E-one Extreme Series User manual

Service
Manual
E/One Extreme
Grinder Pumps
240V, 50 Hz • Hardwired Controls
Australia • New Zealand

1
Chapter 1 — Service Manual Overview ...........................................................................................1
Safety Warnings ...............................................................................................................................1
About E/One Grinder Pumps ............................................................................................................1
Basic Operation ................................................................................................................................1
Chapter 2 — Troubleshooting...........................................................................................................2
Hardwired-Communicating Models...................................................................................................2
Site Survey (Panel)...........................................................................................................................2
Supply Voltage Checks.....................................................................................................................3
Motor Controller Board .....................................................................................................................3
Protection Features ..........................................................................................................................3
Identifying Pumps that use the Motor Controller Board ....................................................................4
Continuity Tests ................................................................................................................................5
Megohmmeter / Cable Insulation Integrity Check.............................................................................5
Continuity Checks — Pumps with Control Bracket...........................................................................6
Out of Water Continuity Checks — Pumps with Motor Controller Board..........................................7
Pump in Water Continuity Checks — Pumps with Motor Controller Board.......................................8
Amperage Checks ............................................................................................................................9
Site Survey (Tank) ............................................................................................................................9
Troubleshooting Charts ..................................................................................................................10
Chapter – 3 Core Removal/Replacement .......................................................................................14
WH (Open Wet Well Versions) .......................................................................................................14
Chapter 4 – Start-Up Procedure......................................................................................................15
Station Inspection ...........................................................................................................................15
Panel Inspection .............................................................................................................................15
Voltage, Continuity and Cable Insulation Integrity Test ..................................................................15
Run Test .........................................................................................................................................15
Chapter 5 – Pump End/Grinder Mechanism ..................................................................................17
Removing the Pump Stator.............................................................................................................17
Pump Stator Inspection ..................................................................................................................20
Inspecting a Pump Rotor ................................................................................................................21
Removing the Pump Rotor .............................................................................................................22
Assembling the Pump/Grinder Mechanism ....................................................................................22
Chapter 6 – EQD Disassembly and Reassembly...........................................................................25
EQD Disassembly...........................................................................................................................25
EQD Reassembly ...........................................................................................................................26
EQD Retrofit (2000-Series to Extreme Series)...................................................................................28
Chapter 7 - Cable Replacement ......................................................................................................30
Cable Removal ...............................................................................................................................30
Cable Installation ............................................................................................................................30

2
Chapter 8 – Level Sensor ................................................................................................................32
Level Sensor Removal....................................................................................................................32
Level Sensor Test Procedure .........................................................................................................32
Test Procedure ...............................................................................................................................33
Level Sensor Leak Troubleshooting & Repair ................................................................................33
Level Sensor Disassembly .............................................................................................................33
Level Sensor Reassembly ..............................................................................................................35
Equalizer Field Reset......................................................................................................................37
Equalizer Field Reset (New Style) ..................................................................................................39
Chapter 9 - Control Cavity ...............................................................................................................42
Hardwired-Communicating Models.................................................................................................42
Control Housing Removal...............................................................................................................42
Troubleshooting Controls................................................................................................................44
Motor Contactor and Controls.........................................................................................................44
Motor Start Switch ..........................................................................................................................44
Control Bracket Removal................................................................................................................45
Motor Capacitor ..............................................................................................................................45
Thermal Protector ...........................................................................................................................45
Motor Cavity Water Test .................................................................................................................46
Motor Windings Test.......................................................................................................................46
Control Bracket Installation.............................................................................................................47
Motor Controller Board – Pumps Manufactured After 9/2020.........................................................48
Installing the Motor Controller Board ..............................................................................................48
Removing the Motor Controller Board ............................................................................................48
Control Housing Installation............................................................................................................49
Chapter 10 – Motor Cavity ...............................................................................................................50
Major Repair and Rebuilding ..........................................................................................................50
Core and Motor Disassembly .........................................................................................................50
Assembling the Core and Motor .....................................................................................................52
Motor Drying Techniques................................................................................................................52
Chapter 11 – Mechanical Seal Assembly .......................................................................................56
Installing the Mechanical Seal ........................................................................................................56
Chapter 12 – Final Test Procedures ...............................................................................................57
Leak Tests ......................................................................................................................................57
Motor Cavity & Seal Assembly Leak Test.......................................................................................57
Control Cavity Leak Test ................................................................................................................57
Test Run .........................................................................................................................................58
Amperage Draw Test......................................................................................................................60
Amperage Draw Readings..............................................................................................................60

