E-one Extreme Series, Service Manual

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

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Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

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

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

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

Page 36: ...Pump End 5 12...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

Page 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...

Page 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...

Page 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...

Page 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...

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