Power-flo PFG3022, PFG3062, PFG3032, PFG3042, PFG5022 Installation, Service & Parts Manual

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Page 1

INSTALLATION, SERVICE & PARTS MANUAL

Series: PFG3022, PFG3062, PFG3032, PFG3042, PFG5022, PFG5062, PFG5032, PFG5042, PFG7532, PFG7542

3, 5 & 7.5HP•3450RPM•60Hz

Submersible Grinder Pump

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

ISP No: PFGrinder357 - 5/13

Page 2

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

General Safety Information

Before installation, read the following instructions carefully. Failure to follow instruction and Safety information could cause serious bodily injury, death and/or property damage. Each Power-Flo pump is individually factory tested to insure proper performance. Closely following these instructions will eliminate potential operating problems, assuring years of trouble-free service.

“Danger” indicates

an immanent hazardous situation which, if not avoided, WILL result in death or serious injury.

“Warning” indicates an immanent hazardous situation which, if not avoided, MAY result in death or serious injury.

“Caution” indicates an potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.

IMPORTANT - Power-Flo Pumps and Systems is not responsible for losses, injury or death resulting from failure to observe these safety precautions, misuse, abuse or misapplication of pumps or equipment.

All returned Products must be Cleaned,

sanitized, Or decontaminated Prior to shipment, to insure

employees will not be exposed to health hazards in handling said material. All applicable laws and regulations shall apply.

Bronze/brass  tted pumps may contain levels higher than considered safe for potable water systems. Government agencies have determined that leaded copper alloys should not be used in potable water applications.

Installation, wiring, and junction connections must be in accordance with the National Electric Code and all applicable state and local codes. Requirements may vary

depending on usage and location.

Installation and servicing is to be conducted by quali ed personnel only.

Keep clear of suction and discharge

openings. Do not insert  ngers in pump with power connected.

Always wear eye protection when working on pumps. Do not wear loose clothing that may become entangled in moving parts

Pumps build up heat

and pressure during operation. Allow time for pumps to cool before handling or servicing.

This pump is not

intended for use in swimming pools or water installations where human

contact with pumped  uid. Pumps when used as a decorative water fountain pump MUST be used in circuit protected by a Ground Fault Interrupter.

Risk of electric shock.

To reduce risk of

electric shock, always disconnect

pump from power source before

handling. Lock out power & tag.

Do not us these pumps in water over 104˚F. Do not exceed manufactures recommended maximum performance, as this could cause the motor to overheat.

Do not lift, carry or

hang pump by the

electrical cables. Damage to the

electrical cables can cause shock,

burnes or death. Never handle connected power cords with wet hands. Use appropriate lifting device.

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 basin after it has been used.

Failure to permanently ground the pump,

motor and controls before connecting to power can cause shock, burns or death.

These pumps are NOT

to be installed in locations classi ed as hazardous in accordance with the National Electric Code, ANSI/NFPA 70.

DO NOT introduced into any sewer, either directly, or through a kitchen waste disposal unit or toilet: Seafood

Shells, Aquarium Gravel, Cat Litter, Plastic Objects (toys, utensils, etc.), Sanitary Napkins or Tampons, Diapers, Rags, Disposable Wipes or Cloth, Medications, Flammable Material, Oil or Grease, Strong Chemicals, Gasoline.

IMPORTANT!

Prior to installation, record Model Number, MFG Date, Amps, Voltage, Phase and HP, from pump name plate for future reference. Also record the Voltage and Current Readings at Startup:

1 Phase Models

Amps: Volts:

3 Phase Models

Amps L1-2: Volts L1-2:

Amps L2-3: Volts L2-3:

Amps L3-1: Volts L3-1:

Model Number: ____________________

MFG Date: ____________

PHASE: ______ HP: _________________

® Power-Flo is a registered trademark of Power-Flo Technologies Inc. Other brand and product names are trademarks or registered trademarks of their respective holders. Alteration Rights Reserved. 5/08, 6/09, 9/09, 5/10, 11/10, 1/12, 5/12, 8/12, 11/12, 2/13, 5/13

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

Page 3

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Speci cations

DISCHARGE 2” NPT Vertical, Bolt-on Flange

Series: PFG3022, PFG3062, PFG3032, PFG3042, PFG5022, PFG5062, PFG5032, PFG5042, PFG7532, PFG7542

3, 5 & 7.5HP•3450RPM•60Hz

Submersible Grinder Pump

Description

Designed to reduce domestic, commercial, institutional and light industrial sewage to a  nely ground slurry.

LIQUID TEMPERATURE

VOLUTE Cast Iron, Class 30

MOTOR HOUSING Cast Iron, Class 30

SEAL PLATE Cast Iron, Class 30

IMPELLER Cast Iron, Class 30

SHREDDING RING Stainless Steel

CUTTER Stainless Steel

SHAFT Stainless Steel

SQUARE RINGS Buna-N

HARDWARE Stainless Steel

PAINT Air dry enamel

SEAL

UPPER BEARING Single row, Ball, Oil Lubricated

INTERMEDIATE BEARING

LOWER BEARING Sleeve, Oil Lubricated

POWER CORD

MOTOR

SINGLE PHASE

THREE PHASE

MOISTURE SENSOR

TEMPERATURE SENSOR

104°F (40°C) Intermittent

Tandem Double Mechanical, Oil Filled Reservoir, Upper -Carbon/Ceramic/Buna-N, Lower - Silicon Carbide/Silicon Carbide/Viton Stainless Hardware

Single row, Ball, Oil Lubricated

30 ft. Cord . Pressure grommet for Sealing and Strain Relief.

Oil Filled, Squirrel Cage Induction, Class F Insulation

Capacitor Start/Capacitor Run. Requires overload protection in the control panel, Requires starter or control panel which includes capacitors.

Dual Voltage 230/460. Requires overload protection in control panel

Normally Open (NO). Requires relay in control panel

Normally Closed (NC). Requires relay in control panel

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PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Speci cations

MODEL HP Hz Volts/Ph RPM

PFG3022*

PFG3062 3 60 208/3 3450 17 65 J SOW 10/4 .75

PFG3032 3 60 230/3 3450 14.5 62 K SOW 10/4 .75

PFG3042 3 60 460/3 3450 7.2 31 K SOW 10/4 .75

PFG5022* 5 60 230/1 3450 39 136 H SOW 10/4 .75

PFG5062 5 60 208/3 3450 25 122 K SOW 10/4 .75

PFG5032 5 60 240/3 3450 21.9 120 L SOW 10/4 .75

PFG5042 5 60 460/3 3450 11 60 L SOW 10/4 .75

PFG7532 7.5 60 230/3 3450 22.3 136 J SOW 10/4 .75

PFG7542 7.5 60 460/3 3450 11.2 68 J SOW 10/4 .75

Moisture & Temperature sensor cable for all other models is 18/5 SOW. 0.47 inches O.D. See page 17 for Relay kits.

(*) IMPORTANT! - These pumps require a control panel with start, run capacitors and relay. Capacitor kits which include Start & Run capacitors and Start Relay, are available if a Power-Flo control panel is not used, see page 17.

3 60 230/1 3450 26 90 H SOW 10/4 .75

Full Load

Amps

Locked

Rotor Amps

NEMA Start

Code

Cord Typ e

Cord

Size

Cord

O.D.

Recommended Breaker & Heater Sizes

MODEL HP Hz Volts/Ph Breaker Size

PFG3022*

3 60 230/1 80 AMP K-70 MARS 64 189-227 mfd-220 volt 40 mfd - 370 volt

Heater Size **

Voltage Relay Start Capacitor Run Capacitor

PFG3062 3 60 208/3 40 AMP K-56 N/R N/R N/R

PFG3032 3 60 230/3 30 AMP K-54 N/R N/R N/R

PFG3042 3 60 460/3 15 AMP K-41 N/R N/R N/R

PFG5022* 5 60 230/1 80 AMP K-70 MARS 64 189-227 mfd-220 volt 40 mfd - 370 volt

PFG5062 5 60 208/3 50 AMP K-63 N/R N/R N/R

PFG5032 5 60 240/3 50 AMP K-62 N/R N/R N/R

PFG5042 5 60 480/3 20 AMP K-50 N/R N/R N/R

PFG7532 7.5 60 230/3 50 AMP K-67 N/R N/R N/R

PFG7542 7.5 60 460/3 30 AMP K-54 N/R N/R N/R

N/R = Not Required Winding resistance ± 5% at terminal block. Rated operation at ± 10% voltage at motor. (**) Recommended heater sizes may very depending on pump station requirements. ( ) This data is for the PFG3022, from Sept 2010 and newer. For units prior to Sept 2010 use to following: FLA - 21.7, LRA - 75, NEMA code - G, Breaker Size - 50amp, Heaters K-64, Relay MARS 65, Start Cap. 257mfd - 220volts, Run Cap. 20mfd-370volts.

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

Page 5

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Performance

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

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PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Dimensions

IMPORTANT! - Pump Suction MUST be a minimum of 4” from basin  oor with use of legs, stand or slide rail system.

Receiving & Installation

Receiving Inspection

Upon receiving the pump, it should be inspected for damage or shortages. If damage has occurred, le a claim immediately with the company that delivered the pump. If the manual is removed from the packaging, do not lose or misplace.

Storage

Any product that is stored for a period longer than six (6) months from the date of purchase should be bench tested prior to installation. A bench test consists of, checking the impeller to assure it is free turning and a run test to assure the motor (and switch if provided) operate properly. Do not pump out of liquid.

Controls

PFG series grinders require a separate approved pump control device or panel for automatic operation. Be sure the electrical speci cation of the control selected properly match the electrical speci cations of the pump.

Location

The grinder pump is designed to  t in basin or wetwell by using a slide rail system.

IMPORTANT ! - A CLEARANCE UNDER THE PUMP FOR ENTRANCE OF SEWAGE SOLIDS MUST BE A MINIMUM OF 3 INCHES TO A MAXIMUM OF 4.5 INCHES.

