Liberty Pumps LSGX202-RE User Manual

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RE/REX Series Installation Manual

5672000H

Omnivore Grinder Pump Retrofit Unit

For E/One* GP200, GP2000 and EXTREME D-Series

IMPORTANT:

Prior to installation, record Model, Serial Number, and Code Number from pump nameplate for future reference.

MODEL _____________________

SERIAL _____________________

CODE _____________________

INSTALLATION DATE _____________________

7000 Apple Tree Avenue Bergen, NY 14416 Phone: (800) 543-2550 Fax: (585) 494-1839 www.libertypumps.com

Core replacement for GP200 and GP2000:

LSG202-RE 2Hp, 208/230V, 1 phase, Automatic LSGX202-RE 2Hp, 208-230V, 1 phase, Automatic

Core replacement for Extreme D-Series:

LSG202-REX 2Hp, 208/230V, 1 phase, Automatic LSGX202-REX 2Hp, 208-230V, 1 phase, Automatic

*Do not throw away or lose this manual. Keep it with the installation and refer to it often.

* E-One is a registered Trademark of Environment One Corporation and is not affiliated with Liberty Pumps.

TABLE OF CONTENTS

SECTION 1 GENERAL INFORMATION------------------------------------------------------------------------------ 3

SECTION 2 INTRODUCTION-------------------------------------------------------------------------------------------- 4

SECTION 3 INSTALLATION ------------------------------------------------------------------------------------------- 4-6

SECTION 4 OPERATION -------------------------------------------------------------------------------------------------7

TROUBLESHOOTING CHART ------------------------------------------------------------------------ 9

PANEL INSTALLATION SHEET----------------------------------------------------------------------- 10

SECTION 5 WARRANTY INFORMATION--------------------------------------------------------------------------- 11

Model

Type

Volts

Phase

Full Load

Amps

FNPT

Discharge

Automatic or

Manual*

Drop in

replacement for

LSG202-RE

1 Stage

208\230

1.25”

Automatic

GP200 OR

GR2000

LSGX202-RE

2 Stage

208-230

1.25”

Automatic

LSG202-REX

1 Stage

208\230

1.25”

Automatic

EXTREME OR

D-SERIES

LSGX202-REX

2 Stage

208-230

1.25”

Automatic

General Information – All Models

Before installation, read the following instructions carefully. Each Liberty pump is individually factory tested to ensure proper performance. Closely following these instructions will eliminate potential operating problems, assuring years of trouble-free service.

Risk of electric shock.



Note: Make sure the electrical specifications of the control selected properly match the electrical specifications of the pump. Always refer to control panel instructions for proper installation. A separate branch circuit is recommended. It must be sized in accordance with the National electric code for the current shown on the pump nameplate and literature.

 Risk of electric shock. Always disconnect the pump from the power source before handling or making adjustments.  The electrical connections and wiring for a pump installation should only be made by qualified personnel.

 This pump is supplied with a grounding conductor and grounding-type attachment plug. To reduce the risk of electric

shock, be certain that it is connected only to a properly grounded, grounding-type receptacle.

 DO NOT bypass grounding wires or remove ground prong from attachment plugs.  DO NOT use an extension cord.  This pump requires a separate, properly fused and grounded branch circuit. Make sure the power source is properly

sized for the voltage and amperage requirements of the pump, as noted on the nameplate.

 The electrical outlet shall be within the length limitations of the pump power cord, and at least 4 feet above floor level

to minimize possible hazards from flood conditions.

 The installation must be in accordance with the National Electric Code, Uniform Plumbing Code, International

Plumbing Code, as well as all applicable local codes and ordinances.

 Sump and sewage pumps often handle materials which could cause illness or disease. Wear adequate protective

clothing when working on a used pump or piping.

 Never enter a pump basin after it has been used. Sewage and effluent can emit several gases which are poisonous.  Keep clear of suction and discharge openings. To prevent injury, never insert fingers into pump while it is plugged in.  DO NOT use this product for flammable or corrosive liquid.  DO NOT use this product in applications where human contact with the pumped fluid is common (such as swimming

pools, fountains, etc.)

 NEVER dispose of materials such as paint thinner or other chemicals down drains, as they can chemically attack and

damage pump components, potentially causing product malfunction or failure.

 DO NOT use pumps in water over 140F (60C).  DO review applicable codes concerning maximum allowable temperature of water discharged into drain systems.  DO NOT use pumps in mud, sand, cement, oil or chemicals.  DO NOT modify the pump in any way.  DO NOT lift or carry pump by power cord.  DO NOT remove any tags from pump or cords.  If pump is installed during construction before power is available, it must be protected from the environment to prevent

water from entering through the cord plug end, etc.

