2 HP Centrifugal Grinder Semi Open Impeller Pump HPG200 - Manuel

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 HPG200ADVANCED SUBMERSIBLE GRINDER PUMPINSTALLATION AND SERVICE MANUALItem # E-03-407 | Part # 5625-407-1 | © 2013 Pentair Ltd. | 11/20/13 2General 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 tin ued safe product use. DO NOT THROW AWAY OR LOSE THIS MAN U AL. Keep it in a safe place so that you may refer to it often. Reasonable care and safe meth ods should be practiced. Check local codes and requirements before installation.WARNING: Before handling these pumps and controls, always disconnect the power first. Do not smoke or use sparkable electrical devices or flames in a septic (gaseous) or possible septic sump.Pump Cautions and Warnings 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. 1. CAUTION – To reduce risk of electrical shock, pull plug before servicing this pump. 2. WARNING – Risk of electrical shock– this pump has not been investigated for use in swimming pool areas. 3. WARNING – See installation and service manual for proper installation. 4. WARNING – To reduce risk of electrical shock, pump is provided with grounding wire. Be certain that it is connected to ground. 5. WARNING – Hazardous moving parts. To reduce the risk of injury, disconnect power before servicing pump. 6. CAUTION – To reduce the risk of electrical shock, DO NOT remove cord or strain relief. DO NOT connect conduit to pump. Electrical installations shall be in accordance with the National Electrical Code and all applicable local codes and ordinances. 7. For use with maximum 140°F water. 8. Septic tank should be vented in accordance with local plumbing codes and should not be installed in locations classified as hazardous, in accordance with the National Electrical Code, ANSI/NFPA 70-1999. 9. WARNING – Severe injury may result from accidental contact with moving cutters. Keep clothing, hands and feet away from cutters any time power is connected to the pump. 10. CAUTION – Never work on pump with power on. Make sure that the ground wire is securely connected and that the unit is properly grounded in accordance with local codes.The Pump Pump Description:The Hydromatic® pumps covered by these instructions are submersible grinder pumps.The cutter blades are on the suction side of the cen trif u gal pump impeller and dis charge directly into the inlet of the im pel ler. The integral stain less steel pump motor shaft is sealed by two me chan i cal seals with an oil chamber between the seals to pro vide lubrication for both seal faces.Two ball bearings are used to handle the loads in this de sign, similar to most of Hydromatic’s solids handling pumps. The upper bearing takes radial load, while the larger lower bear ing handles both thrust and radial loads. Both bearings are permanently lu bri cat ed by the dielectric oil in the motor housing. The motor is fixed within the motor housing and is com plete ly submerged in the di elec tric oil for maximum heat transfer. The motor housing and seal cham ber are com pletely sealed with O-rings located at mating part faces.The power cord entry system is designed to give double seal ing. The chamfered pilot of the motor housing mates with the molded cord end to form the first seal. The cord grip forms the second seal around the molded cord end and provides strain relief. The ca ble on the HPG model includes the leads for both heat sensors (motor protection) and the seal sen sor lead for seal leakage de tec tion. The cutters are designed to be self adjusting and will not need to be shimmed or reset.Application:These pumps are designed for either residential or industrial sew age discharge ap pli ca tions with a pH ranging from 5 to 9, spe cif ic gravities from 0.9 to 1.1, viscosities ranging from 28 to 35 S.S.U., and tem per a tures up to 140°F.Codes:All local wiring codes must be observed. Consult the local inspector before in stal la tion to avoid costly delays that can occur due to rejection after job is finished.3Pump Installation Unpacking Pump:Remove pump from carton. When un pack ing unit, check for con cealed damage. Claims for damage must be made at the receiving end through the delivery carrier. Dam age cannot be processed from the factory.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 fur nished for mounting to walls of basin. In either case, be sure that the Hydromatic® solids handling check valve is used and that the pumps are submerged in a vertical position. The complete factory built packaged system is recommended for the most satisfactory installation and generally for the low est cost where expensive instal la tion labor is involved.Electrical Connections:Make all connections from motor to control panel to com ply with local codes.CAUTION: Make sure that the ground wire is securely connected and that the unit is properly grounded in accordance with local codes. ELECTRICAL CONNECTIONS 1 Phase 3 PhaseGreen Ground Ground Red Start Power Line Power LineWhite Main Power Line Power LineBlack Common Power Line Power LineOrange Seal Failure Seal FailureBlue Heat Sensor Heat SensorWhite Heat Sensor Heat Sensor w/ black stripe:+,7(?:?%/$&.?675,3(???3?%/8(???3?25$1*(???6($/?352%(6(1625?/($'6?????????9?6,1*/(?3+$6(7??:+,7(? ?%/$&.? ?5('?7? 7?%/$&./?:+,7(/? 5('/? 3???3853/(?3???%52:1?02725?/($'6???9??'8$/?92/7$*(??7+5((?3+$6(3???3853/(?3???'$5.?%52:1?7??3,1.? ?5('? ?/7??%52:1??%/8(? ?7$1? ?25$1*(?7? 7?7? 7? 7?7??<(//2:? ?%/$&.? ?/$9(1'(5?7? 7?%/$&./?:+,7(/? 5('/????9?$1'????9?7+5((?3+$6(7??%/8(? ?7$1? ?25$1*(?7? 7?%/$&./?:+,7(/? 5('/? 3???3853/(?3???%52:1????9??'8$/?92/7$*(??7+5((?3+$6(3/??3853/(?3???'$5.?%52:1?7??3,1.? ?5('? (LT. BROWN)?%/8(? ?7$1? ?25$1*(?7? 7?7? 7? 7?7??<(//2:? ?%/$&.? ?/$9(1'(5?7? 7?%/$&./?:+,7(/? 5('/?Pump OperationsStarting the Pump:To start the pump, perform the following steps in order: 1. If pump is 3 phase, the rotation of the cutters must first be checked. Lift pump from sump, lay it down, and quickly turn pump on and then off. The cutter should turn counterclockwise 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 rotation check is necessary. 2. Run water into sump until motor is covered. 3. Open the gate valve in the dis charge 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 permanently, and still does not operate properly af ter venting, rotation is wrong and can be reversed by in ter chang ing any two line leads. 6. Level controls should be set so that pump turns off when level is about 2 inches above inlet of pump suction and turns on when level is about 2 inches above motor. 7. If problems occur check the power source. Make sure a separate supply line is available. Verify the voltage supply. 8. Check resistance windings (see chart). If not within guidelines, return pump to an authorized Hydromatic service center.4ring that secures the lower seal. Remove the lower seal rotating elements by sliding the spring off the shaft. Then using two screwdrivers, slide the carbon assembly off by prying on the retaining ring. 5. Loosen and remove the cap screws that hold on the seal housing, then re move the seal housing. Using a socket that will fit onto the back of the seal, tap the sta tionary seal assembly out of the seal housing. 6. Using a pair of snap ring pliers, remove the snap ring that secures the up per seal. Remove the spring retainer and spring from the shaft, and using the same method as used for the lower seal, remove the carbon seal assembly. 7. With a pair of screwdrivers, pry up on the seal/bearing plate. Remove the seal/bearing plate until you have access to the seal sensor wire, then carefully pull the seal sensor wire off the seal probe which will allow the complete removal of the seal bearing plate.2 3450 208 1 1.30 5.08 6.35 2 3450 230 1 1.57 8.00 9.572 3450 200 3 2.86 2.86 2.862 3450 230 3 3.31 3.31 3.312 3450 460 3 13.25 13.25 13.252 3450 575 3 28.2 28.2 28.2hp RPM VOLT PHASE BLACK TO BLACK RED WHITE TO RED TO WHITE WINDING RE SIS TANCE IN OHMSMAXIMUM AMP & WINDING RESISTANCE VALUESSINGLE PHASE THREE PHASEBLACK - COMMON BLACK - L1WHITE - MAIN WHITE - L2RED - START RED - L3Pump MaintenancePump Disassembly, Inspection, Reassembly: 1. Close gate valve at pump discharge. 2. Turn off circuit break er. 3. Remove pump from sump. 4. Unscrew cap screws and remove the volute from the pump. Note: under certain circumstances it may be necessary to remove the discharge piping. 5. Remove the axial and radial cutters from the shaft and inspect for excessive wear or damage. If the axial cutter is damaged or is excessively worn, flip the axial cutter to the unworn side and reattach to the radial cutter. 6. Inspect the stationary cutter for wear or damage. If the cutter requires removal, loosen the machine screw in cutter retainer and remove cutter retainer and slide the cutter out of the volute. If cutter is damaged or worn, reinstall on the opposite side, making sure to snug (DO NOT OVERTIGHTEN) the Allen head screw. It is good practice to add a light coat of removable locking adhesive to the Allen screw. 