Hydromatic HPD200 Manual

NOTE! To the installer: Please make sure you provide
this manual to the owner of the pumping equipment or to
the responsible party who maintains the system.
Submersible
Positive Displacement
Grinder Pump
HPD200 – 60 Hz
HPDY200 – 50 Hz
Pump Installation and Service Manual
Part # 5625-428-1 Item # E-03-428 03/09

2
Thank you for purchasing your
Hydromatic®pump. To help
ensure years of trouble-free
operation, please read the
following manual carefully.
WARNING: Only qualified
personnel shall install or service
this pump.
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. 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.
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.
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.
WARNING: Read all the
instructions before starting any
operation on pump.
Always disconnect the pump and
controls from its power source
before handling or making any
adjustments.
WARNING: Risk of Electrical
Shock—This pump has not been
investigated for use in swimming
pool areas.
WARNING: Risk of Electrical
Shock—This pump is supplied
with a grounding conductor
and grounding-type attachment
plug. To reduce risk of electrical
shock, be certain that it is
connected only to a properly
grounded, grounding-type
receptacle.
1. Connect only to a properly
grounded, grounding type
receptacle or control panel.
2. Septic tank is to be vented
in accordance with local
plumbing codes.
3. Do not smoke or use sparkable
electrical devices or flame in
a septic (gaseous) or possible
septic sump.
4. 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.
5. Do not install pump in location
classified as hazardous per
N.E.C., ANSI/NFPA 70 - 1999.
Failure to heed the above
cautions could result in
injury or death.
General
Information
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 manual 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 – To reduce the
risk of electric 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 with maximum
140°F water.
8. 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. CAUTION – Risk of electric
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.
Pump Cautions
and Warnings

3
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.
Receiving Pump:
Inspect pumps on arrival for
possible concealed damage in
shipping. Any damage should
be reported immediately to
delivering carrier. Claims for
damage must originate at the
receiving end. Claims for shipping
damage cannot be processed at
the factory.
Codes:
All local wiring codes must be
observed. Consult the local
inspector before installation to
avoid costly delays that can
occur due to rejection after job
is finished.
Pump Not Operating or in
Storage:
Pumps with carbon ceramic
seals must have manually
rotated (6 revolutions) after
setting non-operational for 3
months or longer and prior to
electrical start-up.
Installing Pump in Sump:
Before installing pump in sump,
lay it on its side and rotate grinder
shaft. Stator boot and rotor
may be slightly stuck due to
factory test water, so it must be
broken loose by rotating shaft
with a screwdriver at grinder end.
The common shaft should turn
with a slight resistance. Slight
lubrication by means of a small
amount of lubricating oil down
the cavity inlet of the stator boot
and rotating shaft to pre-lube
stator boot and rotor before start is
recommended. Do not connect the
power until after this test.
Clean all trash and sticks from
sump and connect pump to piping.
A check valve must be installed
on each pump.
Location:
If pumps are installed in an
existing basin or concrete sump,
the piping can either be connected
permanently or rails and brackets
can be furnished for mounting to
walls of basin. In either case, be
sure that the Hydromatic non-clog
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.
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 Description:
The Hydromatic pumps covered
by these instructions are
submersible grinder pumps.
The cutter blades are on the suction
side of the positive displacement
pump impeller and discharge
directly into the inlet of the
impeller. The integral stainless
steel pump motor shaft is sealed
by a single mechanical seal.
Two ball bearings are used to
handle the loads in this design.
The upper bearing takes radial
loads, 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 reliable sealing.
The first seal is made by
compression of a rubber gasket by
the cord grip, thereby expanding
to fill the cord entry of the motor
housing. The cord grip forms a
second seal around the molded
cord end and provides strain relief.
Application:
These pumps are designed for
either residential or industrial
sewage discharge applications with
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