1
Chapter 1 — Service Manual Overview_ _______________
This manual contains information about servicing, rebuilding, and troubleshooting Extreme-Series
grinder pumps. A thorough understanding of these products will save you valuable time when
troubleshooting and repairing Environment One Grinder Pumps. This manual contains information
specific to the hardwired model.
Safety Warnings __________________________________________________
A Caution statement in this manual designates a situation that could cause equipment failure or
damage. Follow the proper safety procedures as described in the instructions.
A Warning statement in this manual designates a situation that can cause bodily harm and/or
equipment damage. Follow the proper safety procedures as described in the instructions.
About E/One Grinder Pumps _______________________________________
Environment One grinder pumps are designed to grind and pump domestic sewage. The grinder
pumps are not designed to be small lift stations. They are not capable of handling waters with high
concentrations of mud, sand, silt, chemicals, abrasives or machine wastes. Environment One’s semi-
positive displacement, progressing cavity pumps provide predictable flow over a variety of pressures.
High-torque, low-speed motors power the pumps. The unique one-piece core assembly is
interchangeable throughout E/One’s product line.
Basic Operation __________________________________________________
The grinder pump is designed to grind and pump domestic sewage. The pump is a semi-positive
displacement, progressing cavity pump. The grinder pump consists of a pump assembly with an
integral sewage grinder and shredder device. The pump traps a column of air in the sensing bell for
the on-off pressure switch. When water in the tank reaches the normal turn-on level, the pressure in
the sensing line closes the electrical contact points. The relay coil is energized and the relay contact
points close, providing electrical power to the pump motor. When the motor starts and runs, the
grinder pulverizes any solids. The slurry is then pumped until the liquid in the tank is lowered to the
shut-off level. This reduces pressure on the diaphragm of the on-off switch, which opens the
electrical contacts and removes power from the motor.
In the event of a pump failure, the liquid in the basin rises and activates an alarm pressure switch.
The electrical contacts close, activating the alarm indicator (light and/or buzzer). The alarm alerts the
homeowner about a pump problem.

2
Chapter 2 — Troubleshooting
Hardwired-Communicating Models__________________________________
Site information is vital to proper diagnosis of a pump failure and getting the station back to normal.
When a pump requires service, an inspection of the site should be the first task performed. The
following procedure details the proper method for gathering the maximum amount of data that can
be collected during a service call.
Site Survey (Panel) ________________________________________________
1. Observe the site. Record the following on the service tag:
a. Customer Information
b. Date
c. Time
d. What is the alarm status?
e. Is the pump running? (without opening the station)
2. Open the Panel. Record the following on the service tag:
a. Is the panel dry and free of moisture?
b. Have any breakers tripped?
c. Was the panel correctly installed (penetrations on bottom, sealed conduits, etc.)?
d. Is any service needed to the panel?
Figure 2 – 1

3
Supply Voltage Checks ____________________________________________
The Environment One grinder pump is equipped with a 1450 rpm, 1 hp, 230 - 240V motor. The
operating voltage parameters of the motor are plus or minus 10% of the specific application. This
would equate to 207Vto 264V in the 230 - 240V application. Refer to the following chart for voltage
checks.
Supply Voltage and Breakers 240V (hardwired controls)
Table 2 – 1
Motor Controller Board ___________________________________________
In September 2020, E/One replaced the control bracket in all of its hardwired grinder pumps with a
Motor Controller Board (MCB). The motor controller board controls the operation of the pump and
introduces electrical condition monitoring at the pump level. The MCB improves system reliability by
preventing pump operation during unideal conditions.
The motor controller board replaces the motor start contactor, start switch and thermal protector.
Control brackets are no longer available and pumps that require replacement of the control bracket
must be retrofitted with the motor controller board.
Protection Features _______________________________________________
If the incoming line voltage is outside of the safe operating range (below 210V) the MCB will interfere
with operation. This condition will continue until voltage is back to the appropriate level.
Color 1 Color 2
Normal Reading Operation If Reading is Wrong, Check:
L1 Neutral 207V - 264V
Incoming
Voltage to
Breaker OK
Breaker Tripped or Off in Main Panel, Lost Leg of
Power
Red 2 Black 3 207V - 264V
Pump
Breaker OK
Bad Breaker, Lost Leg of Power
Neutral
Alarm
Breaker
(Incoming)
207V - 264V
Incoming
Voltage to
Breaker OK
Breaker Tripped or Off in Main Panel, Lost Leg of
Power, Jumper Wire not Connected, No Neutral
Neutral
Alarm
Breaker
(Outgoing)
207V - 264V
Alarm
Breaker OK
Bad Breaker
Neutral Yellow 5 207V - 264V
Voltage to
Alarm Switch
OK
Loose Wire between Alarm Board and Single Pole
Breaker, Bad Alarm Board

