5961 Hydro HPGR200 FINAL (Page 1)
Contents
1. using two screwdrivers slide the carbon seal assembly off by prying on the retaining ring 5 Using a screwdriver break the old stationary portion of the seal 24 to allow for removal 6 Take the stationary portion of the new seal 24 and lube the rubber material with good quality dielectric oil Press the stationary portion of the new seal into the seal bearing plate 21 CAUTION Do not reuse old seal parts Replace all parts with new Mixing old and new parts could cause immediate seal failure 7 Using a good quality dielectric oil lube the rubber material on the carbon seal assembly 24 and press it on the shaft Place the spring bellows on the shaft as removed 8 Using a pressure gauge with a fill stem pressurize the motor housing 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 continue with assembly NOTE 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 9 Reassemble the cutter and volute as outlined in the replacing grinder parts section of this manual 10 Refill motor housing with a good quality paraffinic oil 25 Fill the motor housing so that the tops of the motor windings have been covered but leave an air gap to allow for expansion of the oil NOTE Wh2. in accordance with local plumbing codes Do not smoke or use sparkable electrical devices or flame in a septic gaseous or possible septic sump If a septic sump condition may exist and if entry into sump is necessary then 1 provide proper safety precautions per OSHA requirements and 2 do not enter sump until these precautions are strictly adhered to Do not install pump in location classified as hazardous per N E C ANSI NFPA 70 2000 Failure to heed above cautions could result in injury or death CAUTION To reduce risk of electrical shock pull plug before servicing this pump WARNING Risk of electrical shock this pump has not been investigated for use in a swimming pool WARNING SEE installation and service manual for proper installation WARNING To reduce risk of electrical shock pump is provided with grounding wire Be certain that it is connected to ground WARNING Hazardous moving parts To reduce the risk of injury disconnect power before servicing pump 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 This marking is required on 3 phase models only 7 CAUTION For use with maximum 140 F water 8 CAUTION Tank should be vented in acco
3. recommended for the most satisfactory installation and generally for the lowest cost where expensive installation labor is involved Making Electrical Connections All electrical wiring must be in accordance with local code and only qualified electricians should make the installations Complete wiring diagrams are included for use in making the installation All wires should be checked for shorts to ground with an ohmmeter or Megger after the connections are made This is important as one grounded wire can cause considerable trouble Pump Operation Starting the Pump 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 To start the pump perform the following steps in order 1 Grinder pump is single phase no rotation 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 Level control 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 6 If problems occur check power source Make sure a separate sup
4. 6337 2007 Hydromatic Ashland Ohio All Rights Reserved Part 5625 401 1 Item W 03 401 4 07
5. Pump Installation and Service Manual L HYDROMATIC HPGR200 Submersible Grinder Pump E dy O HYDROMATIC NOTE To the installer Please make sure you provide this manual to the owner of the pumping equipment or to Pe ntair the responsible party who maintains the system General Information Thank you for purchasing your Hydromatic ensure pump To help years of trouble free operation please read the following manual carefully Before Operation Read the following instructions carefully Reasonable care and safe methods should be practiced Check local codes and requirements before installation Attention This manual contains important information for the safe use of this product completely before using Read this manual this product and refer to it often for continued safe product use DO NOT THROW AWAY OR LOSE THIS MANUAL Keep it in a safe place so that you may refer to it often 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 To reduce risk of electrical shock 1 Risk of Electrical Shock This pump has not been investigated for use in swimming pool areas Risk of Electrical Shock Connect only to a properly grounded receptacle Septic tank to be vented
6. e with a new or remanufactured part FO 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 from accident alteration design misuse or abuse The pump must be installed operated and maintained in accordance with the published instructions of the appropriate Installation amp Service Manual All dual seal non clogs and 3 5 HP grinders must have seal failure and heat sensors attached and functional for Warranty to be in effect If a seal failure should occur Hydromatic will cover only the lower seal and labor thereof Labor is based on Authorized Service Center contract allowance If the heat sensor is not attached and 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 point of delivery and shall furnish instruction for its disposition Any transportation charges involved in such disposition shall be for the Buyer s account The Buyer s exclusive and sole remedy on account or in respect of the furnishing of material that does not conform to this contract or to this written warran