4
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 cutter. Keep
clothing, hands and feet away
from cutter any time power is
connected to the pump.
Replacing Cutter 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 the 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 (5) and
remove stationary cutter ring
assembly (4). Radial cutter
(3) can be screwed off the
common shaft by lightly
tapping cutter and unscrewing
it counterclockwise while
holding end of common shaft
with a screwdriver in slot at
cutter end of shaft.
5. Radial cutter (3) and stationary
cutter (4) can now be inspected
for wear and be replaced if
necessary.
Stator Boot and Rotor
Inspection and/or Replacement:
If necessary to inspect or replace
the stator boot and rotor,
the following procedure should
be followed:
1. Unscrew socket head screws
(12) and remove volute case
(1). Note: Turning common
shaft clockwise while
removing volute case can ease
removal.
2. Radial cutter (3) and
stationary cutter (4) can be
inspected for wear and
replaced if necessary.
3. Stator boot and rotor are now
exposed to check for any
obstructions in or wear of
stator boot.
4. If necessary to replace stator
boot (21), remove screws
(9) and retainer ring (8) from
volute (1). Stator boot (21)
can now be lifted out from the
volute recess. To replace
pump rotor (22), use a
suitable size center punch and
remove lower roll pin (6) from
common shaft. Pump rotor
(22) can now slide off
common shaft.
6. If problems occur, check power
source. Make sure a separate
supply line is available. Verify
voltage supply.
7. Check resistance of windings.
(See Chart) 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
Maintenance
Pump
Operations
Starting the Pump:
WARNING: Severe injury may
result from accidental contact
with moving cutter. Keep
clothing, hands and feet away
from cutter 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.
CAUTION:
Positive displacement pump
is designed to operate at
minimum 5 GPM capacity.
Running pump at shut-off
condition or with gate valve
closed can result in damage
to the pumping stator boot
and rotor.
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.

and “Replacing Cutter Parts”
sections of this manual.
3. Remove the pump rotor per
instructions listed under replacing
grinder parts section in this
manual.
4. Remove the seal (17) rotating
elements by sliding the spring
bellows off the common 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 (17) to allow for removal.
6. Take the stationary portion of
the new seal (17), and lube the
rubber material with good
quality dielectric oil. Press the
stationary portion of the new
seal into the seal/bearing
housing (2).
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 (17) and press it on
the common shaft.
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.
5. Clean all parts thoroughly
before proceeding with
reassembly. Slide new rotor
(22) on common shaft and
carefully replace lower roll
pin (6). Place stator boot
(21) back in volute recess,
replace retainer ring (8) and
tighten screws (9). Place
volute (1) carefully back over
rotor (22) and reattach to
seal/bearing housing (2) with
socket head screws (12).
6. Replace radial cutter (3) on
common shaft. Lightly tap
radial cutter (3) clockwise to
ensure full engagement onto
common shaft.
7. Replace stationary cutter
assembly (4) and screw
it down with screws (5).
Carefully rotate shaft by using
screwdriver in slot on shaft, to
ensure free rotation of pump.
8. Plug pump into power source
and operate for a few seconds
only (refer to caution note
below) to ensure parts are
not rubbing under electrical
operation.
9. Replace stationary cutter
assembly (4), and screw down
with screws (5).
10. Plug pump into power and
operate for a few seconds only
to ensure parts are not rubbing.
CAUTION: Do not run dry
longer than 10 seconds maximum,
otherwise damage to stator boot
can occur.
Replacing Seal:
1. Drain the oil from the pump by
removing the fill plug (10)
located on the side of the
motor housing (18).
2. Remove the volute and cutters
per the instructions listed
under “Stator Boot and Rotor
Inspection and/or Replacement”
9. Reassemble the pump rotor,
cutter and volute as outlined
in the replacing cutter parts
section of this manual.
10.Refill motor housing with a
good quality dielectric oil. 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 cutter. Keep
clothing, hands and feet away
from cutter any time power is
connected to the pump.
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. Cutter partially plugged or
damaged
3. Stator boot or rotor damaged
or worn
4. Speed too low
Insufficient discharge pressure
1. Air or gases in liquid
2. Stator boot or rotor damaged
or worn
3. Speed too low
5

6
HPD200
PERFORMANCE CURVE
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
Pump is noisy
1. Defective bearings
2. No diametral clearance
Pump
Maintenance
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.

