Pentair Hydromatic TG-Pro System Installation And Service Manual

TG-PRO SYSTEM

COMPLETE GRINDER
PACKAGE OFFERING

INSTALLATION AND SERVICE MANUAL

For use with Hydromatic grinder pumps: HPG200, HPGR200 and HPD200 (shown on cover).

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-03-434 | Part # 5625-434-1 | © 2012 Pentair Pump Group, Inc. | 10/31/12

General
Information

Thank you for purchasing your
Low Pressure Sewer Basin System.

Before Installation:

This manual contains important
information for the safe use of
this product. Read this manual
completely and follow the
instructions carefully. Reasonable
care and safe methods relating
to the installation and operation
of this product should be
practiced. Check local codes and
requirements before installation.

Risk of fire or explosion. Do not
smoke or use open flames in or
around this system. This system is
not intended for use in hazardous
locations per NFPA 70 National
Electric Code. Consult factory
for optional equipment rated for
this use.

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.

Installation Skill
Requirements

The installation of a basin system
is a specialized skill, which
requires individuals with the basic
understanding of excavating, pipe
fitting, and electrical wiring.

These instructions are meant only to
be an installation guide; therefore,
unusual installation conditions not
covered in these instructions require
experienced personnel capable
of using reasonable engineering
principles for the installation and
operation of the system.

Excavation

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. 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.

Biohazard risk. Once the
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
the system.

2

Hydromatic does not recommend
basins with base/bottom diameters
greater than 30" when installing
a simplex Positive Displacement
pump (HPD200) system. When
operational conditions require a
basin with base/bottom diameter
of greater than 30" it is necessary
to perform a sludge pump-out
on the basin at least once per
year to prevent any septic/odor
conditions.

DO NOT THROW AWAY OR
LOSE THIS MANUAL. Keep it

in a safe place so that you may refer
to it often for the continued safe
operation of the product.

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.

Instructions

Excavation location shall be
made according to local codes
and regulations. Check with
local utility companies for
the location of underground
utilities prior to excavation.
Care should be taken to avoid
buried utility lines, piping, and
other buried structures and
foundations. Failure to follow
these instructions may result
in serious personal injury or
death.

Excavation for Basin Systems:

Effect appropriate excavation
based on size of the basin, desired
entrance point of the influent line,
and entrance of power connection.

Basin
Installation
Instructions

Basin System Handling:

Factory built basin systems must
not be dropped, dragged, rolled,
or handled with sharp objects.
Improper handling of basins may
result in damage to the basin,
damage to basin components, or
leaks in the piping assemblies.

Step 1:

The pad under the basin requires
4 to 6 inches of appropriate fill.
The ideal basin pad is concrete
in conjunction with antiflotation
tie-down studs. Basin antiflotation
tie-down kits are available from
Hydromatic. If concrete pad is
not used, the aggregate must be
compacted to a minimum 85%
standard proctor density per
ASTM D698, or as required by the

authority having jurisdiction.

Concrete pad or aggregate surface
must be leveled flat and free of
voids to conform to the basin
bottom. Basin bedding depth
should be calculated such that the
basin top will protrude 3" above
the normal grade upon final
installation.

Step 2:

Lifting of the basin may be
done with a nylon or other non­damaging type material sling. Do
not wrap a chain or steel cable
around the basin as damage may
result. The two t-shaped molded­in lugs (polybasin only) may be
used for lifting the basin. Do not
attach lifting mechanism around
the discharge hub or electrical hub.

Risk of electrical shock or
electrocution. May result in
serious injury or death or fire
hazard. Failure to properly
support electrical conduit,
lines and connections may
result in structural failure.
Electrical connections may be
damaged exposing live electrical
connections.

If the basin is not tied down
during installation, rain or
flood conditions may cause the
basin to float upward, causing
damage to the basin or basin
con nec tions. Claims for this type
of damage cannot be processed
by Hydromatic.

Step 3:

Lower the basin into excavation,
position and level properly.
Mount basin to base anchor bolts
if an antiflotation tie-down kit
is used. If basin is fiberglass,
inspect basin and seal off any cuts
or scratches to prevent fiberglass
deterioration.

