PENTAIR HWG Submersible Sewage Grinder Pumps Owner’s Manual

PENTAIR HWG Submersible Sewage Grinder Pumps

Product Information

This is a submersible sewage grinder pump designed to handle sewage, wastewater, and storm water in hazardous locations Class I, Division 1, Groups C & D. The product should only be used for the intended purpose and must be repaired and serviced only at Hydromatic Authorized Service Centers or at the Hydromatic Factory. Any unauthorized field repair voids the warranty, the hazardous location rating, and Factory Mutual approval.

Product Features

• 2 HP motor
• Submersible design
• Sewage grinder pump
• Designed for hazardous locations Class I, Division 1, Groups C & D
• Complies with National Electrical Code, Canadian Electrical Code, and local codes for all wiring
• California Proposition 65 Warning: This product and related accessories contain chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Safety Information

Before installation, servicing, or operating the pump, read and follow all safety instructions in the manual and on the pump. Keep safety labels in good condition and replace missing or damaged safety labels. The product contains hazards that could cause serious personal injury or property damage if ignored. Only qualified personnel may install this system, and they must follow NFPA 70/ National Electric Code (NEC) or local codes. The system must be properly grounded according to NEC. Do not lift the pump by power cord. Once wastewater source has been connected to the system, biohazard risk exists. Installer(s) and/or service personnel must use proper personal protective equipment and follow handling procedures per OSHA 29 CFR 1910.1030 when handling equipment after wastewater source has been connected to the system. Installer(s) and/ or service personnel must use proper personal protective equipment and follow OSHA 29 CFR 1910.146 or OSHA 29 CFR 1926. Pump may be installed in a location classified as a confined space. Do not smoke or use open flames in or around this system. HWG(X) 200 systems are not intended for use in hazardous locations per NFPA 70 National Electric Code. Do not pump flammable liquids.

This is the safety alert symbol. When you see this symbol on your pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury:

DANGER  warns about hazards that will cause serious personal injury, death or major property damage if ignored.

WARNING  warns about hazards that can cause serious personal injury, death or major property damage if ignored.
CAUTION warns about hazards that will or can cause minor personal injury or property damage if ignored.

The word NOTE indicates special instructions that are important but not related to hazards. Carefully read and follow all safety instructions in this manual and on pump. Keep safety labels in good condition. Replace missing or damaged safety labels.

CALIFORNIA PROPOSITION 65 WARNING
This product and related accessories contain chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

• Wire motor for correct voltage. See “Electrical” section of this manual and motor nameplate.
• Ground motor before connecting to power supply.
• Meet National Electrical Code, Canadian Electrical Code, and local codes for all wiring.
• Follow wiring instructions in this manual when connecting motor to power lines.

Thank you for purchasing your Hydromatic® pump. To help ensure years of trouble-free operation, please read the following manual carefully. READ THESE SAFETY WARNINGS FIRST BEFORE INSTALLATION, SERVICING OR OPERATING ANY PUMP. THESE INSTRUCTIONS ARE WRITTEN WITH THE UNDERSTANDING THAT THE INDIVIDUALS HAVE EXPERIENCE IN BUILDING WET WELLS AND INSTALLING BASINS, GRINDER PUMPS AND PUMPING EQUIPMENT.

NOTE : Models with Third Party approval(s) are clearly marked on individual pump nameplates.

Hazardous Location Service: HWG(X) 200 pumps are to be used for handling sewage, wastewater and storm water only. DO NOT use in other hazardous locations. These motors must be repaired and serviced only at Hydromatic Authorized Service Centers or at the Hydromatic Factory. Any unauthorized field repair voids the warranty, the hazardous location rating, and Factory Mutual approval.

SAFETY WARNINGS:

• RISK OF ELECTRICAL SHOCK. May result in serious injury or death or fire hazard. Installer must disconnect all electrical sources prior to installation, handling or servicing. Only qualified personnel may install this system. NFPA 70/ National Electric Code (NEC) or local codes must be followed. System must be properly grounded according to NEC. Do not lift pump by power cord.
• BIOHAZARD RISK. Once wastewater source has been connected to system, biohazard risk exists. Installer(s) and/or service personnel must use proper personal protective equipment and follow handling procedures per OSHA 29 CFR 1910.1030 when handling equipment after wastewater source has been connected to system.
• RISK OF ASPHYXIATION. Installer(s) and/ or service personnel must use proper personal protective equipment and follow OSHA 29 CFR 1910.146 or OSHA 29 CFR 1926. Pump may be installed in a location classified as a confined space.
• RISK OF FIRE OR EXPLOSION. Do not smoke or use open flames in or around this system. HWG(X) 200 systems are not intended for use in hazardous locations per NFPA 70 National Electric Code. Do not pump flammable liquids.
• CUTTING RISK. Risk of serious cutting or amputation exists. Disconnect all power sources prior to servicing pump or grinding mechanism. Pump may start without warning. Grinding mechanism is extremely sharp. Use caution when handling grinder mechanism.

DO NOT modify the cord strain relief. When wiring to a system control, connect the pump ground lead to the system ground. DO NOT run the pump dry. Dry running can overheat the pump (causing burns to anyone handling it) and will void the warranty. The pump normally runs hot. To avoid burns, allow it to cool for 30 minutes after shutdown before handling it.

Product Usage Instructions

Before using the pump, ensure that it is wired for the correct voltage. See the Electrical section of the manual and motor nameplate for instructions. Ground the motor before connecting it to the power supply. Follow wiring instructions in the manual when connecting the motor to power lines. These instructions are written with the understanding that individuals have experience in building wet wells and installing basins, grinder pumps, and pumping equipment. Only use the product for handling sewage, wastewater, and storm water in hazardous locations Class I, Division 1, Groups C & D. Do not use it in other hazardous locations.

INSTALLATION & OPERATION

Submersible grinder pumps are not approved for use in swimming pools, recreational water installations, decorative fountains or any installation where human contact with the pumped fluid is common. This specialized pump is designed to incorporate a grinding mechanism to remove wastewater particulate and pump the resulting slurry from a residential structure to a collection system. ON THREE PHASE PUMPS ONLY “MOTOR PROTECTION” MUST BE PROVIDED BY THE INSTALLER. ALL THREE PHASE PUMPS MUST BE INSTALLED WITH MAGNETIC STARTERS HAVING THREE LEG OVERLOAD PROTECTION IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE. FOR INSTALLATIONS WITH MORE THAN ONE PUMP, EACH PUMP MOTOR MUST HAVE SEPARATE OVERLOAD PROTECTION. PUMPS WITH SEAL LEAK DETECTORS MUST BE CONNECTED TO THE PROPER CONTROL CIRCUITRY. Examine all lifting devices, rope or chain for damage before and after each lift. DO NOT exceed manufacturers recommendation for maximum
performance, as this could cause the motor to overheat. Secure the pump in its operating position so it cannot tip over, fall or slide. DO NOT pump without safety devices in place. For hazardous locations, use pumps that are listed and classified for such locations. Basin must be vented in accordance with the local plumbing codes.

IMPORTANT : Hydromatic is not responsible for losses, injury or death resulting from failure to observe these safety precautions, misuse or abuse of pumps or equipment

CONTROL PANELS
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 CSA certified waterproof. If intrinsically safe controls used in hazardous locations are required, Hydromatic can furnish a UL listed or CSA certifiedB panel.

Note : Hydromatic built control panels supply the correct circuitry for moisture and heat sensor connections. Failure to install the correct circuitry with proper connection would negate warranty and Factory Mutual Approval.

LEVEL SENSING CONTROLS
Intrinsically-safe type float controls are recommended for all applications and required for hazardous location 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 level by controlling 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. The upper turn-on control should be set above the 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 maximum of 10 starts per hour should not be exceeded.
3. The override control is set at a specified height above the upper turn-on control.
4. The alarm control is set about 6″ to 12″ above the override control.
5. No control should be set above the inlet invert.

JUNCTION BOXES
If a junction box is used in a hazardous location, it must be a hazardous location approved type with hazardous location cord connectors. Wires from the junction box must pass through a hazardous location seal connector.

AIR VENTING
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. PUMP MODELS: The HWG(X) 200 models are offered in 208 and 230 volt single phase and 208, 230, 460 and 575 three phase. They are offered in 50 and 60 Hz configurations. INSTRUCTIONS: Instructions cover only the pump unit. Separate instructions for the electrical control panel and basin packaged system are included with these items. PUMP IS ONLY TO BE DISASSEMBLED AT Hydromatic FACTORY OR AN AUTHORIZED HYDROMATIC SERVICE FACILITY.

DESCRIPTION OF PUMP
This pump is intended to grind and pump all normal sewage for home or commercial use. Pump is of heavy duty construction and submersible type for long life when pumping ground sewage. Motor is capacitor start, capacitor run for single phase. Capacitors and start relay are mounted in electrical control box. 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. A heat sensor is attached to stator winding to sense any abnormal heat. If motor temperature for any cause rises above 221ºF the pump is immediately stopped and will not restart until motor cools to a safe temperature.

PUMP CORDS : Each pump has two cords. The power cord contains 4 conductors and the control cord has 5 conductors. The power cord for single phase uses the color coding for start and main windings and connects to control box terminal strip black (common), white (run), and red (start). The green wire is always ground and connects to ground terminal in control box. For three phase the same 4 conductor color coded cords are used, the black, white and red can be connected to any of the three phase terminals in the control box. The smaller control cord uses black and white leads for heat sensor and connects to terminal strip in control box. The red and orange wires connect to seal failure terminals in control box and the green or ground lead connects to ground terminal in control box.

CAUTION
After pump is installed NEVER WORK ON MOTOR OR GRINDER UNIT WITHOUT DISCONNECTING MOTOR LEAD WIRES FROM CONTROL PANEL. DO NOT RELY ON OPENING CIRCUIT BREAKER ONLY. INSTALLING PUMP IN BASIN – Complete installation and piping instructions are included with the basin package. THREE PHASE – When pump is installed to operate on three phase power, pump rotation must be checked. For inside installation where control box is near the sump basin, pump can be laid on side to check rotation before installing in sump. To check rotation turn Hand-Off-Auto switch to OFF position and turn on circuit breaker. Quickly turn H-O-A switch to HAND position, then OFF. Note grinder impeller rotation. Impeller must rotate counterclockwise. If rotation is wrong, change any two line leads to motor at control box terminal. Recheck for proper rotation.

CAUTION
KEEP HANDS COMPLETELY AWAY FROM GRINDER IMPELLER WHEN MAKING THIS CHECK. Where pump is installed remote from control box in outside installation a different method is used. Set the pump in the basin and run in some water so pump can operate. Turn H-O-A switch to hand position and let pump pull water down in basin. When water reaches the bottom of pump, rotation of the water can be observed. Water should rotate in a clockwise direction if pump rotation is correct. If not correct rotation, interchange any two line leads to motor at control panel. When replacing a pump with a new unit, rotation must be checked.

HWG(X) PUMP PARTS LIST

3

| 12672A880| Double Lever Nut| 4–7
12672A885| Triple Lever Nut| 0–4
4| 10649A102| Tube, Plastic| 2
5| 19100A012| Cap Screw, 5/16″-18 x 1-1/4″ Lg .| 8
6| 05876A122| Gasket, Rubber Tetraseal| 1
7| 21570B100X| Cap, Upper Bearing| 1
8| 05876A123| Gasket, Rubber Tetraseal| 1
9| 05022A092| Pipe Plug, 1/4″ NPT, Hex HD .| 2
10| 05434A043| Screw, Mach ., #10-24 x 1/2″ Lg .| 1
11| 06107A015| Lock Washer, #10| 1
12| 07597A017| Screw, Mach ., Flat Hd .| 2
13| 21571D100X| Housing Motor| 1
14| 05013A039| Set Screw, 1/4″-20 x 3/8″ Lg .| 2
15| 19331A005| Washer, Spring| 2
16| 08565A013| Bearing, Ball| 1
17| 11816A006| Ring Retaining| 1

18

| 21572C100| Rotor, w/Shaft 1ø| 1
21572C101| Rotor, w/Shaft 3ø| 1

19

| 21573C104| Stator 208/1ø| 1
21573C100| Stator 230/1ø| 1
21573C102| Stator 208/230/460/3ø| 1
21573C103| Stator 575/3ø| 1
20| 08565A018| Bearing, Ball| 1
21| 21574D100X| Housing, Upper Seal| 1
22| 21576A010| Seal, 7/8″ Shaft| 2
23| 12558A006| Ring Retaining| 1
24| 22578A004A| Electrode| 2
25| 05876A125| Gasket, Rubber Tetraseal| 2
26| 22579A000| Ferrule, Rubber| 1
27| 21577A000| Plug, Special| 1
28| 21578C100X| Housing, Lower Seal| 1
29| 22581A001| Gasket, Vellumoid| 1
30| 21580D102P| Casing, Volute| 1

31

| 28201C301| Pump Impeller, HWG200/HWGX200| 1
28201C305| 28201C305 Pump Impeller, F Series Only 1| 1
32| 21582B000| Impeller, Grinding| 1
33| 07597A018| Mach . Screw, 1/4″-20 x 1″ Lg .| 1
34| 21583A000*| Retainer, Impeller| 1
35| 21584B000| Flange w/Shredding Ring, WG20/X| 1
36| 19099A012| Cap Screw, Hex 1/4″-20 x 1″ Lg .| 3

TROUBLESHOOTING

CHECK LIST TO DETERMINE MOTOR TROUBLE

CHECKING FOR MOISTURE IN MOTOR:
Use ohmmeter and set on highest scale. Readings on the large power cord between any of the conductors red, black, white to green conductor or motor shell should be more than 500,000 ohms. Both motor housing and stator must be replaced as a unit as stator is pressed in at the factory and cannot be removed in the field.

RESISTANCE OF WINDINGS:
Every motor winding has a fixed resistance and winding must check close to the specification values. This winding resistance also determines if motor is connected for voltage being used. Use ohmmeter for this test and set on scale to read directly in ohms.

WINDING RESISTANCE VALUES IN OHMS (MARATHON)

Motor Type & Voltage| Black To White Main Winding| Black To Red Main Winding| White to Red
---|---|---|---
Single Phase, 208V| 1 .2| 4 .87| 6 .07
Single Phase, 230V| 1 .54| 7 .60| 9 .14
Three Phase, 200V| 2 .79| 2 .79| 2 .79
Three Phase, 230V| 3 .29| 3 .29| 3 .29
Three Phase, 460V| 13 .15| 13 .15| 13 .15
Three Phase, 575V| 19 .68| 19 .68| 19 .68

TROUBLE CHECK LIST
Troubles listed below are generally not caused by the pump. Other trouble can occur from faulty control box operation. These will be listed with the control box instructions

be air locked, this occasionally occurs on a new installation. Remove pump and clean volute case weep hole and reinstall pump allowing 2 to 3 minutes for air to weep from pump.

2.         Remove pump and guides from wet well, and test in 5 gallon bucket after checking weep hole again. If pump still does not pump, disassemble check valve and check to insure that check valve flapper has not adhered to sealing face. This condition results from assembled basin units setting in the sun before installation. NOTE: Check valve bolts should have Loctite 242 or equivalent applied before reassembly of check valves.

3.         If pump will pump water from bucket, try in wet well again. If it still will not pump, the following problems may exist:

a)   Ball Valve – Gate Valve may be in off position.

b)   Discharge piping obstructed

c)    Valve at street or in main line may be off – redundant check valve in backwards.

d)    Tap at force main obstructed – hole not drilled through enough – pipes pushed into tee too far.

4.         If pump has been installed for some time an does not pump, it may be clogged at grinder inlet.

5.         Discharge head may be too high. Check elevation. Maximum pump head at zero flow is 105 feet.

6.         If above checks do not locate trouble, motor rotor may be loose on shaft which allows motor to run but will not turn impeller or only at low RPM.

Red light comes on at control box.| 1.     This indicates some water has leaked past the lower seal and has entered the seal chamber and made contact with the electrode probe. Pump must be removed from basin immediately for replacement of lower seal. This preventative repair will save an expensive motor.
Overload trips and alarm buzzer or flashing red light comes on due to high water level

in basin.

| 1.         Push in red reset button to reset overload. If overload trips again after short run, pump has some damage and must be removed from basin for checking.

2.         Trouble may be from clogged grinder causing motor to overload or could be from failed motor.

3.         Trouble may be from faulty component in control box. Always check control box before removing pump.

in the hand position.

2.         Level control switch may have failed causing pump to continue to operate when water is below lower float.

3.         Grinder assembly may be partially clogged causing pump to operate at very reduced capacity.

4.         Check valve may be clogged causing low pump flow. Gate valve or street valve may be in off position.

5.         Pump may be air locked.

Circuit breaker trips.| 1.         Reset breaker by pushing clear down on handle then back to “ON” position. If breaker trips again in few seconds it indicates excessive load probably caused by a short in the motor or control box. Check out instructions given with control box before pulling pump.

2.         If this condition happens after an electrical storm, motor or control box may be damaged by lightning.

3.         Resistance reading of the motor with lead wires disconnected from the control box can determine if trouble is in motor or control box.

Pump is noisy and pump rate is low.| 1.         Grinder assembly may be partially clogged with some foreign objects causing noise and overload on the motor.

2.         Grinder impeller may be rubbing on grinder ring due to bent shaft or misalignment.

Grease and solids have accumulated around pump and will not pump out of basin.| 1.         Water shut-off level may be set too high or volume of pumping cycle may be too great allowing solids to settle out of suspension. Set pump shut-off level at the pumps widest part where volute case mates with seal chamber – to 1″ below. Set water level control (float or weight) to following approx. levels:

2 ft. dia. basin 12″ – 14″

3 ft. dia. basin 6″ – 8″

4 ft. dia. basin 6″ – 7″ above pump shut-off.

2.         Run pump on hand operation for several minutes with small amount of water running into basin to clean out solids and grease. This allows pump to break suction and surge which will break up the solids. If level switch lower weight or float is set properly this condition generally will not occur.

3.         Where all type switches are installed trash may have accumulated around lower weight causing pump to turn off too soon. Clean trash from weight and suspension cable.

MOTOR WIRING DIAGRAMS

NOTE : Probe test resistor is used on HWG(X) 200 UL Hazardous Location only

WARRANTY

STANDARD LIMITED WARRANTY
Pentair Hydromatic® warrants its products against defects in material and workmanship for a period of 12 months from the date of shipment from Pentair Hydromatic or 18 months from the manufacturing date, whichever occurs first – provided that such products are used in compliance with the requirements of the Pentair Hydromatic catalog and technical manuals for use in pumping raw sewage, municipal wastewater or similar, abrasive-free, noncorrosive liquids. during the warranty period and subject to the conditions set forth, Pentair Hydromatic, at its discretion, will repair or replace to the original user, the parts that prove defective in materials and workmanship. Pentair Hydromatic reserves the right to change or improve its products or any portions thereof without being obligated to provide such a change or improvement for prior sold and/or shipped units. Start-up reports and electrical schematics may be required to support warranty claims. Submit at the time of start up through the Pentair Hydromatic website: http://forms.pentairliterature.com/startupform/startupform.asp?type=h. Warranty is effective only if Pentair Hydromatic authorized control panels are used. All seal fail and heat sensing devices must be hooked up, functional and monitored or this warranty will be void. Pentair Hydromatic will cover only the lower seal and labor thereof for all dual seal pumps. under no circumstance will Pentair Hydromatic be responsible for the cost of field labor, travel expenses, rented equipment, removal/reinstallation costs or freight expenses to and from the factory or an authorized Pentair Hydromatic service facility. This limited warranty will not apply: (a) to defects or malfunctions resulting from failure to properly install, operate or maintain the unit in accordance with the printed instructions provided; (b) to failures resulting from abuse, accident or negligence; (c) to normal maintenance services and parts used in connection with such service; (d) to units that are not installed in accordance with applicable

1101 Myers Parkway Ashland, OH 44805 Ph: 855.274.8947 490 Pinebush Road, Unit 4 Cambridge, Ontario, Canada N1T 0A5 PH: 800-363-7867 pentair.com

All indicated Pentair trademarks and logos are property of Pentair. Third party registered and unregistered trademarks and logos are the property of their respective owners. Because we are continuously improving our products and services, Pentair reserves the right to change specifications without prior notice. Pentair is an equal opportunity employer.

References

• Start-Up Report
• Pentair
• Hydromatic | Brands | Pentair

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