Introduction

Mechanical Installation

2-1 INTRODUCTION

This manual was prepared to assist you in the correct installation, operation, and maintenance of your Liberty Pump. Please read it completely before installing the pump. Make certain that you are familiar with the contents, and the chapters on installation and operation are fully understood before running the pump.

Liberty pumps are designed for minimal maintenance. However, regular checks will ensure longer life and greater operating reliability.

WARRANTY: No repair work should be carried out during the warranty period without prior factory approval. To do so may render the warranty void.

SERIAL # : In all correspondence and reports, make certain that the pump serial number is given.

2-2 DESIGN OF PUMP

The grinder pump contains metal parts that rotate at high speeds. Be careful around pump base

while power is connected. Make sure that the pump is either in the tank or clear from people and wires when in operation.

1. The Liberty grinder pump is designed for continuous underwater operation; the induction motor is insulated against heat and

moisture.

2. A thermal overload protector is imbedded in the stator windings. This is connected in series and wired to shut down the pump

if overheating occurs. The overload switch resets automatically when the motor cools.

3. The motor is protected against damage from water entry by a mechanical face seal with two silicon-carbide faces.

4. The impeller and volute are designed for efficient flow characteristics and clog-free operation. The hardened cutters grind

solids and fibrous matter into small particles that can be safely pumped through small diameter piping.

5. For sewage systems, consult local plumbing codes on requirements of venting the tank. The pump shall not be installed in

locations classified as hazardous in accordance with the National Electrical Code, ANSI/ NFPA70.

NOTE: The major material of Liberty Grinder Pumps is cast iron. They should not be used to pump corrosive liquids.

3-1 INSPECTION UPON RECEIPT

The shipping container should be immediately inspected for damage that may have occurred in shipment. Exercise care in opening the shipping container to avoid damage to the pump. Remove any blocking and cushioning from within the container.

Check all cushioning for spare parts before discarding. Visually check the pump and any spare parts for damage. Check for damaged electrical wires, especially where they exit the motor housing. Report any damage or shortage of parts. The cutter located at the bottom of the pump should be turned several rotations clockwise. This will insure that the impeller and cutter are free of any seizure due to prolonged storage. If the impeller is not rotated, the pump may fail to activate. If the impeller’s rotation is difficult or completely resistant, adjustments must be made.

3-2 STORAGE BEFORE USE

Liberty pumps are shipped from the factory ready for installation and use. They should be held in storage if the pump station is not complete. If storage is necessary, the pump should remain in its shipping container. It should be stored in a warehouse or storage shed that has a clean, dry temperature-stable area where the pump and its container should be covered to protect it from water, dirt, dust, etc. The ends of the cables - (plugs) must be protected against moisture.

AT NO TIME SHOULD THE PUMP BE STORED WITHIN AN INCOMPLETE WET PIT OR BEFORE POWER CAN BE SUPPLIED. THE PUMP SHOULD NOT BE PLACED INTO THE PIT UNTIL IT CAN BE FULLY OPERATED.

LONG TERM STORAGE

1. If it is necessary to store a pump for a long period of time, it should be stored indoors in a clean, dry temperature-stable environment. The pump should be covered to protect it from dust, dirt and water. The plug end of the cable must be protected against moisture.

2. Do not allow the pump to freeze.

3. Prior to installation, the pump motor should be rotated to ensure the seals and cutters are free spinning.

4. Installed pumps which are idle for long periods of time should be manually operated through the breaker panel once a month to lubricate the seals in.

3-3 PUMP INSTALLATION

Grinder pumps must be installed in a tank that is vented in accordance with local plumbing codes. This pump is not to be installed in locations classified as hazardous in accordance with the National Electrical Code, ANSI/NFPA 70. Installation should be at a sufficient depth to ensure that all plumbing is below the frost line.

NEVER LIFT THE PUMP BY PULLING ON THE POWER CORD.

USE THE LIFTING ROPE ONLY

3-4 OLD PUMP REMOVAL

1. The supply power must be turned off.

2. Liberty Pumps recommends the use of a 30 amp circuit breaker to prevent nuisance tripping due to spikes in amp draw that may occur during heavy grinding events. Before making any changes, the amperage capacity of the branch circuit wiring and components must be verified and upgraded as required to conform to applicable codes and standards.

3. Locate the riser and remove basin lid from current unit.

4. If the basin is flooded, it should be pumped out with separate pump or vacuum discharge must be disposed of in accordance with local, state, and national codes.

5. Disconnect the electrical quick-disconnect plug which is hanging in the basin if applicable.

6. Remove bolts securing the current unit if applicable.

7. Close valve on current unit.

8. Secure rope to hooks on cover. Lift the unit out of the basin.

9. Measure the distance from the cover to the base of the discharge elbow. Record this dimension so that you can set the new one to the same dimension.

