HPGB750/1000/1500
Contents
1. This Warranty gives you specific legal rights and you may also have other rights which vary from state to state In the absence of suitable proof of this purchase date the effective date of this warranty will be based upon the date of manufacture Your Authorized Local Distributor LD 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 6337 2008 Hydromatic Ashland Ohio All Rights Reserved Part 4 23833A617 Item 4 E 03 617 1 072. run pump has some damage and must be removed from basin for checking Trouble may be from clogged grinder causing motor to overload or could be from failed motor Trouble may be from faulty component in control box Always check control box before removing pump Indicates H O A switch may be in the hand position Level control switch may have failed causing pump to continue to operate when water is below lower weight o lower weight may have dropped off Grinder assembly may be partially clogged causing pump to operate at very reduced capacity Gate valve or check valve may be clogged causing low pump flow Pump may be air logged Reset breaker by pushing clear down on handle then back to on position If breaker trips again in few seconds it indicates excessive load probably caused by a short in the motor or control box Check out instructions given with control box before pulling pump If this condition happens after an electrical storm motor or control box may be damaged by lightning Resistance reading of the motor with lead wires disconnected from the control box can determine if trouble is in motor or control box Grinder assembly may be partially clogged with some foreign objects causing noise and overload on the motor Grinder impeller may be rubbing on grinder ring due to bent shaft or misalignment Lower weight of level switch may be set too high Set bo
3. screw 1 4 20 UNC x 1 2 1 Pipe plug 1 4 NPT not shown 2 Rotor Shaft Cord Cap Assy Housing w Catalog No Assembly Stator 25 Stator Impeller HPGB750M6 2 27098D100 141452031 228720010 22874D357K HPGB750M3 2 27098D100 141450031 22872C010 22874D362K 27096D002 HPGB750M4 2 27098D100 141450031 22872C010 22874D362K HPGB750M5 2 27098D100 141456031 22872C011 22874D367K HPGB1000M6 2 27098D100 141452031 22872C012 22874D358K HPGB1000M3 2 27098D100 141450031 228726012 22874D363K 27096D001 HPGB1000M4 2 27098D100 141450031 22872C010 22874D363K HPGB1000M5 2 27098D100 141456031 22872C010 22874D368K HPGB1500M6 2 27098D100 141462031 22872C012 22874D372K HPGB1500M3 2 27098D100 141460031 22872C012 22874D377K 27096D000 HPGB1500M4 2 27098D100 141460031 22872C010 22874D377K HPGB1500M5 2 27098D100 141466031 22872C010 22874D382K 7 23833A617 MOTOR INTERNAL CONNECTION DIAGRAMS CONTROL CORO HEAT SENSOR ON STATOR PROBE TEST RESISTOR CONTROL CORD HEAT SENSOR ON STATOR MOTOR STATOR PROBE TEST ELECTRODE RESISTOR 230 VOLT THREE PHASE 23833A617 ELECTRODE 200 OR 575 VOLT THREE PHASE POWER CORD STATOR HEAT SENSOR ON STATOR MOTOR STATOR PROBE TEST ELECTRODE RESISTOR 460 VOLT THREE PHASE WIRING DIAGRAM 200 230 amp 460V SIMPLEX 7 10 amp 15 HP CIRCUIT OVERLOAD ELEMENTS PUMP MOTOR O X He NI Ml IROL CIRCUIT PRIMAR
4. set about 6 to 12 above the override control 5 No control should be set above the inlet invert 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 connec tions are made This is important as one grounded wire can cause failure the pump control panel or personal injury Pump The fluid end of the pump is field serviceable and can be disassembled in case of wear damage plugging or outboard seal failure The following will describe the disassembly and reassembly process 23833A617 REPLACING GRINDER IMPELLER AND GRINDER SHREDDING RING This is the only disassembly operation allowed in the field All other repairs must be done at the factory at an authorized service station STANDARDTOOLS REQUIRED All had socket set Standard socket wrench set Setofopen end wrenches Plastichammer Vise grip pliers Large screwdriver 5 8 wide blade heavy handle Wire brush Three cornered file Several smaller screwdrivers IMPORTANT Pump should be thoroughly cleaned of trash and deposits before starting disassembly operations CAUTION DISCONNECT ALL POWER AND CONTROL WIRES TO MOTOR AT CONTROL PANEL BEFORE STAR
5. Pump Installation and Service Manual HYDROMATIC HPGB 750 1000 1500 Submersible Grinder Pumps NOTE T the installer Pentair this manual to the own of the equ nn nt or to the a sible pa io maintai syst Water 1 23833A617 CAUTION Read these safety warnings first before installing servicing or operating any pump GENERAL 1 Most accidents can be avoided by using COMMON SENSE 2 Read the operation and maintenance instruction manual supplied with the pump 3 Donotwear loose clothing that can become entangled in the impeller or other moving parts 4 This pump is designed to handle materials which could cause illness or disease through direct exposure Wear adequate protective clothing when working on the pump or piping ELECTRICAL WARNING Only qualified persons shall conduct services and installations of this pump The pump must be wired by a qualified electrician using an approved starter box and switching device 5 To reduce the risk of electrical shock pump must be properly grounded in accordance with the National Electric Code and all applicable state and local codes and ordinances 6 To reduce risk of electrical shock disconnect the pump from the power source before handling or servicing 7 Any wiring to be done on pumps should be done by a qualified electrician 8 Never oper
