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MODEL HPG200
ADVANCED SUBMERSIBLE
GRINDER PUMP
INSTALLATION AND SERVICE MANUAL
NOTE! To the installer: Please make sure you provide this manual to the owner of the equip ment or to the responsible
party who maintains the system.
Item # E-03-407 | Part # 5625-407-1 | © 2017 Pentair plc | 02/17/17
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General
Information
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
con tin ued safe product use.
DO NOT THROW AWAY OR
LOSE THIS MAN U AL. Keep it in
a safe place so that you may refer
to it often. Reasonable care and
safe meth ods should be practiced.
Check local codes and
requirements before installation.
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.
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.
DANGER: 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.
DANGER: Risk of Fire or
Explosion. Do not smoke or use
open flames in or around this
system. HPG200 systems are not
intended for use in hazardous
locations per NFPA 70: National
Electric Code. Do not pump
flammable liquids.
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.
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.
Basin must be vented in accordance
with the local plumbing codes.
Pump Cautions
and Warnings
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.
DANGER: Risk of Electrical
Shock or Electrocution. 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
or local codes must be followed.
System must be properly grounded
according to NEC. Do not lift pump
by power cord.
DANGER: Biohazard Risk.
Once wastewater source has been
connected to system, biohazard risk
2
®
(NEC)
DANGER: 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.
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
The Pump
Pump Description:
The Hydromatic
covered by these instructions are
submersible grinder pumps.
The cutter blades are on the
suction side of the cen trif u gal pump
impeller and dis charge directly
into the inlet of the im pel ler. The
integral stain less steel pump motor
shaft is sealed by two me chan i cal
seals with an oil chamber between
the seals to pro vide lubrication for
both seal faces.
Two ball bearings are used to
handle the loads in this de sign,
similar to most of Hydromatic’s
solids handling pumps. The upper
bearing takes radial load, while
the larger lower bear ing handles
both thrust and radial loads.
Both bearings are permanently
lu bri cat ed by the dielectric oil in
the motor housing. The motor is
fixed within the motor housing and
is com plete ly submerged in the
di elec tric oil for maximum heat
transfer. The motor housing and
®
pumps
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seal cham ber are com pletely sealed
WHITE W/BLACK STRIPE - P1
BLUE - P2
ORANGE - SEAL PROBE
SENSOR LEADS
208 - 230V SINGLE PHASE
T4
(WHITE) (BLACK) (RED)
T5 T8
BLACK
L2
WHITE
L1
RED
L3
P1 (PURPLE)
P2 (BROWN)
MOTOR LEADS
230V (DUAL VOLTAGE) THREE PHASE
P1 (PURPLE)
P2 (DARK BROWN)
T7
(PINK) (RED) (LT. BROWN)
(BLUE) (TAN) (ORANGE)
T8 T9
T1 T2 T3
T4
(YELLOW) (BLACK) (LAVENDER)
T5 T6
BLACK
L2
WHITE
L1
RED
L3
200V AND 575V THREE PHASE
T1
(BLUE) (TAN) (ORANGE)
T2 T3
BLACK
L2
WHITE
L1
RED
L3
P1 (PURPLE)
P2 (BROWN)
460V (DUAL VOLTAGE) THREE PHASE
PL (PURPLE)
P2 (DARK BROWN)
T7
(PINK)
(RED)
(LT. BROWN)
(BLUE) (TAN) (ORANGE)
T8 T9
T1 T2 T3
T4
(YELLOW) (BLACK) (LAVENDER)
T5 T6
BLACK
L2
WHITE
L1
RED
L3
with O-rings located at mating part
faces.
The power cord entry system is
designed to give double seal ing.
The chamfered pilot of the motor
housing mates with the molded
cord end to form the first seal. The
cord grip forms the second seal
around the molded cord end and
provides strain relief. The ca ble
on the HPG model includes the
leads for both heat sensors (motor
protection) and the seal sen sor lead
for seal leakage de tec tion.
The cutters are designed to be self
adjusting and will not need to be
shimmed or reset.
Application:
These pumps are designed for
either residential or industrial
sew age discharge ap pli ca tions
with a pH ranging from 5 to 9,
spe cif ic gravities from 0.9 to 1.1,
viscosities ranging from 28 to 35
S.S.U., and tem per a tures up to
140°F.
Codes:
All local wiring codes must
be observed. Consult the local
inspector before in stal la tion to
avoid costly delays that can
occur due to rejection after job
is finished.
Pump Installation
Unpacking Pump:
Remove pump from carton. When
un pack ing unit, check for
con cealed damage. Claims for
damage must be made at the
receiving end through the delivery
carrier. Dam age cannot be
processed from the factory.
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 fur nished for mounting to
walls of basin. In either case, be
sure that the Hydromatic
®
solids
handling 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 low est cost where
expensive instal la tion labor is
ELECTRICAL CONNECTIONS
1 Phase 3 Phase
Green Ground Ground
Red Start Power Line Power Line
White Main Power Line Power Line
Black Common Power Line Power Line
Orange Seal Failure Seal Failure
Blue Heat Sensor Heat Sensor
White Heat Sensor Heat Sensor
w/ black
stripe
involved.
Electrical Connections:
Make all connections from motor to
control panel to com ply with local
codes.
CAUTION: Make sure that
the ground wire is securely
connected and that the unit
Pump Operations
To reduce the risk of electrical
shock, install only on a GFCI
protected circuit. See pump
nameplate for electrical ratings.
To start the pump, perform the
following steps in order:
is properly grounded in
accordance with local codes.
1. When grinder pump is single
phase, no rotation check
is necessary. Correct rotation is
counter-clockwise.
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. Lift pump
until sealing ange 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.
3
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6. If problems occur, check
power source.
Make sure a separate supply
line is available.
Verify voltage supply.
NOT OVERTIGHTEN) the
Allen head screw. It is good
practice to add a light coat of
removable locking adhesive to
the Allen screw.
2. Remove the volute and
cutters per the instrutions
listed under the Pump Disas-
sembly, Inspection, Reassembly section in this manual.
7. Check resistance of
windings. If not within
guidelines, return pump to
authorized factory service
center.
As the motors are oil lled, no
lubrication or other maintenance
is required. Pump should be
checked every quarter for
corrosion and wear.
Pump Maintenance
Pump Disassembly, Inspection,
Reassembly:
1. Close gate valve at pump
discharge.
2. Turn off circuit break er.
3. Remove pump from sump.
4. Unscrew cap screws and
remove the volute from the
pump. Note: under certain
circumstances it may be
necessary to remove the
discharge piping.
5. Remove the axial and radial
cutters from the shaft and
inspect for excessive wear
or damage. If the axial cutter
is damaged or is excessively
worn, flip the axial cutter to
the unworn side and reattach
to the radial cutter.
6. Inspect the stationary cutter
for wear or damage. If the
cutter requires removal,
loosen the machine screw in
cutter retainer and remove
cutter retainer and slide
the cutter out of the volute.
If cutter is damaged or worn,
reinstall on the opposite side,
making sure to snug (DO
4
7. Inspect the volute O-ring
for damage. If cracked or
torn, replace with the proper
Hydromatic® part.
8. To reassemble the pump, place
the cutters on the splined
shaft and orient the cutters
so that the axial cutter blades
fall between the impeller
vanes. Hold tension on the
cutters and replace the volute
and cap screws, making sure
the O-ring is placed in the
proper position. Evenly torque
the cap screws.
