Pentair Hydromatic HPG200V Troubleshooting guide

HPG200V Packages
Installation & Service Manual
with Parts List
2 HP Grinder Pump and Control Panel
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.
Pump Installation and Service Manual

2
MUST BE INSTALLED BY EXPERIENCED
PROFESSIONALS ONLY
CAUTION: READTHESE SAFETYWARNINGS FIRST
BEFORE INSTALLATION, SERVICING OR OPERAT-
ING ANY PUMP. THESE INSTRUCTIONS ARE
WRITTENWITHTHE UNDERSTANDINGTHATTHE
INDIVIDUALS HAVE EXPERIENCE IN BUILDING
WETWELLS AND INSTALLING BASINS, GRINDER
PUMPS AND PUMPING EQUIPMENT.
NOTE: ModelswithThird Party approval(s) are clearly
markedonindividualpumpnameplates.
WARNING! RISK OF ELECTRICAL SHOCK. TO
REDUCE RISK OF ELECTRICAL SHOCK, SEE
INSTRUCTIONMANUAL FORINSTALLATION.
DO NOT REMOVE CORD AND STRAIN RELIEF.
ALLTHREE PHASE PUMPS MUST BE INSTALLED
WITHMAGNETICSTARTERSHAVINGTHREELEG
OVERLOADPROTECTIONINACCORDANCEWITH
THENATIONAL ELECTRIC CODE. FOR DUPLEX
INSTALLATIONS,BOTH PUMP MOTORSMUSTHAVE
SEPARATE OVERLOAD PROTECTION.
WARNING! ONLY QUALIFIED PERSONS SHALL
CONDUCT SERVICES AND INSTALLATIONS OF
THIS PUMP. THE PUMP MUST BEWIRED BY A
QUALIFIED ELECTRICIAN.
PUMPSWITH SEAL LEAK DETECTORS, MUST BE
CONNECTEDTOTHEPROPERCONTROLCIR-
CUITRY. SEE INSTRUCTIONSMANUAL.
DANGER! HAZARDOUS MOVING PARTS. TO
REDUCERISKOF INJURYDISCONNECTPOWER
BEFORE SERVICING. NEVER PUT FINGERS NEAR
GRINDERIMPELLERORINPUMPINLETWEN
PUMPCORDISCONNECTEDORPUMP IS OPERAT-
ING.
FOR USEWITH MAXIMUM 140°F LIQUID. ACCEPT-
ABLEFOROUTDOORUSE.
DANGER! INTHE INITIAL INSTALLATION, BE-
FORE SEWAGE IS ADMITTEDTOTHE BASIN,
THERE IS NO DANGER ON ENTERINGTHE BASIN,
BUT AFTER SEWAGE HAS BEEN INTHE BASIN
THERE IS DANGER. SEWAGEWATER GIVES OFF
METHANE AND HYDROGEN SULFIDE GASSES,
BOTH OFWHICH ARE HIGHLY POISONOUS. A
BREATHING DEVICE MAY BE REQUIRED. NEVER
ENTER BASIN UNLESS COVER IS OPEN AND AN
OUTSIDE BLOWER IS USED.TO FORCE FRESH AIR
INTOTHE BASIN. ALSO,THEWORKER INTHE
BASIN MUSTWEAR A HARNESS ATTACHEDTOTHE
SURFACE SOTHAT HE CAN BE PULLED OUT IN
CASE OF ASPHYXIATION. NEVERWORK ALONE!
WARNING! DONOTEXCEEDWORKINGLOAD
LIMIT OF LIFTING ROPE OR CHAIN. DO NOT USE
LIFTINGROPEORCHAINWHEREFAILURECOULD
RESULT IN LOSS OF LIFE.
EXAMINE ALL LIFTING DEVICES, ROPE OR CHAIN
FOR DAMAGE BEFORE AND AFTER EACH LIFT.
DO NOT USE ANY LIFTING DEVICESTHAT ARE NOT
RATED FOR AND DESIGNEDTOLIFTTHEWEIGHTS
INVOLVEDWITHTHESE PUMPS.
DONOT INSTALL OR REMOVEPUMPWITH
PERSON(S) IN BASIN.
GENERAL
1. Most accidents can be avoided by using COMMON
SENSE.
2. Readtheoperation and maintenance instructions
manualsuppliedwiththepump.
3. DO NOT wear loose clothing that can become
entangled in the impeller or other moving parts.
4. This pump is designed to handle materials which
could cause illness or disease through direct
exposure.
Wearanduseprotectiveclothingwhenworkingonthe
pumporpiping.
ELECTRICAL
1. To reduce the risk of electrical shock, pump must
beproperlygroundin accordance with the National
Electric Code and all applicable state and local
codesandordinances.
2. To reduce risk of electrical shock, disconnect the
pumpfromthe power source before handling or
servicing.
3. Any wiring to be done on pumps should be done by
aqualifiedelectrician.
4. NEVER operate a pump with a power cord that has
frayedor brittle insulation.
9. NEVER let cords or plugs lay in water.
10. NEVER handleconnectedpowercordswith wet
hands.

