from sump to control panel are open, gases from sump could enter panel and an explosive condition could exist. Seal openings!

Replacing Cords:

The power cord and heat sensor/ seal failure cord are potted into the con nec tion box cap, forming the cord and cap assembly.

If cords require replacement due to damage or cords being too short, cord and cap assembly must be replaced as a complete as sem bly from the factory. Check pump for proper rotation before returning to normal service.

Replacing Grinder Parts:

If necessary to replace grinder parts because of wear or to inspect for clog ging:

1. Close gate valve at pump dis charge.

2. Turn off circuit breaker.

3. Remove pump from sump.

4. Remove machine screws and remove cutter ring retainer.

Remove cutter ring.

5. Unscrew cap screws and remove volute case.

6. Radial cutter and axial cutter are now exposed. If checking for clogging, these parts can now be cleaned without removing them from the shaft.

7. If necessary to replace cutters, remove screw, washer, and radial cutter from shaft.

Radial cutter and impeller are screwed onto shaft. The thread is right-hand. Tap radial cutter with plastic hammer if necessary to loosen. Axial cutter lifts off impeller and is held from rotation by pin. Unscrew impeller from shaft in same manner as radial cutter, and remove washer.

8. Clean all parts thoroughly before proceeding with assembly. Make sure spring pin is inserted into impeller.

Replace case volute and cap screws.

9. Replace cutter ring and cutter ring retainer with machine screws.

10. Plug pump into power and operate for a few seconds only to ensure parts are not rubbing.

Replacing Lower Seal, Impeller or Volute:

The wet end components may be repaired or replaced by an authorized Hydromatic service facility without compromising the hazardous location rating to the pump.

NOTE: Any time the seal is disturbed, it must be replaced.

Pump Troubleshooting No liquid delivered.

1. Pump air bound

2. Discharge head too high

3. Pump or piping plugged

4. Wrong rotation

5. Speed too low

Insufficient liquid delivered.

1. Discharge head too high

2. Impeller or cutters partially plugged or damaged

3. Wrong rotation

4. Incorrect diameter impeller

5. Speed too low

Insufficient discharge pressure.

1. Wrong rotation

2. Air or gases in liquid

3. Impeller damaged

4. Incorrect impeller diameter

5. Speed too low

Pump overloads motor.

1. Wrong rotation

2. Specific gravity or viscosity of liquid too high

3. Speed too high

4. Head lower than rating, pumping too much liquid

5. Pump clogged

6. Defective bearings

7. Defective impeller

Pump is noisy.

1. Defective bearings

2. No axial clearance between im pel ler and volute

3. No axial clearance between radial cutter and cutter ring

If the cause of the trouble cannot be determined and corrected, contact the factory or an authorized Hydromatic® service facility.

Wiring Diagrams

Notes: S — Parts in Seal Kit.

HPGX200 Parts List Ref.

No.

Part No.

Part Description Qty.

1 152750325 35' Cord Assembly

– 14-4

152750305 35' Cord Assembly

– 12-4

152750315 35' Cord Assembly

– 10-4

2 19100A029 Screw – Cap 2 3 05876A244 O-Ring S 1 4 108980001 Connector 2 5 077630001 Cutter Retaining Ring 1 6 049180001 Lower Seal Seat S 1 7 054050012 Radial Cutter 1 8 05876A120 O-Ring S 1 9 109000015 Seal Sensor Assy. 1 10 109010011 Seal Failure Probe 2 11 000650271 Lower Bearing 1 12 055060022 Axial Cutter 1 13 05876A103 O-Ring S 1 14 055050002 Cutter Ring 1 15 008340231 O-Ring S 1 16 054040075 Seal Plate Assy. 1 17 070333022 Impeller – 5.00"

Diameter

070333032 Impeller – 4.75" Diameter

070333042 Impeller – 4.50" Diameter

070333052 Impeller – 4.25" Diameter

070333062 Impeller – 4.00" Diameter

070333072 Impeller – 3.75" Diameter

18 000190011 Machine Screw – (Rd Hd)

19 055700051 Impeller Washer 1 20 148850001 Impeller Screw 1 21 054190011 Roll Pin 1 22 049170001 Lower Seal –

