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Troubleshooting 2–11

Figure 2-3a, Wiring Schematic, 240V, May 2015 & Later (Serial Number 531884)

CAPACITOR

BLEED

RESISTOR

MOTOR

COMPARTMENT

START

GRN-G

MAIN

YEL

ORN

GRAY

RED

BLU

PROTECTOR

THERMAL

SWITCH

SMART

BLK

CONTROL COMPARTMENT

MOTOR section

CONTROL COMPARTMENT

COVER section

(ALARM)

SWITCH

(ON-OFF)

SWITCH

TO MOTOR

GROUND

MOTOR CONTACTOR

GRINDER PUMP CORE

Level Control Compartment

Tray Cable

BRN-L1 Control

RED-L1

EQD
Pin #

Wire Color

Function

Brown

Manual Run

Red

Black

Ground

Yellow

Alarm Power Feed

Blue

Alarm Power Return

Green w/ Yellow Stripe

240VAC

NEUTRAL

AMP

MAIN SUPPLY PANEL

240VAC 60Hz

TWO POLE - HARDWIRE

(RECOMMENDED WIRING CONFIG,
NOT SUPPLIED BY E/ONE)

HARD WIRE OPTION

Alarm Yellow and Blue wires go to the alarm panel only
Motor Control Red and Brown wires go to both alarm panel and motor contactor

ALARM/DISCONNECT

GROUND

PUMP

BREAKER

ALARM

BREAKER

ALARM LAMP

REDUNDANT

RUN

COIL

COM

N.O.

N.C.

Basic Alarm

Board

(PC1139G01)

SILENCE

RELAY

COIL

COM

N.O.

N.C.

PTC

RESIST

AUT

O-RESET

FUSE

Resistor

LED
GREEN
RUN

SER

VICE

NEUTRAL

MANUAL

RUN

ALARM

FEED

ALARM

RETURN

BUZZER

SILENCE
SWITCH

MANUAL

RUN

Resistor

PUMP

ALARM

WIRED

WIRELESS

LEVEL CONTROL

Using the EXTREME color Scheme

NA0035P11 REV. B

BLK-L2

Содержание Extreme Series

Страница 1: ...Service Manual E One Extreme Grinder Pumps 240V 60 Hz Hardwired Controls...

Страница 2: ......

Страница 3: ...ion Integrity Tests 4 1 Run Test 4 2 Chapter 5 Pump End 5 1 Removing the Pump Stator 5 1 Pump Stator Inspection 5 3 Swollen Pump Stator 5 4 Inspecting a Pump Rotor 5 5 Removing the Pump Rotor 5 6 Asse...

Страница 4: ...hapter 9 Control Cavity 9 1 Removing the Control Housing 9 1 Motor Contactor and Controls 9 2 Motor Cavity Water Test 9 4 Motor Windings Test 9 5 Control Housing Installation 9 6 Chapter 10 Motor Cavi...

Страница 5: ...onproof DX and WX pumps contact your local distributor or E One Field Service at 518 346 6161 or ssbfieldservice eone com Each station name is made up several identifiers For example the model DH272 D...

Страница 6: ...any solids The slurry is then pumped until the liquid in the tank is lowered to the shut off level This reduces pressure on the diaphragm of the on off switch which opens the electrical contacts and...

Страница 7: ...Observe the site Record the following on the service tag Customer information Date and time Alarm status Is the pump running without opening the station 2 Open the alarm panel enclosure Record the fo...

Страница 8: ...nected Neutral Alarm breaker pump side 108V 132V Alarm breaker OK Bad breaker Neutral Yellow 5 108V 132V Voltage to alarm switch OK Loose wire between alarm board and single pole breaker bad alarm boa...

Страница 9: ...120V 120V 120V 120V 120V 120V 120V 120V 120V 120V 120V 120V 120V 120V 88V 88V 88V 88V 88V 88V 88V 88V 88V 88V 152V 152V 152V 1 Phase 240V 180 Degrees out of Phase 3 Phase 208V 120 Degrees out of Phase...

Страница 10: ...rwise The meter must be in the 200K scale to read the coil and alarm circuits Auto ranging meters must be set manually Identify the wires that come from the pump and go to the panel The test points on...