Replacing Seals on Dual Seal
HPG200 Model:
1. Drain the oil in the seal
chamber by removing the
drain plug on the side of the
pump. If it con tains water,
the lower seal has failed and
should be replaced. The motor
hous ing should be drained and
the upper seal replaced if the
lower seal has failed, since
foreign material in the seal
chamber may have dam aged
the upper seal.
hp RPM VOLT PHASE BLACK TO BLACK RED
WHITE TO RED TO WHITE
2 3450 208 1 1.30 5.08 6.35
2 3450 230 1 1.57 8.00 9.57
2 3450 200 3 2.86 2.86 2.86
2 3450 230 3 3.31 3.31 3.31
2 3450 460 3 13.25 13.25 13.25
2 3450 575 3 28.2 28.2 28.2
MAXIMUM AMP & WINDING RESISTANCE VALUES
SINGLE PHASE THREE PHASE
BLACK - COMMON BLACK - L
WHITE - MAIN WHITE - L
RED - START RED - L
3. To remove the impeller, secure
the shaft by threading the
radial cutter onto the shaft and
holding it with a pair of pliers.
Hold a wood block against the
impeller vane and tap it with a
hammer until it spins off.
4. Using a pair of snap ring
pliers, remove the snap
ring that secures the lower
seal. Remove the lower seal
rotating elements by sliding
the spring off the shaft. Then
using two screwdrivers, slide
the carbon assembly off by
prying on the retaining ring.
5. Loosen and remove the cap
screws that hold on the seal
housing, then re move the seal
housing. Using a socket that
will fit onto the back of the
seal, tap the sta tionary seal
assembly out of the
seal housing.
6. Using a pair of snap ring
pliers, remove the snap ring
that secures the up per seal.
Remove the spring retainer
and spring from the shaft, and
WINDING RE SIS TANCE IN OHMS
1
2
3
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using the same method as used
for the lower seal, remove the
carbon seal assembly.
7. With a pair of screwdrivers,
pry up on the seal/bearing
plate. Remove the seal/
bearing plate until you have
access to the seal sensor wire,
then carefully pull the seal
sensor wire off the seal probe
which will allow the complete
removal of the seal bearing
plate.
8. Take a socket and tap out the
stationary portion of the seal
from the seal/bearing plate in
the same manner as used for
the lower stationary seal.
9. After checking both of the
O-rings, replace the seal
bearing plate in the motor
housing, making sure that
the seal sensor wire has been
reattached to the seal probe.
Use O-ring lube to prevent
cutting in assembly.
10. Take the sta tion ary portion
of the new seal, and lube the
rubber material with a good
quality dielectric oil. Press the
stationary portion of
the new seal into the seal/
bearing plate.
CAUTION: Do not reuse old seal
parts. Replace all parts with new.
Mixing old and new parts could
cause im me di ate seal failure.
11. Using a good quality dielectric
oil, lube the rubber material on
the carbon seal assembly and
press it on the shaft. Place the
spring
and the seal retainer on the
shaft as removed. Replace the
snap ring.
12. Carefully place the seal
housing onto the seal bearing
plate, re place the cap screws,
and evenly tighten.
13. Using a pressure gauge with a
fill stem, pres sur ize the motor
housing to 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
con tin ue 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.
14. Following the same procedure
outlined in steps 10 through
13, install the low er seal
assembly. Re place the impeller
using a re mov able locking
adhesive.
15. Reassemble the cut ters and
volute as outlined in the
Pump Disassembly,
Inspection, Reassembly
section of this manual.
16. Refill all cham bers with a
good quality di elec tric oil. Fill
the motor housing so that the
tops of the motor windings
have been covered (2500 ml),
but leave an air gap to allow
for ex pan sion of the oil.
Fill the seal chamber with 700
ml of oil so that an air gap also
exists.
Replacing Motor Stator:
1. If the replacement of the stator
is necessary, first follow the
disassembly steps outlined
in the previous sections of
the manual.
2. Remove the shaft rotor
assembly from the motor
housing, making note that a
wave washer is used on the top
of the upper bearing.
3. Place motor housing vertically
on the bench and remove the
cord grip. Carefully remove
the power cord from the pump,
making sure that the wires are
not damaged. Clip the power
cable leads, taking note of the
wire connections, and then
remove the power cable.
4. Turn the motor housing
over and remove the stator
bolts from the stator, then
remove the stator from the
motor housing.
5. Place new stator into the motor
housing while pulling the new
leads through the power cord
opening in the motor housing.
Replace the stator bolts and
tighten. Replace the seal
sensor wire along the side of
the stator.
6. Attach the power cord to the
stator leads and the sensor
leads using insulated butt
connector.Once attached,
carefully tuck
the wires into the motor
housing making sure that they
will not come in contact with
the rotor. Press the power cord
molded end into chamber in
the motor housing.
7. Apply a sealant to the threads
on the body of the cord grip
that will enter the motor
housing, then slide onto the
power cord and tighten snugly.
DO NOT OVERTIGHTEN.
Attach the cord grip nut onto
the cord grip and snug.
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8. Examine the bearings on
the shaft/rotor assembly. If
when rotated they feel rough,
replace. When reinstalling
new bearings, press only on
the inner ring of the bearing or
damage may occur.
9. Replace the wave washer into
the upper bearing pocket in the
motor housing, then reinstall
the rotor and shaft assembly.
10. Follow the previously outlined
steps to reassemble the pump
from this point.
11. Always run pump for a
few seconds after assembly
work to be sure all parts run
smoothly before replacing it
in the sump. Check again for
correct rotation. Pump should
rotate counterclockwise when
viewed from the suction end.
NOTE: When applying pow er,
be sure the pump is restrained
from turning by holding the
pump at the motor hous ing,
or by clamping it in a holding
fixture.
Pump
Troubleshooting
Below is a list of troubles and their
probable causes:
No liquid delivered
1. Pump air bound
2. Discharge head too high
3. Pump or piping plugged
4. Wrong rotation
5. Speed too low
Insufficient liquid de liv ered
1. Discharge head too high
2. Impeller or cutters impartially
plugged or damaged
3. Wrong rotation
4. Incorrect diameter im pel ler
5. Speed too low
Insufficient discharge pressure
1. Wrong rotation
2. Air or gases in liquid
3. Impeller damages
4. Incorrect impeller di am e ter
Pump overloads motor
1. Wrong rotation
2. Specific gravity or vis cos i ty of
liquid too high
3. Speed too high
4. Head lower than rat ing,
pumping too much liquid
5. Pump clogged
6. Defective bearings
7. Defective impeller
Pump is noisy
1. Defective bearings
2. No axial clearance be tween
impeller and volute
3. No diametral clear ance
between radial cutter and cutter
ring
If the cause of the trouble cannot
be determined and cor rect ed
as outlined above, con tact your
nearest factory rep re sen ta tive.
5. Speed too low
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HPG200 Parts List
32
31
30
28
27
25 26
24
23
22
8
21
20
191817
6
1
3
9
2
4
5
7
8
10
11
12 13 14 15 16
29
33
ORDERING REPLACEMENT PARTS: Product improvements are made from time to time. The latest part design will be furnished as long as it is in ter change able with the old part.When ordering re place ment parts, always furnish the fol low ing information:
(1) pump serial num ber, (2) pump model and size, (3) part description, (4) part number, (5) im pel ler diameter (if ordering impeller),
(6) quan ti ty required and (7) shipping instructions.
Ref.
Part
No.
1 144240025 POWER CORD – 20' 1
144240115 POWER CORD – 35' 1
2 116750001 BUTT CONNECTOR
3 116910001 BUTT CONNECTOR 3
4 060000141 WIRE w/TERMINAL 1
5 134880002 SEAL/BEARING PLATE 1
6 084720015 SEAL FAILURE ASSY. 1
7 05876A120 O-RING S 2
8 003000001 SHAFT SEAL – 1" S 2
9 000730011 WIRE CONNECTOR – 230, 3
10 001500421 O-RING S 1
11 070330023 IMPELLER – 5.00" 1
070330043 IMPELLER – 4.50" 1
070330063 IMPELLER – 4.00" 1
12 055060022 AXIAL CUTTER 1
13 054050012 RADIAL CUTTER 1
14 148850001 MACHINE SCREW 1
15 055700051 IMPELLER WASHER 1
16 055050002 STATIONARY CUTTER 1
17 000300041 MACHINE SCREW 3
18 077630001 CUTTER RETAINER 1
19 135001002 VOLUTE CASE 1
20 19100A012 HEX HEAD CAP SCREW – 5/16 4
21 009750021 RETAINING RING 2
22 134890012 SEAL HOUSING 1
23 001010111 HEX HEAD CAP SCREW – 5/16 4
24 000650271 BALL BEARING 1
25 000250091 MACHINE SCREW PER B/M 4
26 05454A009 LOCK WASHER 4
27 21573C100 STATOR – 230V, 1f 1
21573C102 STATOR – 230–460V, 3f 1
21573C103 STATOR – 575V, 3f 1
21573C101 STATOR – 200V, 3f 1
21573C104 STATOR – 200V, 1
28 108321005 ROTOR/SHAFT – 1
108231005 ROTOR/SHAFT – 3
29 134950002 HORIZONTAL ADAPTER 1
30 134941002 MOTOR HOUSING 1
31 08565A013 BALL BEARING 1
32 000640011 WAVE SPRING 1
33 134962002 VERTICAL ADAPTER (std.) 1
* 517004027 SEAL KIT
131880001 CUTTER SHIM As
006280391 IMPELLER SHIM As
Notes: S – Parts in Seal Kit
– Fill oil to above motor windings
Part
No.
Description Qty.
230, 1f; 200, 1f; 575, 3f; 200, 3
f
230, 3
f
460, 3
f
f
f
f
6
3
9
f
1
1
1
1
Req’d.
Req’d.
77
Page 8
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 local codes, ordinances and good trade practices; (e) if the unit is
moved from its original installation location; (f) if unit is used for purposes other than for what it is designed and
manufactured; (g) to any unit that has been repaired or altered by anyone other than Pentair Hydromatic or an
authorized Pentair Hydromatic service provider; (h) to any unit that has been repaired using non factory specified/
OEM parts.
Warranty Exclusions: PENTAIR HYDROMATIC MAKES NO EXPRESS OR IMPLIED WARRANTIES THAT EXTEND
BEYOND THE DESCRIPTION ON THE FACE HEREOF. PENTAIR HYDROMATIC SPECIFICALLY DISCLAIMS THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE.
Liability Limitation: IN NO EVENT SHALL PENTAIR HYDROMATIC BE LIABLE OR RESPONSIBLE FOR
CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES RESULTING FROM OR RELATED IN ANY MANNER TO
ANY PENTAIR HYDROMATIC PRODUCT OR PARTS THEREOF. PERSONAL INJURY AND/OR PROPERTY DAMAGE
MAY RESULT FROM IMPROPER INSTALLATION. PENTAIR HYDROMATIC DISCLAIMS ALL LIABILITY, INCLUDING
LIABILITY UNDER THIS WARRANTY, FOR IMPROPER INSTALLATION. PENTAIR HYDROMATIC RECOMMENDS
INSTALLATION BY PROFESSIONALS.
Some states do not permit some or all of the above warranty limitations or the exclusion or limitation of incidental or
consequential damages and therefore such limitations may not apply to you. No warranties or representations at any
time made by any representatives of Pentair Hydromatic shall vary or expand the provision hereof.
1101 MYERS PARKWAY 490 PINEBUSH ROAD, UNIT 4
ASHLAND, OHIO 44805 CAMBRIDGE, ONTARIO, CANADA N1T 0A5
PH: 855-274-8947 PH: 800-363-7867
WWW.HYDROMATIC.COM WWW.HYDROMATIC.COM
Warranty Rev. 12/13
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