Submergence

The pump should always be operated in the submerged condition. The minimum sump liquid level should never be less than above the pump’s volute (See Figure

1).

Recommended Submergence Level

Minimum Submergence Level

5”

Figure 1

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

Bottom of Feet

Page 7

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Receiving & Installation

Installation

There are several methods of installing grinder pumps. See contract plans and/ or speci cation: A slide rail in a package system or concrete wet well is the most common, which allows the pump(s) to be installed or removed without requiring personnel to enter the wet well.

The sump or basin shall be sealed and vented in accordance with local plumbing codes. This pump is designed

to pump grinder or wastewater, nonexplosive and noncorrosive liquids and shall NOT be installed in locations classi ed as hazardous in accordance with the National Electrical Code (NEC) ANSI/NFPA 70 or Canadian Electric Code (CEC). The pump should never be

installed in a trench, ditch, or hole with a dirt bottom. The legs will sink into the dirt and the suction will become plugged. The installation should be at a su cient depth to ensure that all plumbing is below the frost line. If this is not feasible, remove the check valve and size the basin to accommodate the additional back ow volume.

Discharge Piping

Discharge piping should be as short as possible and sized no smaller than the pump discharge. Do not reduce

the discharge pipe size below that which is provided on the pump. Both

a check valve and a shut-o valve are recommended for each pump. The check valve is used to prevent backow into the sump. The shut-o valve is used to manually stop system ow during pump servicing.

Liquid Level Controls

The level control(s) should be mounted on the discharge piping, a cable rack or  oat pole. The level control should have adequate clearance so it cannot hang up in it’s swing and that the pump is completely submerged when the level control is in the “O ” mode. By adjusting the cord tether the control level can be changed. One cycle of operation should be observed, so that any potential problems can be corrected.

It is recommended that the level control  oat should be set to insure that the liquid in the sump never drops below the top of the motor housing or a minimum level of 10 inches above the basin  oor.

Electrical Connections

Power cable - The power cable mounted

to the pump must not be modied in any way except for shortening to a specic application. Any splice between the pump and the control panel must be made in accordance with the electric codes. It is recommended that a junction box, if used, be mounted outside the sump or be of at a minimum Nema 4 construction if located within the wet well. DO NOT USE

THE POWER CABLE TO LIFT PUMP.

Always rely upon a Certi ed Electrician for installation.

Thermal Protection:

The normally closed (N/C) over temperature sensor is embedded in the motor windings and will detect excessive heat in the event an overload condition occurs. The thermal sensor will trip when the windings become too hot and will automatically reset when the pump motor cools to a safe temperature. It is recommended that the thermal sensor be connected in series to an alarm device to alert that an overtemperature condition and/or motor starter coil to stop pump.

In the event of an overtemperature, the source of this condition should be determined and repaired immediately. Thermal protection shall not be used as a motor overload device. A separate motor overload device must be provided in accordance with NEC code.

WARNING! - DO NOT LET THE PUMP CYCLE OR RUN IF AN OVERLOAD CONDITION OCCURS !

If current through the temperature sensor exceeds the values listed, an intermediate control circuit relay must be used to reduce the current or the sensor will not work properly.

TEMPERATURE SENSOR ELECTRICAL

RATINGS

Volts Continuous

Amperes 110-120 3.00 30.0 220-240 1.50 15.0 440-480 0.75 7.5

600 0.60 6.0

Moisture Sensor:

To detec any moisture present a normally open (N/O) probe is installed in the seal chamber. The probe should be connected in series to an alarm device or motor starter coil to alert the operator that moisture has been detected. Check the probe leads for continuity, (∞ resistance = no moisture). Also check the junction box and control panel for moisture content as this may induce a false signal.

IF MOISTURE DETECTION OCCURRES, MAINTENANCE SHOULD BE DONE TO IDENTIFY AND REPAIR.

Inrush

Amperes

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Page 8

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Installation & Service

Wire Size:

If longer power cable is required consult a quali ed electrician for proper wire size.

Pre-Operation

1. Check Voltage and Phase Compare the voltage and phase information stamped on the pump name plate.

2. Check Pump Rotation - Improper motor rotation can result in poor pump performance and can damage the motor and/or pump. Check rotation on three phase units by momentarily applying power and observe the “kickback”.

Kickback should always be in a counter-clockwise direction as viewed from motor end or opposite to impeller rotation. Incorrect rotation for Single-Phase pumps is unlikely. If the rotation is incorrect contact factory.

3. Name Plate - Record the information from the pump name plate to drawing in front of manual for future reference.

4. Insulation Test - An insulation (megger) test should be performed on the motor. Before the pump is put into service. The resistance values (ohms) as well as the voltage (volts) and current (amps) should be recorded.

5. Pump-Down Test - Be sure pump has been properly wired, lowered into the basin, sump or lift station, check the system by lling with liquid and allowing the pump to operate through its pumping cycle. The time needed to empty the system, or pump-down time along with the volume of water, should be recorded.

Maintenance

No lubrication or maintenance is required. Perform the following checks when pump is removed from operation or when pump performance deteriorates: a). Inspect motor chamber for oil level and contamination. b). Inspect impeller and body for excessive build-up or clogging. c). Inspect motor and bearings. d). Inspect seal for wear or leakage.

Servicing

NOTE: Item numbers in ( ) refer to Figures 7 & 8.

Cooling Oil - Anytime the pump is removed from operation, the cooling oil in the motor housing should be checked visually for oil level and contamination. To check oil, set unit upright. Remove pipe plug (30) from housing (8). With a ashlight, visually inspect the oil in housing (8) to make sure it is clean and clear, light amber in color and free from suspended particles. Milky white oil indicates the presence of water. Oil level should be just above the motor when pump is in vertical position.

Oil Testing

• Drain oil into a clean, dry container by placing pump on it’s side, remove pipe plug (30), from housing (8).

• Check oil for contamination using an oil tester with a range to 30 Kilovolts breakdown.

• If oil is found to be clean and uncontaminated (measuring above 15 KV. breakdown), rell the housing.

• If oil is found to be dirty or contaminated (or measures below 15 KV. breakdown), the pump must be carefully inspected for leaks at the shaft seal, cable assembly, square ring and pipe plug, before relling with oil. Tolocate the leak, perform a pressure test.

After leak is repaired, dispose of old oil properly, and rell with new oil.

Pressure Test (If oil has been drained)

If, after ve minutes, the pressure is still holding constant, and no “bubbles” are observed, slowly bleed the pressure and remove the gauge assembly. Replace oil. Leek must be located and repaired if pressure does not hold.

Pressure Test (If oil has NOT been drained) - Oil should be at normal level.

Remove pipe plug (30) from housing (8). Apply pipe sealant to pressure gauge assembly and tighten into hole. Pressurize motor housing to 10 P.S.I. Use soap solution around the sealed areas above the oil level and inspect joints for “air bubbles”. For sealed areas below oil level, leeks will seep oil. If, after ve minutes, the pressure is still holding constant, and no “bubbles” / oil seepage is observed, slowly bleed the pressure and remove the gauge assembly. Replace oil. Leek must be located and

repaired if pressure does not hold.

Figure 2

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

Page 9

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Service

Pressure builds up extremely fast, increase pressure by

“TAPPING” air nozzle. Too much pressure will damage seal. DO

NOT exceed 10 P.S.I.

Seal Chamber - Set pump on its side with  ll plug (30) downward, remove plug (30) and drain all oil from seal chamber. Apply pipe sealant to pressure gauge assembly and tighten into hole in intermediate coupling (5). Pressurize seal chamber to 10 P.S.I. and check for leaks.

Oil Replacement: Motor Housing - Drain all oil (if not

already done so) from motor housing and dispose of properly per Local and Environmental Standards.

Set pump upright and re ll with new cooling oil, see “Cooling Oil” chart. Fill to just above motor as an air space must remain in the top of the motor housing to compensate for oil expansion. Apply pipe thread compound to threads of pipe plug (30) then assemble to motor housing (8).

Seal Chamber - Drain all oil (if not already done so) from seal chamber and dispose of properly per Local and Environmental Standards. Place pump on its side with plug (30) upward, and re ll with new oil, see “Cooling Oil” chart. Apply pipe thread compond to threads of pipe plug (30) and assemble to intermediate coupling (5).

DO NOT overll oil. Overlling of housing with oil can create

excessive and dangerous hydraulic pressure which can destroy the pump and create a hazard. Overlling oil voids warranty.

Cooling Oil

Recommended Supplier/Grade

BP Enerpar SE100 Conoco Pale Parafn 22 Mobile D.T.E. Oil Light Shell Canada Transformer-10 Texaco Diala-Oil-AX

WARNING ! - Before any service work is done, disconnect and lock out electrical power to pump.

Disassembly

Cutter - Lay pump on its side and remove

the cutter retaining screw (29) and washer (28). A small amount of heat may be needed to loosen screw. DO NOT overheat. Wedge a  at screwdriver between cutter and shredding ring and remove screw. With a hammer and punch, tap the cutter (27) counter-clockwise to remove.

CAUTION ! - Cutter edges are very SHARP. Cutter must be

removed before removing volute.

Volute - Remove hex nuts (25) and washers (9) from studs (26) and remove volute (23) and square ring (24) from pump.

Shredding Ring - To replace or reverse the shredding ring (20), remove allen screws (22) and lift throat (21) from volute (23) then press out using an arbor press. The shredding ring (20) can be pressed out and reversed when cutting edges dull.

Impeller - Remove impeller (18) by turning counter-clockwise while holding the motor shaft stationary with a screwdriver. NOTE: Seal spring is relaxed with impeller removed, some oil may seep from seal cavity. Do Not store pump

without impeller in place.

Outer Seal - Handle seal parts with care. Remove seal (34) spring and rotating member from shaft. Examine all seal parts. Inspect contact faces for signs of uneven wear tracks on stationary, chips and scratches on either seal face. DO NOT

interchange seal components, replace the entire shaft seal (34).

Seal Plate - Remove cap screws (35) and

washers (38) from seal plate (19). Remove seal plate (19) and square ring (24) from intermediate coupling (5). With  at screwdriver, press out seal (34) stationary member. Inspect square ring (24) for cuts or abrasions.

Cable Assemblies - Remove Hex plugs (13B) and (14B), washers (13C) and (14C) and gromeents (13D) and (14D) from conduit box (11).

Motor - Remove pipe plug (30) and drain oil if not already done so. Position pump upright using blocks or pvc pipe to avoid resting pump on the shaft. Remove cap screws (15) and lockwashers (16) from cable box assembly (11) and slide conduit box up the cords until motor lead wires are exposed. Disconnect connectors (17) from motor leads wires to remove cable assemblies (13) and (14). Remove ground screw (31). Remove and inspect o-ring (12).

Remove cap screws (10) and lockwashers (9) from motor housing (8). Vertically lift motor housing (8) from intermediate coupling (5) along with square ring (7), replace if cut or damaged. Remove motor bolts and carefully remove stator housing from rotor. Remove retaining ring (2) from intermediate (5) and pull rotor out with bearing (3) and rotating member of inner seal.

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Page 10

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Service

Inspect motor winding for shorts and check resistance values. Check rotor for wear. If rotor or the stator windings are defective, the complete motor must be

replaced.

Bearings & Inner Seal - Remove seal (4) rotating member and spring from rotor shaft. Press stationary from intermediate (5) with  at screwdriver. Examine all seal parts. Inspect contact faces for signs of uneven wear tracks on stationary, chips and scratches on either seal face. DO

NOT interchange seal components, replace the entire shaft seal (4).

Remove retaining rings (6) from shaft. Using a wheel puller or arbor press remove bearing (3) from shaft. Remove upper motor bearing from shaft with a bearing puller. (See Figure 3)

Check sleeve bearing (39) for excessive wear, if replacement is required the complete intermediate coupling (5) should be replaced.

Moisture Probes - Remove screws (37) and wire (33) from probes (36). Remove probes (36) from intermediate (5).

IMPORTANT! - All parts must be clean before reassembly. Handle seal parts with extreme care. DO NOT damage lapped surfaces.

Reassembly

Moisture Probes - Apply thread

compound to thread on probes (36) and install in intermediate (5). Connect wires (33) with screws (37).

Bearings - Be careful not to damage the rotor shaft when replacing bearings. Using an arbor press, hold the rotor and press the upper bearing on the rotor shaft, applying force to the inner race of

the bearing only. Replace upper retaing ring onto rotor shaft. In the same manner replace lower bearing (3) onto rotor shaft. Place lower retaining rings (6) onto shaft.

Inner Seal - Clean and oil seal cavity in intermediate coupling (5). Lightly oil (Do not use grease) outer surface of stationary member. Press seal’s (4) stationary member rmly into intermediate coupling (5), using a seal tool or pipe.

Nothing should come in contact with the seal face except the seal tool. Be sure the stationary is in straight. Place seal’s (4) retaining ring and spring over shaft until seated on shaft shoulder. Slide a bullet tool over rotor shaft threads. Lightly oil (Do not use grease) shaft, bullet, and inner surface of bellows on rotating member, with  nished end away from motor, slide rotating member over bullet and onto shaft until it engages spring. Make sure spring is seated in retaining ring and spring is lined up on rotating member and not cocked or resting on bellows tail. (See Figure 3)

Motor - Slide rotor/shaft with bearing (3) and seal parts (4) into intermediate coupling (5) until bearing seats into intermediate coupling. Install retaining ring (2) into intermediate coupling (5). Place motor stator over rotor, lining up motor bolts with holes in intermediate coupling (5). Place end bell on top of motor and insert motor bolts and torque to 17 in-lbs.

Wiring Connections - Set square ring (7) in grove on intermediate coupling (5). Pull wires through opening in top of motor housing (8) while lowering motor housing onto intermediate coupling (5). Insert capscrews (10) with lockwasher (9) through motor housing into intermediate and tighten. Place square ring (12) on motor housing (8). Place conduit box with cables next to motor housing and make wire connections (see Figure 4). Connect ground wire (42) with screw (31) to conduit box (11) if disconnected.

Figure 3

Check power cable (13) and control cable (14) for damage and replace complete conduit box and cable assembly if required.

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Page 11

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Pump Wiring Schematics

FIGURE 4 - THREE PHASE 230 VOLT AC

Power Cable Motor Lead Number Green (Ground) Green Black 1 & 7

FIGURE 4 - SINGLE PHASE

230 VOLT AC

Power Cable Motor Lead Number Green (Ground) Green Black 4 run Red 8 start White 5 common

Red 2 & 8 White 3 & 9

T4, T5 & T6 Together

FIGURE 4

MOISTURE & TEMPERATURE SENSORS

Control Cable Lead Number Green (Ground) Green Black or White P1 (Temp Sensor) In

series with starter coil

White P2 (Temp Sensor) In

series with starter coil

Red or Orange W1 (Moisture Sensor)

Orange W2 (Moisture Sensor)

FIGURE 4 - THREE PHASE 208 VOLT AC

Power Cable Motor Lead Number Green (Ground) Green Black 1 Red 2 White 3

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FIGURE 4 - THREE PHASE 460 VOLT AC

Power Cable Motor Lead Number Green (Ground) Green Black 1 Red 2 White 3

T4 & T7 Together T5 & T8 Together T6 & T9 Together

FIGURE 4

1 Phase Capacitor Pack for

Control Panel

Page 12

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Service

Shredding Ring - Install shredding ring (27) into volute with the use of an arbor press. Assemble throat (21) into volute (23) with tree allen screws (22).