7. Inspect the volute O-ring for damage. If cracked or torn, replace with the proper Hydromatic® part. 8. To reassemble the pump, place the cutters on the splined shaft and orient the cutters so that the axial cutter blades fall between the impeller vanes. Hold tension on the cutters and replace the volute and cap screws, making sure the O-ring is placed in the proper position. Evenly torque the cap screws.Replacing Seals on Dual Seal HPG200 Model: 1. Drain the oil in the seal chamber by removing the drain plug on the side of the pump. If it con tains water, the lower seal has failed and should be replaced. The motor hous ing should be drained and the upper seal replaced if the lower seal has failed, since foreign material in the seal chamber may have dam aged the upper seal. 2. Remove the volute and cutters per the instrutions listed under the Pump Disassembly, Inspection, Reassembly section in this manual. 3. To remove the impeller, secure the shaft by threading the radial cutter onto the shaft and holding it with a pair of pliers. Hold a wood block against the impeller vane and tap it with a hammer until it spins off. 4. Using a pair of snap ring pliers, remove the snap 5NOTE: It is normal to observe some air bubbles in the seal area initially as the seal seats. If bubbles do not stop within a few seconds, the seal is either not properly installed or is damaged. 14. Following the same procedure outlined in steps 10 through 13, install the low er seal assembly. Re place the impeller using a re mov able locking adhesive. 15. Reassemble the cut ters and volute as outlined in the Pump Disassembly, Inspection, Reassembly section of this manual. 16. Refill all cham bers with a good quality di elec tric oil. Fill the motor housing so that the tops of the motor windings have been covered (2500 ml), but leave an air gap to allow for ex pan sion of the oil. Fill the seal chamber with 700 ml of oil so that an air gap also exists.Replacing Motor Stator: 1. If the replacement of the stator is necessary, first follow the disassembly steps outlined in the previous sections of the manual. 2. Remove the shaft rotor assembly from the motor housing, making note that a wave washer is used on the top of the upper bearing. 3. Place motor housing vertically on the bench and remove the cord grip. Carefully remove the power cord from the pump, making sure that the wires are not damaged. Clip the power cable leads, taking 8. Take a socket and tap out the stationary portion of the seal from the seal/bearing plate in the same manner as used for the lower stationary seal. 9. After checking both of the O-rings, replace the seal bearing plate in the motor housing, making sure that the seal sensor wire has been reattached to the seal probe. Use O-ring lube to prevent cutting in assembly. 10. Take the sta tion ary portion of the new seal, and lube the rubber material with a good quality dielectric oil. Press the stationary portion of the new seal into the seal/bearing plate. CAUTION: Do not reuse old seal parts. Replace all parts with new. Mixing old and new parts could cause im me di ate seal failure. 11. Using a good quality dielectric oil, lube the rubber material on the carbon seal assembly and press it on the shaft. Place the spring and the seal retainer on the shaft as removed. Replace the snap ring. 12. Carefully place the seal housing onto the seal bearing plate, re place the cap screws, and evenly tighten. 13. Using a pressure gauge with a fill stem, pres sur ize the motor housing to no more than 7 psig with dried air and check for leaks. If after several minutes the gauge reads the same, the seal is good and you can con tin ue with assembly.note of the wire connections, and then remove the power cable. 4. Turn the motor housing over and remove the stator bolts from the stator, then remove the stator from the motor housing. 5. Place new stator into the motor housing while pulling the new leads through the power cord opening in the motor housing. Replace the stator bolts and tighten. Replace the seal sensor wire along the side of the stator. 