4
If the pump’s current is greater than approximately 17 amps for longer than 2 seconds, the MCB
sees this as a “locked rotor” condition and will interfere with operation. After this is sensed, the MCB
has a timer that will stop operation for approximately 5 minutes. This can be cleared by cycling the
breakers off for a few seconds, and then back on.
If the pump’s current rises above approximately 9 amps for longer than 4 seconds, the MCB will
interfere with the pump’s operation. After this is sensed, the MCB has a timer that will stop operation
for approximately 5 minutes. This can be cleared by cycling the breakers off for a few seconds, and
then back on.
Identifying Pumps that use the Motor Controller Board _________________
Currently, the MCB is standard on all hardwired pumps manufactured after September 2020. There
are two ways to confirm that the pump has a motor controller board:
1. The flag tag on the pump cable includes the date of manufacture and pump serial number.
To confirm that the pump is “hardwired,” the second character in the serial number is the
letter “H.”
Figure 2-3
2. The most reliable method for identifying the presence of an MCB is to check the “Identification
Resistor” or ID Resistor. Depending on the voltage and frequency of the pump, use a
multimeter at the alarm panel or EQD and compare the reading to those on Table 2-4, below.
The readings shown are with a meter at the 2M ohm scale. All continuity checks must be
performed with the alarm panel breakers in the OFF position.
Voltage/Hz
Meter Setting
Wires (pin)
Reading
240V / 50 Hz
2M
Brown (1) / Black (3)
0.086 – 0.096
Table 2-4

5
Continuity Tests __________________________________________________
All continuity readings should be taken after the power isturned off and verified with a voltmeter.
With the pump power off, set an ohmmeter (Wavetek #5XPor equivalent) to the 2–meg or 2000K
ohm scale. Identify the wires coming from the pump into the panel. All the test points listed below
refer to pump wires only. Allow at least 5 seconds for the meter to obtain a stable reading. Note any
incorrect readings on the service tag. The charts are true for Protect and Protect Plus Panels.
Megohmmeter/Cable Insulation Integrity Check ______________________
There is really onlyone way to test the integrity of the insulation on the wires in the cable that is
buried in the ground and that is with a Megohm meter. As stated previously, the higher the scale or
range that a meter isset to, the more sensitive it becomes. A Megohm meter isin the 1000M or
1,000,000,000 ohms range, rated at 500V and is extremely sensitive to loss of integrity in insulation.
This test can also identify EQD insert problems as well. The most common failure associated with
cable issues isa continuous run condition, or run dry, which can lead to other failures such as control
bracket failure, seal failure, flooded motors, etc. Ultimately a run dry condition could be the first
domino that leads to complete catastrophic failure of the pump. The importance of this
troubleshooting tool cannot be stressed enough.
Separate the EQD at the station and remove all but the ground wire inside the panel. Check every
wire to every wire for shorts.
Good: 500M or higher
Marginal: Between 200M and 500M
Bad: Below 200M
If a bad reading is detected, then isolate the cable by removing the EQD insert, and retest the cable.
If the bad reading goes away then replace the insert and retest the wires once more to make sure
that new EQD insert resolved the problem. If a bad reading persist then you could try clipping the
cable back some. Always retest after any repair attempt. If the readings don’t go away, then the
cable should be replaced.
Note: If there is the presence of moisture in the EQD, the inserts must be replaced and the
housings dried and cleaned before reassembly. If the housings are flooded,water may have wicked
into the wires and it may be necessary to trim the cable back. If the bad readings don’t go away,
then the cable should be replaced.