Volute - Lubricate square ring (24) and place in groove in bottom of seal plate (19). Place volute (23) on seal plate (19) being careful not to damage square ring (24). Place nuts (25) with lockwashers (9) onto studs (26) and torque evenly to 11 ft/lbs.

Figure 5

Place conduit box (11) on motor housing (8) and insert capscrews (15) with washers (16) into motor housing and torque to 16 ft/lbs.

Cable Assemblies - Power cable, Place one friction ring (13C), grommet (13D), one friction ring (13C) and hex plug (13B) into conduit box (11). Control Cable, Place one friction ring (14C), grommet (14D), one friction ring (14C) and hex plug (14B) into conduit box (11). Torque hex plugs to 15 ft. lbs. to prevent leakage. See Figures 7 & 8.

Seal Plate - Lubricate and set square ring (24) in bottom groove of seal plate (19). Place seal plate (19) over shaft and onto intermediate coupling (5), being sure square ring (24) is not twisted and in the groove. Place two capscrews (35) with lockwashers (38) into seal plate and torque to 6.5 ft/lbs.

Press stationary  rmly into seal plate (19) using a seal pusher tool. Be sure the stationary member is in straight. Nothing but the seal tool is to come in contact with seal face. (See Figure 5)

IMPORTANT ! Do not hammer on the seal pusher. It will damage the seal face.

With seal guide tool over motor shaft, Lightly oil (Do not use grease) guide, shaft and inner surface of bellows on rotating seal.

With lapped surface of rotating member facing inward toward stationary, slide rotating member over guide and onto shaft, using seal pusher tool, until lapped faces of stationary and rotating seal are together. Place spring over shaft and rotating member. Be sure it is seated on the retainer and not cocked or resting on bellows tail.

Cutter - Screw radial cutter (27) onto shaft, turning it clockwise while holding the shaft stationary with a screwdriver. The radial cutter (27) should be  ush with shredding ring (20), on suction side to within ± .020. Place washer (28) on screw (29), apply green Loctite on threads and place into shaft and tighten.

Outer Seal - Clean and oil stationary seal cavity in seal plate (19). Slide seal guide tool over motor shaft. Lightly oil (Do not use grease) outer surface of seal’s (34) stationary member.

Impeller - Place impeller (18) on motor shaft, with machined step  tting inside the inside diameter of seal spring, by

turning clockwise while holding shaft stationary with screwdriver.

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

Page 13

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Typical Panel Wiring Schematic

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

Figure 6

Page 14

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Repair Parts

For Repair Part Please supply: Model Number and MFG Date as shown on Name Plate, and Part Description and Part Number as shown on Parts List.

Figure 7

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

Page 15

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

For Repair Part Please supply: Model Number and MFG Date as shown on Name Plate, and Part Description and Part Number as shown on Parts List.

Repair Parts

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

Figure 8

Page 16

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Repair Parts

Ref. Qty Name Used On Part Number

Motor

22 31 41 5 1 Bearing Housing PF03040026 62 71 8 1 Motor housing PF03100011 9 10 Lockwasher, 7/16 Stainless

10 4 Screw, 7/16-14 x 2.25” Lg., Stainless

11assy

11 1 * Conduit box 12 1 * O-ring PF92010063

13 1 * Power Cable 10/4 SOW PF31030003 13B 1 * Hex Plug PF30400903 13C 2 * Friction ring PF91010055 13D 1 * Grommet PF92010001

14 1 * Moisture & Temperture Sensor Cable, 18/5 SOW, 30Ft. PF31030005 14B 1 * Hex plug PF30400901 14C 2 * Friction ring PF91010057 14D 1 * Grommet PF92010005

15 4 Capscrews, 1/4-20 x 1”Lg., Stainless

16 4 Lockwashers, 1/4” Stainless

11 Three Phase 460V



() Do NOT use PF40040054, Replaced by PF40040055, size capacitors accordingly, see page 4.

Retaining ring PF31010004

Ball bearing, lower, 6207ZZC3 PF31020022

Seal, inner C/C/B PF31030136

Retaining ring PF31010011

Square ring PF92010087

Conduit Box & Cable Assembly, 10/4 SOW, 30Ft. PF067585



Wire Connectors

For Repair Part Please supply: Model Number and MFG Date as shown on Name Plate, and Part Description and Part Number as shown on Parts List.