Страница 11: ...tube 240V Continuity Checks This table assumes the pump has shut off on its own or is not installed in a tank Table 2 3 This table assumes enough water is in the tank to turn on the alarm Color Pin C...

Страница 12: ...ctor coil Bad coil wet controls 120V Continuity Checks This table assumes the pump has shut off on its own or is not installed in a tank Table 2 5 This table assumes enough water is in the tank to tur...

Страница 13: ...ays a comparison of back pressure psi flow gpm current draw amperes and head feet of water pressure A jammed grinder may trip the circuit breaker or cause the overload protector to cycle This causes t...

Страница 14: ...accessway flooded If yes where did the water enter Was the EQD below water Is the Equalizer hung properly as high in the tank as possible Are other signs of infiltration present 2 Disconnect and inspe...

Страница 15: ...Chapter 5 Pump End describes how to identify and correct causes of stator and rotor wear Alarm On Pump Running but not Pumping Table 2 8 Possible Causes Troubleshooting Steps Incorrect voltage Check t...

Страница 16: ...ection procedure Worn Motor Bearing Remove the pump stator and hand rotate the shaft If the shaft turns roughly replace the pump Return the failed pump to the shop and replace the motor bearings as de...

Страница 17: ...4 Ground 5 Yellow Alarm Power Feed 6 Blue Alarm Power Return Green w Yellow Stripe 240VAC NEUTRAL L2 L1 AMP 30 MAIN SUPPLY PANEL N G 240VAC 60Hz TWO POLE HARDWIRE RECOMMENDED WIRING CONFIG NOT SUPPLIE...

Страница 18: ...QD Pin Wire Color Function 1 Brown Manual Run 2 Red L1 3 Black Neutral 4 Ground 5 Yellow Alarm Power Feed 6 Blue Alarm Power Return Green w Yellow Stripe 1 3 2 ALARM SWITCH 2 1 3 ON OFF SWITCH Level C...

Страница 19: ...lack L2 4 Ground 5 Yellow Alarm Power Feed 6 Blue Alarm Power Return Green w Yellow Stripe 240VAC NEUTRAL L2 L1 AMP 30 MAIN SUPPLY PANEL N G 240VAC 60Hz TWO POLE HARDWIRE RECOMMENDED WIRING CONFIG NOT...

Страница 20: ...60Hz SINGLE POLE HARDWIRE GROUND RECOMMENDED WIRING CONFIG NOT SUPPLIED BY E ONE PUMP BREAKER 20 15 ALARM BREAKER L1 N YEL ORN Note A1 A2 are for the contactor coil 1 3 2 ALARM SWITCH 2 1 3 ON OFF SW...

Страница 21: ...rench to close the stainless steel ball valve Insert the bent end of the core wrench into the hole on the handle of the valve and push down until the handle is horizontal 5 Use the core wrench to turn...

Страница 22: ...discharge tube Equalizer tube or power cable 6 Lower the new pump into the tank 7 Connect the discharge hose to the valve and open the valve 8 Perform start up procedures as described in Chapter 4 Sta...

Страница 23: ...xposed outside of panel 4 Conduits must be sealed 5 Test incoming line voltage If the voltage varies more than 10 percent of the nameplate voltage do not continue Rectify the voltage problem Voltage C...

Страница 24: ...tage going to the pump at the alarm panel voltage must be within 10 percent of the nameplate voltage 240V 216V to 264V and 120V 108V to 132V If it is not do not continue Rectify the voltage problem 2...

Страница 25: ...the pump There is a hole in the suction housing where a 1 8 inch punch can be used in to aid the removal of the wire stand 4 Use a 5 16 nut driver to remove the four inlet shroud retaining screws and...

Страница 26: ...t hand thread If the cutter wheel is difficult to loosen apply penetrating oil and let it soak for a few minutes Never strike the cutter bars with a metal hammer or punch Replace the cutter wheel if i...

Страница 27: ...f the pump runs for a long period of time against a blocked line the high pressure approximately 150 psi in the pump cavity will rupture or tear the stator The blockage must be cleared before the pump...

Страница 28: ...the pump inlet shroud An obstruction will restrict the flow Check for objects such as a board junction box cover heavy glove or plate 5 Inspect and troubleshoot the electrical controls Refer to Chapt...