6
Continuity Checks — Pumps with Control Bracket _____________________
This table assumes the pump has shut off on its own or is not installed in a station.
Color 1 Color 2
Normal
Reading Operation If Reading is Wrong, Check:
Brown 1 Red 2 OL or Open On/Off Switch
off
Switch stuck closed, wet EQD, mis-wired, plugged
sensing line obstructed vent, restricted breather
tube
Yellow 5 Blue 6 OL or Open Alarm Switch off
Switch stuck closed, wet EQD, mis-wired, plugged
sensing line obstructed vent, restricted breather
tube
Green 4
Black 3
Closed
Ground - Neutral
Verify neutral is good
Green 4
Brown 1
Red 2
Yellow 5
OL or Open No Shorts to
Ground
Supply cable cut, water in EQD or pump controls,
unplug EQD and retest to isolate the shorts.
Green 4 Blue 6 OL or Open
No Shorts to
Ground
Supply cable cut, water in EQD or pump controls,
unplug EQD and retest to isolate the shorts.
Brown 1
Yellow 5
Blue 6 OL or Open Redundant run
to Alarm
Supply cable cut, water in EQD or pump controls,
unplug EQD and retest to isolate the shorts.
Brown 1 Black 3 0.001 Contactor Coil
Coil mis-wired, shorted or open, water in EQD or
controls
Table 2 – 2
Assumes enough water is in the tank to turn on the alarm.
Color 1 Color 2
Normal
Reading Operation If Reading is Wrong, Check:
Brown 1 Red 2
0.00 -
Closed
Circuit
On/Off Switch
on
Low water level, EQD unplugged, broken wire or
mis-wired, bad switch, sensing line leak or
blockage, blocked vent, restricted breather tube
Yellow 5 Blue 6
0.00 -
Closed
Circuit
Alarm Switch on
Switch stuck closed, wet EQD, mis-wired, plugged
sensing line obstructed vent, restricted breather
tube
Green 4
Black 3
Closed
Ground - Neutral
Verify neutral is good
Green 4
Brown 1
Red 2 OL or Open
No Shorts to
Ground
Supply cable cut, water in EQD or pump controls,
unplug EQD and retest to isolate the shorts.
Green 4
Yellow 5
Blue 6 OL or Open
No Shorts to
Ground
Supply cable cut, water in EQD or pump controls,
unplug EQD and retest to isolate the shorts.
Brown 1
Yellow 5
Blue 6 OL or Open
Redundant run
to Alarm
Supply cable cut, water in EQD or pump controls,
unplug EQD and retest to isolate the shorts.
Brown 1 Black 3 0.001 Contactor Coil
Coil mis-wired, shorted or open, water in EQD or
controls
Table 2 – 3

7
Out of Water Continuity Checks — Pumps with Motor Controller Board
This table assumes the pump has shut o󰀨 on its own or is not installed in a tank.
On/O󰀨 Switch
Meter
Scale
Red Probe
(pin)
Black Probe
(pin)
Normal
Reading Corrective Action
Auto Brown (1) Red (2) 1M-11M Check switch
Check EQD (wet)
Plugged sensing line
Obstructed vent
Restricted breather tube
MCB fault
Auto Red (2) Brown (1) M Ohms
Increasing
Manual Brown (1) Red (2) OL
Manual Red (2) Brown (1) OL
Alarm Switch
Meter
Scale
Red Probe
(pin)
Black Probe
(pin)
Normal
Reading Corrective Action
Manual Yellow (5) Blue (6) OL or Open Check switch
Check EQD (wet)
Plugged sensing line
Obstructed vent
Restricted breather tube
Ground Short Checks
Meter
Scale
Red Probe
(pin)
Black Probe
(pin)
Normal
Reading Corrective Action
Manual Green (4) Blue (6) OL or Open Check Neutral
Check bulb or relay on board
Jump Yellow/Blue to verify alarm
Manual Green (4) Brown (1)
Red (2)
Yellow (5)
OL or Open Check supply cable for damage
Check EQD or pump controls (wet)
Unplug EQD to isolate
Manual Green (4) Black (3) OL or Open Check EQD, control, motor (wet)
Motor winding short to Ground
Manual Run Shorts
Meter
Scale
Red Probe
(pin)
Black Probe
(pin)
Normal
Reading Corrective Action
Manual Brown (1) Yellow (5)
Blue (6)
OL or Open Check supply cable for damage
Check EQD or pump controls (wet)
Unplug EQD to isolate
Table 2–4
MCB ID Resistor
Meter
Scale
Red Probe
(pin)
Black Probe
(pin)
Normal
Reading Corrective Action
Manual Brown (1) Black (3) 0.086 — 0.096 Check EQD or controls (wet)
Faulty MCB

8
Table 2–5
Pump in Water Continuity Checks — Pumps with Motor Controller Board
This table assumes enough water is in the tank to turn on the alarm.
On/O󰀨 Switch
Meter Scale Red Probe
(pin)
Black Probe
(pin)
Normal
Reading Corrective Action
Manual Brown (1) Red (2) 0.00 (Closed) Add water (too low)
Check EQD (wet)
Check wiring
Check switch
Plugged sensing line
Alarm Switch
Meter Scale Red Probe
(pin)
Black Probe
(pin)
Normal
Reading Corrective Action
Manual Yellow (5) Blue (6) 0.00 (Closed) Add water (too low)
Check EQD (wet)
Check wiring
Check switch
Plugged sensing line
Ground Short Checks
Meter Scale Red Probe
(pin)
Black Probe
(pin)
Normal
Reading Corrective Action
Manual Green (4) Yellow (5)
Blue (6)
OL or Open Check Neutral
Check bulb or relay on board
Jump Yellow/Blue to verify alarm
Manual Green (4) Brown (1)
Red (2)
OL or Open Check supply cable for damage
Check EQD or pump controls (wet)
Unplug EQD to isolate
Manual Green (4) Black (3) OL or Open Check EQD, control, motor (wet)
Motor winding short to Ground
Manual Run Shorts
Meter Scale Red Probe
(pin)
Black Probe
(pin)
Normal
Reading Corrective Action
Manual Brown (1) Yellow (5)
Blue (6)
OL or Open Check supply cable for damage
Check EQD or pump controls (wet)
Unplug EQD to isolate
MCB ID Resistor
Meter
Scale
Red Probe
(pin)
Black Probe
(pin)
Normal
Reading Corrective Action
Manual Brown (1) Black (3) 0.086 — 0.096 Check EQD or controls (wet)
Faulty MCB

9
Amperage Checks_________________________________________________
The use of a clamp on amp meter can be helpful for identifying problems such as a restricted/
blocked discharge line, blown stator, faulty check/anti-siphon valve, etc.
1. Set the clamp-on amp meter to the appropriate scale.
2. Hook the probe around the Black power lead in the alarm panel.
3. With the power on, fill the tank until the pump operates, or depress the push to run switch in
the panel.
4. Read the current directly. Refer to the following table for troubleshooting.
Table 2 – 6
The figures shown are averages and meant to be used for approximation because motors, voltages
and amp meters vary. The table displays a comparison of back pressure (kPa), flow (LPM), current
draw (amperes) and head (meters of water pressure). By knowing the current draw, you may
discover a restricted or blocked discharge line, blown pump Stator, high head operation, etc.
A jammed grinder may trip the circuit breaker or cause the overload protector to cycle. This causes
the pump to cycle on and off, and eventually results in an alarm condition. A torn or worn out pump
stator results in a “runs but does not pump” condition and eventually, as the water rises, causes an
alarm. Replace the Stator and, if necessary, the Rotor.
Site Survey (Tank) ________________________________________________
1. Open the Tank and Inspect. Record the following on the service tag:
a. Is the tank/access way flooded?
b. If yes, where did the water enter?
c. Was the EQD below water?
d. Is the equalizer hung properly?
2. Disconnect the EQD and Inspect. Record the following on the service tag:
a. Is the EQD Dry?
b. Is the EQD assembled correctly?
3. Repeat the power-off Continuity Checks at the EQD.

10
Troubleshooting Charts ____________________________________________
The following troubleshooting tips will help diagnose frequent causes of grinder pump problems.
Alarm On – Pump Running but not Pumping
Possible
Causes Troubleshooting Steps
Blocked
Discharge Line,
Worn Stator or
leak in pump
discharge
assembly
Check the amperage. If the amperage is high (8 amps or higher), turn off
the pump and check the discharge line for blockage. Confirm that the
pump has not been damaged by disconnecting the discharge piping and
recycling the fluid in the tank. Turn the pump power on and check the
amperage. If the amperage remains high, replace the pump and return
the failed pump to shop for possible repair. If amperage returns to
normal, clear blockage in discharge line and re-check amperage.
If the amperage is low (4.9 amps or less), the pump must be pulled and
the Stator (and possibly the Rotor) replaced, or the leaking discharge
line repaired. The cause of the Stator and/or Rotor failure must be
determined and corrected before reinstallation or the pump will fail
prematurely again. Chapter 5 – Pump End, describes how to identify and
correct causes of Stator and Rotor wear.
Table 2 – 7
Alarm On — Pump not Operating
Possible
Causes Troubleshooting Steps
Incorrect Voltage
Check the voltage at a location nearest the pump, such as the junction
box or electrical quick disconnect (EQD) plug. The correct voltage is
listed on the pump nameplate. Note: Voltage must be within 10 percent
of nameplate voltage (230 - 240V: 207 to 264V)
Bad Contactor
Perform continuity check per tables 2 - 2 and 2 – 3.
Wet or Corroded
Controls
Inspect the electrical controls. Replace any wet or corroded controls. See
Chapter 9 – Control Cavity.
Inoperative
Control Test the controls as described in Chapter 9 – Control Cavity
Table 2 – 8

11
Alarm Activates Frequently
Possible
Causes Troubleshooting Steps
High Flow
The incoming flow is greater than the pump can handle. Infiltration, a
sump pump, a hot tub or any other device that causes excessive water
flow can cause high flow.
Plugged Vent or
Equalizer Tube
Check the Vent and the Equalizer Tube. A plugged or partially plugged
Vent or Equalizer Tube will cause the alarm to activate frequently.
Replace the Equalizer Tube if kinked or damaged.
Level Sensor
Leak
Pull the pump out of the tank. Inspect the Level Sensors for cracks and
debris; use Level Sensor test to check for leaks.
Line Blockage or
Worn Stator Check the amperage. If the amperage is high, look for a line blockage. If
the amperage is low, inspect the Stator for excessive wear.
Underground
Wire Damage
Check the Tray Cable wiring for cuts, breaks and shorts. Use a Meg-
Ohm Meter to check for shorts between each pair of leads. Replace the
Tray Cable if a short is found.
Table 2 – 9
Noisy Pump
Possible
Causes Troubleshooting Steps
Normal
Operation
The pump may be grinding up material. Wait a few minutes. If the pump
does not quiet down, remove the core and clean the basin.
Low Voltage
Check the voltage level. The voltage is listed on the pump nameplate.
Note: Voltage must be within 10 percent of nameplate voltage (230 -
240V: 207V to 264V)
Blocked
Discharge Check the amperage. If the amperage is high (8 amps or higher on 230 -
240V), turn off the pump and check the discharge line for a blockage.
Confirm that the pump has not been damaged by disconnecting the
discharge piping and recycling the fluid in the tank. Turn the pump power
on and check the amperage. If the amperage remains high, replace the
pump and return the failed pump to shop for possible motor repair. If it
returns to normal, clear discharge and re-check amperage.
Damaged Stator
Check the Stator for holes or tears. Chapter 5 – Pump End, describes
the pump stator inspection procedure.
Worn Motor
Bearing
Remove the pump Stator and hand–rotate the shaft. If the shaft turns
roughly, replace the pump. Return the failed pump to the shop and
replace the motor bearings.
Table 2 – 10

CAPACITOR
BLEED
RESISTOR
MOTOR
COMPARTMENT
GRN-G
1
3
2
1
3
PROTECTOR
THERMAL
SWITCH
SMART
CONTROL COMPARTMENT
MOTOR section
CONTROL COMPARTMENT
COVER section
TO MOTOR
GROUND
2T1 4T2 6T3 14NO A2
A1 13NO 5I3 3L2 1L1
MOTOR CONTACTOR
GRINDER PUMP CORE
BRN-L1 Control
NA0035P17 REV. B
RED-L1
EQD
Pin # Wire Color Function
1 Brown Manual Run
2 Red L1 (Active)
3 Black Neutral
4 Green w/ Yellow Stripe Ground (Earth)
5 Yellow Alarm Power Feed
6 Blue Alarm Power Return
240VAC
NEUTRAL
L1
ACTIVE
AMP
30
MAIN SUPPLY PANEL
NG
240VAC 50Hz
SINGLE POLE - HARDWIRE
EARTH
(RECOMMENDED WIRING CONFIG,
NOT SUPPLIED BY E/ONE)
PUMP BREAKER
15 15
ALARM BREAKER
L1
ACTIVE
N
START
MAIN
MAIN
RED
BLK
PROTECTOR
THERMAL
WHT
1
3
2
(ALARM) SWITCH
2
1
3
(ON-OFF)
SWITCH
Level Control Compartment
Tray Cable
HARD WIRE OPTION
Alarm Yellow and Blue wires go to the alarm panel only
Motor Control Red and Brown wires go to both alarm panel and motor contactor
ALARM LAMP
REDUNDANT
RUN
REDUNDANT
RUN
COIL
COM
N.O.
N.C.
Basic Alarm
Board (PC1139G02)
SILENCE
RELAY
SILENCE
RELAY
COIL
COM
N.O.
N.C.
PTC RESISTOR
AUTO-RESET FUSE
Resistor
LED
GREEN
RUN
SERVICE
NEUTRAL
MANUAL RUN
ALARM FEED
ALARM RETURN
BUZZER
SILENCE
SWITCH
MANUAL RUN SW.
Resistor
PUMP L2
ALARM L1
WIRED WIRELESS
LEVEL CONTROL
Using the EXTREME color Scheme
BLK-N
ROAD MAP, 240V/50Hz, 1L, HW
ALARM/DISCONNECT
Figure 2-2 — Wiring Schematic, 240V, 50 Hz May 2015 – Sep 2020 (Serial Number 531884 to 715548)
Alarm panel wiring varies based on panel type. Refer to wiring instructions
in alarm panel for more detail.

