advanced submersible grinder pump
Contents
1. Reassemble the cutters and volute as outlined in the Pump Disassembly Inspection Reassembly section of this manual Refill all chambers with a good quality dielectric 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 expansion of the oil Fill the seal chamber with 700 ml of oil so that an air gap also exists Replacing Motor Stator I If the replacement of the stator is necessary first follow the disassembly steps outlined in the previous sections of the manual Remove the shaft rotor assembly from the motor housing making note that a wave washer is used on the top of the upper bearing 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 Turn the Examine note of the wire connections and then remove the power cable motor housing over and remove the stator bolts from the stator then remove the stator from the motor housing 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 Attach the power cord to the stator leads and the sensor leads using insulated butt connector Once attached carefully2. the carbon assembly off by prying on the retaining ring Loosen and remove the cap screws that hold on the seal housing then remove the seal housing Using a socket that will fit onto the back of the seal tap the stationary seal assembly out of the seal housing Using a pair of snap ring pliers remove the snap ring that secures the upper 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 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 pliers remove the snap WINDING RESISTANCE IN OHMS hp RPM VOLT PHASE BLACK TO BLACK RED WHITE TO RED TO WHITE 2 3450 208 1 1 30 5 08 6 35 2 3450 230 1 1 57 8 00 9 57 2 3450 200 3 2 86 2 86 2 86 2 3450 230 3 3 31 3 31 3 31 2 3450 460 3 13 25 13 25 13 25 2 3450 575 3 28 2 28 2 28 2 MAXIMUM AMP amp WINDING RESISTANCE VALUES SINGLE PHASE BLACK COMMON WHITE MAIN RED START THREE PHASE BLACK L1 WHITE L2 RED L3 8 10 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 After checking both of the O ri
3. LEADS 208 230V SINGLE PHASE WHITE BLACK RED P1 PURPLE H1 Le L3 P2 BROWN T4 T5 T8 WHITE BLACK RED 230V DUAL VOLTAGE THREE PHASE WHITE BLACK RED L1 L2 L3 P1 PURPLE P2 DARK BROWN T1 T2 BLUE TAN ORANGE T7 T8 T9 PINK RED LT BROWN O08 T4 T5 T6 YELLOW BLACK LAVENDER 200V AND 575V THREE PHASE WHITE BLACK RED P1 PURPLE L1 L2 L3 P2 BROWN T1 T2 T3 BLUE TAN ORANGE 460V DUAL VOLTAGE THREE PHASE WHITE BLACK RED L1 L2 L3 PL PURPLE Ti T2 T3 m cant orc P2 DARK BROWN T7 T8 T9 PINK RED LT BROWN T4 T5 T6 YELLOW BLACK LAVENDER Pump Operations Starting 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 Run water into sump until motor is covered Open the gate valve in the discharge line 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
4. 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 reinstal
5. gt PENTAIR HYDROMATIC MODEL HPDOZUL ADVANCED SUBMERSIBLE GRINDER PUMP INSTALLATION AND SERVICE MANUAL NOTE To the installer Please make sure you provide this manual to the owner of the equipment or to the responsible party who maintains the system Item E 03 407 Part 5625 407 1 2013 Pentair Ltd 11 20 13 General Information Attention This manual contains important information for the safe use of this product Read this manual completely before using this product and refer to it often for 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 Reasonable care and safe methods 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 AWARNING 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 m
6. pump again If pump is 3 phase piped in permanently and still does not operate properly after venting rotation is wrong and can be reversed by interchanging any two line leads Level controls should be set so that pump turns off when level 1s about 2 inches above inlet of pump suction and turns on when level is about 2 inches above motor If problems occur check the power source Make sure a separate supply line is available Verify the voltage supply Check resistance windings see chart If not within guidelines return pump to an authorized Hydromatic service center Pump Maintenance Pump Disassembly Inspection Reassembly 1 Close gate valve at pump discharge 2 Turn off circuit breaker 3 Remove pump from sump Inspect Unscrew cap screws and remove the volute from the pump Note under certain circumstances it may be necessary to remove the discharge piping 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 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 OVER
7. 000141 WIRE w TERMINAL 134880002 SEAL BEARING PLATE 084720015 SEAL FAILURE ASSY 05876A120 O RING 003000001 SHAFT SEAL 1 000730011 WIRE CONNECTOR 230 3 001500421 O RING 070330023 IMPELLER 5 00 070330043 IMPELLER 4 50 070330063 IMPELLER 4 00 055060022 AXIAL CUTTER 054050012 RADIAL CUTTER 148850001 MACHINE SCREW 055700051 IMPELLER WASHER 055050002 STATIONARY CUTTER 000300041 MACHINE SCREW 077630001 CUTTER RETAINER 135001002 VOLUTE CASE 19100A012 HEX HEAD CAP SCREW 5 16 009750021 RETAINING RING 134890012 SEAL HOUSING 001010111 HEX HEAD CAP SCREW 5 16 000650271 BALL BEARING 000250091 MACHINE SCREW PER B M 054544009 LOCK WASHER 21573100 STATOR 230V 1 21573C102 STATOR 230 460V 3 21573C103 STATOR 575V 3 21573C101 STATOR 200V 3 21573C104 STATOR 200V 1 08321005 ROTOR SHAFT 1 08231005 ROTOR SHAFT 3 34950002 HORIZONTAL ADAPTER 34941002 MOTOR HOUSING 08565A013 BALL BEARING 000640011 WAVE SPRING 34962002 VERTICAL ADAPTER std 517004027 SEAL KIT 31880001 CUTTER SHIM 006280391 IMPELLER SHIM Notes S Parts in Seal Kit Fill oil to above motor windings STANDARD LIMITED WARRANTY Pentair Hydromatic warrants its products against
8. 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 gt PENTAIR HYDROMATIC 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 COM Warranty Rev 12 13