Discharge elbow

Discharge flange

Rotating cover cam-locks

3-5 INSTALLING THE RE/REX CORE

Function

GP200/GP2000

(square connector body)

Extreme D-Series

(round connector body)

Liberty

RE/REX

Manual Run

Red

Brown

Red 2 L1

Black

Red

Black 3 L2

White

Black

Yellow

Ground

Green

Green/Yellow

Brown

Alarm Feed

Orange

Yellow

Orange

Alarm Return

Blue

1. Apply gasket tape to the under or bottom side of the cover at the perimeter.

2. Adjust the discharge elbow’s height by sliding it up or down in the discharge flange - matching that of the unit which was removed. DO NOT fully tighten the three bolts on the discharge flange yet. The height of the discharge elbow might need to be slightly adjusted after the unit is assembled into the pit.

3. Located on the cover are three rotating cam-locks which are used to secure the unit. The cam-lock must be orientated such that the pointer aligns with the “OPEN” mark before lowering the unit into the pit.

4. Float switches must be positioned so that they will be free of any objects in the tank or tank walls. If adjustments are made to either one, make sure that floats will activate properly. Specifically, confirm that the alarm float activates before hitting

top cover.

5. Although the Liberty Pumps RE/REX models come equipped with 6-pin connectors that mate perfectly with existing control hardware, the following table may be used for troubleshooting, repair, or custom installation purposes.

6. Lubricate the triple O-ring seal on the discharge elbow to ease installation of elbow into receiver. With what? Is grease packet included?

7. Using the lifting rope, lower the grinder assembly into the basin. Align the cover tabs to the mating tank slots, and discharge elbow to the receiver/ball valve. The unit should come to rest squarely on the tank flange.

8. The three cam-locks for the cover should now be secured by rotating the 3/8” hex bolts (9/16 SOCKET) clockwise to the “CLOSED” position. The cam-locks will wedge under the tank flange securing the cover.

9. Press downward on the discharge elbow such that it seats fully in the ball valve’s receiver. Tighten the three 3/8 bolts (9/16 SOCKET) on the discharge flange. This will compress the rubber ring and seal the unit.

10. Open the valve so that the handle/ latch encompasses the discharge elbow. If problems exist with opening the valve, adjustments can be made to the height of the discharge elbow by loosening the three screws on the discharge flange and raising or lowering the height as needed. Be sure to retighten the screws after adjustment.

11. The control box is designed to be mounted higher in the pit’s access chamber and above a potential flood level should a power outage occur. 8 feet of cable is provided to the control box to accommodate various pit heights. Mount the control box as high as possible to the existing vent pipe using the supplied brackets and hose clamps. The brackets must first be screwed onto the control panel, then install the hose clamps through the slotted openings on the bracket.

12. The 6-pin electrical connector (either round or square) will mate up with the existing E/one® plug in the pit. No splicing is required. Simply connect the plugs together and ensure they are fully engaged. Note: The manual over-ride switch will remain operational in the original equipment E/one® panel.

13. An auxiliary or second nameplate is provided and should be fastened to the existing control panel to properly identify the new pump.

Operation

4-1 OPERATION

After the electrical and mechanical installations have been performed, the pump is ready for operation. No operational procedures are required except to apply rated power to the pump. There are no specific shutdown procedures beyond disconnecting the power supply. NOTE: The alarm float if activated will also act as a redundant “ON” float – activating the pump.

ALWAYS ENSURE THAT THE PUMP IS FREE OF WIRES OR OTHER OBSTRUCTIONS THAT MAY CAUSE

HARM OR INJURY.

4-2 PERIODIC MAINTENANCE & LUBRICATION

Liberty pumps are designed for long lasting, efficient and reliable service with a minimum of preventive maintenance checks. These checks are few but will add years of satisfactory service to the life of the pump. Maintenance checks should be performed at the intervals stated. Severe operating environments will require more frequent checks.

4-3 LUBRICATION

Ball Bearings: None required Mechanical Seal: Lubricated by the motor oil Seal Oil: 32W HIGH Detergent Oil Qty: .7 Gal

NEVER LIFT THE PUMP BY PULLING ON THE POWER CORD. USE THE LIFTING “ROPE” ONLY.

0.0

4.3

8.7

13.0

17.3

21.6

26.0

30.3

34.6

39.0

43.3

47.6

51.9

56.3

60.6

64.9

69.3

73.6

77.9

82.3

0 5 10 15 20 25 30 35 40 45 50 55

100

110

120

130

140

150

160

170

180

190

200

0 5 10 15 20 25 30 35 40 45 50 55

HEAD (PSI)

HEAD (FEET)

FlOW (GPM)

PERFORMANCE CURVE

Omnivore Grinders

1-1/4" PIPE

1-1/2" PIPE

2" PIPE

LSGX-SERIES

LSG-SERIES

Minimum flow rate to carry solids in

pipe is generally accepted to be 2 feet per second; "dashed" lines represent

this flow rate for different pipe sizes.