6. TING DISASSEMBLY OPERATIONS NEVER RELY ON OPENING CIRCUIT BREAKER ONLY DISASSEMBLY OF SHREDDING RING AND IMPELLER 1 Remove screws from holding ring and remove ring 2 Use two screwdrivers one each on opposite side of ring and pry shredding ring out Remove shredding ring 3 Hold impeller by prying against impeller cutting bar and remove cap screw from end of shaft 4 Use large screwdriver in slot end of shaft and bump on cutter vane with plastic hammer Bump in counterclockwise direction as thread is right hand It may take several bumps to loosen impeller If impeller cannot be loosened it will be neces sary to take unit to service station for service DON T CONTINUE TO POUND ON IMPELLER AS IMPELLER AND SHAFT CAN BE DAMAGED 10 11 12 If impeller comes off easily clean up and replace if worn Be sure pump impeller has not loosened when grinder impeller is removed This can be checked on reassembly of grinder impeller and shredding ring Tips of impeller cutter vanes should extend about 1 8 below bottom of shredding ring If more than 1 8 extends below ring it means pump impeller has loosened See sectional drawing Fig 1 or Fig 2 Remove grinder impeller and ring as described above and remove bolts from pump case and remove case Use back off screws in motor mounting plate to pry loose from pump case After case is removed wrap emery paper around shaft and hold with vise grip pliers Use
7. Y FUSES _ NEN Hi 2 100VA FUSE RANSFORMER 11 AMP FUSE x 12 N ET a HIGH WATER F Na is o 10 w AL ALARN LIGHT ED ALARM TES E FLASHER Hl a RUN 6H WHS NOTOR HEAT SENSOR wre T 0 C D me ML NOTOR CONTACTOR TOC THERAAL SEAL LEAK CONTACT R SEAL LEAK LISHT RED N NOTE CONNECT ALL GREEN WIRES TO GROUND BAR FLOAT CONTROLS MUST BE RATED FOR 2 AMPS AT 115 VOLTS PUMP OFF PUMP ON HIGH WATER 23833A617 PUMP PERFORMANCE PUMP PERFORMANCE SUBMERSIBLE GRINDER PUMPS MODELS HPGB750 1000 1500 SPEED 3450 RPM 1 Available Models Motor Electrical Data Service Service NEC Run Factor Factor Code Service Standard Amps Amps KW KW Letter Factor HPGB750M6 2 HPGB750M3 2 HPGB750M4 2 HPGB750M5 2 HPGB1000M6 2 HPGB1000M3 2 HPGB1000M4 2 HPGB1000M5 2 HPGB1500M6 2 HPGB1500M3 2 HPGB1500M4 2 HPGB1500M5 2 lt WW OOVDOOITITJZAAAA 23833A617 10 PUMP DIMENSIONS dimensions in mm Flange drilled for 21 2 std pipe flange 11 23833A617 CHECK LIST IF PUMP DOES NOT OPERATE PROPERLY CHECKING FOR MOISTURE IN MOTOR Use ohmmeter megger and set on highest scale Readings on the large power cord between any ofthe conductors red
8. ate a pump with a power cord that has frayed or brittle insulation Never let cords or plugs lay in water 10 Never handle connected power cords with wet hands PUMPS 11 Pump builds up heat and pressure during opera tion allow time for pump to cool before handling or servicing 12 Only qualified personnel should install operate or repair pump 13 Keep clear of suction and discharge openings DO NOT insert fingers in pump with power connected 14 Do not pump hazardous material not recom mended for pump flammable caustic etc 15 Make sure lifting handles are securely fastened each time before lifting 16 Do not lift pump by the power cord 23833A617 17 Do not exceed manufacturers recommendation for maximum performance as this could cause the motor to overheat 18 Secure the pump in its operating position so it can not tip over fall or slide 19 Keep hands and feet away from impeller when power is connected 20 Submersible grinder pumps are not approved for use in swimming pools recreational water installa tions decorative fountains or any installation where human contact with the pumped fluid is common 21 Do not operate pump without safety devices in place IMPORTANT Hydromatic is not responsible for losses injury or death resulting from a failure to observe these safety precautions misuse or abuse of pumps or equipment GENERAL INFORMATION Pump Models These instructions cover the in