NA0035P17 REV. C
240VAC
NEUTRAL
L1
ACTIVE
AMP
30
MAIN SUPPLY PANEL
NG
240VAC 50Hz
SINGLE POLE - HARDWIRE
ALARM/DISCONNECT
EARTH
(RECOMMENDED WIRING CONFIG,
NOT SUPPLIED BY E/ONE)
PUMP BREAKER
15 15
ALARM BREAKER
L1
ACTIVE
N
ALARM LAMP
REDUNDANT
RUN
COIL
COM
N.O.
N.C.
Basic Alarm
Board (PC1139G02)
SILENCE
RELAY
COIL
COM
N.O.
N.C.
PTC RESISTOR
AUTO-RESET FUSE
Resistor
LED
GREEN
RUN
SERVICE NEUTRAL
MANUAL RUN
ALARM FEED
ALARM RETURN
BUZZER
SILENCE
SWITCH
MANUAL RUN SW.
Resistor
PUMP L2
ALARM L1
WIRED WIRELESS
LEVEL CONTROL
Using the EXTREME color Scheme
ROAD MAP, 240V/50Hz, 1L, HW
HARD WIRED LEVEL CONTROL
SUPPLY CABLE WIRE COLOR & OPERATION
10 MOTOR
GROUND
MOTOR COMPARTMENT
GRINDER PUMP CORE
CONTROL
COMPARTMENT
MOTOR SECTION
CONTROL
COMPARTMENT
COVER SECTION
Hard Wire Option
Alarm Yellow and Blue wires go
to the alarm panel only. Motor
Control Red and Brown wires
go to both alarm panel and
control board.
NC
COM
NO
SUPPLY CABLE
3 3
(ALARM)
SWITCH
LEVEL CONTROL COMPARTMENT
1
2 2
1
(ON-OFF) SWITCH
BROWN
GRAY
ORG/WHT
BLEED
RESISTOR
CAPACITOR
MAIN
MAIN
THERMAL PROTECTOR
WHT
RED
BLK
CONTROL
BRACKET
MOTOR
BLACK
START
EQD PIN # WIRE COLOR FUNCTION
1 BROWN MANUAL RUN
2 RED L1
3 BLACK L2 OR NEUTRAL
4
GREEN W/ YELLOW STRIPE
GROUND
5 YELLOW ALARM POWER FEED
6 BLUE ALARM POWER RETURN
Figure 2-2a — Wiring Schematic, 240V, 50 Hz, Sep 2020 (Serial Number 715549 & Later)
Alarm panel wiring varies based on panel type. Refer to wiring instructions in
alarm panel for more detail.

14
Chapter - 3 Core Removal/Replacement ________________
WH (Open Wet Well Versions) _____________________________________
1. Open the control panel and shut off all power going to the pump and alarm system.
2. Remove the lid to the station.
3. Disconnect the EQD. If the Tray Cable EQD is wet or has moisture in it, then the EQD insert
must be replaced and the source of moisture determined and corrected before connecting a
new pump to it.
4a. If the unit is equipped with a slide face valve,close the slide face discharge by lifting up on
the handle to close the valve. Pull the slide face,with the discharge hose connected to
the pump,out of the discharge assembly; this isusually done with a long piece of PVC
pipe with a 1” female threaded coupling on the end of it.
4b. If the unit is equipped with a ball valve, close the valve and loosen the compression nut on
the discharge hose.
5. Utilizing the rope attached to the pump, pull the pump out of the station (the pump weighs
approximately 50 kg). This can be done using the E/One lifter or appropriate lifting device. If
lifting manually, this isa two-man lift. Note: DONOT pull the pump out of the station by
the discharge hose, equalizer tube, or the power cable.
6. Install new pump into station.
7. Connect the discharge hose to the valve and open the valve.
8. Perform start up procedures as described in Chapter 4 – Start-Up Procedure.