Maximum Total Dynamic Head

is dependent on friction factors of the piping system. Consult factory for proper pump sizing.

1-800-543-2550

NOTE: Single stage units (“LSG” models) may not meet pressure requirements in all applications. Use of the 2-stage (“LSGX” models) may be required in certain applications. Consult factory for proper sizing and technical assistance where forced pressure mains or multiple homes tie into a common waste line.

SYMPTOM

TROUBLESHOOTING CHART

POSSIBLE CAUSE

ACTION

1. PUMP WILL NOT START

2. REPEATED TRIPPING

A. Power supply failure

B. Burned out fuse or tripped

circuit breaker

C. Damaged power cable

D. Jammed impeller

E. Water inside motor

A. Circuit protection under-rated

B. Current unbalance

C. Pump connected to incorrect

voltage

D. Wet or damaged wiring

A. Check power supply

Check out electrical system

for loose connections

Check operating voltage

B. Check circuit protectors

C. Check external cable for

damage – replace

D. Inspect and remove jamming

object

E. Refer to Symptom 5 and 6

A. Check rating and replace with

proper size

B. Check current draw

C. Verify connections. See wiring

diagram

D. Inspect external cable,

3. PUMP WILL NOT SHUT

OFF

4. LOW FLOW

5. WATER IN OIL

CHAMBER

6. WATER INSIDE MOTOR

CASING

E. Obstruction in pump

F. Incorrect motor rotation

G. Foreign matter build-up

A. Control panel failure

B. Switch Failure

C. Pump does not meet pressure

requirements of the system

A. Incorrect pump rotation

B. Low liquid level

C. Obstruction in pump or piping

D. Partially closed valve(s)

A. Loose or damaged oil plug

A. Damaged lower lip seal or

mechanical seal

replace if worn or damaged

E. Remove obstruction

F. Check rotation

G. Clean motor housing

A. Check control panel

B. Replace the switch

C. Use of high-pressure 2-stage

model (LSGX) may be

required. Consult factory

A. Check rotation

B. Check liquid level

C. Remove obstruction

D. Check and adjust valve

A. Check plug and sealing

washer

A. Replace seal

IF SYMPTOMS CONTINUE, CONSULT THE LIBERTY PUMPS PRODUCT SERVICE DEPT. 1-800-543-2550

B. Damaged O-Ring between oil

chamber and motor plate

C. Damaged cable

B. Replace O-Ring

C. Replace cable

ILLUSTRATION 2 CONTROL PANEL INSTALLATION

7000 Apple Tree Avenue Bergen, NY 14416 Phone: (800) 543-2550 Fax: (585) 494-1839 www.libertypumps.com

3 Year Limited Warranty



NOTE: Liberty Pumps, Inc. assumes no responsibility for damage or injury due to disassembly in the field.

Disassembly, other than at Liberty Pumps or its authorized service centers, automatically voids warranty.

Liberty Pumps, Inc. warrants that pumps of its manufacture are free from all factory defects in material and workmanship for a period of 3 years from the date of purchase. The date of purchase shall be determined by a dated sales receipt noting the model and serial number of the pump. The dated sales receipt must accompany the returned pump if t he date of return is more than 3 years from the "CODE" (date of manufacture) number noted on the pump nameplate.

The manufacturer's obligation under this Warranty shall be limited to the repair or replacement of any parts found by the manufacturer to be defective, provided the part or assembly is returned freight prepaid to the manufacturer or its authorized service center, and provided that none of the following warranty-voiding characteristics are evident.

The manufacturer shall not be liable under this Warranty if the product has not been properly installed; if it has been disassembled, modified, abused or tampered with; if the electrical cord has been cut, damaged or spliced; if the pump discharge has been reduced in size; if the pump has been used in water temperatures above the advertised rating, or water containing sand, lime, cement, gravel or other abrasives; if the product has been used to pump chemicals or hydrocarbons; if a non-submersible motor has been subjected to excessive moisture; or if the label bearing the serial, model and code number has been removed. Liberty Pumps, Inc. shall not be liable for any loss, damage or expenses resulting from installation or use of its products, or for consequential damages, including costs of removal, reinstallation or transportation.

There is no other express warranty. All implied warranties, including those of merchantability and fitness for a particular purpose, are limited to three years from the date of purchase.

This Warranty contains the exclusive remedy of the purchaser, and, where permitted, liability for consequential or incidental damages under any and all warranties are excluded.

Liberty Pumps LSGX202-RE User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual