Submersible Grinder Pumps D2CX20-21- Brochure

23833A596 1Submersible CentrifugalGrinder PumpInstallation & Service Manualwith Parts ListNOTE To the installer: Please make sure you providethis manual to the owner of the pumping equipment orto the responsible party who maintains the system.D2CX20-2123833A5962MUST BE INSTALLED BY EXPERIENCEDPROFESSIONALS ONLYCAUTION: READ THESE SAFETY WARNINGS FIRSTBEFORE INSTALLATION, SERVICING OR OPERAT-ING ANY PUMP. THESE INSTRUCTIONS AREWRITTEN WITH THE UNDERSTANDING THAT THEINDIVIDUALS) HAVE EXPERIENCE IN BUILDINGWET WELLS AND INSTALLING BASINS, GRINDERPUMPS AND PUMPING EQUIPMENT.NOTE: Models with Third Party approval(s) are clearlymarked on individual pump nameplates.WARNING RISK OF ELECTRICAL SHOCK. TOREDUCE RISK OF ELECTRICAL SHOCK, SEEINSTRUCTION MANUAL FOR INSTALLATION.DO NOT REMOVE CORD AND STRAIN RELIEF.ALL THREE PHASE PUMPS MUST BE INSTALLEDWITH MAGNETIC STARTERS HAVING THREE LEGOVERLOAD PROTECTION IN ACCORDANCE WITHTHE NATIONAL ELECTRIC CODE. FOR DUPLEXINSTALLATIONS, BOTH PUMP MOTORS MUST HAVESEPARATE OVERLOAD PROTECTION.WARNING ONLY QUALIFIED PERSONS SHALLCONDUCT SERVICES AND INSTALLATIONS OFTHIS PUMP. THE PUMP MUST BE WIRED BY AQUALIFIED ELECTRICIAN.PUMPS WITH SEAL LEAK DETECTORS, MUST BECONNECTED TO THE PROPER CONTROL CIR-CUITRY. SEE INSTRUCTIONS MANUAL.DANGER HAZARDOUS MOVING PARTS. TOREDUCE RISK OF INJURY DISCONNECT POWERBEFORE SERVICING. NEVER PUT FINGERS NEARGRINDER IMPELLER OR IN PUMP INLET WENPUMP CORD IS CONNECTED OR PUMP IS OPERAT-ING.FOR USE WITH MAXIMUM 140°F LIQUID. ACCEPT-ABLE FOR OUTDOOR USE.DANGER IN THE INITIAL INSTALLATION, BE-FORE SEWAGE IS ADMITTED TO THE BASIN,THERE IS NO DANGER ON ENTERING THE BASIN,BUT AFTER SEWAGE HAS BEEN IN THE BASINTHERE IS DANGER. SEWAGE WATER GIVES OFFMETHANE AND HYDROGEN SULFIDE GASSES,BOTH OF WHICH ARE HIGHLY POISONOUS. ABREATHING DEVICE MAY BE REQUIRED. NEVERENTER BASIN UNLESS COVER IS OPEN AND ANOUTSIDE BLOWER IS USED. TO FORCE FRESH AIRINTO THE BASIN. ALSO, THE WORKER IN THEBASIN MUST WEAR A HARNESS ATTACHED TO THESURFACE SO THAT HE CAN BE PULLED OUT INCASE OF ASPHYXIATION. NEVER WORK ALONEWARNING DO NOT EXCEED WORKING LOADLIMIT OF LIFTING ROPE OR CHAIN. DO NOT USELIFTING ROPE OR CHAIN WHERE FAILURE COULDRESULT IN LOSS OF LIFE.EXAMINE ALL LIFTING DEVICES, ROPE OR CHAINFOR DAMAGE BEFORE AND AFTER EACH LIFT.DO NOT USE ANY LIFTING DEVICES THAT ARE NOTRATED FOR AND DESIGNED TO LIFT THE WEIGHTSINVOLVED WITH THESE PUMPS.DO NOT INSTALL OR REMOVE PUMP WITHPERSON(S) IN BASIN.GENERAL1. Most accidents can be avoided by using COMMONSENSE.2. Read the operation and maintenance instructionsmanual supplied with the pump.3. DO NOT wear loose clothing that can becomeentangled in the impeller or other moving parts.4. This pump is designed to handle materials whichcould cause illness or disease through directexposure.Wear and use protective clothing when working on thepump or piping.ELECTRICAL1. To reduce the risk of electrical shock, pumpmust be properly ground in accordance with theNational Electric Code and all applicable stateand local codes and ordinances.2. To reduce risk of electrical shock, disconnect thepump from the power source before handling orservicing.3. Any wiring to be done on pumps should be done bya qualified electrician.4. NEVER operate a pump with a power cord that hasfrayed or brittle insulation.5. NEVER let cords or plugs lay in water.6. NEVER handle connected power cords with wethands.SAFETY CAUTIONS AND WARNINGS23833A596 3PUMP1. Pump builds up heat and pressure during opera-tion, allow time for pump to cool before handling orservicing.2. Only qualified personnel should install, operate orrepair pump.3. Keep clear of suction and discharge openings. DONOT insert fingers in pump with power connected.4. DO NOT pump hazardous material not recom-mended for pump (flammable, caustic, etc.).5. Make sure lifting devices are securely fastenedeach time before lifting pump.6. DO NOT LIFT PUMP BY THE POWER CORD.7. DO NOT exceed manufacturer’s recommendationfor maximum performance, as this could cause themotor to overheat.8. Secure the pump in its operating position so itcannot tip over, fall or slide.9. Keep hands and feet away from impeller whenpower is connected.10. Submersible grinder pumps are not approved foruse in swimming pools, recreational water installa-tions, decorative fountains or any installation wherehuman contact with the pumped fluid is common.11. DO NOT pump without safety devices in place.12. For hazardous locations, use pumps that are listedand classified for such locations.13. DO NOT use non-explosion proof rated pumps inlocations considered hazardous in accordance withthe National Electrical Code, ANSI/NFPA 70-1993.14. Basin must be vented in accordance with the localplumbing codes.IMPORTANT: Manufacturer is not responsible forlosses, injury or death resulting from failure to observethese safety precautions, misuse or abuse of pumpsor equipment.CONTROL PANELSAll control panels used on these grinders are UL listedand CSA certified. Control panels mounted directly tothe basin used outdoors are UL listed and CSAcertified waterproof.If intrinsically safe controls used in hazardous loca-tions are required, manufacturer can furnish a UL listedor CSA certified panel. Otherwise the installer mustobtain a source for the panel required.LEVEL SENSING CONTROLSIntrinsically-safe type float controls are recommendedfor all applications and required for explosion-proofservice. An intrinsically safe control panel relay willlimit the current and voltage to the level controls. ADelta control panel can be supplied with this typecircuitry.The float level controls maintain the basin sewage waterlevel by controlling pump turn-on and turn-off level.1. The lower turn-off control should be set so that thepump stops at approximately the top of the pump.2. The upper turn-on control should be set above thelower turn-off control. The exact height between thetwo controls is determined by the number of pumpstarts desired and the depth of the basin. A maxi-mum of 10 starts per hour should not be exceeded.3. The override control is set at a specified heightabove the upper turn-on control.4. The alarm control is set about 6” to 12” above theoverride control.5. No control should be set above the inlet invert.JUNCTION BOXESIf a junction box is used in a hazardous location, it mustbe an explosion-proof approved type with explosion-proofcord connectors. Wires from the junction box must passthrough an explosion-proof seal connector.CAUTION: No persons should be in the basin whenpump is lowered into position DO NOT lift pump in amanner where any failure could result in loss of life.AIR VENTINGAir tends to trap in the pump volute when water raises inthe sump or when the pump is lowered into water afterservice. To vent off this air, a small hole is drilled intothe pump volute. Be sure this vent hole is clean afterany service work on pump.PUMP MODELS — This grinder pump is made in onemodel only for use with single phase and three phasepower. Motor rating is 2 HP, 3540 RPM, 60 Hz. Alsocan be used for 50 Hz. operation. Single phase is for230 volt.PACKAGING — Each pump is packaged with 15 feet ofpower cord in a carton that is marked with ModelNumber and Engineering Number. Longer cords areavailable for special jobs.INSTRUCTIONS — Instructions cover only the pumpunit. Separate instructions for the electrical control paneland basin packaged system are included with theseitems.CAUTION: PUMP IS NOT TO BE DISASSEMBLED INTHE FIELD EXCEPT AT CERTIFIED SERVICE STA-TIONS OR AT FACTORY. WARRANTY IS VOID IFPUMP IS TAKEN APART FOR ANY REASON EXCEPTTO REPLACE GRINDER IMPELLER AND GRINDERRING WHICH IS COVERED IN THESE INSTRUCTIONS.PUMP CAUTIONS AND WARNINGS23833A5964DESCRIPTION OF PUMP — This pump is intended togrind and pump all normal sewage for home or commer-cial use. It will also handle reasonable quantities ofdisposable diapers, sanitary napkins, paper towels,rubber material, wood, plastic, string, cigarette buttsand other material not normally found in sewage.Pump is of heavy duty construction and submersibletype for long life when pumping ground sewage. Motoris capacitor start, capacitor run for single phase.Capacitors and start relay are mounted in electricalcontrol box.Pump has two oil-filled chambers: (1) the motor andball bearings and (2) the seal chamber - for long life andbest heat transfer.The lower seal above the pump impeller acts as abuffer for upper seal that holds oil in the motor chamber.If lower seal leaks for any reason, water enters the sealchamber. If motor has the seal leak detector, theelectrode will contact the water and close the circuit tothe red seal light in the control panel indicting motormust be serviced before upper seal fails.A heat sensor is attached to stator winding to senseany abnormal heat. If motor temperature for any causerises above 221°F the pump is immediately stoppedand will not restart until motor cools to a safe tempera-ture.PUMP CORDS — Each pump has two cords. Thepower cord contains 4 conductors and the control cordhas 5 conductors. The larger of the two cords is thepower cord and smaller cord is the control cord.The power cord for single phase uses the color codingfor start and main windings and connects to control boxterminal strip black (common), white (run), and red(start). The green wire is always ground and connectsto ground terminal in control box. For three phase thesame 4 conductor color coded cords are used, theblack, white and red can be connected to any of thethree phase terminals in the control box.The smaller control cord uses black and white leads forheat sensor and connects to terminal strip in controlbox. The red and orange wires connect to seal failureterminals in control box and the green or ground leadconnects to ground terminal in control box.IMPORTANT — Ground wires must be connected in thecontrol box to grounding bar, which is connected to agood outside ground. MOTOR IS NOT SAFE UNLESSGROUNDED.INSPECTING PUMP — Before making any piping orelectrical connections check pump for any shippingdamage and turn grinder impeller to be sure it is free.DO NOT TURN IMPELLER WITH FINGERS ASEDGES ARE SHARP, use socket wrench in theimpeller screw.CAUTION: After pump is installed NEVER WORK ONMOTOR OR GRINDER UNIT WITHOUT DISCONNECT-ING MOTOR LEAD WIRES FROM CONTROL PANEL.DO NOT RELY ON OPENING CIRCUIT BREAKERONLY.INSTALLING PUMP IN BASIN — Complete installationand piping instructions are included with the basinpackage.To check rotation turn Hand-Off-Auto switch to OFFposition and turn on circuit breaker. Quickly turn H-O-Aswitch to HAND position, then OFF. Note grinderimpeller rotation. Impeller must rotate counterclock-wise. If rotation is wrong, change any two line leads tomotor at control box terminal. Recheck for properrotation. CAUTION: KEEP HANDS COMPLETELYAWAY FROM GRINDER IMPELLER WHEN MAKINGTHIS CHECK.Where pump is installed remote from control box inoutside installation a different method is used.Set the pump in the basin and run in some water sopump can operate. Turn H-O-A switch to hand positionand let pump pull water down in basin. When waterreaches the bottom of pump, rotation of the water canbe observed. Water should rotate in a clockwisedirection if pump rotation is correct. If not correctrotation, interchange any two line leads to motor atcontrol panel.When replacing a pump with a new unit, rotation mustbe checked.PUMP INSTALLATION23833A596 5Fig. 1PUMP PARTS LISTRef No. Part No. Description Qty.1 22407C100 Cord Cap 13 12672A001 Connector 74 10649A102 Tube, Plastic 25 19100A012 Cap Screw, 5/16"-18 x1 1/4" Lg. 86 05876A122 Gasket, Rubber Tetraseal 17 21570B100 Cap, Upper Bearing 18 05876A123 Gasket, Rubber Tetraseal 19 05022A092 Pipe Plug, 1/4" NPT, Hex HD. 210 05434A043 Screw, Mach., #10-24 x1/2" Lg. 111 06107A015 Lock Washer, #10 112 07597A017 Screw, Mach., Flat Hd. 213 21571D100 Housing, Motor 114 11009A003K Oil, Transformer 1.0615 19331A005 Washer, Spring 216 08565A013 Bearing, Ball 117 11816A006 Ring Retaining 118 21572C100 Rotor, w/Shaft 119 21573C100 Stator 120 08565A018 Bearing, Ball 121 21574D100 Housing, Upper Seal 122 21576A010 Seal, 7/8" Shaft 223 12558A006 Ring Retaining 125 22578A004A Electrode 226 05876A125 Gasket, Rubber Tetraseal 227 22579A000 Ferrule, Rubber 128 21577A000 Plug, Special 129 21578C100 Housing, Lower Seal 133 22581A001 Gasket, Vellumoid 134 21580D102 Casing, Volute 135 21581C500 Impeller, Pump 136 21582B000 Impeller, Grinding 137 07597A018 Mach. Screw, 1/4"-20 x1" Lg. 139 21583A000 Retainer, Impeller 140 21584B000K Flange, w/Shredding Ring 141 19099A012 Cap Screw, Hex 1/4"-20 x1" Lg. 355 05013A039 Set Screw, 1/4"-20 x3/8" Lg. 212A 06106A008 Cap Screw, 5/16"-18 x1" Lg. 823833A5966REPLACING PARTS ANDCOMPLETE DISMANTLING OF PUMPStandard Tools Required:1. Allen head socket set2. Standard socket wrench set3. Set of open end wrenches.4. Plastic hammer5. Vise grip pliers6. Large screwdriver with heavy handle7. Wire brush8. Three-cornered file9. Flat file10. Snap ring pliers for outside snap ring11. Crimping pliers for electrical connectors12. Arbor press13. Loctite #27114. Submersible motor oilIMPORTANT— Before any repair work is done onpump it should be sandblasted, if possible, toremove any deposits. After cleaning, pump shouldbe submerged in a strong “clorox” solution for onehour before handling pump.CAUTION: DISCONNECT ALL POWER ANDCONTROL WIRES TO MOTOR AT CONTROLPANEL BEFORE STARTING DISASSEMBLYOPERATIONS. NEVER RELY ON OPENINGCIRCUIT BREAKER ONLY.DISASSEMBLY OF SHREDDING RING ANDGRINDER IMPELLER1. Hold impeller from moving by placing small allenwrench or screwdriver in shredding ring slot andremove socket head screw and washer frompump shaft. See Figure 2.2. Remove three screws from grinder ring flange.Grinder ring is pressed into flange for easyremoval. See Figure 3.3. Thread two screws into tapped back-off holes inflange and evenly tighten screws to backgrinding ring out of pump housing.4. Place large flat blade screwdriver into slot inshaft.5. Bump impeller vane counterclockwise withplastic hammer to loosen impeller and continueto unscrew impeller from shaft. See Figure 4.Fig. 2Fig. 3Fig. 4REPLACING PARTS AND DISMANTLING PUMP23833A596 76. Use wire brush and thoroughly clean anydeposit from passage above grinder impellerand in cavity for grinder ring. See Figure 5.7. Replace new grinder impeller, use screwdriverin slot while turning on impeller, until handtight, with screwdriver still in shaft slot bumpwith plastic hammer. See Figure 6.8. Replace new grinder ring and plate. Use oil onring for easy fit.9. To provide proper alignment use three sectionsof an old ½” tape measure as shims 120degrees apart and then tighten bolts. Be sureto pull screws down evenly applying pressureon all three screws. DO NOT TIGHTEN ONESCREW CLEAR DOWN BEFORE ADJUST-ING OTHER SCREWS. See Figure 7.10. Replace holding screw and washer, use smallamount of Loctite #271 screw. See Figure 811. Bump set screw wrench with plastic hammerto tighten, working against small allen wrenchor screwdriver in shredding ring.12. Check freedom of rotation using finger onimpeller vanes. Pump should turn free withslight drag due to seals. Use caution to avoidinjury from shredding ring while turning grindingimpeller.13. As a final check, measure distance from endof ring to bottom of impeller vanes. Thisshould be 3/32” to 1/8”. If distance is only 1/16” orless it will indicate pump impeller has partiallyunscrewed when grinder impeller was re-moved. See Figures 9 and 10. If this is thecase, pump case will have to be removed totighten pump impeller. These steps will begiven in the following instructions. In rarecases if the impeller is jammed so tight it can’tbe removed by the steps given it will benecessary to remove the motor housing sothat the motor rotor can be gripped to breakloose the grinder impeller. See Figure 11.Fig. 5Fig. 6Fig. 723833A5968Fig. 10Fig. 8Fig. 9Fig. 11Fig. 12Fig. 1323833A596 9REPLACING LOWER SEAL1. Use steps 1 through 5 for removing grinderring and grinder impeller.2. Before removing any other parts use a mark-ing pen to mark joining parts so that they canbe replaced in same position as removed.See Figure 12.3. Remove oil fill plug slowly from seal chamberas pressure may have built up in this cavity,and pour out oil. See Figures 13 & 14.4. Remove volute case bolts and pull off volutecasing. Plastic hammer can be used to bumpon casing discharge to loosen. Place gasketin oil to prevent drying out.5. Insert large flat blade screwdriver in slotprovided in pump shaft and hold impeller hubwith vise grip pliers. Turn impeller counter-clockwise to loosen. It may be necessary togive pliers a sharp blow with plastic hammer toloosen impeller. See Figure 15. Turn counter-clockwise to loosen.6. Use wire brush and putty knife and cleancasting before removing seal.7. Remove Allen socket head screws from sealplate. See Figure 16.8. Pry carbon portion of seal from shaft by usingflat blade screwdrivers on each side of shaft.DO NOT SCRATCH SHAFT. It does notmatter if carbon cracks as it may be replacedwith new part. See Figure 17.9. Remove ceramic seal face and rubber retain-ing boot by prying seal out with flat bladescrewdrivers. (Seal can be pressed out with ascrewdriver from the opposite side.) Becareful not to scratch bronze bushing. Dam-age to seal is not important, as a new partmust be installed. See Figure 18.10. Thoroughly clean inside of seal chamber andpocket where new seal is to be installed. SeeFigure 19. Use rags and solvent cleaner.11. Use care to avoid touching sealing faces withhands, use protective cardboard circle pro-vided with seal, while handling. Use an artistsbrush to coat bottom outside portion of rubberretaining boot with conservative application ofSTP or equivalent lubrication to ease installa-tion. See Figure 20.Fig. 14Fig. 15Fig. 1623833A59610Fig. 17Fig. 18Fig. 19 Fig. 22Fig. 21Fig. 2023833A596 1112. Place seal in seal cavity loosely and usingcardboard protector use both thumbs to pressseal into seal plate. The cardboard protector canbe moved about to insure seal is pressed inevenly. See Figure 21.13. Wetting finger and touching center of cardboardprotector will allow it to be easily removed.14. Coat lower rubber shaft boot portion of carbonhalf of rotary seal with conservative applicationof STP or equivalent lubricant. Next immerseseal in small container of Transformer Oil (smallbaby food jar recommended). See Figure 22.Firmly press seal on shaft using thumbs.Observe that carbon seal is firmly in contactwith ceramic portion of seal, and that carbonportion has not slipped out of its metal holder.See figure 23. Install spring for lower seal only.NOTE: Discard spring retaining ring providedwith the seal, as a groove is machined in theback side of the bronze impeller to locate andretain this seal spring.15. Replace impeller and tighten with vise grippliers, holding shaft with large flat blade screw-driver.16. File off any burrs made on impeller neck withvise grip pliers. See figure 24.17. Clean casing thoroughly with wire brush andwash out with solvent. Be sure the dischargeport and small weep hole in the volute case isclean and free of any deposits. See Figure 25.18. Replace volute case being careful to havegasket in place. Line up with center marksmade before dismantling pump. See Figure 26.19. Replace grinder ring and impeller as describedunder “Replacing Grinder Ring & Grinder Impel-ler”.20. Air test repaired pump with approximately 6 lbs.of air pressure using piping with pressure gaugeand air valve stem. Submerse in water and afterevacuating air from volute case observe forleaks, remove and dry off pump.21. Refill seal chamber with Transformer Oil. SeeFigure 27. Fill until oil is ¾” below top of oil plugboss. See Figure 28.22. Clean oil plug with wire brush, reapply Teflontape and reinstall oil plug.23. In rare case when impeller is locked too tight toremove as described, it may be necessary to liftoff the motor housing so that rotor can be heldwhile impeller is removed.Fig. 23Fig. 24Fig. 2523833A59612Fig. 26Fig. 27Fig. 28Fig. 29Fig. 30Fig. 3123833A596 13REPLACING UPPER SEALTo replace upper seal it is necessary to completelydismantle the pump. Usually if upper seal is out, themotor stator will be ruined with water, so it will also benecessary to be replaced.1. Remove oil fill plugs slowly and drain oil frommotor and seal chamber. See Figures 29, 30 and31.2. Remove motor end cap screws and thread intotapped back-off holes to force cap from motorhousing. See Figure 323. Lift cap and remove lead from ground screw. SeeFigure 334. Cut off all motor leads ¾” down from the connec-tor on the stator side, this way the cap and cordassembly and the connectors can be checked forcontinuity. See Figures 34 and 35.5. Remove socket type flat head screws frombearing cap and thread into tapped back-off holesto force cap from housing. See Figure 36.6. Remove bolts from motor stator housing and liftoff casting. Please Note: Bearing housingcontains two finger spring washers which may fallout of casting when removed. The red and theorange seal failure wires will pull out of hole instator. See Figure 37.7. The rotor is now exposed and the red and orangeseal failure wires are exposed. Rotor can now beheld for removing grinder impeller and pumpimpeller as described before.8. To remove upper seal use snap ring pliers andremove snap ring that holds upper seal in place.See Figure 38.9. After snap ring is removed, bump on end of shaftwith plastic hammer to force shaft through upperseal and to push lower ball bearing from housing.See Figure 39.10. Push old seal out of housing. Clean thoroughlyand press in new seal seat as described in thefirst section steps 8 thru 14.11. Replace ball bearings if worn or rusted from waterbeing in motor.12. Use arbor press to push off bearings. Use flatsteel bars to get under bearing. See Figure 40.13. In replacing bearings always press on inner faceof bearing.Fig. 32Fig. 33Fig.3423833A59614Fig. 35Fig. 36Fig. 37Fig. 38Fig. 39Fig. 4023833A596 1514. Replace red and orange seal failure wires ifnecessary. Loosen nut in seal chamber toremove wire.15. Put in new seal failure wires and adjust so thatthe probe portion of the seal leak wires arestaggered, the end of the longest wire being up¼” from the machined face of the casting. SeeFigure 41. Position shorter lead above the firstso probes do not touch. See drawing front cover.Retighten seal nut. Be sure rubber seal ring is inplace to seal wire. See Figure 42.16. Using fine picture hanging wire pull seal failurewire up through stator hole before replacing stator.See Figure 43. The stator is pressed into housingat the factory and is shipped as a unit. Do not tryto replace stator in housing in the field, they mustbe replaced as a unit.17. Using Allen wrench or small screwdriver in boltholes to hold parts in place, position upperbearing casting upside-down and run wires downthrough holes in segmented casting. Next applySTP or equivalent to bearing cup liberally andinsert the first finger spring washer flat side down.Apply more STP and insert second finger springwasher flat side down, to make paired fingerwashers. Apply STP again to hold washers inplace when casting is turned over and installedon top of rotor. Bearing housing will be held off ofstator housing approximately 1/16” and will depressto touch stator housing when pushed downward.See Figures 44, 45 and 46.Fig. 41Fig. 42Fig. 43Fig. 4Fig. 523833A5961618. Reassemble all parts as taken apart. BE SURENEW O-RINGS ARE IN PLACE BEFOREBOLTING PARTS TOGETHER. If necessary toreplace cords use cap with cords potted in. Inemergency, cut cord can be spliced and taped.Reconnect all motor lead wires to power cord withpressure type insulated connectors. Crimp tightwith crimping pliers that will not penetrate theinsulation of the connector.19. Reinstall cap and cord assembly. Run OHMMeter resistance test at this time to checkwindings and test for grounding. Test seals withair pressure as described earlier.20. Fill motor chamber and seal chamber withsubmersible oil. Fill top motor chamber to bottomof seal plug threads and fill seal chamber towithin ¾” of top of plug fill boss.IMPORTANT — AFTER ALL ASSEMBLY ANDREPLACEMENT OF PARTS BE SURE PUMPTURNS FREE BY HAND. PUMP MUST NOT BINDIN ANY POSITION OR ROTATION.ELECTRICAL CONTROL BOX — All instructionsand wiring diagrams for connecting pump to controlbox are included with the control box.CHECK LIST TO DETERMINEMOTOR TROUBLEChecking For Moisture in Motor:Use ohmmeter and set on highest scale. Readings onthe large power cord between any of the conductorsred, black, white to green conductor or motor shellshould be more than 500,000 ohms. Motor probably willrun with a lower reading, but if pump is out of serviceand reading is below 500,000 ohms the motor housingand stator should be removed and baked in a dryingoven at 220°F. to dry out winding. If winding cannot bedried out it must be replaced.Both motor housing and stator must be replaced as aunit as stator is pressed in at the factory and cannot beremoved in the field.Resistance of