9. black or white 10 green conductor or to the motor housing should be greater than 1 000 000 ohms 1 megaohm Motor probably will run with a lower reading but if pump is out of service and reading is below 1 000 000 ohms 1 megaohm the motor housing and stator should be removed and baked in a drying oven at 220 F This service work should only be done at an authorized service station TROUBLE CHECK LIST Readings should be taken with line leads discon nected from the control panel RESISTANCE OF WINDINGS Every motor winding has a fixed resistance and winding must check close to the values given below to operate properly Verifi cation ofthe proper wiring of a dual voltage motor can also be checked by measuring the motor winding resistance See the motor electrical data chart Use an ohmmeter and the one ohm scale Read the resistance with the motor leads disconnected from the pump control panel Troubles listed are generally caused by the pump Other trouble can occur from faulty control box operation CONDITION Pump runs but does not pump liquid from basin Red light comes on at control box 23833A617 12 PROBABLE CAUSE 1 Pump impeller may be air locked this occasion ally occurs on a new installation Start and stop pump several times to purge air 2 Run additional water into basin so that pump will be submerged deeper to clear air 3 If pump is three phase rotation may be wrong See instructions f
10. cloth on impeller and screw up against shoulder Now pump can be reassembled Clean all threads with wire brush and file smooth any threads that may be nicked Use Never Seeze or other graphite compound on threads before replacing grinder impeller Be sure cap screw in bottom of shaft is tight Hold impeller with screwdriver between cutter bar and teeth of shredding ring while tightening cap screw Be sure impeller turns free by hand after reas sembly Some drag will occur due to seals but there should be no binding or tight spots when turning the grinder impeller ALWAYS use a rag on the impellers when turning to prevent cutting hands on the sharp corners of shredding ring 23833A617 8906 69 IN NN MT 3 leg ji i DE T E N AGG 7 9 ZAS Edo Mm Z We LU Ny DVA SR num aa 7 AN A EEE gt S RRQ BEST CATE EMERY NN be S 23833A617 Parts List NO i i 4 i 2 6 Ball bearing upr 08565402 1 7 Rotor shaft assembly 1 Mi Motor Rousing 29874500 1 _ 1 i 4 2 i 2 8 i i i i i i i i i i i i i 2 2 31 wire 2 Resistor X PRF only 1 110098008 TB gal 2 i 2 37 Washer i Machine
11. cord cap is epoxy potted The cord cap provides for a sealed wire connection with terminals so that connections can be made without breaking the motor seal This allows the cord cap with cords to be removed from the motor With this arrangement the cords can be permanently installed in a sealed fitting the sump The control and power cables cannot be spliced When the pump is removed for service the cord cap can stay and be reinstalled when pump is returned Note Each cable has a green ground wire and must be properly grounded per the National Electric Code and local codes 23833A617 Electrical Motor Controls All electrical controls and motor starting equipment should be as specified in these instructions Consult factory for any accept able alternates Level Sensing Controls The float level controls maintain the basin sewage water level by controlling pump turn on and turn off levels 1 The lower turn off control should be set so that pump stops with the water covering the entire motor housing Consult the factory for any settings below this point 2 The upper turn on control should be set above the lower turn off control The exact height between the two controls is determined by the number of pump starts desired and the depth of the basin A maximum of 10 starts per hour should not be exceeded 3 The override control is set at a specified height above the upper turn on control 4 The alarm control is
12. d control panels are used where applicable All dual seal pumps must have seal failure and heat sensors attached functional and monitored for the warranty to be in effect If a seal failure should occur HYDROMATIC will only cover the lower seal and labor thereof If the heat sensor and seal fail sensor is not attached and functional the warranty is void LABOR ETC COSTS HYDROMATIC shall in NO EVENT be responsible or liable for the cost of field labor removal and or reinstallation charges of any HYDROMATIC product part or component thereof or the expense of freight THIS WARRANTY WILL NOT APPLY a to defects or malfunctions resulting from failure to properly install operate or maintain the unit in accordance with printed instructions provided b to failures resulting from Ea accident or negligence c to normal maintenance services sid te parts used in connection with such service 4 to units are not installed accordance with applicable local codes ordinances and good trade practices or e if the unit is moved from its original installation location f unit is used for purposes other than for what it was designed and manufactured g to any unit which has been repaired or altered by anyone other than HYDROMATIC a HYDROMATIC distributor or a HYDROMATIC authorized service center and h to any unit which has been repaired using non factory specified parts OEM parts RETURN OR REPLACED COMPONENTS any item to be replaced unde