 3 HP 230 Volt 1 Ph  PF40040054

3 & 5 HP 230 Volt 1 Ph PF40040055 3 HP 230/460 Volt 3 Ph PF40040051 5 HP 230/460 Volt 3 Ph PF40040052

7.5 HP 230/460 Volt 3 Ph PF40040053

 

PF03100010

Included

Item

#11ASSY

 

Single Phase 230V

PF940100129 Three Phase 230 V

18 1

Impeller

IMPORTANT: Standard impeller sizes prior to June 2011 were as followes;



7.5HP - A; 6.46; 5HP - B; 6.25; 3HP - C; 5.00

 = Aquire standard hardware locally.  = Cutter Kit

6 = Overhaul Kit

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

5.87” Dia. STD for 7.5HP PF03140079A

5.75” Dia. STD for 5HP PF03140079B

5.50” Dia. ---

5.25” Dia. ---

5.00” Dia. ---

4.75” Dia. ---

4.56” Dia. STD for 3 HP PF03140079C

4.25” Dia. ---

4.12” Dia. ---

 = Supplied as individual items * = Supplied with item #11 Assy

■ = Seal Probe Kit

Page 17

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

For Repair Part Please supply: Model Number and MFG Date as shown on Name Plate, and Part Description and Part Number as shown on Parts List.

Repair Parts

19 1 Seal plate PF03180028 20 1

Shredding ring PF31010020

6

21 1 Throat PF03190021 22 3 Allen Screw, 1/4-20 x .75” Lg, Stainless



23 1 Volute PF03090083 24 2

25 4 Hex nut, 7/16-14 Stainless 26 4 Stud, 7/16-14 x 3.25” Lg., Stainless 27 1

28 1

29 1

30 2 Pipe plug, 1/4” NPT 31 1 * Ground screw, 3/16” x 1/2”

4¾ qts

1½ qts

33 2 34 1

35 2 Screw, 5/16-18 x 1.25” Lg. Stainless 36 2 37 2 38 2 Lockwasher, 5/16” Stainless

Square ring PF92010081

Radial cutter PF31030301

6

Washer, Stainless PF30400426

6

Screw, 3/8-16 x 1.75” Lg., Stainless PF91010398

6

Cooling oil, Motor housing Seal cavity

■

Wire Assembly, Moisture Sensor PF31030011 Seal, outer S/S/V PF31030137

■

Moisture Sensor Probe PF31160001

■

Machine screw, 6-32 x 1/4” Lg., Stainless Moisture sensors

See chart on page 9

 



 

39 1 Bearing sleeve Supplied in item #5 40 2 Screw, 7/16-14 x 1.25” Lg., Stainless



41 1 Lifting bail PF30400843 42 1 * Round terminal, 3/16 PF94010043 43 1 Upper Ball Bearing, 6203ZZ PF070715

Repair Kits

CUTTER KIT - Includes Item numbers: 20, 27, 28, 29



OVERHAUL KIT - Includes Item numbers: 2, 3, 4, 6, 7, 20, 24, 27, 28, 29, 34

■

SEAL PROBE KIT - Includes item numbers: 33, 36 & 37 PF69775-1

PFGL-CT

PFGL-OHK

Capacitor Pack for, Other than Power-Flo’s control panel: For units PRIOR to Sept. 2010 use, P/N: PF73303 - for PFG3022, 230 volt, 1 phase 3 Hp (See page 11 for wiring schematic). For units AFTER Sept. 2010 use, P/N: PF73305 - for PFG3022, 3HP & PFG5022 5HP, 230 volt, 1 phase (See page 11 for wiring schematic).

Recommended Moisture & Temperature Sensor Relays for control panel, (or equal): P/N: PF0861 - Warrick relay #IDIEO rated for 25 volt amperes, 115 volt input, 500 volt output (one per pump). P/N: PF0876 - IDEC relay #RH2BUAC120V (one per pump).

 = Aquire standard hardware locally.  = Cutter Kit

6 = Overhaul Kit

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

 = Supplied as individual items * = Supplied with item #11 Assy

■ = Seal Probe Kit

Typical Name Plate

Model Number

MFG Date

AMPS VOLTAGE

PHASE HP

60 Hz

877-24 PUMPS

www.powerflopumps.com

Page 18

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Notes:

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

Page 19

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

Trouble Shooting Chart

Risk of electric shock. Always disconnect the pump from the power source before handling inspections or repairs.

Symptom Possible Cause(s) Corrective Action

1. Poor electrical connection, blown fuse, tripped breaker or other interruption of power; improper power supply

2. Motor or switch inoperative (go to manual

Pump will not run

Pump will not turn o

Pump hums but doesn’t run

Pump delivers insu cient capacity

Pump cycles too frequently or runs periodically when  xtures are not in use

Pump shuts o and turns on independent of switch, (trips thermal overload protector). CAUTION! Pump may start unexpectedly. Disconnect power supply.

