Xylem IM038 User Manual [en, es, fr]

INSTRUCTION MANUAL
IM038
Single Phase, Single Seal Grinder Pump
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
SUBJECT PAGE
Safety Instructions ........................................................................................................................................................ 3
Pre-Installation Checks ................................................................................................................................................. 3
Lifting of Pump ............................................................................................................................................................ 3
Optional Guide Rail or Lift-Out System ....................................................................................................................... 3
Piping ........................................................................................................................................................................... 4
Wiring and Grounding .................................................................................................................................................4
Selecting and Wiring Pump Control Panels and Switches ........................................................................................... 4-5
Installation ...................................................................................................................................................................5
Operation .................................................................................................................................................................. 5-6
Float Switch and Panel Chart ........................................................................................................................................6
Engineering Data ..........................................................................................................................................................7
Insulation Resistance Readings .....................................................................................................................................8
Typical Installations and Simplex Wiring Diagrams .................................................................................................... 8-9
Troubleshooting .........................................................................................................................................................10
Limited Warranty .......................................................................................................................................................11
Owner’s Information
Pump Model Number: Pump Serial Number: Control Model Number: Dealer: Dealer Phone No. Date of Purchase: Installation:
Current Readings at Startup:
Amps: Volts:
2
DANGER
WARNING
CAUTION
WARNING
WARNING
Hazardous voltage can shock, burn or cause death.
WARNING
WARNING
SAFETY INSTRUCTIONS
TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN MANUAL AND ON PUMP.
THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH THE PUMP.
This is a SAFETY ALERT SYMBOL. When you see this symbol on the pump or in the manual, look for one of the fol­lowing signal words and be alert to the potential for personal injury or property damage.
Warns of hazards that WILL cause serious personal injury, death or major property damage.
Warns of hazards that CAN cause serious personal injury, death or major property damage.
Warns of hazards that CAN cause per­sonal injury or property damage.
NOTICE: INDICATES SPECIAL INSTRUCTIONS
WHICH ARE VERY IMPORTANT AND MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS PRIOR TO PERFORMING ANY WORK ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
All electrical work must be performed
by a qualified technician. Always follow the National Electrical Code (NEC), or the Canadian Electrical Code, as well as all local, state and provincial codes. Code questions should be directed to your local electrical inspector. Failure to follow electrical codes and OSHA safety standards may result in personal injury or equipment damage. Failure to follow manufacturer’s installation instructions may result in electrical shock, fire hazard, personal injury or death, damaged equipment, provide unsatisfactory performance, and may void manu­facturer’s warranty.
Standard units are not designed for use in
swimming pools, open bodies of water, hazardous liquids, or where flammable gases exist. These fluids and gases may be present in containment areas. Tank or wetwell must be vented per local codes.
Only pumps specifically Listed for Class 1, Division 1 are allowable in hazardous liquids and where flammable gases may exist. See specific pump catalog bulletins or
pump nameplate for all agency Listings.
Disconnect and lockout electrical power
before installing or servicing any electrical equipment. Many pumps are equipped with automatic thermal overload protection which may allow an over­heated pump to restart unexpectedly.
PRE-INSTALLATION CHECKS
Open all cartons and inspect for shipping damage. Report any damage to your supplier or shipping carrier immedi­ately.
Important: Always verify that the pump nameplate Amps, Voltage, Phase, and HP ratings match your control panel and power supply.
Many of our sewage pumps are oil-filled. If there are any signs of oil leakage or if the unit has been stored for an extended period check the oil level in the motor dome and the seal housing, if so equipped.
Check the motor cover oil level through the pipe plug on top of the unit. The motor chamber oil should just cover the motor. Do not overfill, leave room for expansion!
If low, refill with an ASTM 150 turbine oil. Replace the plug.
Oil is available in 5 gallon cans through our distributors. You can also source oil locally at motor repair shops. Typical oil brands are: Shell Turbo 32, Sunoco Sunvis 932, Texaco Regal R&O 32, Exxon Nuto 32 and Mobil DTE Light.
Check the strain relief nut on power cable strain assem­blies. Power cables should be torqued to 75 in. lbs. for #16 cables and 80 in. lbs. for all other cable assemblies.