Influent and
Discharge
Connections for
Fiberglass Basins

Step 1:

An inlet grommet is the standard
supplied influent connection
device. If another type of inlet
hub is used, refer to the directions
included with the hub.

Determine point at which influent
line will enter basin and, using

a properly maintained piloted
hole saw sized per chart below,
drill a hole through the basin
wall. If using a fiberglass basin,
clean cut hole and apply a sealant
coating to the cut section to
prevent fiberglass deterioration.
Insert the inlet grommet into the
drilled hole.

PIPE HOLE SAW

SIZE DI AM E TER*

3" 4"

4" 5"

6"** 7"

* Contact the factory for availability
of proper size hole saw if necessary.

** 6" pipe size requires use of a
fiberglass basin.

Failure to use a properly piloted
hole saw may result in damage
to basin which may result in
structural failure or serious leaks.

Step 2:

Lubricate inside lip of inlet
grommet with pipe soap. Clean
outer end of influent pipe and
push pipe through grommet.
Ensure pipe does not protrude
inside basin so as to interfere with
pump removal or float operation.

Step 3:

Close shut-off valve and make
discharge line connection. It is
strongly recommended that
an additional shutoff valve and
redundant check valve be located
outside the basin at any force main
entrances – check local codes for
specific requirements.

3

Backfill

B. Stone or gravel crushings with

Instructions

The authority having
jurisdiction has the right to
require alternative materials or
procedures for backfilling the
installation.

Failure to properly backfill
may result in damage to the
basin which could cause leaks
or structural failure. Failure to
follow these backfill instructions
during the installation of the
basin voids the basin warranty.

In freezing conditions the backfill
must be dry and free of ice. Do
not use other backfill materials.
Failure to use the recommended
bed and backfill materials during
the installation of the basin voids
the basin warranty.

Step 1:

Obtain proper backfill material.
The backfill material provides
as much as 90% of the basin’s
support under certain stress
conditions. The installer must
be positive that correct bed and
backfill materials are used per
instructions as follows:

A. Gravel – clean and free

flowing with particle size not
less than 1/8" nor more than
3/4" in diameter. Use this
description when ordering or
specifying as material varies
upon geographical location.
This material is commonly
known as “pea gravel”.

4

Step 2:

At least a 4–6 inch wide band
of compacted aggregate must be
placed in successive layers (6"
lifts) around the entire periphery
of the basin. Carefully compact
aggregate under all piping and
electrical lines. Cover grade
should slope down 3" to the
normal surrounding grade. Care
must be taken to prevent damage
to any influent, discharge, or
electrical connections made to
the basin.

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.

Systems Description:

Factory built basin systems are
available in 24" and 30" diameter
basins with 60" through 156"
depths in one-foot increments. In
a flex hose system, the pump is
raised and lowered in the basin
using rope or chain attached to
pump and lifting handle attached
to ball check valve. A hydraulic
sealing diaphragm on ball check
valve allows the pump to be
removed without disconnecting
piping.

angular particle size of not
less than 1/8" nor more than
1/2" diameter, washed and
free flowing, is acceptable as
an alternative material.

Internal Basin
Installation
Instructions

Application:

These pump systems are designed
for pumping effluent or sewage
water with 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.

Pump Models:

The basin system may employ any
1 through 2 HP submersible grinder
pump that uses cutter blades to
grind solids into a slurry. Refer
to the pump service manual when
adjusting, dismantling, or repairing
the pump.

Inspection:

Check to be sure that all items for
your particular system are included,
and that the phase and voltage on
the pump nameplate are correct
as ordered. Codes: All local codes
must be observed. Consult the local
inspector(s) before installation to
avoid costly delays or rework.

Grinder Pump Attachments:

Step 1:

Attach the stainless steel foot
bracket to bottom of the pump
with bolts and washers provided.

Apply Pipe:

Step 2:

Apply thread sealant to pipe
threads and screw the discharge
piping assembly into the pump
discharge.

Step 3:

Attach lifting chain, cable or rope
as supplied to the lifting eye bolts.