Windings:Every motor winding ha a fixed resistance and windingmust check close to the values given to operateproperly. This winding resistance also shows if motor isconnected for voltage being used.Use ohmmeter for this test and set on scale to readdirectly in ohms.Black To Black ToWhite RedMain Start White toMotor Type & Voltage Winding Winding RedSingle Phase, 230V 1.56 7.84 9.40Winding Resistance Values in OhmsFull Load Amp Readings for MotorsMotor Type Volts Amps Locked Rotor AmpsSingle Phase 230 12 41.0If amp readings are higher than listed, it indicatesvoltage may be higher or lower than normal or thatpump grinder may be clogged with trash causing extraload on motor.Fig. 46MOTOR TROUBLE23833A596 17TROUBLE CHECK LISTTroubles listed below are generally not caused by the pump. Other trouble can occur from faulty control boxoperation. These will be listed with the control box instructions.CONDITIONPump runs but does not pumpliquid from basin.Red light comes on at controlboxOverload trips and alarmbuzzer or flashing red lightcomes on due to high waterlevel in basinYellow run light stays oncontinuouslyPROBABLE CAUSE1. Pump impeller may be air locked, this occasionally occurs on a newinstallation. Remove pump and clean volute case weep hole andreinstall pump allowing 2 to 3 minutes for air to weep from pump.2. Remove pump and guides from wet well, and test in 5 gallon bucketafter checking weep hole again. If pump still does not pump, disas-semble check valve and check to insure that check valve flapper hasnot adhered to sealing face. This condition results from assembledbasin units setting in the sun before installation. NOTE: Check valvebolts should have Loctite 242 or equivalent applied before reassemblyof check valves.3. If pump will pump water from bucket, try in wet well again. If it still willnot pump, the following problems may exist:a) Ball Valve - Gate Valve may be in off position.b) Discharge piping obstructedc) Valve at street or in main line may be off — redundant check valvein backwards.d) Tap at force main obstructed — hole not drilled through enough —pipes pushed into tee too far.4. If pump has been installed for some time an does not pump, it may beclogged at grinder inlet.5. Discharge head may be too high. Check elevation. Maximum pumphead at zero flow is 105 feet. See pump curve.6. If above checks do not locate trouble, motor rotor may be loose onshaft which allows motor to run but will not turn impeller or only at lowRPM.1. This indicates some water has leaked past the lower seal and hasentered the seal chamber and made contact with the electrode probe.Pump must be removed from basin within approximately two (2) weeksfor replacement of lower seal. This preventative repair will save anexpensive motor.1. Push in red reset button to reset overload. If overload trips again aftershort run, pump has some damage and must be removed from basinfor checking.2. Trouble may be from clogged grinder causing motor to overload orcould be from failed motor.3. Trouble may be from faulty component in control box. Always checkcontrol box before removing pump.1. Indicates H-O-A switch be in the hand position.2. Level control switch may have failed causing pump to continue tooperate when water is below lower float.3. Grinder assembly may be partially clogged causing pump to operate atvery reduced capacity.4. Check valve may be clogged causing low pump flow. Gate valve orstreet valve may be in off position.5. Pump may be air locked.TROUBLESHOOTING23833A59618Circuit breaker tripsPump is noisy and pump rateis lowGrease and solids haveaccumulated around pumpand will not pump out ofbasin1. Reset breaker by pushing clear down on handle then back to “ON”position. If breaker trips again in few seconds it indicates excessive loadprobably caused by a short in the motor or control box. Check outinstructions given with control box before pulling pump.2. If this condition happens after an electrical storm, motor or control boxmay be damaged by lightning.3. Resistance reading of the motor with lead wires disconnected from thecontrol box can determine if trouble is in motor or control box.1. Grinder assembly may be partially clogged with some foreign objectscausing noise and overload on the motor.2. Grinder impeller may be rubbing on grinder ring due to bent shaft ormisalignment.1. Water shut-off level may be set too high or volume of pumping cycle maybe too great allowing solids to settle out of suspension. Set pump shut-off level at the pumps widest part where volute case mates with sealchamber - to 1” below. See Figure 47. Set water level control (float orweight) to following approx. levels:2 ft. dia. basin 12” - 14”3 ft. dia. basin 6” - 8”4 ft. dia. basin 6” - 7”above pump shut-off.2. Run pump on hand operation for several minutes with small amount ofwater running into basin to clean oout solids and grease. This allowspump to break suction and surge which will break up the solids. If levelswitch lower weight or float is set properly this condition generally will notoccur.3. Where all type switches are installed trash may have accumulatedaround lower weight causing pump to turn off too soon. Clean trash fromweight and suspension cable.Fig. 4723833A596 19MOTOR WIRING DIAGRAMNOTE: Probe test resistor is used on D2CX20-21 UL explosion-proof only.23833A59620PUMP DIMENSIONS23833A596 21PERFORMANCE CURVE23833A59622LIMITED WARRANTYDelta Environmental Products warrants to the original purchaser of each Delta Environmental Product grinder pumpsystem(s) that any part thereof which proves to be defective in material or workmanship within two year from dateof installation or 27 months from manufacture date, (extended warranty available) whichever comes first, will bereplaced at no charge with a new or remanufactured part, F.O.B. factory. Purchaser shall assume all responsibilityand expense from removal, reinstallation, and freight. Any item(s) designated as manufactured by others shall becovered only by the express warranty of the manufacturer thereof. This warranty does not apply to damageresulting from accident, alteration, design, misuse or abuse. The pump must be installed, operated, and maintainedin accordance with the published instructions of the appropriate Installation & Service Manual.All dual seal grinders must have seal failure and heat sensors attached and functional for Warranty to be in effect.If a seal failure should occur, Delta Environmental Products will cover only the lower seal and labor thereof. Laborbased on Authorized Service Center contract allowance. If the heat sensor is not attached and functional, Warrantyis void. If the seal failure sensor is not attached and functional, Warranty is void. If the material furnished to theBuyer shall fail to conform to this contract or to any of the terms of this written warranty, Delta EnvironmentalProducts shall replace such nonconforming material at the original point of delivery and shall furnish instruction forits disposition. Any transportation charges involved in such disposition shall be for the Buyer’s account. TheBuyer’s exclusive and sole remedy on account or in respect of the furnishing of material that does not conform tothis contract or to this written warranty, shall be to secure replacement thereof as aforesaid. Delta EnvironmentalProducts shall not in any event be liable for the cost of any labor expended on any such material or for anyincidental or consequential damages to anyone by reason of the fact that such material does not conform to thiscontract or to this written warranty.ALL IMPLIED WARRANTIES, INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY AND THEIMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, ARE DISCLAIMED TO THE SAMEEXTENT AS THE EXPRESS WARRANTY CONTAINED HEREIN. Some states do not allow limitations on howlong an implied warranty lasts, so the above limitation may not apply to you. MANUFACTURER EXPRESSLYDISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES FORBREACH OF ANY EXPRESS OR IMPLIED WARRANTY ARISING IN CONNECTION WITH THIS PRODUCT,INCLUDING WITHOUT LIMITATION, WHETHER IN TORT, NEGLIGENCE, STRICT LIABILITY CONTRACT OROTHERWISE. Some States do not allow the exclusion or limitation of incidental or consequential damages, so theabove limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may alsohave other rights which vary from State to State.7/05