3
PUMP
1. Pumpbuildsup heat and pressure during opera-
tion, allow time for pump to cool before handling or
servicing.
2. Onlyqualifiedpersonnelshouldinstall,operate or
repairpump.
3. Keep clear of suction and discharge openings. DO
NOT insertfingersinpump with powerconnected.
4. DO NOT pumphazardous materialnot recom-
mended for pump (flammable, caustic, etc.).
5. Make sure lifting devices are securely fastened
each time before lifting pump.
6. DO NOT LIFT PUMP BYTHE POWER CORD.
7. DO NOT exceedmanufacturer’s recommendation
for maximum performance, as this could cause the
motortooverheat.
8. Secure the pump in its operating position so it
cannot tip over, fall or slide.
9. Keep hands andfeetaway from impeller when
powerisconnected.
10. Submersiblegrinderpumps arenot approvedfor
useinswimmingpools,recreationalwaterinstalla-
tions, decorative fountains or any installation where
human contact with the pumped fluid is common.
11. DO NOT pump without safety devices in place.
12. For hazardous locations, use pumps that are listed
and classified for such locations.
13. DO NOT usenon-explosionproofratedpumps in
locationsconsideredhazardousin accordance with
theNationalElectric Code,ANSI/NFPA 70-1993.
14. Basin must be vented in accordance with the local
plumbingcodes.
IMPORTANT: HYDROMATIC is not responsible for
losses, injury or death resulting from failure to observe
these safety precautions, misuse or abuse of pumps
orequipment.
CONTROLPANEL
All HYDROMATIC control panels used on these
grinders are UL listed and CSA certified. Control
panels mounted directly to the basin used outdoors
are UL listed and CSAcertifiedwaterproof.
If intrinsically safe controls used in hazardous loca-
tions are required, HYDROMATIC can furnish a UL
listed or CSA certified panel.
LEVEL SENSING CONTROLS
Intrinsically-safe type float controls are recommended for
allapplicationsand required for explosion-proof service.
An intrinsically safe control panel relay will limit the
current and voltage to the level controls. A HYDROMATIC
control panel can be supplied with this type circuitry.
The float level controls maintain the basin sewage water
levelbycontrolling pump turn-on and turn-off level.
1. The lower turn-off control should be set so that the
pump stops at approximately the top of the pump.
2. Theupperturn-oncontrolshouldbesetabovethe
lower turn-off control. The exact height between the
two controls is determined by the number of pump
starts desired and the depth of the basin. A maxi-
mum of 10 starts per hour should not be exceeded.
3. The override control is set at a specified height
abovetheupper turn-on control.
4. The alarm control is set about 6” to 12” above the
overridecontrol.
5. No control should be set above the inlet invert.
JUNCTIONBOXES
If a junction box is used in a hazardous location, it must
beanexplosion-proof approved type withexplosion-proof
cord connectors. Wires from the junction box must pass
throughanexplosion-proofsealconnector.
CAUTION: No persons should be in the basin when
pump is lowered into position! DO NOT lift pump in a
manner where an failure could result in loss of life.
AIRVENTING
Air tends to trap in the pump volute when water raises in
the sump or when the pump is lowered into water after
service. To vent off this air, a small hole is drilled into
the pump volute. Be sure this vent hole is clean after
any service work on pump.
USAGE
TheHPG200Vgrinderpumps are forpumping domestic
sewageandonepumpcanhandlethesewagefroma
maximum of 2 homes.