Warranty does not cover damage caused by connecting pumps and controls to an incorrect power source (volt­age/phase supply).
Record the model numbers and serial numbers from the pumps and control panel on the front of this instruction manual for future reference. Give it to the owner or affix it to the control panel when finished with the installation.
LIFTING OF PUMP
DO NOT LIFT, CARRY OR HANG PUMP BY THE ELECTRICAL CABLES. DAMAGE TO THE ELECTRICAL CABLES CAN CAUSE SHOCK, BURNS OR DEATH.
Lift the pump with an adequately sized chain or cable at­tached to the lifting eye bolt. DO NOT damage electrical and sensor cables while raising and lowering unit.
OPTIONAL GUIDE RAIL OR LIFT-OUT SYSTEM
In many effluent and sewage basins or lift stations it is advisable to install the pump on a guide rail system or on a lift-out adapter to facilitate installation and removal for inspection and/or service. Most codes do not allow personnel to enter a wetwell without the correct protective equipment and training. Guide rails are designed to allow easy removal of the pump without the need for entry into the wetwell or need to disturb piping. The guide rail or lift-out adapter should locate the pump opposite the influent opening preventing stagnate areas where solids can settle. The basin or pit must be capable of supporting the weight of the pump and guide rail. The pit floor must be flat.
NOTICE: FOLLOW THE INSTRUCTIONS THAT
ARE PROVIDED WITH THE GUIDE RAIL ASSEMBLY.
3
WARNING
Hazardous voltage
WARNING
WARNING
PIPING
Discharge piping should be no smaller than the pump discharge diameter and kept as short as possible, avoiding unnecessary fittings to minimize friction losses.
Install an adequately sized check valve to prevent fluid backflow. Backflow can allow the pump to “turbine” backwards and may cause premature seal and/or bearing wear. If the pump is turning backwards when it is called on to start the increased torque may cause damage to the pump motor and/or motor shaft and some single-phase pumps may actually run backwards.
Install an adequately sized gate valve AFTER the check valve for pump, plumbing and check valve maintenance.
Important – Before pump installation. If pumping waste water containing solids, drill a 3⁄16” (4.8mm) relief hole in the discharge pipe. It should be located within the wetwell, 2” (51mm) above the pump discharge but below the check valve. The relief hole allows any air to escape from the casing. Allowing liquid into the casing will insure that the pump can start when the liquid level rises. Unless a relief hole is provided, a bottom intake pump could “air lock” and will not pump water even though the impeller turns.
All piping must be adequately supported, so as not to impart any piping strain or loads on the pump.
The pit access cover must be of sufficient size to allow for inspection, maintenance and crane or hoist service.
WIRING AND GROUNDING
Important notice: Read Safety Instructions before proceeding with any wiring.
Use only stranded copper wire to pump/motor and ground. The ground wire must be at least as large as the power supply wires. Wires should be color coded for ease of maintenance and troubleshooting.
Install wire and ground according to the National Electrical Code (NEC), or the Canadian Electrical Code, as well as all local, state and provincial codes.
Install an all leg disconnect switch where required by code.
Disconnect and lockout electrical power before performing any service or installation.
The electrical supply voltage and phase must match all equipment requirements. Incorrect voltage or phase can cause fire, motor and control damage, and voids the warranty.
All splices must be waterproof. If using splice kits follow manufacturer’s instructions.
Select the correct type and NEMA grade junction box for the application and loca­tion. The junction box must insure dry, safe wiring connections.
Seal all controls from gases present which may damage electrical components.
FAILURE TO PERMANENTLY GROUND THE PUMP, MOTOR AND CONTROLS BEFORE CONNECTING TO POWER CAN CAUSE SHOCK, BURNS OR DEATH.
4
SELECTING AND WIRING PUMP CONTROL PANELS AND SWITCHES
FLOAT SWITCH TYPES
There are two types of float switches available for use with 2 HP, single phase grinder pumps; single action con­trol switches and wide angle mechanical switches.
Single action control switches can only be connected through a control panel. Connecting them directly to a pump will cause rapid cycling and may burn up the mo­tor, and/or the motor start switch and/or the float switch. If using single action switches with a control panel please see the Float Switch and Panel Section.
Model A2G33 wide angle pump float switches can be hard wired directly to the pump. Wide angle switches can operate the pump via connection to a control panel. The tether length or distance from the switch body to the piv­ot point controls the On and Off points and the amount pumped in one cycle. The pivot point is where the float is attached to the discharge pipe. See Figures 1 and 2.
SETTING THE FLOAT SWITCHES
There are no absolute rules for where to set the float switches, it varies from job to job.
Suggested Rules to Follow: All floats should be set below the Inlet pipe!
Off Float: Best: set so the water level is always above the
top of the pump (motor dome). Next Best: set so the wa­ter level is not more than 6” below the top of the pump.
On Float: set so the volume of water between the On and Off floats allows two (2) HP and larger pumps to run a minimum of 2 minutes. Basin literature states the gallons of storage per inch of basin height.
Lag/Alarm Float(s): should be staggered above the Off and On floats. Try to use most of the available storage provided by the basin, save some space for reserve stor­age capacity. See Diagrams and Charts in Float Switch
Chart Section.
PANEL WIRING DIAGRAMS
Our control panels are shipped with instructions and wir­ing diagrams. Use those instructions in conjunction with this IOM. Electrical installation should be performed only by qualified technicians. Any problem or questions pertaining to another brand control must be referred to that control supplier or manufacturer. Our technical people have no technical schematics or trouble shooting information for other companies’ controls.
ALARMS
We recommend the installation of an alarm on all Waste­water pump installations. Many standard control panels come equipped with alarm circuits. If a control panel is not used, a stand alone high liquid level alarm is avail­able. The alarm alerts the owner of a high liquid level in the system so they can contact the appropriate service personnel to investigate the situation.
SINGLE PHASE PUMPS
WARNING
Hazardous voltage can shock, burn or cause death.
PLUG-CONNECTED UNITS MUST BE CONNECTED TO A PROPERLY GROUNDED, GROUNDING TYPE RECEPTACLE.
ON NON-PLUG UNITS, DO NOT RE­MOVE CORD AND STRAIN RELIEF. DO NOT CONNECT CONDUIT TO PUMP.
Pumps with bare lead power cords can be hard-wired to a float switch, wired to a 1Ø contactor, a Simplex controller or a Duplex controller. Always verify that the float switch is rated for the maximum run amperage, maximum starting amperage, and the HP rating on the pump. Single-phase wastewater pumps contain on-wind­ing overloads, unless noted on the pump nameplate. See
Figure 1.
SINGLE PHASE CONTROL PANELS:
Control panels are available as Simplex (controls 1 pump) or Duplex (controls 2 pumps). Our standard control panels are available with many standard features and can be built with our most popular options. We also custom build panels which offer many more design op­tions than the standard panels. Custom control panels are available in many different configurations. Custom panel quote requests may be forwarded to Customer Service through any authorized distributor.
Our standard duplex panels feature a solid-state printed circuit board design with standard high level alarm cir­cuits. Other standard features are: an auxiliary dry alarm contact for signaling a remote alarm and float switch po­sition indicator lights. Most standard panels are in stock for immediate delivery.
INSTALLATION
STANDARD PUMP INSTALLATION
Connect the pump(s) to the guide rail pump adapters or to the discharge piping. Guide rail bases should be anchored to the wetwell floor.
Complete all wiring per the control panel wiring dia­grams and NEC, Canadian, state, provincial and/or local codes.
!
DANGER
Hazardous Machinery
Connect the piping per local codes and the drawings in Typical Drawings Section.
DO NOT PLACE HANDS IN PUMP SUCTION WHILE CHECKING MOTOR ROTATION. TO DO SO WILL CAUSE SEVERE PERSONAL INJURY.
Lower the pump(s) into the wetwell. Check to insure that the floats will
operate freely and will not contact the piping.
OPERATION
Once the piping connections are made and checked you can run the pumps.
Hard Wired Float Switch Operation – Turn circuit break­er or fused disconnect to On. Test the pump by filling the wetwell until the pump goes On. If the pumps run but fail to pump, they are probably air locked, drill the relief holes per the instructions in the Piping Section.
Check the operating range to insure a minimum two min­ute run time and that the pump goes Off in the correct position.
Control Panel Operation – Fill the wetwell with clear water.
Use the pump H-O-A (Hand-Off-Automatic) switches in Hand to test the pumps. If they operate well in Hand proceed to test Automatic operation. If the pumps run but fail to pump, they are probably air locked, drill the relief holes per the instructions in the Piping Section.
Place Control Panel switch(es) in Automatic position and thoroughly test the operation of the ON, OFF, and Alarm floats by filling the wetwell with clear water. Important: Failure to provide a Neutral from the power supply to a 1Ø, 230 volt Control Panel will not allow the panel control circuit to operate. The Neutral is necessary to complete the 115 volt control circuit.
Check voltage and amperage and record the data on the front of this manual for future reference. Compare the amperage readings to the pump nameplate maximum amperage. If higher than nameplate amperage investigate cause. Operating the pump off the curve, i.e. with too little head or with high or low voltage will increase am­perage. The motor will operate properly with voltage not more than 10% above or below pump nameplate ratings. Performance within this range will not necessarily be the same as the published performance at the exact rated nameplate frequency and voltage. Correct the problem before proceeding.
Reset the Alarm circuit, place pump switch(es) in the Automatic position and Control Switch in ON position. The system is now ready for automatic operation.
Explain the operation of the pumps, controls and alarms to the end user. Leave the paperwork with the owner or at the control panel if in a dry, secure location.
5
FLOAT SWITCH AND PANEL CHART
Inlet
Alarm SW4
Lag Pump On
SW3
Pump Off
SW1
Discharge
Lead Pump On
SW2
The purpose of this chart is to show the required switch quantities and the function of each switch in a typical wastewater system. The quantities required vary de­pending on the switch type, single-action or wide-angle. Switch quantities also vary by panel type: simplex with and without alarms, and duplex with alarms.
Discharge
Duplex Panels using single-action switches:
Three Float Panel Wiring SW1 Bottom Pumps Off
SW2 Middle 1st Pump On SW3 Top 2nd Pump & Alarm On
Four Float Panel Wiring SW1 Bottom Pumps Off
SW2 2nd 1st Pump On SW3 3rd 2nd Pump On SW4 Top Alarm On
Duplex Panels using wide-angle switches:
Three Float Panel Wiring SW1 Bottom 1st Pump On/Both Off
SW2 Top 2nd Pump & Alarm On
Four Float Panel Wiring SW1 Bottom 1st Pump On/Both Off
SW2 Middle 2nd Pump On SW3 Top Alarm On
Simplex Panel using single-action switches:
Simplex Panel with Alarm SW1 Bottom Pump Off
SW2 Middle Pump On SW3 Top Alarm On/Off
Simplex Panel with No Alarm SW1 Bottom Pump Off
SW2 Top Pump On
Inlet
Alarm SW3
Pump On SW2
Pump Off SW1
Simplex
Simplex Panel using wide-angle switches:
Simplex Panel with Alarm SW1 Bottom Pump On/Off
SW2 Top Alarm On/Off Simplex Panel with No Alarm
SW1 Pump On/Off
6
Duplex
ENGINEERING DATA
PUMP OPERATION
Minimum Submergence
Continuous Duty
Intermittent Duty
A2G33 - Hard Wired
Fully Submerged
6” Below Top of Motor
Maximum Fluid Temperature
Continuous Operation
Intermittent Operation
Determining Pumping Range
104º F 40º C
140º F 60º C
Figure 1
Wide-Angle Float Switch
Pump plug
Piggyback switch plug
Pumping
range
Figure 2
Figure 3
Single-Action Float Switch
“Typical” Installation
WEIGHT
6" (15.3 cm)
8" (20.3 cm) TURN ON LEVEL
6" (15.3 cm)
Figure 4
7
INSULATION RESISTANCE READINGS
Normal Ohm and Megohm Values between all leads and ground
Condition of Motor and Leads Ohm Value Megohm Value
A new motor (without drop cable). 20,000,000 (or more) 20 (or more)
A used motor which can be reinstalled in well. 10,000,000 (or more) 10 (or more)
Motor in well. Readings are for drop cable plus motor.
New motor. 2,000,000 (or more) 2 (or more)
Motor in good condition. 500,000 - 2,000,000 .5 - 2
Insulation damage, locate and repair. Less than 500,000 Less than .5
Insulation resistance varies very little with rating. Motors of all HP, voltage and phase ratings have similar values of insulation resistance.
Insulation resistance values above are based on readings taken with a megohmmeter with a 500V DC output. Readings may vary using a lower voltage ohmmeter, consult factory if readings are in question.
TYPICAL PLUMBING AND INSTALLATION
INFLUENT
SERVICE POLE
CONTROL PANEL
INLET HUB
MERCURY SWITCH HIGH LEVEL ALARM (OPTIONAL)
MERCURY SWITCH
ALARM LIGHT
HINGED ACCESS DOOR
GUIDE RAIL
VENT
VALVE OPERATING ROD
DISCHARGE
CHECK VALVE
LOWER PUMP GUIDE
INFLUENT
SERVICE POLE
CONTROL PANEL
INLET HUB
MERCURY SWITCH HIGH LEVEL ALARM (OPTIONAL)
MERCURY SWITCH
ALARM LIGHT
HINGED ACCESS DOOR
GUIDE RAIL
VENT
VALVE OPERATING ROD
DISCHARGE
CHECK VALVE
LOWER PUMP GUIDE
SIMPLEX
DUPLEX
8
TYPICAL INSTALLATIONS (continued)
RUN
AUTO
OFF
HAND
S1
FLASH HIGH
SILENCE
R1
R2
R2
R2
HORN
FLASHER
56
T1
T2
PUMP
1T
Simplex Single Phase Wiring Diagram S10020
115/230 VAC (FOR 115 VAC, USE TERMINALS L1 AND N, JUMP L2 AND N). SINGLE PHASE, 60 Hz
L1
L2
N
NOTE: WHEN USING SEPARATE 115 VAC CONTROL POWER SUPPLY, REMOVE
GND
J1
JUMPER (J1) FROM TERMINALS (L1) AND LL1). CONNECT 15 AMP MAX.
LL1
PROTECTED 115 VAC SUPPLY TO TERMINALS (LL1) AND (N) WITH THE NEUTRAL OF THE SUPPLY TO (N).
S1
T1
PUMP
T2
A 230 VOLT SYSTEM REQUIRES A 4 WIRE POWER SUPPLY LINE L1, L2,
N AND GND.
WITHOUT A
NEUTRAL THE CONTROL CIRCUIT WILL NOT WORK.
2
FOR 115 VAC OPERATION, USE TERMINALS L1 AND N, JUMP TERMINALS L2 AND N.
115/230 VAC SINGLE PHASE 60 Hz
CONTROL ON-OFF
RUN
S1-AUX
123
OFF FLOATON FLOAT
4
ALARM FLOAT
TEST
R1
HIGH LEVEL ALARM
DRY CONTACTS
HAND
OFF
AUTO
FLASHER
R2
SILENCE
R2
S1
FLASH HIGH
R1
HORN
R2
J1
L1 L2 LL1 N1 23456T
2
R1
2
ALARM
DRY CONTACTS
FLOAT
ON FLOAT
PUMP
OFF FLOAT
9
TROUBLESHOOTING
WARNING
Hazardous voltage
FAILURE TO DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE ATTEMPTING ANY SERVICE CAN CAUSE SHOCK, BURNS OR DEATH.
SYMPTOM PROBABLE CAUSE RECOMMENDED ACTION
MOTOR NOT RUNNING Motor thermal protector tripped. Allow motor to cool. Insure minimum pump submergence. Clear debris from casing and impeller.
NOTE: If circuit breaker “OPENS” repeatedly,
Open circuit breaker or blown fuse. Determine cause, call a qualified electrician. DO NOT reset. Call
Pump impeller binding or jammed. Check motor amp draw. If two or more times higher qualified electrician.
than listed on pump nameplate, impeller is locked, a) Manual operation Power cable is damaged. motor bearings or shaft is damaged. Clear
Resistance between power leads and ground should b) Automatic operation No neutral wire read infinity. If any reading is incorrect, call a connected to control panel. qualified electrician.