15
Chapter 4 – Start-Up Procedure ______________________
Station Inspection_________________________________________________
Check:
1. Proper burial depth 2 to10 cm (1 to 4 inches) below the hinged cover/transition joint).
2. The ground must be graded away from the unit to prevent the water from pooling around it.
3. Damage free, leak free.
4. The Equalizer Tube/Power Cable must be hung at the top of the station and not lay on the
core.
5. Supply cable run in suitable conduit and buried with adequate clearance.
6. Cable entry Liquid tight cord grip tightened.
7. Check the discharge valve in the station to make sure it is open.
8. Make sure that the EQD’s and discharge hose are connected properly.
Panel Inspection __________________________________________________
Check:
1. Proper wiring (see the wiring diagram in the panel).
2. Damage free.
3. All cable entries through approved fittings in the bottom of panel.
4. Conduits must be sealed.
5. Test incoming line voltage. If the voltage varies more than 10 percent of nameplate voltage,
do not continue!Rectify the voltage problem.
Voltage, Continuity and Cable Insulation Integrity Test _________________
Refer to the pertinent Voltage and Continuity Tables in Chapter 2 to perform voltage and
continuity tests. Refer to Chapter 2 for the Cable Insulation Integrity Test.
Read all meter instructions for safety information, scale setting, and proper operational
procedures.
Always perform continuity checks with the power off! Use your volt meter to ensure that
there is no power applied to the pump circuits.
Test points are taken in the alarm panel. The colors listed in the tables are the leads coming from the
station and connect in the panel. Using the tables, perform the checks to assure that you are getting
the appropriate readings. The values listed are the average numbers you should read on your meter.
Give the meter at least 5 seconds to obtain a correct reading. The meter may give a false reading
while bleeding off to an open circuit. This is the impedance of the wire bleeding off and is expected.
If the tests do not pass, unplug the EQD in tank and repeat test at the alarm panel, then at the pump
EQD. The EQD pin numbers are listed with the corresponding wire colors in the tables. This will help
narrow down where a problem is located. Note: Green (4) to Yellow (5) and Blue (6) must show
infinity or open line when testing at the pins in the pump EQD.
Run Test ________________________________________________________
This test assumes that the station has enough water to operate the alarm and that all discharge lines
and valves are open. Any problems found during startup are to be noted on the start–up sheet. This
includes problems that are repaired during startup. When a problem is repaired, the date, type of
repair and repairperson should be noted.

16
1. Test the voltage going to the pump at the panel; it must be within 10 percent of the
nameplate voltage (230-240=207 to 264). If it is not correct, do not continue. Rectify the
voltage problem.
2. Turn on the alarm breaker and verify that the alarm is activated.
3. Silence the horn.
4. Clip Amp meter onto the Black Wire of the Tray Cable.
5. Turn on the pump breaker.
6. Amperage should be between 5 and 7 amps at 230 - 240V. Higher amperage indicates
higher pressure. Over 7 amps at 230 - 240V could indicate a plugged or closed line. If you
experience a high amperage reading shut pump off immediately and rectify the problem.
7. Once the alarm turns off, the pump will run for about 1 minute depending upon the size of the
tank.
8. After the pump automatically turns off, turn off the power to pump and the alarm.
9. Perform the out of water or pumped down continuity checks.

17
Chapter 5 – Pump End/Grinder Mechanism ____________
Removing the Pump Stator _________________________________________
1. Remove the retaining clips from the bottom of the Level Sensor.
2. Lay the pump core on its side. Support the Motor Head on a 4 x 4 wooded block.
3. (If Applicable). Remove the wire stand from the pump core. There is a hole in the Suction
Housing that a 4 mm (5/32”) punch can be used in to aid the removal of the wire stand.
Figure 5 - 1
4. Remove the four Inlet Shroud retaining screws using a 5/16 nut driver and pull the Inlet
Shroud off of the Shredder Ring.
Figure 5 – 2