4
PACKAGING — Each pump is packaged with 10 feet of
power cord in a carton that is marked with Model
Numberand Engineering Number. Longercordsare
available - consult catalog.
INSTRUCTIONS — Instructions cover only the pump
unit. Separate instructions for the electrical control
panel and basin packaged system are included with
these items. Complete disassembly instructions are
furnished only to authorized service stations.
CAUTION: PUMP IS NOTTO BE DISASSEMBLED IN
THE FIELD EXCEPT AT CERTIFIED SERVICE
STATIONS OR AT HYDROMATIC FACTORY. WARRANTY
IS VOID IF PUMP ISTAKEN APART FOR ANY REASON
EXCEPTTOREPLACEGRINDER IMPELLER AND
GRINDERRINGWHICH IS COVEREDINTHESE
INSTRUCTIONS.
DESCRIPTION OF PUMP —This pump is intended to
grind and pump all normal sewage for home use. It will
alsohandlereasonablequantities of disposable diapers,
sanitarynapkins,papertowels,rubber material, wood,
plastic, string, cigarette butts and other material not
normallyfoundinsewage.
INSPECTING PUMP — Before making any piping or
electrical connections check pump for any shipping
damage and turn grinder impeller to be sure it is free.
DONOTTURN IMPELLERWITHFINGERSAS
EDGES ARE SHARP, use socket wrench in the
impellerscrew.
CAUTION: After pump is installed NEVERWORK ON
MOTORORGRINDERUNITWITHOUTDISCONNECT-
INGMOTOR LEADWIRESFROMCONTROLPANEL.
DONOT RELY ON OPENING CIRCUIT BREAKER
ONLY.
Pump has two oil-filled chambers: (1) the motor and
ball bearings and (2) the seal chamber - for long life and
best heat transfer.
The lower seal above the pump impeller acts as a
buffer for upper seal that holds oil in the motor chamber.
If lower seal leaks for any reason, water enters the seal
chamber. If motor has the seal leak detector, the
electrode will contact the water and close the circuit to
the red seal light in the control panel indicting motor
must be serviced before upper seal fails.
MOTOR OVERLOAD PROTECTION —The motor is
providedwithanon-windingoverloadswitch. Ifthe
motor overloads or overheats for any reason, the switch
opens stopping motor. As soon as the motor cools to
normal temperature the switch closes and restarts the
motor.
MOTOR POWER CORDS — Pump modelswiththe
seal leak detector use a 5 conductor #14 gauge cord.
Thethreepowerconductors are BLACK,WHITE, RED,
the BROWN conductor connects to the seal leak probe
andGREENconductorconnectsthegroundscrew
inside the cord cap.
With 14/5 cords the BLACK andWHITE are main
winding leads and the RED is for start winding.
CORD SEAL —The lines from the motor chamber are
sealedwith a rubber sealing grommet that prevents oil
from leaking into the cord cap compartment. If neces-
sary to replace power cord, the sealing grommet must
not be loosened. This wire seal is removed only for
complete motor repair that must be done at an autho-
rizedmotorrepairshop.
IMPORTANT — Ground wires must be connected in the
control box to grounding bar, which is connected to a
goodoutsideground. MOTOR IS NOTSAFE UNLESS
GROUNDED.
INSTALLING PUMP IN BASIN — Complete installation
and piping instructions are included with the basin
package.
IF PUMP DOES NOT OPERATE PROPERLY,CHECK
FOR MOISTURE IN MOTOR —Disconnectlineleads
from terminal strip. Use ohm meter and set on highest
scale. Readingsonthelargepowercordbetween any
of the conductors red, black, white to green or motor
housingshouldbemorethan500,000ohms. Motor
probably will run with a lower reading, but if pump is out
of service and reading is below 500,000 ohms, the
motorhousingandstatorshouldberemovedand
backed by an authorized service station.

5
VARIABLE SPEED AC MOTOR DRIVE
The SCF Sub-Micro Drive
GroundLug
3-DigitLED
Display
Control
Terminal
Strip
Output(Motor)Terminals
Programming
Buttons
Electronic
Programming
Module(EPM)
InputPowerTerminals
TROUBLESHOOTINGTHE SCF DRIVE
To aidintroubleshooting,Parameters50through60can
be accessed without entering the PASSWORD. Simply
press the Mode button twice to “skip” over the
PASSWORD prompt, and “P50” will be displayed to
indicatethatthe parameter menu hasbeenenteredand
Parameter 50 (FAULT HISTORY) can be viewed. The s
andtbuttonscan then be used to scroll from Parameter
50toParameter60. Oncethedesiredparameterisfound,
press the Mode button to view its “contents”. When
finished, press Mode to exit the parameter menu.
Seeexample:
Press Mode once
Upper right decimal point blinks
Display reads "00"
Press Mode again
Display reads "P50" (FAULT HISTORY)
Use s and t to scroll to the desired
parameter number
Press Mode to view parameter
contents (77 = 77% LOAD)
Press Mode again to exit
Upper right decimal point blinks
(In this example Parameter 54 has been
selected, which is MOTOR LOAD)
Inthe example above, Parameter 54- MOTOR LOAD is beingviewed.
The “77” in the example indicates that the load on the motor is 77%
of the output current rating of the drive.