Страница 29: ...bes that spiral the length of the rotor If the lobes have been worn flat into a 1 4 inch or wider band the rotor is worn and must be replaced Rubber found on the rotor indicates that the pump has run...

Страница 30: ...ove pin will help to ease the installation Do not use a hammer to beat in groove pin doing so may bend the armature shaft 2 Install the new pump stator and liner over the rotor The rotor or internal b...

Страница 31: ...to ensure it does not interfere with the shredder ring 8 Install the inlet shroud Tighten the four screws diagonally 9 Reinstall the core Open all the valves on the discharge plumbing before turning o...

Страница 32: ...Pump End 5 8 Figure 5 9a D Series Pump Exploded View...

Страница 33: ...Pump End 5 9 Figure 5 9b W Series Pump Exploded View...

Страница 34: ...Pump End 5 10 Figure 5 9c Gatorgrinder GH Series Pump Exploded View...

Страница 35: ...Pump End 5 11 Figure 5 9d IH091 Pump Exploded View...

Страница 36: ...Pump End 5 12...

Страница 37: ...not use Teflon paste on the cord grip threads that screw into the EQD housing Disassembling the EQD 1 Loosen the compression nut on the cable fitting 2 Loosen the four screws that hold the insert in t...

Страница 38: ...e side install the watertight grommet onto the wires Keep the tapered side toward the cable jacket not the cable end 3 Insert the wire ends of the power cable into the EQD insert ensuring proper pin n...

Страница 39: ...sition install the six foam pads onto the underside of the new top housing Flats on the underside will guide you 2 With the power off loosen the screws on both sides of the 2000 Series EQD Unplug the...

Страница 40: ...dividual wires to the electrical insert as indicated 11 Tighten the set screws 12 Slip the EQD housing down to the electrical insert 13 Tighten the four corner screws compressing the water block gromm...

Страница 41: ...e anti siphon 2 Loosen and remove the four top housing bolts 3 Spray the power cable and Equalizer tube with soapy water and lift off the top housing from the top of the control compartment Simultaneo...

Страница 42: ...e Removal 1 Remove the O rings from the discharge tube 2 Bend and remove the split washer 3 Remove the compression nut by positioning it at an angle and knocking it off using a plastic or rubber malle...

Страница 43: ...cable through the top housing D Series Top Housing Reassembly and Installation 1 Remove the power cable and Equalizer tube grommets from the top housing Push a fish tape rope or solid wire through th...

Страница 44: ...grommet 5 Secure the top housing onto the control compartment casting with the four bolts and four new Nyloc nuts Tighten in an X pattern to 120 inlb IH Station Top Housing Removal 1 Remove the four...

Страница 45: ...ve the cord grips and grommet from top housing discharge Equalizer tube and power cable IH Station Top Housing Reassembly and Installation 1 Install the discharge grommet into top housing 2 Install th...

Страница 46: ...ure the Equalizer tube to the power cable with the retaining clips Cable Replacement Cable Removal 1 Remove top housing following the appropriate instructions for top housing removal and replacement a...

Страница 47: ...ert the wires through the cable entry 3 While inserting the cable into the control housing spread Loctite 598 onto the threads of the cable entry until they are coated completely Install a new split n...

Страница 48: ...n Chapter 9 Control Cavity 7 Air test the control compartment as described in Chapter 12 Final Test Procedures 8 Connect the wires to the level sensor and reassemble as described in Chapter 8 Level Se...

Страница 49: ...ies Gatorgrinder and Upgrade pumps loosen the two rope hooks and move them out of the way of the level sensor 3 Disconnect one side of each of the level sensor retaining clips Separate the columns and...

Страница 50: ...manufactured after 8 25 2009 or serial number 353742 Level Sensor Leak Troubleshooting Repair If a substandard result occurs perform the following procedure to determine where the leak is occurring a...

Страница 51: ...the switches Fig 8 7 3 Remove the on off switch Fig 8 8 and the molded radial seal Fig 8 9 Note The seal will also stick in the alarm side 4 Clip the flag terminals from the wires loosen the cord gri...

Страница 52: ...p enough at least 19 inches to submerge it up to the top of the column at the switch compartment 3 Look for bubbles coming out of the column Level Sensor Reassembly Ensure that the inside of the two l...