Pump operates noisily or vibrates excessively

NOTE: Power-Flo Pumps & Systems assumes no responsibility for damage or injury due to disassembly in the  eld. Disassembly of the pumps or supplied accessories other than at Power-Flo Pumps & Systems or its authorized service centers, automatically voids warranty.

operation) 2a. Float movement restricted 2b. Switch will not activate pump or is defective 2c. Defective motor

3. Insu cient liquid level

2a. Float movement restricted 2b. Switch will not activate pump or is defective

4. Ecessive in ow or pump not properly sized for application

9. Pump may be air locked causing pump not to  ow

14. H-O-A switch on panel is in “HAND” position

1. Incorrect low voltage

8. Impeller jammed or loose on shaft, or inlet plugged

1. Incorrect low voltage

4. Ecessive in ow or pump not properly sized for application

5. Discharge restricted

6. Check valve partially closed or installed backwards

7. Shut-o valve closed

8. Impeller jammed or loose on shaft, or inlet plugged

9. Pump may be air locked causing pump not to  ow

10. Pump running backwards

6. Check valve partially closed or installed backwards

11. Fixtures are leaking

15. Ground water entering basin

1. Incorrect low voltage

4. Ecessive in ow or pump not properly sized for application

8. Impeller jammed or loose on shaft, or inlet plugged

12. Excessive water temperature (internal protection only)

2c. Worn bearings, motor shaft bent

5. Debris in impeller cavity or broken impeller

10. Pumprunning backwards

13. Piping attachments to building structure too loose or rigid

1. Check all electrical connections for security. Have electrician measure current in motor leads, if current is within ± 20% of locked rotor Amps, impeller is probably locked. If current is 0, overload may be tripped. Remove power, allow pump to cool, then re-check current. 2a. Reposition pump or clean basin as required to provide adaquate clearance for  oat 2b. Disconnect level control. Set ohmmeter for a low rang, such as 100 ohms full scale and connect to level control leads. Actuate level control manually and check to see that ohmmeter shows zero ohms for closed switch and full scale for open switch. (Float Switch) 2c. Check winding insulation (Megger Test) and winding resistance. If check is outside of range, dry and re-check. If still defective, replace per service instructions.

3. Make sure liquid level is above the pump

4. Re-check all sizing calculations to determine proper pump size.

5. Check discharge line for restrictions, including ice if line passes through or into cold areas.

6. Remove and examine check valve for proper installation and freedom of operation

7. Open valve

8. Check impeller for freedom of operation, security and condition. Clean impeller cavity and inlet of any obstruction

9. Loosen union slightly to allow trapped air to escape. Verify that turn-o level of switch is set so that the suction is always  ooded. Clean vent hole

10. Check rotation. If power supply is three phase, reverse any two of three power supply leads to ensure proper impeller rotation

11. Repair  xtures as required to eliminate leakage

12. Check pump temperature limits and  uid temperature

13. Replace portion of discharge pipe with  exible connector or tighten existing piping.

14. Turn to automatic position

15. Check for leaks around basin inlet and outlets

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com

Page 20

PFG 3, 5 & 7.5HP Submersible Grinder Pumps

LIMITED WARRANTY

Manufacturer warrants, to the immediate purchaser and subsequent initial owner during the warranty period,

every new pump to be free from defects in material and workmanship under normal use and service, when properly

used and maintained, for a period of eighteen (18) months from date of manufacture or twelve (12) months from

date of installation (which ever comes  rst). Failure due to wear due to excessive abrasives is not covered. The

initial owner is the purchaser who  rst uses the pump after its initial installation, or for non-permanent installation,

the  rst owner who uses the pump. The date of installation 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. Product will be

repaired, replaced or remanufactured at Manufacturer’s option. No allowance will be made for shipping charges,

damages, labor or other charges that may occur due to product failure, repair or replacement. This warranty does

not apply to and there shall be no warranty for any material or product that has been disassembled without prior

approval of Manufacturer, subjected to misuse, misapplication, neglect, alteration, accident or act of God; that has

not been installed, operated or maintained in accordance with Manufacturer’s installation instructions; that has

been exposed to outside substances including but not limited to the following: sand, gravel, cement, mud, tar,

hydrocarbons, hydrocarbon derivatives (oil, gasoline, solvents, etc.), or other abrasive or corrosive substances, wash

towels or feminine sanitary products, etc. in all pumping applications. The warranty set out in the paragraph above

is in lieu of all other warranties expressed or implied; and we do not authorize any representative or other person

to assume for us any other liability in connection with our products. Contact Manufacturer at: 1-877-24PUMPS or

www.power opumps.com, Attention: Customer Service Department, to obtain any needed repair or replacement

of part(s) or additional information pertaining to our warranty.

MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR SPECIAL, CONSEQUENTIAL OR INCIDENTAL

DAMAGES OR BREACH OF EXPRESSED OR IMPLIED WARRANTY; AND ANY IMPLIED WARRANTY OF FITNESS

FOR A PARTICULAR PURPOSE AND OF MERCHANTABILITY SHALL BE LIMITED TO THE DURATION OF THE

EXPRESSED WARRANTY.

Some states do not allow limitations on the duration of an implied warranty, so the above limitation may not apply

to you. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above

limitation or exclusion may not apply to you. This warranty gives you speci c legal rights and you may also have

other rights which vary from state to state.

Power-Flo Pumps & Systems • 877-24PUMPS • www.power opumps.com