Inadequate electrical connection Inspect control panel wiring. Call a qualified in control panel. electrician.
NOTE: Check the pump
Defective liquid level switch. With switch disconnected, check continuity while
in manual mode first to
activating liquid level switch. Replace switch, as
confirm operation. If pump
required.
operates, the automatic
Insufficient liquid level to Allow liquid level to rise 3” to 4” (76 mm - 101 mm)
control or wiring is at fault.
activate controls. above turn-on level.
If pump does not operate,
Liquid level cords tangled. Untangle cords and insure free operation.
see above.
PUMP WILL NOT Liquid level cords tangled. Untangle cords and insure free operation. TURN OFF
Pump is air locked. Shut off pump for approximately one minute, then restart. Repeat until air lock clears. If air locking persists in a system with a check valve, a 3⁄16” (4.8 mm) hole may be drilled in the discharge pipe approximately 2” (51 mm) above the discharge connection.
Influent flow is matching pump’s Larger pump may be required. discharge capacity.
LITTLE OR NO LIQUID Check valve installed backwards, Check flow arrow on valve and check valve DELIVERED BY PUMP plugged or stuck closed. operation.
Excessive system head. Consult with dealer. Pump inlet plugged. Inspect and clear as required. Improper voltage or wired Check pump rotation, voltage and wiring.
incorrectly. Consult with qualified electrician. Pump is air locked. See recommended action, above. Impeller is worn or damaged. Inspect impeller, replace as required. Liquid level controls defective Inspect, readjust or replace as required.
or improperly positioned. PUMP CYCLES Discharge check valve inoperative. Inspect, repair or replace as required.
CONSTANTLY
Liquid level controls defective or Inspect, readjust or replace as required. improperly positioned.
Influent excessive for this size Consult with dealer. pump.
Sewage containment area too small. Consult with dealer.
Inadequate electrical connection in control panel.
dealer.
debris from cutter, casing and impeller, consult with
10
GOULDS WATER TECHNOLOGY LIMITED WARRANTY
This warranty applies to all water systems pumps manufactured by Goulds Water Technology. Any part or parts found to be defective within the warranty period shall be replaced at no charge to the dealer during the warranty period. The warranty period shall exist for a
period of twelve (12) months from date of installation or eighteen (18) months from date of manufacture, whichever period is shorter. A dealer who believes that a warranty claim exists must contact the authorized Goulds Water Technology distributor from whom the pump was purchased and furnish complete
details regarding the claim. The distributor is authorized to adjust any warranty claims utilizing the Goulds Water Technology Customer Service Department.
The warranty excludes:
(a) Labor, transportation and related costs incurred by the dealer; (b) Reinstallation costs of repaired equipment; (c) Reinstallation costs of replacement equipment; (d) Consequential damages of any kind; and, (e) Reimbursement for loss caused by interruption of service.
For purposes of this warranty, the following terms have these definitions:
(1) “Distributor” means any individual, partnership, corporation, association, or other legal relationship that stands between Goulds Water Technology and the dealer in pur-
chases, consignments or contracts for sale of the subject pumps. (2) “Dealer” means any individual, partnership, corporation, association, or other legal relationship which engages in the business of selling or leasing pumps to customers. (3) “Customer” means any entity who buys or leases the subject pumps from a dealer. The “customer” may mean an individual, partnership, corporation, limited liability com-
pany, association or other legal entity which may engage in any type of business.
THIS WARRANTY EXTENDS TO THE DEALER ONLY.
Xylem, Inc. 2881 East Bayard Street Ext., Suite A Seneca Falls, NY 13148 Phone: (866) 325-4210 Fax: (888) 322-5877 www.xyleminc.com/brands/gouldswatertechnology
Goulds is a registered trademark of Goulds Pumps, Inc. and is used under license.
© 2012 Xylem Inc. IM038 Revision Number 5 July 2012
11
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