13. d orange control wires from the control panel and measuring the resistance with an ohm meter between the wires For a standard non explosion proof pump the reading should be 100 000 ohms or greater and for an explosion proof pump the reading should be above 30 000 ohms If the mea sured values are below those indicated above the pump may have a lower seal failure and require service Note Hydromatic built control panels supply the correct circuitry for moisture and heat sensor connec tions Failure to install the correct circuitry with proper connection would negate warranty See Figure 3 Motor Power Cord Control Cord and Cord Cap Assembly Each motor power cord has 4 conductors white black red and green For a three phase motor the red black and white conductors connect to the three line leads and the green is connected to a good ground Interchanging any two line leads will reverse the rotation of the motor Note Rotation should be clockwise when observed from the top of the pump This can be checked by noting which direction the pump torques upon initial starting A properly rotating pump will torque counter clockwise upon start The control cable has 5 conductors black white red orange and green White and black connect to the heat sensor terminals in the control panels red and orange connect to the seal failure terminals in the control panel and the green connects to the ground in the control panel The
14. ng resin surrounding the electrical wires Internal connection wiring diagrams are shown in Figure 2 All of the pump fasteners and shafts are mad from corro sion resistant stainless steel while the pump castings are made of ASTM A 48 Class 30 cast iron and the multi vane vortex impellers are made from ductile iron General Installation Various configurations and methods of plumbing this series of non clog pumps may be used however for ease of installation and service a Hydromatic rail lift out system is recommended Service These pumps are to be used for handling sewage wastewater and storm water only Do not use in hazardous locations These motors must be repaired and serviced only at Hydromatic Authorized Service Centers or at the Hydromatic Factory Any unauthorized field repair voids warranty CAUTION After the pump is installed and sewage has entered the basin there is Danger Sewage water gives off methane and hydrogen sulfide gases which are poisonous Never enter a wetwell unless the cover is open for a sufficient period of time to allow fresh air into the basin It is recommended that a man in the basin has a harness on with a rope to the surface so that he can be pulled out in case of asphyxiation It is for this reason that Hydromatic recommends using the rail lift out system so that no service is required inside the basin Motor Each motor is provided with heat sensor thermostats attached directly to the mo
15. or checking proper rotation 4 If air does not clear it may be necessary to lift pump out of sealing elbow and start motor to allow pump to pump for a few seconds Air vent hole is provided in pump case so some water will flow from this hole when pump is operating If vent hole gets clogged clean out 5 If pump has been installed for some time and does not pump it may be clogged at grinder inlet 6 Discharge gate valve may be closed 7 Discharge check valve may be clogged or have a broken clapper 8 Discharge head may be too high Check elevation Maximum pump head at zero flow is shown on pump curve sheet 9 Ifabove checks do not locate trouble motor rotor may be loose on shaft which allows motor to run but will not turn impeller or only at low RPM This indicates some water has leaked past the lower seal and has entered the seal chamber and made contact with the electrode probe Pump must be removed from basin within approximately 2 weeks fro replacement of lower seal This preventative repair will save an expensive motor Overload trips control box and alarm buzzer or flashing red light comes on due to high water level in basin Yellow run light stays on continuously Circuit breaker trips Pump 15 noisy and pump rate 15 low Grease and solids have accumulated around pump and will not pump out of basin 13 Push in on red reset button to reset overload If overload trips again after short
16. r this Warranty must be returned to HYDROMATIC in Ashland Ohio or such other place as HYDROMATIC may designate freight prepaid PRODUCT IMPROVEMENTS 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 units sold and or shipped prior to such a change or improvement WARRANTY EXCLUSIONS HYDROMATIC MAKES NO EXPRESS OR IMPLIED WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF HYDROMATIC SPECIFICALLY DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE Some states do not permit some or all of the above warranty limitations and therefore such limitations may not apply to you No warranties or representations at any time made by any representatives of HYDROMATIC shall vary or expand the provision hereof LIABILITY LIMITATION IN NO EVENT SHALL HYDROMATIC BE LIABLE OR RESPONSIBLE FOR CONSEQUENTIAL INCIDENTAL OR SPECIAL DAMAGES RESULTING FROM OR RELATED IN ANY MANNER TO ANY HYDROMATIC PRODUCT OR PARTS THEREOF PERSONAL INJURY AND OR PROPERTY DAMAGE MAY RESULT FROM IMPROPER INSTALLATION HYDROMATIC DISCLAIMS ALL LIABILITY INCLUDING LIABILITY UNDER THIS WARRANTY FOR IMPROPER INSTALLATION HYDROMATIC RECOMMENDS INSTALLATION BY PROFESSIONALS 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