(Rotating) S 1

23 109570002 Volute 1 24 105-014034-263 Screw – Socket 4 25 009750021 Snap Ring 1 26 109561002 Seal Housing 1 27 003000001 Upper Seal S 1 28 001780061 Screw – Socket 4 29 001450101 Machine Screw 4 30 05454A009 Lock Washer 4 31 21573C102 Stator – 2 hp, 230/460/3/60

21573C101 Stator – 2 hp, 200/3/60

21573C103 Stator – 2 hp, 575/3/60

21573C100 Stator – 2 hp, 230/1/60

21573C104 Stator – 2 hp, 200/1/60

32 108231015 Rotor & Shaft Assy. – 2 hp, 3f

108321015 Rotor & Shaft Assy. – 2 hp, 1f

33 134940042 Motor Housing 1 34 000650011 Upper Bearing 1 35 000640011 Wave Spring 1

517005007 Seal Kit 131880001 Shim – Cutter As

Req’d.

006280391 Shim – Impeller As

Req’d.

Warranty Rev. 12/13

STANDARD LIMITED WARRANTY

Pentair Hydromatic® warrants its products against defects in material and workmanship for a period of 12 months from the date of shipment from Pentair Hydromatic or 18 months from the manufacturing date, whichever occurs first – provided that such products are used in compliance with the requirements of the Pentair Hydromatic catalog and technical manuals for use in pumping raw sewage, municipal wastewater or similar, abrasive-free, noncorrosive liquids.

During the warranty period and subject to the conditions set forth, Pentair Hydromatic, at its discretion, will repair or replace to the original user, the parts that prove defective in materials and workmanship. Pentair Hydromatic reserves the right to change or improve its products or any portions thereof without being obligated to provide such a change or improvement for prior sold and/or shipped units.

Start-up reports and electrical schematics may be required to support warranty claims. Submit at the time of start up through the Pentair Hydromatic website: http://forms.pentairliterature.com/startupform/startupform.asp?type=h.

Warranty is effective only if Pentair Hydromatic authorized control panels are used. All seal fail and heat sensing devices must be hooked up, functional and monitored or this warranty will be void. Pentair Hydromatic will cover only the lower seal and labor thereof for all dual seal pumps. Under no circumstance will Pentair Hydromatic be responsible for the cost of field labor, travel expenses, rented equipment, removal/reinstallation costs or freight expenses to and from the factory or an authorized Pentair Hydromatic service facility.

This limited warranty will not apply: (a) to defects or malfunctions resulting from failure to properly install, operate or maintain the unit in accordance with the printed instructions provided; (b) to failures resulting from abuse, accident or negligence; (c) to normal maintenance services and parts used in connection with such service; (d) to units that are not installed in accordance with applicable local codes, ordinances and good trade practices; (e) if the unit is moved from its original installation location; (f) if unit is used for purposes other than for what it is designed and manufactured; (g) to any unit that has been repaired or altered by anyone other than Pentair Hydromatic or an authorized Pentair Hydromatic service provider; (h) to any unit that has been repaired using non factory specified/ OEM parts.

Warranty Exclusions: PENTAIR HYDROMATIC MAKES NO EXPRESS OR IMPLIED WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. PENTAIR HYDROMATIC SPECIFICALLY DISCLAIMS THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE.

Liability Limitation: IN NO EVENT SHALL PENTAIR HYDROMATIC BE LIABLE OR RESPONSIBLE FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES RESULTING FROM OR RELATED IN ANY MANNER TO ANY PENTAIR HYDROMATIC PRODUCT OR PARTS THEREOF. PERSONAL INJURY AND/OR PROPERTY DAMAGE MAY RESULT FROM IMPROPER INSTALLATION. PENTAIR HYDROMATIC DISCLAIMS ALL LIABILITY, INCLUDING LIABILITY UNDER THIS WARRANTY, FOR IMPROPER INSTALLATION. PENTAIR HYDROMATIC RECOMMENDS

INSTALLATION BY PROFESSIONALS.

Some states do not permit some or all of the above warranty limitations or the exclusion or limitation of incidental or consequential damages and therefore such limitations may not apply to you. No warranties or representations at any time made by any representatives of Pentair Hydromatic shall vary or expand the provision hereof.

1101 MYERS PARKWAY 490 PINEBUSH ROAD, UNIT 4

ASHLAND, OHIO 44805 CAMBRIDGE, ONTARIO, CANADA N1T 0A5

PH: 855-274-8947 PH: 800-363-7867

WWW.HYDROMATIC.COM