9. TIGHTEN the Allen head screw It is good practice to add a light coat of removable locking adhesive to the Allen screw the volute O ring for damage If cracked or torn replace with the proper Hydromatic part 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 l Remove the To remove the Drain the oil in the seal chamber by removing the drain plug on the side of the pump If it contains water the lower seal has failed and should be replaced The motor housing should be drained and the upper seal replaced if the lower seal has failed since foreign material in the seal chamber may have damaged the upper seal volute and cutters per the instrutions listed under the Pump Disassembly Inspection Reassembly section in this manual 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 Using a pair of snap ring ring that secures the lower seal Remove the lower seal rotating elements by sliding the spring off the shaft Then using two screwdrivers slide
10. anual 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 Toreduce 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 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 with maximum 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 centrifugal pump impeller and discharge directly into the inlet of the impeller The integral stainless steel pump motor shaft is sealed by
11. high 2 Impeller or cutters impartially plugged or damaged 3 Wrong rotation 4 Incorrect diameter impeller 5 Speed too low Insufficient discharge pressure 1 Wrong rotation 2 Air or gases in liquid 3 Impeller damages 4 Incorrect impeller diameter 5 Speed too low Pump overloads motor 1 Wrong rotation 2 Specific gravity or viscosity of liquid too high 3 Speed too high 4 Head lower than rating pumping too much liquid 5 Pump clogged 6 Defective bearings 7 Defective impeller Pump is noisy 1 Defective bearings 2 No axial clearance between impeller and volute 3 No diametral clearance between radial cutter and cutter ring If the cause of the trouble cannot be determined and corrected as outlined above contact your nearest factory representative HPG200 Parts List ORDERING REPLACEMENT PARTS Product improvements are made from time to time The latest part design will be fur nished as long as it is interchangeable with the old part When ordering replacement parts always furnish the following information 1 pump serial number 2 pump model and size 3 part description 4 part number 5 impeller diameter if ordering impeller 6 quantity required and 7 shipping instructions Part Description 144240025 POWER CORD 20 144240115 POWER CORD 35 116750001 BUTT CONNECTOR 230 14 200 16 575 30 200 36 230 36 460 30 116910001 BUTT CONNECTOR 060
12. lation 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
13. ngs 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 Take the stationary 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 immediate seal failure 11 12 13 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 Carefully place the seal housing onto the seal bearing plate replace the cap screws and evenly tighten Using a pressure gauge with a fill stem pressurize 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 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 14 Following the same procedure 15 16 outlined in steps 10 through 13 install the lower seal assembly Replace the impeller using a removable locking adhesive
14. ore installation to avoid costly delays that can occur due to rejection after job is finished Pump Installation Unpacking Pump Remove pump from carton When unpacking unit check for concealed damage Claims for damage must be made at the receiving end through the delivery carrier Damage 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 furnished 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 lowest cost where expensive installation labor is involved Electrical Connections Make all connections from motor to control panel to comply 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 Phase Ground Ground Start Power Line Power Line White Main Power Line Power Line Black Common Power Line Power Line Seal Failure Orange Seal Failure Blue Heat Sensor Heat Sensor White Heat Sensor w black stripe Heat Sensor SENSOR LEADS WHITE W BLACK STRIPE P1 BLUE P2 ORANGE SEAL PROBE MOTOR
15. 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 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 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 Replace the wave washer into the upper bearing pocket in the motor housing then reinstall the rotor and shaft assembly 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 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 Pump Troubleshooting Below 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 low Insufficient liquid delivered 1 Discharge head too
16. two mechanical seals with an oil chamber between the seals to provide lubrication for both seal faces Two ball bearings are used to handle the loads in this design similar to most of Hydromatic s solids handling pumps The upper bearing takes radial load while the larger lower bearing handles both thrust and radial loads Both bearings are permanently lubricated by the dielectric oil in the motor housing The motor is fixed within the motor housing and is completely submerged in the dielectric oil for maximum heat transfer The motor housing and seal chamber are completely sealed with O rings located at mating part faces The power cord entry system is designed to give double sealing 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 cable on the HPG model includes the leads for both heat sensors motor protection and the seal sensor lead for seal leakage detection 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 sewage discharge applications with a pH ranging from 5 to 9 specific gravities from 0 9 to 1 1 viscosities ranging from 28 to 35 S S U and temperatures up to 140 F Codes All local wiring codes must be observed Consult the local inspector bef
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