7. efective impeller Pump is noisy 1 Defective bearings 2 No axial clearance between impeller and volute 3 No diametral clearance between radial cutter and cutter ring If the cause of the trouble cannot be determined and 12 1617 13 corrected as outlined above contact your nearest factory representative Start Windings Run Windings 18 19 15 HPGR200 Typical Installation NO PANEL REQUIRED HPGR200 Parts List Part No Description Part No Description 14981 001 1 253388001 14589 002 2 14570 000 1 07033 020 3 00101 008 1 00101 011 1 05405 001 2 05506 002 2 05505 000 2 07763 000 1 00030 004 1 05570 005 1 Oil Fill Plug Power Cord Motor Housing Motor Impeller Screw Screw Radial Cutter Axial Cutter Stationary Cutter Cutter Retainer Screw Impeller Washer w CCC eS 14885 000 1 10957 000 2 14569 000 1 00077 011 1 00834 023 1 14573 000 1 24709110000 00589 002 1 01032 002 1 14595 020 1 Impeller Screw Volute Bearing Housing O ring O ring Shaft Seal Paraffinic Oil Eye Bolt Hex Nut For Automatic Operation Wide Angle Switch 20 WARRANTY Hydromatic warrants to the original purchaser of each Hydromatic product s that any part thereof 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 charg
8. emove volute case 20 Radial cutter 13 and axial cutter 14 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 19 washer 18 and radial cutter 13 from shaft Radial cutter 13 and impeller 9 are screwed onto shaft The thread is right hand Tap radial cutter 13 with plastic hammer if necessary to loosen Axial 3 cutter 14 lifts off impeller 9 and is held from rotation by pin Unscrew impeller 9 from shaft in same manner as radial cutter 13 8 Clean all parts thoroughly before proceeding with assembly Replace case 20 but do not replace cutter ring 15 at this point 9 Replace cutter ring 15 and cutter ring retainer 16 Screw down with screws 17 10 Plug pump into power and operate for a few seconds only to ensure parts are not rubbing Replacing Seal 1 Drain the oil from the pump by removing the fill plug 5 located on the side of the motor housing 7 2 Remove the volute and cutters per the instructions listed under the replacing grinder parts section in this manual 3 To remove the impeller 9 secure the shaft by a flat bladed screwdriver into slot on end of the shaft Hold a wood block against the impeller vane and tap it with a hammer until it spins off 4 Remove the seal 24 rotating elements by sliding the spring bellows off the shaft then
9. en applying power be sure the pump is restrained from turning by holding the pump at the motor housing or by clamping it in a holding fixture 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 PERFORMANCE CURVE 40 105 ee 90 I esi HEAD FEET HEAD METERS FS a 30 US GPM 0 75 15 22 5 30 37 5 45 52 5 60 M 3 HR 25 5 75 10 25 5 Pump Troubleshooting Below is a list of troubles and their probable causes No liquid delivered 1 Pump airbound 2 Discharge head too high 3 Pump or piping plugged 4 Speed too low Insufficient liquid delivered 1 Discharge head too high 2 Impeller or cutters partially plugged or damaged 3 Incorrect impeller diameter 4 Speed too low Insufficient discharge pressure 1 Air or gases in liquid 2 Impeller damaged 3 Incorrect impeller diameter 4 Speed too low Pump overloads motor 1 Specific gravity or viscosity of liquid too high 2 Speed too high 3 Head lower than rating pumping too much liquid 4 Pump clogged 5 Defective bearings 6 D
10. ply line is available Verify voltage supply 7 Check resistance of windings See Chart page 5 If not within guidelines return pump to authorized Hydromatic service or repair center As the motors are oil filled no lubrication or other maintenance is required Pump should be checked every quarter for corrosion and wear Pump Servicing Read the following instructions carefully before replacing any parts Reasonable care and safe methods should be practiced Check local codes and requirements before installation Only a competent electrician should make the installations 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 CAUTION 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 Replacing Grinder Parts If necessary to replace grinder parts because of wear or to inspect for clogging 1 Close gate valve at pump discharge 2 Turn off circuit breaker CAUTION Never work on pump with power on Be sure ground wire from pump is connected to a good ground such as a water pipe 3 Remove pump from sump 4 Unscrew screws 17 and remove cutter ring retainer 16 Stationary cutter 15 cannot be removed from volute 20 5 Unscrew hex head cap screws 12 and r
11. rdance 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 CAUTION Risk of electrical shock Do not remove cord and strain relief Do not connect conduit to pump 10 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 11 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 Pump Installation Installing Pump in Sump Before installing pump in sump lay it on its side and rotate impeller Impeller may be slightly stuck due to factory test water so 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 that the Hydromatic nonclog check valve is used and that the pumps are submerged in a vertical position The complete factory built packaged system is
12. ty shall be to secure replacement thereof as aforesaid Hydromatic shall not in any event be liable for the cost of any labor expended on any such material or for any incidental or consequential damages to anyone by reason 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 MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE ARE DISCLAIMED TO THE SAME EXTENT AS THE EXPRESS WARRANTY CONTAINED HEREIN Some states do not allow 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 IMPLIED WARRANTY ARISING IN CONNECTION WITH THIS PRODUCT INCLUDING WITHOUT LIMITATION 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 and you may also have other rights which vary from state to state Your Authorized Local Distributor LO HyDROMATIC Pentair Water USA CANADA 740 East 9th Street Ashland Ohio 44805 269 Trillium Drive Kitchener Ontario Canada N2G 4W5 Tel 419 289 3042 Fax 419 281 4087 www hydromatic com Tel 519 896 2163 Fax 519 896
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