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32269 Hydro HGRS200 E-03-499 FINAL2
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1. Press the stationary portion of the new seal into the seal bearing plate 9 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 12 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 23 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 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 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 th
2. rien are not installed in 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 aie 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 under 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 HYDROMAT
3. IC 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 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 wyDROMATIC 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 5625 499 1 Item E 03 499 6 08 START UP REPORT Distributor Order Installing Contractor Phone Sales Contact Phone Customer amp Location 1 SYSTEM INFORMATION Size of wet well Manufacturer Discha
4. LASTIC HGRS200 05014A193 GASKET RUBBER 264340013 IMPELLER CAST IRON HGRSH200 05030A234 WASHER SST 1 32 THICK 264340060 IMPELLER PLASTIC HGRS200F 25341A002 NUT CORD PLUG SOLID 26430000 PLATE SEAL amp BEARING HGRS200 GRINDER PUMP 25338800 CORD POWER ASSY 14 3 W 230V PLUG 20FT 05014A181 GASKET RUBBER TETRASEAL 7X6 3 4X1 8 27601A990 NAMEPLATE 1 PHASE HYDROMATIC 253270000 HOUSING MOTOR HGRS200 045800011 SCREW DRIVE 19100A012 SCREW HHC 5 16 18UNC X 1 1 4 24709110000 PARAFFINIC OIL 215764010 SEAL 7 8 SHAFT 098224032 SCREW TAPPING SST 316 SST 085654018 BEARING BALL 20333A004 CLIP TUBE CAPACITOR MTG ST 26466101 STATOR LONG SHELL 2 HP 230V 23838A010 CAPACITOR RUN 26466 002 ROTOR W SHAFT FOR HGRS200 GRINDER PUMP 17190A004 TIE CABLE NYLON 1 MAX BUNDLE DIA 098594827 WIRE W TERMINALS 14GA BLACK 9 LG 12074A064 TERMINAL INSULATED MALE 098594828 WIRE W TERMINALS 14GA BLACK 4 1 2 LG 098594829 WIRE W TERMINALS 14GA YELLOW 4 LG gt co co CO NI amp PD sss 55 ss og SS Siw LIMITED PRODUCT WARRANTY HYDROMATIC warrants that its eae are free from defects in material and workmanship for a period of twelve 12 months from the date of 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
5. Pump Installation and Service Manual L HYDROMATIC HGRS200 Submersible Grinder Pump ake sure you provide m this manual to the owner of the pumping equipment or to Pentair the responsible party who maintains the system wW t 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 tank to be vented with local Septic in accordance plumbing codes Do no
6. d should not be installed 1 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 pumps are submerged in a vertical position The complete factory built packaged system is recommended for the most satisfactory installation and generally for the low
7. d without removing from the shaft 7 If necessary to replace cutter remove screw 5 washer 4 and radial cutter 6 from shaft Radial cutter 6 and impeller 8 are screwed onto shaft The thread is right hand Tap radial cutter 6 with plastic hammer if necessary to loosen Unscrew impeller 8 from shaft in same manner as radial cutter 6 3 8 Clean all parts thoroughly before proceeding with assembly 9 Replace case Replace cutter ring assembly 2 Screw down with screws 3 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 19 located on the side of the motor housing 10 2 Remove the volute and cutters per the instructions listed under the replacing grinder parts section in this manual 3 To remove the impeller 8 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 12 rotating elements by sliding the spring bellows off the shaft then 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 12 to allow for removal 6 Take the stationary portion of the new seal 12 and lube the rubber material with good quality dielectric oil
8. e pump PERFORMANCE CURVE 120 105 90 A Ss HEAD FEET HEAD METERS gt a 30 US GPM 0 5 10 15 25 30 35 40 M3 HR 17 34 51 68 85 10 2 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 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 fact
9. est 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 supply line is available Verify voltage supply 7 Check resistance of winding
10. ile on this order H 02 7590 3 08
11. 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 authorized 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 accident or negligence c to normal maintenance services end iis parts used in connection with such service d to units
12. ory representative HGRS200 Parts List 21 14 NPT DISCHARGE 1S 22 rl X 20 MOTOR HOUSING MUST 19 25 POSITIONED 1 16 AS SHOWN aLZESZ 16A 18 17 17A REER 23 oo aes KO J 14A 14B 13 xo 11 26A 12 11 140 19 14D 16 CAPACITOR ITEM 25 8 CAPACITOR WIRING DIAGRAM t 14F A 146 4 C2 INSULATED TERMINALS NON INSULATED TERMINALS Ref No Part No Description g Part Description 2604390002 CASE VOLUTE C I HGRS200 1 1 4 NPT DISCHARGE 098594830 WIRE W TERMINALS 14GA RED 3 LG 220844000 PLATE WARNING GRINDER PUMP 09859A831 WIRE W TERMINALS 14GA WHITE 8 LG 215848000 FLANGE W SHREDDING RING HGRS200 26466 003 SWITCH CENTRIFUGAL MECH FOR HGRS200 215848003 FLANGE W SHREDDING RING HGRSH200 12141A015 CAPACITOR START 215848004 FLANGE W SHREDDING RING HGRS200F 20333A001 CLIP TUBE CAPACITOR MTG ST 19099A012 SCREW CAP HEX 1 4 SST 1 LG 20UNC 08565A013 BEARING BALL 215834000 RETAINER IMPELLER SST 118164006 RING RETAINING 07597A018 SCREW MACH FLT HD SKT SST 1 4 20 3A X 3 416 19331A005 WASHER SPRING FINGER 215828000 IMPELLER GRINDING SEWAGE GRINDER PUMP 050224092 PLUG PIPE ST GALV 1 4 HEX HD 050134039 SCREW SET HDLS HEX SST 1 4 20X3 8 CUP 050304235 WASHER SST 3 32 THICK 26434C010 IMPELLER P
13. rge from bottom of basin Location Inlet from bottom of basin Location Type of check valves Type of piping Does system have suction and discharge gauges Pressure reading Suction Discharge Liquid being pumped Temperature of solid Sketch or photograph of system attached Any additional comments on system 2 ELECTRICAL INFORMATION A Control panel part Panel rated amps Manufacturer Voltage Phase Heater size Location of panel to wet well Incoming line voltage Actual Voltage to pumps Actual Type of junction box Manufacturer Are floats installed in wet well Are floats set to engineer s spec Are floats wired for proper sequencing Any additional comments on electrical 3 PUMP INFORMATION Qammogomp gt Any additional comments on pumps Type of pump Serial Voltage Phase RPM Amps Impeller size C 0 S TDH GPM Voltage supplied from panel Actual Actual amperage all phases amps amps amps Have you checked pump rotation Acknowledge that all information is accurate and proper procedures have been followed Customer Signature Date Start up Technician Date Send to Warranty Department 740 E Ninth Street Ashland OH 44805 Fax 419 207 3344 or e mail to startupreport hydromatic com We will make this a permanent part of our f
14. s 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 3 and remove cutter ring assembly Stationary cutter 2 cannot be removed from volute 5 Unscrew hex head cap screws 11 and remove volute case 1 Radial cutter 6 is now exposed If checking for clogging it can now be cleane
15. t 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 accordance with local plumbing codes an
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