17. stalla tion and service of the Hydromatic HPGB750 1000 1500 submersible grinder pumps Motor HP amp Voltages These submersible grinder pumps are offered in three phase 7 10 and 15 HP Voltages will vary according to the application and can be seen in the tables in this manual Three phase stators are available with dual voltage configurations that will allow either 230V or 460V internal connection Electrical Controls All of these pump models must be used with a control panel Hydromatic built control panels are designed to supply the correct electrical controls motor starting equipment and include the circuitry for moisture and heat sensors It is recom mended that a Hydromatic built control panel be used so that all warranties apply General Construction A cross sectional view of the internal workings of the pumps can be seen on page 6 The motor chamber and seal chamber are filled with a high dielectric type oil for improved lubrication and heat transfer of the bearings and motor Since the bearings have been designed for 50 000 hours of life the oil should never require replacement under normal operat ing conditions An air space above the oil level in both the seal and motor chambers is provided to allow for the expansion of the oil when at operating temperature The power and control lines are sealed and strain relieved on the outside entrance with a standard cord grip and internally through the use of a dielectric potti
18. tor windings The thermostats open if the motor windings see excessive heat and in turn open the motor contactor in the control panel breaking the power to the pump When the motor is stopped due to an overheat condition it will not start until the motor has cooled and the heat sensor reset button is manually pushed on the front of the Hydromatic control panel This circuitry is provided in the Hydromatic control panel designs The HPGB750 1000 1500 pumps are equipped with internal thermostats To meet Class H heat rise of 356 F 180 C Note Failure to use proper circuitry and to connect the motor overheat protection in the control panel would negate all warranties Motor Seal Failure Warning The seal chamber is oil filled and provided with moisture sensing probes to detect water leakage through the lower shaft seal The probes can also detect moisture present in the upper motor housing The presence of water energizes a red seal leak warning light at the control panel This is a warning light only and does not stop the motor It indicates a leak has occurred and the pump must be repaired Normally this indicates the outboard seal has leaked Allowing the unit to operate too long after the warning could cause upper seal leakage along with motor failure The resistance across the moisture sensing seal failure probes should be checked after a seal leak warning light has lit This can be done by disconnect ing the red an
19. ttom of lower weight even with bottom of inlet flange to grinder Run pump on hand operation for several minutes with small amount of water running into basin to clean out solids and grease This allows pump to break suction and surge which will break up the solids If level switch lower weight is set properly this condition generally will not occur Trash may have accumulated around lower weight causing pump to turn off too soon Clean trash from weight and suspension cable 23833A617 23833A617 1 07 14 15 23833A617 LIMITED PRODUCT WARRANTY HYDROMATIC warrants that its N are free from defects in material and workmanship for a period of twelve 12 months from the date ot purchase or eighteen 18 months from the date of manufacture whichever occurs first During the warranty period and subject to the conditions hereinafter set forth HYDROMATIC will repair or replace to the original user or consumer parts which prove defective due to defective materials or workmanship of HYDROMATIC Contact the nearest authorized HYDROMATIC distributor HYDROMATIC authorized service center or HYDROMATIC for warranty service At all times HYDROMATIC shall have and possess the sole right and option to determine whether to repair or replace defective equipment parts or components Start up reports and electrical system schematics may be required to support warranty claims Warranty is effective only if HYDROMATIC supplied or authorize
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HPGB750/1000/1500