WIRING DIAGRAM
START
CAP
RUN
CAP
POWER CORD
CONNECTION
T5 T4 T1
BW
T2
18
13
17
23
3
4
5
622
21
9
8
7
12
11
24
10
14
26
15
16
19 20
2
1
25
7
1 14624-000-2 Case – Volute 1
2 14569-001-2 Housing – Seal/Bearing 1
321582B000K Cutter – Radial 1
4 21584B000K Cutter – Stationary, Assy 1
5 19099A012 Screw – Cap 3
6 00180-002-1 Pin – Roll, Lower 1
7 00834-023-1 O-Ring 1
8 14627-000-1 Ring – Retainer 1
9 00829-007-1 Screw – Ring Retainer 3
10 14981-001-1 Pipe Plug 2
11 19100A012 Screw – Cap 4
12 00178-006-1 Screw – Socket 4
1300077-011-1 O-Ring 1
14 04580-001-1 Screw – Drive 2
15 00589-002-1 Bolt – Eye 2
16 14596-000-1 Nameplate 1
17 14573-000-1 Seal – Shaft 1
18 14589-002-1 Housing – Motor 1
19 14885-000-1 Screw – Shaft, Motor 1
20 05570-005-1 Washer – Shaft 1
Ref. Part Part
No. No. Description Qty.
21 14761-000-1 Stator – Pump 1
22 14762-101-1 Rotor – Helix 1
2325338B001 Power Cord 1
24 14570-100-1 Motor (60 Hz – HPD200) 1
14570-101-1 Motor (50 Hz – HPDY200) 1
25 24709110000 Paraffinic Oil 0.90
26 01032-002-1 Hex Nut 2
ORDERING REPLACEMENT PARTS: Product improvements are made from time to time. The latest part design will be furnished
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.
Ref. Part Part
No. No. Description Qty.
Ref. Part Part
No. No. Description Qty.
1Ø230V
Start Run
Winding Winding
HPD200 3.15 3.05
HPDY200 4.67 2.37
WINDING RESISTANCE CHART
HPD200/
HPDY200

8
Pump
Notes
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9
Pump
Notes
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Item # E-03-428 03/09Part # 5625-428-1
– Your Authorized Local Distributor –
USA
740 East 9th Street, Ashland, Ohio 44805
Tel: [phone] Fax: [phone] www.hydromatic.com
CANADA
269 Trillium Drive, Kitchener, Ontario, Canada N2G 4W5
Tel: [phone] Fax: [phone]
© 2008 Hydromatic®Ashland, Ohio. All Rights Reserved.
LIMITED PRODUCT WARRANTY
HYDROMATIC®warrants that its products 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 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
abuse, accident or negligence; (c) to normal maintenance services and the parts used in connection with such
service; (d) to units which 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 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 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 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.
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.

START-UP REPORT
Distributor______________________________________________________Order #: _________________
Installing Contractor: _____________________________________ Phone: _________________________
Sales Contact: __________________________________________ Phone: _________________________
Customer & Location _____________________________________________________________________
1. SYSTEM INFORMATION
A. Size of wet well: __________________________________ Manufacturer:_____________________
B. Discharge from bottom of basin: ___________________ Location:__________________________
C. Inlet from bottom of basin:________________________ Location: __________________________
D. Type of check valves: ______________________________________________________________
E. Type of piping ____________________________________________________________________
F. Does system have suction and discharge gauges? _______________________________________
G. Pressure reading? Suction_____________________ Discharge _________________________
H. Liquid being pumped:____________________ Temperature: __________ % of solid: __________
I. Sketch or photograph of system attached? _____________________________________________
J. Any additional comments on system: __________________________________________________
__________________________________________________________________________________
2. ELECTRICAL INFORMATION
A. Control panel part #:__________________________ Panel rated amps: ___________________
Manufacturer ___________________________ Voltage: __________ Phase: _____________
B. Heater size: _____________________________________________________________________
C. Location of panel to wet well: ________________________________________________________
D. Incoming line voltage: _________________________ Actual? _____________________________
E. Voltage to pumps ____________________________ Actual? _____________________________
F. Type of junction box: _____________________________ Manufacturer:_______________________
G. Are floats installed in wet well? _______________________________________________________
H. Are floats set to engineer’s spec? ____________________________________________________
I. Are floats wired for proper sequencing? ________________________________________________
J. Any additional comments on electrical: ________________________________________________
__________________________________________________________________________________
3. PUMP INFORMATION
A. Type of pump:______________________________________ Serial # ______________________
B. Voltage:_____________ Phase:_____________ RPM:_____________ Amps: ___________
C. Impeller size: ______________ C.O.S. TDH:________________ GPM: ___________________
D. Voltage supplied from panel:___________________ Actual?: _____________________________
E. Actual amperage (all phases): _____________ amps _____________amps _____________amps
F. Have you checked pump rotation? ____________________________________________________
G. Any additional comments on pumps: __________________________________________________
__________________________________________________________________________________
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: [phone],
or e-mail to: [e-mail]
We will make this a permanent part of our file on this order.
cut along dotted line