6. Attach the power cord to the stator leads and the sensor leads using insulated butt connector.Once attached, carefully tuck the wires into the motor housing making sure that they will not come in contact with the rotor. Press the power cord molded end into chamber in the motor housing. 7. Apply a sealant to the threads on the body of the cord grip that will enter the motor housing, then slide onto the power cord and tighten snugly. DO NOT OVERTIGHTEN. Attach the cord grip nut onto the cord grip and snug. 8. Examine the bearings on the shaft/rotor assembly. If when rotated they feel rough, replace. When reinstalling new bearings, press only on the inner ring of the bearing or damage may occur. 9. Replace the wave washer into the upper bearing pocket in the motor housing, then reinstall the rotor and shaft assembly.6 10. Follow the previously outlined steps to reassemble the pump from this point. 11. Always run pump for a few seconds after assembly work to be sure all parts run smoothly before replacing it in the sump. Check again for correct rotation. Pump should rotate counterclockwise when viewed from the suction end.NOTE: When applying pow er, be sure the pump is restrained from turning by holding the pump at the motor hous ing, or by clamping it in a holding fixture.Pump TroubleshootingBelow is a list of troubles and their probable causes:No liquid delivered 1. Pump air bound 2. Discharge head too high 3. Pump or piping plugged 4. Wrong rotation 5. Speed too lowInsufficient liquid de liv ered 1. Discharge head too high 2. Impeller or cutters impartially plugged or damaged 3. Wrong rotation 4. Incorrect diameter im pel ler 5. Speed too lowInsufficient discharge pressure 1. Wrong rotation 2. Air or gases in liquid 3. Impeller damages 4. Incorrect impeller di am e ter 5. Speed too lowPump overloads motor 1. Wrong rotation 2. Specific gravity or vis cos i ty of liquid too high 3. Speed too high 4. Head lower than rat ing, pumping too much liquid 5. Pump clogged 6. Defective bearings 7. Defective impellerPump is noisy 1. Defective bearings 2. No axial clearance be tween impeller and volute 3. No diametral clear ance between radial cutter and cutter ringIf the cause of the trouble cannot be determined and cor rect ed as outlined above, con tact your nearest factory rep re sen ta tive.77Notes: S – Parts in Seal Kit – Fill oil to above motor windingsORDERING REPLACEMENT PARTS: Product improvements are made from time to time. The latest part design will be fur-nished as long as it is in ter change able with the old part.When ordering re place ment parts, always furnish the fol low ing information: (1) pump serial num ber, (2) pump model and size, (3) part description, (4) part number, (5) im pel ler diameter (if ordering impeller), (6) quan ti ty required and (7) shipping instructions.HPG200 Parts List32 3130282725 2624232282120191817613924578101112 13 14 15 162933Ref.No.Part No.Part Description Qty.1 144240025 POWER CORD – 20' 1144240115 POWER CORD – 35' 12 116750001 BUTT CONNECTOR230, 1f; 200, 1f; 575, 3f; 200, 3f 6230, 3f 3460, 3f 93 116910001 BUTT CONNECTOR 34 060000141 WIRE w/TERMINAL 15 134880002 SEAL/BEARING PLATE 16 084720015 SEAL FAILURE ASSY. 17 05876A120 O-RING S 28 003000001 SHAFT SEAL – 1" S 29 000730011 WIRE CONNECTOR – 230, 3f 110 001500421 O-RING S 111 070330023 IMPELLER – 5.00" 1070330043 IMPELLER – 4.50" 1070330063 IMPELLER – 4.00" 112 055060022 AXIAL CUTTER 113 054050012 RADIAL CUTTER 114 148850001 MACHINE SCREW 115 055700051 IMPELLER WASHER 116 055050002 STATIONARY CUTTER 117 000300041 MACHINE SCREW 318 077630001 CUTTER RETAINER 119 135001002 VOLUTE CASE 120 19100A012 HEX HEAD CAP SCREW – 5/16 421 009750021 RETAINING RING 222 134890012 SEAL HOUSING 123 001010111 HEX HEAD CAP SCREW – 5/16 424 000650271 BALL BEARING 125 000250091 MACHINE SCREW PER B/M 426 05454A009 LOCK WASHER 427 21573C100 STATOR – 230V, 1f 121573C102 STATOR – 230–460V, 3f 121573C103 STATOR – 575V, 3f 121573C101 STATOR – 200V, 3f 121573C104 STATOR – 200V, 1f 128 108321005 ROTOR/SHAFT – 1f 1108231005 ROTOR/SHAFT – 3f 129 134950002 HORIZONTAL ADAPTER 130 134941002 MOTOR HOUSING 131 08565A013 BALL BEARING 132 000640011 WAVE SPRING 133 134962002 VERTICAL ADAPTER (std.) 1* 517004027 SEAL KIT131880001 CUTTER SHIM As Req’d.006280391 IMPELLER SHIM As Req’d.740 EAST 9TH STREET 490 PinEbuSH RoAd, uniT #4 ASHLAnd, oHio, uSA 44805 CAMbRidGE, onTARio, CAnAdA n1T 0A5 419-289-1144 800-363-PuMP WWW.HYdRoMATiC.CoMWarranty Rev. 12/13STANDARD LIMITED WARRANTYPentair 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.