Страница 53: ...ble entry side Install a new molded radial seal on the On Off side and lubricate the exposed surface Fig 8 17 3 Feed the cable through the cord grip Fig 8 18 reinstall the compression nut and tighten...

Страница 54: ...012 pump serial number 439086 If the Equalizer diaphragm appears to have collapsed disconnect the Equalizer tube from the Equalizer If the problem goes away inspect the Equalizer diaphragm If the prob...

Страница 55: ...e Install the diaphragm onto the base shell and ensure that it is seated completely 4 With the logo upright set the cover on the base evenly and center the cover snap to the base hanger Press the cove...

Страница 56: ...roblem goes away inspect the Equalizer diaphragm If the problem persists the Equalizer diaphragm likely has not collapsed If the Equalizer diaphragm has collapsed perform the following procedure to re...

Страница 57: ...of water coming out of the nipple attached to the Equalizer tube If water is present inspect the level sensor assembly switch compartment 4 Snap the inspection cover back into place on the front of th...

Страница 58: ...Level Sensor 8 10 Figure 8 35 Level Sensor Assembly Exploded View all hardwired pumps...

Страница 59: ...d pump to pressurize the control cavity to 5 psi 4 Use soapy water to test for leaks around the O ring joint and compression nut Submerging the assembly may aid with finding leaks Clearing trapped air...

Страница 60: ...il the contacts close and run the pump To test motor contactor operation 1 With the power off verify that the control bracket is wired correctly and is seated properly into the motor housing 2 Check t...

Страница 61: ...the black wire between the motor and thermal at the butt splice To test the switch 1 Remove the orange wire from the capacitor before testing 2 Connect a continuity tester between Terminals 1 and 3 It...

Страница 62: ...With the control bracket removed and no wires touching the chassis or each other meg test at the EQD between each pin 2 If you get bad readings remove the EQD plug insert and retest at the wires 3 If...

Страница 63: ...g Resistance Table 9 1 Motor Windings Test Perform motor winding resistance checks per the following charts to verify motor condition Note While all of the wires are disconnected between the control b...

Страница 64: ...ol Housing Installation 1 Unhook the control housing from the motor housing 2 Slide the control housing back onto the motor housing making sure not to pinch or crimp any of the wires The air release p...

Страница 65: ...Chapter 7 Top Housing Chapter 8 Level Sensor and Chapter 9 Control Cavity respectively 2 Remove the anti siphon valve by removing the four bolts and lifting it off the discharge elbow 3 Disassemble th...

Страница 66: ...rom the motor head Motor Drying Techniques Note If the motor was wet or flooded clean and dry the motor before reassembling the unit Use a mild detergent such as household dishwashing liquid to clean...

Страница 67: ...1 Motor Field Winding Resistance in Chapter 9 Control Cavity 2 Meg the windings to Ground Readings should be 500M to 1000M at 500 volts Note If the motor winding has failed it does not need to be remo...

Страница 68: ...housing upside down on the bench place the spring washer into the top bearing bore Lift the motor head armature assembly by the motor head Grasp the armature shaft below the motor head and turn it ups...

Страница 69: ...ubrication from drying out otherwise a failure may occur 2 Carefully remove the ceramic portion of the seal from the package Lubricate the O ring with Pac Ease or clean soapy water handling the seal b...

Страница 70: ...Mechanical Seal Assembly 11 2...

Страница 71: ...henever the motor housing or mechanical seal assembly has been disturbed or the controls have flooded This test will ensure no leaks exist between the motor head and motor housing and between the mech...

Страница 72: ...dried and tested 6 Bleed off the air pressure before reassembly Control Cavity Leak Test The pump must be assembled completely in order to perform this test This test is also performed before disassem...

Страница 73: ...4 inch diameter tank 7 Fill the tank again until the pump turns on Carefully close the ball valve until the gauge reads 35 to 40 psi The pump should shut off in approximately one minute The unit must...

Страница 74: ...n amp meter will show 4 0 to 4 5 amps when the motor is running without a load Replace the stator and if necessary the rotor Amps 240V 120V PSI Head ft GPM Comments 4 9 9 8 or less 0 0 0 Worn stator 5...

Страница 75: ......

Страница 76: ...vironment One Corporation ALL RIGHTS RESERVED This book contains material protected under International and Federal Copyright Laws and Treaties Any unauthorized reprint or use of this material is proh...

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